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Optimizing the specifications of the parts that make up the vehicle is essential to develop a high performance and quality vehicle with price competitiveness. Optimizing parts specifications for quality and affordability means optimizing various factors such as engineering design specifications and manufacturing processes of parts. This optimization process must be carried out in the early stages of development to maximize its effectiveness. Therefore, in this paper, we studied the methodology of building a database for parts of already developed vehicles and optimizing them on a data basis. A methodology for collecting, standardizing, and analyzing data was studied to define information necessary for specification optimization. In addition, AI technology was used to derive optimization specifications based on the 3D shape of the parts. Through this study, body parts specification optimization system using AI technology was developed.

The body stiffness plays a key role in vehicle performance, such as noise and vibration, ride and handling, durability and so on. In particular, a body D-pillar ring structure is the most sensitive affecting the body stiffness on vehicle with tail gate. Therefore, since D-pillar body ring structure for high stiffness and lightweight is required, an optimized design methodology that simultaneously satisfies the requirements was studied. It focused on a methodology that body engineering designers can optimize design parameters easily and quickly by themselves in the preceding stages of vehicle’s styling distribution and design conceptual planning. First, it is important to establish the body stiffness design strategy by predicting the body stiffness with the vehicle’s styling at early design stage. The methodology to predict body stiffness with the styling and body dimension specification parameters was introduced.

A body joint is one of the most major factors affecting the overall body stiffness in a body system. Thus, in order to optimize the body system, the joint must be also optimized. In order to optimize a body joint, it is necessary to first identify the efficiency of the joint itself. Then, the joint stiffness targets for each joint must be set by analyzing the interaction between joint stiffness and overall body stiffness and the function of the joint in terms of vehicle performance. Finally, an optimal joint structure should be designed with an optimal design methodology. In this study, an optimal methodology for the joint stiffness and design is introduced. Based on this research, an optimized joint design for each joint was applied to the new SUV model resulting in a lightweight body with a required body stiffness.

It is common knowledge that body structure is an important factor of road noise performance. Thus, a high stiffness of body system is required, and determining their optimized stiffness and structure is necessary. Therefore, a method for improving body stiffness and validating the relationship between stiffness and road noise through CAE and experimental trials was tested. Furthermore, a guideline for optimizing body structure for road noise performance was suggested.

It is common knowledge that body attachment stiffness is an important factor of road noise performance. Thus, a high stiffness of body attachments is required, and determining their optimized stiffness and structure is necessary. Therefore, a method for improving body attachment stiffness and validating the relationship between stiffness and road noise through CAE and experimental trials was tested. Furthermore, a guideline for optimizing body structure for road noise performance was suggested.