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Automotive fenders is one such example where specialized thermoplastic material Noryl GTX* (blend of Polyphenyleneoxide (PPO) + Polyamide (PA)) has successfully replaced metal by meeting functional requirements. The evolution of a fender design to fulfill these requirements is often obtained through a combination of unique material properties and predictive engineering backed design process that accounts for fender behavior during the various phases of its lifecycle. This paper gives an overview of the collaborative design process between Mitsubishi Motors Corporation and SABIC Innovative Plastics and the role of predictive engineering in the evolution of a thermoplastic fender design of Mitsubishi Motors Corporation's compact SUV RVR fender launched recently. While significant predictive work was done on manufacturing and use stage design aspects, the focus of this paper is the design work related to identifying support configuration during the paint bake cycle.

The emergence of thermoplastics in automotive structural parts is constantly increasing as designers recognize the benefits thermoplastics bring, such as light-weighting, cost effectiveness, the ability to integrate parts, the flexibility to design intricate shapes, and the materials’ high specific energy absorption capacity. In order to predict the behavior of plastics by simulation using finite elemental analysis (FEA) tools such as LS-DYNA®1, an extensive understanding of properties and implementation using FEA is very important. In order to obtain reliable results from simulation, the FEA solver should support material models which predict the behavior of plastics accurately. LS-DYNA® supports several material models which are used to predict behaviour of plastics, and one, the Semi-Analytical Model for Polymers (SAMP-1 with GISSMO failure), was developed exclusively for plastics.

Multi-material solutions for the light weighting of electric and internal combustion engine (ICE) vehicles is an emerging trend to replace structural components made of steel/aluminum. Automotive chassis consists of structural members such as rails, posts and rockers, which form frames that need to meet stringent crashworthiness requirements such as frontal, side (IIHS & Pole) and rollover impacts. The high strength steel and aluminum used in these structures are often heavy and require several secondary steps to complete the frame. In the present paper, we discuss the design and optimization of multi-material hybrid rocker panel solutions to meet pole impact requirements and decrease weight with an emphasis on structural battery protection in electric vehicles. Rocker panel structures are situated at the bottom of the lateral edges of the vehicle and extend longitudinally along the length of the vehicle, between the front and rear wheels.

Light-weight solutions are gaining traction in the development of Electric Vehicles to improve the overall range of the vehicle. One key focus area is to replace metallic structural members with thermoplastic solutions as they contribute to the major weight of the vehicle. However, since the structural components influence the crashworthiness requirements of the vehicle such as frontal, side and rollover impact, the design of the lightweight solutions need to be robust. Rocker panel structures are situated at the bottom of the lateral edges of the vehicle and are intended to absorb the energy during a side crash, protecting the battery from intrusion and shock. Rocker reinforcement is one application targeted by OEM’s to reduce weight and carbon footprint compared to the conventional metallic solutions. In this paper, we discuss the design and development of rocker reinforcements using SABIC’s Specialties NORYL GTXTM resin.