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Simplified load path models (SLMs) of the body in white (BIW) are an important tool in the body structure design process providing a highly flexible, idealized concept model to explore the design space through load path evaluation, material selection, and section optimization with rapid turnaround. In partnership with Altair Engineering, the C123 process was used to create and optimize SLMs for BIW models at FCA US LLC. These models help structures engineers to develop efficient load paths, sections, and joints for improved NVH as ultra-high-strength steels enable thinner gauges throughout the body structure. A few key differences in the SLM modeling method are contrasted to previous simplified BIW modeling methods. One such example is the parameterization of cross sections through response surface models rather than using contemporary finite element descriptions of arbitrary cross sections.

The development of a structural magnesium instrument panel (IP) beam is presented in this paper. This magnesium IP was designed to be a structural load bearing member in a crash event. Unlike many IPs in production today, this IP helps mid-engine vehicles achieve certain FMVSS 208, US NCAP, IIHS and OEM standards for occupant crash protection. In typical front engine vehicles, the front-end structure absorbs the crash energy with the sandwiched engine acting as rigid body to resist the crash loads and intrusion into passenger compartment. However, in mid engine vehicles, the front-end structure is inadequate to fully absorb the crash energy and at the same time resist intrusion. Without a structural IP beam to resist crash loads, it is unlikely that mid engine vehicles can successfully meet the FMVSS 208, US NCAP, IIHS and OEM standards for occupant crash protection. With that in mind, this magnesium IP was designed as a structural load-bearing member.