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In the new ThyssenKrupp InCar®plus project, numerous solutions were developed for vehicle components and systems that contribute to increased efficiency through the use of new materials and advanced manufacturing technologies. These solutions are superior to current production applications in terms of weight, cost, performance and sustainability, while also meeting the demand for cost-effective weight reduction. This paper features structural components solutions focusing on Bumpers, and A- and B-pillars which overall attained between 8% to 19% weight reduction compared to their significant reference parts by incorporating flexible design concepts, progressive new materials, virtual analyses, and innovative manufacturing processes that have been tested and validated along the entire value chain. The prototypes developed were subjected to stringent safety assessments.

The ThyssenKrupp InCar Project is a comprehensive R&D development that gives automotive manufacturers modular solution kits for body, chassis and powertrain applications. The solution kits developed within this project offer weight reduction, cost savings or improved functionality. This paper will focus on the two front door solutions developed within the InCar project. The first door solution, called the Lightweight Door, achieved a 13% weight reduction. This door features a 4-piece tailored blank inner panel and a sandwich material outer panel. The second door solution, called the Advanced Door, is a completely new and innovative door architecture that uses a 2-piece tailored blank mid panel and ultra thin Dual Phase 500 outer panel to achieve an 11% weight reduction. Prototypes were manufactured and tested for both door solutions.

In this paper, we looked at the advancements in 3D non-contact measurement to more closely associate the part measurement process and the intended GD&T requirements for those features which are a combination of discrete points. In doing so, we applied various methods to more effectively describe or quantify part features. The potential applications of this work are widespread including improving virtual functional build, tolerance analysis, flush & gap analysis, sensitivity analysis and dimensional problem solving and characterization.

Forming of sheet metal structures induces pre-strains, thickness variations, and residual stresses. Pre-strains in the formed structures introduce work hardening effects and change material fatigue properties such as stress-life or strain-life. In the past, crashworthiness and durability analyses have been carried out using uniform sheet thickness and stress- and strain-free initial conditions. In this paper, crashworthiness and durability analyses of hydroformed front rails, stamped engine rails and shock towers on a full vehicle and a Body-In-White structure are performed considering the residual forming effects. The forming effects on the crash performance and fatigue life are evaluated.