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For a crash analysis using FEM with respect to a structure that is composed of thin plates, we developed a new structure study method (plastic strain equalization method). This method defines the optimality criteria as in the linear analysis of a fully stressed design and indirectly finds an optimal solution. We assume that a structure with both a lightweight and high collapse load should have sufficient strength corresponding to impact loads in each area. This means that at any area the load value and the strength are balanced at a certain value. For the criteria that the plastic strain value is equal over the whole area, a solution can be found by repeating computations. The design variable is the thickness of shell elements and the computation is iterated until plastic strain values are almost equal. In this paper, a structure with both a lightweight and a high collapse load could be optimized by equalizing the plastic strain value.

Aluminum Honeycomb Sandwiches and Extrusions have been applied to a platform for convertibles. The platform, composed of a dashpanel and floor panels (honeycomb sandwiches) and a framework (extrusions), has a much more lightweight and rigid structure than other conventional convertible bodies-in-white. This improves remarkably vibrational behavior and handling characteristics, which deteriorate in a convertible, in the case of a prototype.

To realize high levels of handling, driving performance, and NVH characteristics for a sports car, it is important to develop a lightweight and high-stiffness vehicle body. For the new RX-7, weight saving and higher stiffness were pursued as top priorities from the very first stage of the program. We were able to achieve 20% higher bending stiffness and 15% higher torsional stiffness with vehicle weight reduced by 30 kg, compared with the former model. The development of the lightweight, high-stiffness body for the new RX-7 is discussed under three subjects: 1. Contributions of vehicle components to vehicle stiffness 2. Effective procedure for developing vehicle high stiffness and lightweight construction with emphasis on calculation analysis 3. New RX-7's body structure and accomplishment