Design and structural performance assessment of a composite intensive passenger vehicle

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Design and structural performance assessment of a composite intensive passenger vehicle

Fuchs, Hannes

Decoma International Inc. contracted Multimatic to develop a modular Composite Intensive Vehicle (CIV) concept, including closures and suspension, suitable for production volumes of 50,000 units per year. The proposed CIV was required to meet all typical OEM vehicle packaging standards, and stiffness and applicable crash safety standards, while offering the potential for overall mass reduction and meeting manufacturing cost and volume requirements. The primary structural materials considered in this study were fiberglass composite and metallic materials. The study to develop the CIV Body-In-White (BIW), closures, and suspension systems concepts was conducted in 3 phases: (1) Development of the vehicle content requirements, vehicle occupant and component package, and structural performance targets based on program requirements, provided styling surface, and vehicle benchmarking. (2) Development of a package-feasible three dimensional structural CAD concept model for the BIW, closures, and suspension system. (3) CAE-based structural stiffness optimization and crash performance assessment of the structures developed in (2). The resulting CIV vehicle concept was developed to a level suitable for prototype build, detailed manufacturing feasibility verification, and mass and cost assessment.