Investigation on the optimal simplified model of BIW structure using FEM

At conceptual phases of designing a vehicle, engineers need simplified models to examine the structural and functional characteristics and apply custom modifications for achieving the best vehicle design. Using detailed finite-element (FE) model of the vehicle at early steps can be very conducive; however, the drawbacks of being excessively time-consuming and expensive are encountered. This leads engineers to utilize trade-off simplified models of body-in-white (BIW), composed of only the most decisive structural elements that do not employ extensive prior knowledge of the vehicle dimensions and constitutive materials. However, the extent and type of simplification remain ambiguous. In fact during the procedure of simplification, one will be in the quandary over which kind of approach and what body elements should be regarded for simplification to optimize costs and time, while providing acceptable accuracy. Although different approaches for optimization of timeframe and achieving optimal designs of the BIW are proposed in the literature, a comparison between different simplification methods and accordingly introducing the best models, which is the main focus of this research, have not yet been done. In this paper, an industrial sedan vehicle has been simplified through four different simplified FE models, each of which examines the validity of the extent of simplification from different points of views. Bending and torsional stiffness are obtained for all models considering boundary conditions similar to experimental tests. The acquired values are then compared to that of target values from experimental tests for validation of the FE-modeling. Finally, the results are examined and taking efficacy and accuracy into account, the best trade-off simplified model is presented.