DESIGN AND DEVELOPMENT OF A BIW STRUCTURE FOR A 3-SEATER VEHICLE
About
Developed a BIW layout topology structure that meets performance requirements for bending stiffness and torsion stiffness. The layout also provides adequate packaging space for vehicle components and occupants.
The developed body was designed to keep the passengers safe in the event of a front or rear collision by proper front and rear crash energy management.
The body was designed while keeping the mass in check.
I modeled a structural beam frame topology using Solidworks. The B-pillar to rocker joint was analyzed to determine the rotational joint stiffness using Altair Hypermesh.
Evaluated and modeled the body side frame bending and torsion stiffness to meet the requirements.
BODY IN WHITE AND LADDER FRAME DESIGN
A structural beam frame topology was developed using Solidworks taking into account all the packaging requirements for occupants and vehicle components.
ASSEMBLY (PACKAGING OF COMPONENTS)
The complete assembly includes all the major components required for the occupant's packaging and vehicle components such as the powertrain, suspension mounts, battery, radiator, fuel tank and cargo.
ROCKER JOINT SIMULATION
The B-Pillar to rocker joint of a Honda Civic was analyzed using Hypermesh to determine the rotational joint stiffness to use it as a benchmark for the proposed design. This joint stiffness was used in the design calculations to meet the performance requirements for bending and torsion stiffness of the frame.
DRAFTING OF THE MODEL
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Method
An iterative method was followed in determining the bending and torsional stiffness of different joints of the beam frame.
Beam Size Resizing was done in accordance with various constraints and the beams with very high bending energy were altered.
Experimented with various types of cross-section of beams (Hexagonal and Pentagonal) to find which beam used in the front mid-rail had the highest energy absorption capability with the least mass.
Designed a BIW structural cross-members to maintain passenger compartment structural integrity and to reach crash impact loads.
Determined the updated vehicle curb mass after three mass saving opportunities were proposed.
Result
Thus a three-seater vehicle was designed taking into consideration packaging requirements and crashworthiness requirements while keeping the mass of the frame in check.
GALLERY
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