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As worldwide demand for affordable, safe and low greenhouse gas emission vehicles surged, WorldAutoSteel launched the FutureSteelVehicle program (FSV) aimed at helping automakers optimize body structures through advanced steel design concepts suitable for both conventional and electrified powertrains. The objective was to develop detailed design concepts and fully optimize a radically different body structure vehicle in production in 2015-2020 timeframe utilizing the latest grades of advanced and ultra-high strength steels. FSV achieved 35 percent mass reduction [approaching aluminum body structure mass with similar performance], at no additional cost over a conventional steel body while achieving simulated crash test performance enabling a 5-star safety rating. This was accomplished with a portfolio of 34 standard and advanced steel grades and 17 steel manufacturing technologies together with a state-of-the-future design methodology.

Two beam elements chassis/suspension models with rigid vehicle body representation and finite element tires were studied under proving ground conditions. The only difference between the two models was that one used flexible beam elements and the other used rigid beams. Several proving ground road surfaces were modeled and used in the analysis, including a washboard road surface, a Belgian block type track and a pothole track,. Also analyzed were the low speed driveway-ramp and (relatively) high speed lane-change cases. The proving ground simulation results, and system compliance results as well, were compared between the two models. The differences revealed the importance and necessity of using finite element model (even just using deformable beam elements) to include the component flexibility in conducting vehicle chassis/suspension dynamic analysis.

The objective of this research is to study the effect of front seat structure in Federal (FMVSS 214) dynamic side impact Finite Element Analysis (FEA) simulation. This research investigates the side structure behavior, buckling mode, velocity, and deformation of components such as the B-pillar, front door, rear door, floor pan, and rocker in three different configurations, using two different front seal stiffnesses. A methodology was developed to reduce side structure deformation and associated component velocities, thereby minimizing occupant loading.