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The entire commercial vehicle industry is moving towards weight reduction to leverage on the latest materials available to benefit in payload & fuel efficiency. General practice of weight reduction using high strength steel with reduced thickness in reference to Roark’s formula does not consider the stiffness & dent performance. While this helps to meet the targeted weight reduction keeping the stress levels within the acceptable limit, but with a penalty on stiffness & dent performance. The parameters of stiffener like thickness, section & pitching are very important while considering the Stiffness, bucking & dent performance of a dumper body. The Finite Element Model of subject dumper body has been studied in general particularly on impact of dent performance and is correlated with road load data to provide unique solution to the product. The impact of payload during loading of dumper is the major load case.

High strength aluminium alloys are an ideal material in the automotive sector leading to a significant weight reduction and enhancement in product safety. In recent past extensive development in the field of high strength steel and aluminium was undertaken. This development has been propelled due to demand for light weight automotive parts. The high strength to weight ratio possessed by Al alloy helps in reducing the total weight of the vehicle without effecting the overall performance, thereby increasing the fuel economy, and reducing the carbon emission level. Joining of high strength aluminium alloy is critical to develop durable automotive products. Joining of high strength aluminium alloy for mass production in automobile industry is a challenging task. Laser welding is recognized as an advanced process to join materials with a laser beam of high-power, high- energy density.