Optimization of structural adhesives in BIW to improve full vehicle crash performance

Paper #:
  • 2017-01-0255

Published:
  • 2017-03-28
Abstract:
The crashworthiness of body-in-white (BIW), plays a very vital role in the full vehicle crash performance. The structural integrity of BIW is controlled via strength of the spot welds and adhesives that are often considered as only entities to hold the parts together. However optimizing the welds and/or adhesives can not only reduce the number of connections but also improve the structural crashworthiness. This paper discusses the optimization of full vehicle structural performance and the length of adhesives in the BIW for the small overlap crash event. The variables included in the study were length of the adhesives and gage variables, defined in the front end structure of the vehicle. A parametric model was created using ANSA and iSight was used to generate design of experiments (DOE). Automated design generation using ANSA followed by automated script based post-processing was done. The optimization was done using metamodel generated for the crash event. Along with the performance optimization, the impact of the adhesives and their length on the crash mode / deformation of the vehicle in a crash event were discussed in the paper. The optimal design point had improved the crash mode of the vehicle thereby improving the performance and also reduced the structural adhesives significantly. This study highlights the process for optimizing the performance of the vehicle in crash events using the length of the adhesives and also illustrates the opportunity of mass saving in BIW by maintaining /improving the performance with the help of adhesives.
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