Full Vehicle Tailored Parts Optimization - Light Weighting 2015-01-1361

Application of high strength steel (HSS) and advanced high strength steel (AHSS) in automotive vehicle structure has been one of the feasible ways to achieve light weight vehicle. Automotive OEMs continue to engineer body structures with high strength grade steels by reducing component thickness (Gauge and Grade (2G) Optimization) to develop light weight, fuel efficient vehicles. In addition to the 2G optimization, design (Geometry) change of the body structure is also considered as an effective approach of reducing the body structure weight (3G Optimization). However design change lengthens product development time, requires tooling modification and/or new tools design, and increases production time, cost and product-to-market time.

Tailored parts (also known as Tailor made parts), where pieces of varying thickness are combined into one part, involving no design change and less tooling requirements, are good alternatives to reduce the weight of the body structure significantly. EDAG Inc's light weight optimization studies have shown such alternatives as proven techniques in the process of light weight designing.

This paper describes a study of identifying the potential areas of the tailored parts on a full vehicle by means of topometry optimization and the application of tailored parts using a multidisciplinary design optimization (MDO) technique. The tailored parts investigated are of linear/curvilinear tailor welded blanks (TWB) and tailor rolled blanks (TRB). Weight reduction opportunities by using tailored parts are discussed with virtual performance evaluation and CAE techniques.