33Application of a Novel Metal

Folding Technology for Automotive

BiW Design

Prathamesh Marathe

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Prathamesh Marathe

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CU-ICAR (Clemson University International Center for Automotive Research)

• Advanced-technology research campus in collaboration with academia, industry and

government organizations

• The first and only US Automotive Engineering program so far; Master & PhD program

• State-of-the-art equipment & facilities

• Technology neighborhood

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What is Deep Orange• Vehicle prototype program at CU-ICAR that immerses graduate automotive

engineering students into the world of a future OEM and/or supplier

• Helps students to gain hands on experience

– Students are involved from inception to completion in all phases

– Students get to interact with cross functional faculty members

• Students learn about state of the art technologies and how to integrate these

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• Students learn about state of the art technologies and how to integrate these

Deep Orange 3 Spring – Summer ’12 teamDeep Orange 1 car

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Deep Orange: A New Teaching Paradigm

System DesignDay 193

Market AnalysesStart: Day 1

Product/Production Architectures

Annual new Prototype Vehicle releases

from two-year Development Cycles

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ValidationEnd: Day 712

System IntegrationDay 523

Concept

Selection

Target Validation

Graduation

Manufacturing/Assembly

An integral feature of our

MS/PhD Research & Education Program

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The Importance of Industry Participation

• Provide realistic problem statements and challenges that address current

and future (industry) issues.

• Give access to new innovations, materials, technologies and processes.

• Mentor students during regularly scheduled meetings.

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• Mentor students during regularly scheduled meetings.

• Provide crucial background information on subject matter often not

accessible in an academic setting.

• Fund the overall program.

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The Deep Orange 3 Project

• Joint Sponsorship of

– Mazda North American Operations (MNAO)

– Clemson University-International Center for Automotive Research (CU-

ICAR)

– Arts Center College of Design (ACCD)

• Designed to give large scale view of the automobile design and engineering

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• Designed to give large scale view of the automobile design and engineering

process

– Marketing Data

– Design and Engineering

– Validation and Testing

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IOI Technology

• Conventional Technology: Stamping of sheets

• Drawbacks

– High tooling cost

– Complicated process

Source: http://www.industrialorigami.com/solutions/transportation.cfm

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• New Technology: Folding of sheets into simple shapes

• Advantages

– Low cost tooling

– Unskilled labor force can be easily trained (Less complicated)

– Lesser time requirement

– Lower Number of parts

– Accurate laser cut holes for mounting components and riveting

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Source: http://www.industrialorigami.com/solutions/transportation.cfm

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Application of IOI Technology

• Topology of vehicle

• Packaging of other assemblies

• Chassis

• Powertrain

• Occupants

• Analysis of structure for torsion and bending stiffness

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• Analysis of structure for torsion and bending stiffness

• Analysis of structure for dynamic loading

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Application of IOI Technology

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Components of BiW

Front Crash

Structure

Floor And

SpaceframeRear Crash

Structure

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FEA of IOI Structure

• Use of Hypermesh to generate mesh

– Sheet metal parts and Space frame pipes as 2D shell mesh

– Thicker geometries as 3D tetra mesh

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2D Shell Mesh in Floor Assembly

3D Tetra Mesh in

Spaceframe Assembly

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FEA of IOI Structure

• Adhesives used to connect different sheets

• Spot weld connectors used to connect space frame to IOI structure

• Boundary conditions and loads

– For Torsional Stiffness of the BiW

• Loads applied at front strut towers

• Constraints at front and rear with beams to simulate real life situations

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• Constraints at front and rear with beams to simulate real life situations

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FEA of IOI Structure (Contour Plots)

• Use of Hyperview to do post processing of analysis results

– Displacements

– Induced stresses

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FEA of IOI Structure (Twist Angle Vs Vehicle Length)

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Future Steps

• Carryout Dynamic Loading of the structure

• Test the fold ability of the sheets

• Realize the BiW structure form sheets and spaceframe.

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Acknowledgements

• Thanks to Dr Paul Venhovens for support and supervision

• Thanks to DO-3 team for timely help

• Thanks to Altair and Dr David Schmueser for this opportunity to present the

work at this conference

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Thank You

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Thank You

June 5, 2012 CUICAR | Deep Orange 3