Motor Vehicle Structures

Concepts and Fundamentals

List of Chapters
Glossary of ‘body-in-white’ components
Acknowledgements
About the authors
Disclaimer
1 Introduction
1.1 Preface
1.2 Introduction to the simple structural surfaces
(SSS) method
1.3 Expectations and limitations of the SSS
method
1.4 Introduction to the conceptual design stage
of vehicle body-in-white design 4 Introduction to the simple structural surfaces
1.5 Context of conceptual design stage in (SSS) method
vehicle body-in-white design 4.1 Definition of a simple structural surface (SSS)
1.6 Roles of SSS with finite element analysis 4.2 Structural subassemblies that can be
(FEA) in conceptual design represented by a simple structural surface
1.7 Relationship of design concept filtering to (SSS)
FEA models 4.3 Equilibrium conditions
1.8 Outline summary of this book 4.4 A simple box structure
1.9 Major classes of vehicle loading conditions 4.5 Examples of integral car bodies with typical
- running loads and crash loads SSS idealizations
2 Fundamental vehicle loads and their estimation 4.6 Role of SSS method in load-path/stiffness
2.1 Introduction: vehicle loads definition analysis
2.2 Vehicle operating conditions and proving Appendix Edge load distribution for a floor
ground tests with a simple grillage
2.3 Load cases and load factors 5 Standard sedan (saloon) - baseline load paths
2.4 Basic global load cases 5.1 Introduction
2.4.1 Vertical symmetric (‘bending’) load 5.1.1 The standard sedan
case 5.2 Bending load case for the standard sedan
2.4.2 Vertical asymmetric case (and the (saloon)
pure torsion analysis case) 5.2.1 Significance of the bending load case
2.4.3 Longitudinal loads 5.2.2 Payload distribution
2.4.4 Lateral loads 5.2.3 Free body diagrams for the SSSs
2.5 Combinations of load cases 5.2.4 Free body diagrams and equilibrium
2.5.1 Road loads equations for each SSS
3 Terminology and overview of vehicle structure 5.2.5 Shear force and bending moment
types diagrams in major components -
3.1 Basic requirements of stiffness and strength design implications
3.1.1 Strength 5.3 Torsion load case for the standard sedan
3.1.2 Stiffness 5.3.1 The pure torsion load case and its
3.1.3 Vibrational behaviour significance
3.1.4 Selection of vehicle type and concept 5.3.2 Overall equilibrium of vehicle in
3.2 History and overview of vehicle structure torsion
types 5.3.3 End structures
3.2.1 History: the underfloor chassis frame 5.3.4 Passenger compartment
3.2.2 Modern structure types 5.3.5 Summary - baseline closed sedan
Motor Vehicle Structures
Concepts and Fundamentals

5.3.6 Some notes on the standard sedan 7.2.1 Shear panels, and structures
in torsion incorporating them
5.3.7 Structural problems in the torsion 7.2.2 Triangulated truss
case 7.2.3 Single or multiple open bay ring
5.4 Lateral loading case frames
5.4.1 Roll moment and distribution at front 7.2.4 Comparison of stiffness/weight of
and rear suspensions different simple structural surfaces
5.4.2 Additional simple structural surfaces 7.2.5 Simple structural surfaces with
for lateral load case additional external loads
5.5 Braking (longitudinal) loads 7.3 In-plane forces in sideframes
5.6 Summary and discussion 7.3.1 Approximate estimates of pillar loads
in sideframes
6 Alternative construction for body
7.4 Loads normal to surfaces: floor structures
subassemblies and model variants
7.4.1 Grillages
6.1 Introduction
7.4.2 The floor as a load gatherer
6.2 Alternative construction for major body
7.4.3 Load distribution in floor members
subunits
7.4.4 Swages and corrugations
(a) Rear structures
6.2.1 Rear suspension supported on floor 8 Application of the SSS method to an existing
beams vehicle structure
6.2.2 Suspension towers at rear 8.1 Introduction
(b) Frontal structures 8.2 Determine SSS outline idealization from
6.2.3 Grillage type frontal structure basic vehicle dimensions
6.2.4 Grillage type frontal structure with 8.2.1 Locate suspension interfaces to
torque tubes body structure where weight bearing
6.2.5 Missing or flexible shear web in inner reactions occur
fender 8.2.2 Generation of SSSs which simulate
6.2.6 Missing shear web in inner fender: the basic structural layout
upper rail direct to A-pillar 8.3 Initial idealization of an existing vehicle
6.2.7 Sloping inner fender (with shear panel) 8.4 Applied loads (bending case)
6.2.8 General case of fender with 8.4.1 Front suspension tower
arbitrary-shaped panel 8.4.2 Engine rail
6.3 Closed model variants 8.4.3 Centre floor
6.3.1 Estate car/station wagon 8.4.4 Dash panel
6.3.2 Hatchback 8.4.5 Rear seat cross-beam
6.3.3 Pick-up trucks 8.4.6 Rear floor beams
6.4 Open (convertible/cabriolet) variants 8.4.7 Rear panel
6.4.1 Illustration of load paths in open 8.4.8 Sideframe
vehicle: introduction 8.4.9 Bending case design implications
6.4.2 Open vehicle: bending load case 8.5 Applied loads (torsion case)
6.4.3 Open vehicle: torsion load case 8.5.1 Rear floor beams
6.4.4 Torsion stiffening measures for open 8.5.2 Front suspension towers and engine
car structures rails
6.4.5 Simple structural surfaces analysis of 8.5.3 The main torsion box
an open car structure torsionally 8.5.4 Torsion case design implications
stiffened by ‘boxing in’ the engine 8.6 An alternative model
compartment 8.6.1 Front suspension towers and inner
wing panels
7 Structural surfaces and floor grillages
8.6.2 Rear floor beams
7.1 Introduction
8.6.3 The main torsion box
7.2 In-plane loads and simple structural surfaces
Motor Vehicle Structures
Concepts and Fundamentals

8.6.4 Torsion case (alternative model) 10.3.5 Discussion

design implications 10.4 Design example 3: front suspension mounting
8.7 Combined bending and torsion 10.4.1 Forces applied to and through the
8.8 Competing load paths suspension
10.4.2 Forces on the body or subframe
9 Introduction to vehicle structure preliminary
design SSS method 11 Fundamentals and preliminary sizing of
9.1 Design synthesis vs analysis sections and joints
9.2 Brief outline of the preliminary or conceptual 11.1 Member/joint loads from SSS analysis
design stage 11.2 Characteristics of thin walled sections
9.3 Basic principles of the SSS design synthesis 11.2.1 Open sections
approach 11.2.2 Closed sections
9.3.1 Starting point (package and part 11.2.3 Passenger car sections
requirements) 11.3 Examples of initial section sizing
9.3.2 Suggested steps 11.3.1 Front floor cross-beam
9.3.3 Suggested priorities for examination 11.3.2 The “A”-pillar
of local subunits and components 11.3.3 Engine longitudinal rail
9.3.4 Positioning of major members 11.4 Sheet metal joints
9.3.5 Member sizing 11.4.1 Spot welds
9.4 Relation of SSS to FEA in preliminary design 11.5 Spot weld and connector patterns
9.4.1 Scope of SSS method 11.5.1 Spot welds along a closed section
9.4.2 Limitations and assumptions of SSS 11.6 Shear panels
method 11.6.1 Roof panels
9.4.3 Suggested role of SSS method 11.6.2 Inner wing panels (inner fender)
9.4.4 Role of FEA
12 Case studies – preliminary positioning and
9.4.5 Integration of SSS, FEA and other
sizing of major car components
analyses
12.1 Introduction
9.5 The context of the preliminary design stage
12.2 Platform concept
in relation to the overall body design process
12.3 Factors affecting platform capability
9.5.1 Timing
for new model variants
9.5.2 Typical analytical models (FEM etc.)
12.4 Examples illustrating role of SSS method
used at different stages in the design
12.4.1 Weight
cycle
12.4.2 Vehicle type
10 Preliminary design and analysis of body 12.4.3 Sedan to station wagon/estate car
subassemblies using the SSS method – rear floor cross-member
10.1 Introductory discussion 12.4.4 Closed structure to convertible
10.1.1 Alternative 1: employ a bulkhead 12.4.5 Dimensions
10.1.2 Alternative 2: move where the load is 12.5 Proposal for new body variants from an
applied to a more favourable location existing platform
10.1.3 Alternative 3: transfer the load to an 12.5.1 Front end structure
SSS perpendicular to the rear 12.5.2 Dash
compartment pan 12.5.3 Floor
10.2 Design example 1: steering column 12.5.4 Cab rear bulkhead (pick-up truck)
mounting/dash assembly 12.5.5 Sideframe and cargo box side
10.2.1 Design requirements and conflicts 12.5.6 Rear compartment pan and cargo
10.2.2 Attached components box floor
10.3 Design example 2: engine mounting brackets 12.5.7 Steps for preliminary sizing of
10.3.1 Vertical direction components
10.3.2 Lateral direction References
10.3.3 Fore–aft direction Index
10.3.4 Summary