l4 Body Bending

SMC 4133 AUTOMOTIVE STRUCTURES
DESIGN FOR BODY BENDING

 Body bending strength requirement:
• To locate and retain the vehicle subsystem in the correct position
• Does not fail under static/dynamic loading conditions
 Shear loads & moments can be identified from the S-BM diagrams
All materials in this slide are taken from Donald E Malen. 2011. Fundamentals of Automobile Body Structure Design, SAE International.
 Severe bending conditions can be occurred due to dynamic loading and

jacking/towing
 A factor of 2-g loading is typically used to represent dynamic condition
 These two extreme conditions might cause the structure to fail
 The H Point Bending Test is used to

approximate bending moment envelope
 It can be 1 or 2 point loads applied at

the seating location
The H Point Bending Test:

 Body is supported at the suspension
attachments
 The loads are increased incrementally
and the deflections are recorded until it
reachs permanent deformation
Bending stiffness
 Can be measured from the load-deflection curve
 The reason is to cater for body vibration so that it can achieve the feeling of
solidness
 The desired bending frequency is from 22-25 Hz
 Assume that the structure as a uniform beam; the primary bending frequency is
M = wL/g
L
Now, with a single static load at its center span, the bending resonant frequency is
Simply supported
Typical values of body strength and stiffness for a mid size vehicle are;
 6680 N without permanent deformation

 7000 kN/m

Load Path Analysis
o To meet body strength requirement, the structure must be carefully
designed
o Only end and shear loads are allowed in the structural surface model
o The applied load will represent the bending strength requirement
o Each surface must be capable of reacting the loads without excessive
permanent deformation
Example 1

Analysis of Body Bending Stiffness
• Focus on the side frame due to its significant contribution on bending stiffness
• The model consists of beams, rigid plates and pin connections
• Applied load acts at the center of rocker/end of B-pillar
• Approximation of the stiffness is made using finite element method
• Example of the analysis is given below with the initial guess for beam section size
• The result shows that the total bending stiffness is 2088 kN/m
• Only 30% of the target value (7000 kN/m)
• Change the beams section size/shape. BUT which BEAM?
Example 2

Finite element analysis

Importance of joint flexibility
• Previous analysis assumed the beams

were rigidly connected
• In reality, when two or more thin-walled

beams are joined, localized deformation
may occur
• Thus, it has the effect of a flexible joint

and this can be represented by rotational
spring
• The rotational stiffness can be determined

by taking ratio of moment over rotational
angle

Joint Efficiency
• To check whether the joint stiffness is a very stiff or very flexible

• It can be define as the ratio of the combined stiffness of the beam-joint
to the stiffness of the beam alone
Example 3
The steel rocker beam has section size of h = 100mm, w = 50mm, t = 1mm
L = 1000mm. Compute the joint efficiency for Hinge pillar to rocker joint.

Solution
I = 4.15E+5 mm^4
K = 0.2E+6 Nm/rad from diagram
E = 207 GPa
Joint efficiency, f
= 1/(1 + (2x207000x4.15E5/1000x0.2E6))
= 0.537
The joint reduces ½ of the beam alone

Example 4
Consider Example 2 with reasonable joint stiffness to three of the joints.

Re-run FEA.
It is found that the deflection is increased and hence, reduce the bending
stiffness to 1735 kN/m; closer to the test data.
However, the value is far from the target value. HOW to achieve it?
Which beams or joints to adjust?

Strain energy and stiffness
- As the beams deform under load application, strain energy is stored.
- The strain energy can be determined as a function of the end moments
on the beam
- The highest fraction of strain energy will improve stiffness of a structural system

Example 5
Consider the seat mount system consisting of a beam connected by a
Flexible joint to a rocker. The system does not meet the stiffness requirement,.
Which element needs to be changed: the beam or the joint?
Solution
SE beam = 200xM^2/(6x1E10) = 3.33E-9M^2
SE joint = M^2/(2x2E8) = 2.5E-9M^2
The beam stiffness has a larger effect on overall system stiffness

l4 Body Bending

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SMC 4133 AUTOMOTIVE STRUCTURES

DESIGN FOR BODY BENDING

DESIGN FOR BODY BENDING

 Severe bending conditions can be occurred due to dynamic loading and

 A factor of 2-g loading is typically used to represent dynamic condition

 These two extreme conditions might cause the structure to fail

DESIGN FOR BODY BENDING

 The H Point Bending Test is used to

 It can be 1 or 2 point loads applied at

The H Point Bending Test:

DESIGN FOR BODY BENDING

DESIGN FOR BODY BENDING

 6680 N without permanent deformation

DESIGN FOR BODY BENDING

DESIGN FOR BODY BENDING

DESIGN FOR BODY BENDING

DESIGN FOR BODY BENDING

DESIGN FOR BODY BENDING

DESIGN FOR BODY BENDING

• Previous analysis assumed the beams

• In reality, when two or more thin-walled

• Thus, it has the effect of a flexible joint

• The rotational stiffness can be determined

DESIGN FOR BODY BENDING

• To check whether the joint stiffness is a very stiff or very flexible

DESIGN FOR BODY BENDING

The joint reduces ½ of the beam alone

DESIGN FOR BODY BENDING

Consider Example 2 with reasonable joint stiffness to three of the joints.

DESIGN FOR BODY BENDING

DESIGN FOR BODY BENDING

SE beam = 200xM^2/(6x1E10) = 3.33E-9M^2

SE joint = M^2/(2x2E8) = 2.5E-9M^2

The beam stiffness has a larger effect on overall system stiffness

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