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Purpose: In the case study presented, the DFA (Design for Assembly) technique is applied to an automotive fuel intake cover of a currently produced vehicle in order to simplify the current product design. Design/methodology/approach: DFMA and Lucas methodology, which is used in this study, can be adopted not only for the development phase of new products, but also for already developed products, reducing the number of components and the costs. Findings: The Lucas methodology approach for the DFMA has been applied in a successful way to improve a fuel intake cover. Research limitations/implications: Only a prototype part was tested. More specimens must be tested to validate final design. Practical implications: The application of this technique allowed a product cost saving of 10%, a tooling saving of 5%, and a significant product simplification without losing its original functionality.

Technological advances in both hardware (Nano-electronics) and software (artificial intelligence) are increasingly influencing our lives on equipment and devices that surrounds us and more recently our means of locomotion. The autonomous vehicles, which previously appeared only in movie scenes, can already be found in our environment, such as ships, cars, trucks, tractors and aero engines. Considering the autonomous vehicles, its launching is much closer than we could imagine, since many companies signalize having the conditions to launch them in a large scale within 2018 year. The insertion of this type of technology opens a range of advances related to vehicles and the environment in which it is inserted. The communication between the vehicles, roads and people can be highlighted. These advances reveal a series of benefits to the customer such as free time during the route, higher safety, etc.

The new Brazilian automotive regulation, INOVAR, states aggressive energy efficiency targets until 2016 to vehicles sold in Brazil. Many engineering solutions shall be done and implemented by Automakers to adequate current and new vehicles to INOVAR requirements. The Body Structure represents about 40% of vehicle mass and it is fundamental portion of energy efficiency study. The biggest body structure engineers challenge is provide mass reduction changes without jeopardize legal requirements and structural vehicle performance such as: Safety, Reparability, Torsional and Bending Stiffness, Durability, etc. Either Automakers or Suppliers manufacturing have an important task supporting Product Engineers on new parts development with different materials, shapes and joining. The contribution of Body Structure mass reduction for Internal Combustion Engines vehicles is not enough to achieve targets because new Program establishes smaller Energy Consumption for lighter vehicles.

Nowadays quality and efficiency in the process is no longer a question of competition among automakers. Another factor that has been highlighted in the automotive industry and has become a strategic is the sustainability. Processes considered “green” can generate value for the company with less environmental impact, and they are seen favorably by both market and customers. The process to be examined is widely used by automakers to manufacture their bodies in white, the resistant spot welding process. Considering that, this process generates a considerable impact in the environment mainly for the generation of gases, some manufacturers in recent years has replaced it by the clinching process, which also performs the union of sheet metal, but for metal forming. The process of spot welding generates dust, fumes and pollutants gases, which will be transported to the external environment somehow.

Welding is the longest automotive manufacturing process in terms of time. Approximately 95% of an actual body structure joining is consisted by spot welds. In this specific joining process, the panels are joined one against the other, via pressure and an electric current released by the welding machine. Some case studies are demonstrating that, by using CAE optimization algorithm, it is possible to reduce significantly the amount of spot welds, without loss of function or performance. This paper demonstrates a case study with a reduction of approximately ∼ 14 % of spot-welds in a body region of a vehicle, using these tools.

The purpose of this paper is present a successfully application of Design For Assembly (DFA) and Design for Manufacturing (DFM) on Pickup-Box reinforcement. Those powerful quality tools are widely used during automotive design development and it might be a competitive design solution. As an introduction, a complete DFA and DFM revision is provided in order to allow methodology comprehension. Currently automakers technologies are shown as well. An introduction about product development process is presented in order to contextualize the DFA/DFM application in a real design situation. A rich and detailed revision about Pickup versions and body structure concept are covered as well. The study of case about DFA/DFM application on Mid-size Pickup-box Inner asm reinforcement generated 36-42% of mass reduction and 58-66% of cost reduction.

This paper aims present information regarding Automotive Body in White (BIW) development fundamentals, providing a link between physics fundamentals and real automotive development. An introduction about product development process will be shown in order to allow the reader comprehension about timeline decision process. A properly revision regarding applied loads, body in white materials, safety and virtual/physical validation will be covered. Structural fundamental knowledge has a key role of Design Engineer background mindset to achieve challenges vehicle targets about cost, mass and performance. The paper information provides a clear technical reader understanding how product engineers use structural fundamental theories to design BIW in real design development application. A study of case regarding Front-end tie-bar was used. A real vehicle load application was simulated by CAE analysis.