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Idea

? Lightweight parts with load and function-optimized material usage

Implementation

? Flexible Cold-Rolling Process
? Flat material with repeated, varying thickness runs and harmonious transition zones

? An increased number of thickness zones for an optimized TRB solution results in minimal lightweight cost

Targets / Benefits

? Weight reduction
? Part integration

? Functional Improvement

CAE model information
? Re-engineered model
? Five passenger CUV ; model year 2010
? Updated material for the Door-Ring and Rear
Rails to state of the art
? Curb weight: 4,000 lbs
? Dimensions
– Length: 189”
– Width: 75”
– Height: 63”

? Less deformation concerning the B-Pillar
? Slightly lower SWR because of more deformation of the Roof Rail

? Independent thickness run without requiring a symmetry line
? More homogeneous distribution of the crash energy
? High material utilization
? Weight reduction up to 17 %

Potential of a TRB ? Rear Rail Design
? Simulation with generic vehicle
– FMVSS 301 Rear Crash
– Understructure deformation
– Plastic strain at Fuel Tank
– Door opening
– Stiffness comparison

? Harmonic load distribution due to transition zones
? Reduced production and assembly costs by part integration
? 10 % weight reduction + 1 part integration with TRB ? I
? 21 % weight reduction + 3 parts integration with TRB ? II