Design and Optimisation of Body in White of a four-wheel vehicle

Design and Optimisation of Body in White of a four-wheel vehicle | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Design and Optimisation of Body in White of a four-wheel vehicle Mohammed Sadiq Mohiuddin, Anjaneyulu Jalleda This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-4832694/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract The Body in White (BIW) is a critical component in automobile design, providing essential structural integrity to withstand various loads and stresses during vehicle operation. This paper presents the simulation and analysis of a BIW chassis for a Bolero vehicle using finite element (FE) analysis to evaluate its performance under different loading and boundary conditions. The study focuses on structural and crash analysis to ensure high-quality vehicles that offer adequate protection to passengers during accidents. A geometrical model of the BIW chassis was designed using CATIA V5 software, and simulations were conducted using Ansys Workbench. Modal analysis was performed to observe natural frequencies and mode shapes, while the deformation and stress induced during side and frontal impacts were analyzed. The materials considered for the BIW structure included CP Steel, Duralumin, and a combination of both. A parametric study on weight optimization was conducted, determining the thickness of structural members based on allowable stress and deformation to ensure structural integrity and performance. The results showed an 18.6% reduction in vehicle weight using a combination of Duralumin (dominating in reinforcement parts) and CP Steel (in other areas). The combined material structure demonstrated less deformation in static structure, side crash, and frontal impact scenarios compared to using either material individually at 1.2mm thickness. Additionally, stress levels were observed to be comparatively lower. BIW FE Analysis Crash Simulation CATIA V5 Ansys Workbench Weight Optimization Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 1. INTRODUCTION "Body in White" (BIW) is a key stage in car manufacturing where the vehicle's sheet metal components are assembled using welding, riveting, and adhesives before painting. This phase is crucial as it establishes the vehicle's structural integrity, safety, and quality. Mastering BIW can significantly enhance vehicle performance, manufacturing efficiency, and cost-effectiveness [ 1 ][ 2 ]. Traditionally, BIW focused on creating a strong and rigid structure to handle driving stresses and protect passengers in a collision. Nowadays, there is a greater emphasis on reducing the weight of the BIW to improve fuel efficiency and lower emissions while maintaining safety and durability. This shift is driven by environmental regulations, high fuel costs, and consumer demand for efficient vehicles. Optimizing BIW involves balancing material selection, design, manufacturing processes, and cost. Each factor critically influences the final BIW characteristics and overall vehicle performance. For example, choosing the right materials can affect the BIW's weight, strength, and cost, while its design impacts aerodynamics, crashworthiness, and manufacturability [ 3 ]. Material choice is vital for BIW optimization. Although steel has traditionally been used for its strength and affordability, new materials like high-strength steel, aluminum, magnesium, and composites offer benefits such as reduced weight and improved strength. These materials, however, introduce new manufacturing and cost challenges. Advanced computer-aided engineering (CAE) tools help in BIW design optimization by simulating and analyzing various design alternatives. These tools enable engineers to assess different design parameters, such as geometry, material properties, and joining methods, to find the best design that meets performance criteria while minimizing weight and cost. New manufacturing technologies like laser welding, adhesive bonding, and 3D printing also enhance precision and flexibility but require investment in new equipment and workforce training. Balancing these factors with cost considerations ensures that the BIW is efficient, sustainable, and cost-effective. 2. METHODOLOGY 2.1 Modelling The modelling project undertaken involves the BIW structure for a vehicle using CAD software, CATIA V5. "Body in White" refers to the stage in automotive manufacturing where a car's sheet metal components are welded together before adding moving parts, paint, trim, and other elements. The Mahindra Bolero, a popular SUV [ 4 ] known for its robust build and practicality, served as the primary reference for this model. The initial step in the project was to gather precise dimensions of the Bolero, including its length, width, and height. These dimensions are crucial as they form the foundational framework upon which the entire BIW structure is built. Incorporating the Bolero's overall dimensions into the CATIA V5 environment ensured that the model's proportions and scale were accurate. By accurately modelling the BIW structure using the specifications of the Mahindra Bolero, this project aims to achieve a balance between weight reduction and maintaining the necessary strength and stiffness. This balance is essential for ensuring the vehicle's safety and performance while also enhancing fuel efficiency and reducing emissions. Below are the specifications such as height, length, and width of the components, along with an isometric view in the CATIA V5 software interface, providing a comprehensive understanding of the model's design and scale. In CATIA V5, I started modelling the pillars. A, B, and C which are integral for maintaining the structural integrity of the vehicle. These pillars were placed at precise intervals, correlating with the specified dimensions and ensuring they provided adequate support and rigidity to the structure. Following the pillars, I designed the roof structure. Given that the Bolero is known for its rugged design, it was essential to replicate the roof's sturdy characteristics. The roof beams and cross-members were designed to not only provide support but also to distribute the load effectively in case of a rollover, thereby enhancing the safety of the vehicle. Throughout the modelling process, I paid special attention to the joints and weld points. These are crucial in real-life manufacturing as they ensure the components are securely attached, providing overall rigidity and durability to the vehicle. In CATIA V5, I simulated these joints to ensure they would perform as expected under various stress conditions. The use of CATIA V5 allowed for precise control over the design process, enabling me to create a highly detailed and accurate representation of the BIW structure. This model serves as a crucial step in understanding and analysing the vehicle's design, providing insights that are essential for further development and optimization. 2.2 MATERIAL SELECTION The selection of materials for Body in White (BIW) is crucial for a vehicle's performance, safety, and efficiency. Historically, steel, particularly mild steel, dominated BIW due to its strength, durability, and low cost, providing essential structural support. However, as the demand for lighter, more fuel-efficient vehicles increased, the limitations of mild steel became evident. This shift has driven the automotive industry to explore modern materials such as high-strength steel, aluminum, magnesium, and composites, which offer better strength-to-weight ratios but also present new manufacturing and cost challenges. 2.2.1 C P Steel Complex phase steels, similar to TRIP steels but with less retained austenite, feature fine precipitates and a high volume of hard phases within a fine microstructure of ferrite. These steels are precipitation-hardened using niobium, titanium, and/or vanadium, achieving very high strengths of 800 MPa and above. While not as formable as TRIP steels, they offer better weldability and lower costs due to reduced alloy content. This development marks a significant evolution in automotive steel, with most steels used in new vehicles today being unavailable a decade ago. The automotive and steel industries are rapidly advancing in steel manufacturing, with no signs of slowing down. Table 1 Material properties of CP Steel Property Value Density (kg^m3) 7850 Young’s modulus (Pa) 2.1E + 11 Poisons ratio 0.33 Tensile strength (MPa) 800 .1200 2.2.2 Duralumin Duralumin is a notable aluminum alloy, first developed in the early 20th century by the German company Dürener Metallwerke AG, that combines aluminum with copper, and sometimes magnesium and manganese, to create a lightweight yet strong material. Its introduction revolutionized aircraft construction by significantly reducing weight without sacrificing strength or durability. Known for its high tensile strength, corrosion resistance, and machinability, Duralumin was crucial in early aviation and remains widely used today in modern aircraft, automotive parts, and some sporting goods. Its impact on materials science and engineering underscores its ongoing relevance and influence across various industries. Table 2 Material properties of Duralumin Property Value Density (kg^m3) 2800 Young’s modulus (Pa) 7.6E + 10 Poisons ratio 0.33 Tensile strength (MPa) 730 Compressive strength (MPa) 460 2.3 Regulatory Standards 2.3.1 Initial design In body-in-white (BIW) design, vehicle dimensions are crucial for determining the overall structure and layout. The Mahindra Bolero, with its length of 3995 mm and width of 1745 mm, offers key reference points for designers. These dimensions provide ample interior space and allow for the integration of essential components like the powertrain and safety systems, while also ensuring stability and handling. By incorporating the Bolero’s specifications, BIW designers can address packaging challenges, integrate necessary parts, and maintain the vehicle's aesthetic and performance goals, making these dimensions a valuable guide in creating efficient and effective BIW designs. 2.3.2 Crashworthiness standards The Bharat New Car Assessment Program (Bharat NCAP) is set to significantly enhance automotive safety standards in India by compelling manufacturers to prioritize safety in their designs. This initiative involves rigorous testing of vehicles, providing consumers with clear safety ratings to make informed choices and driving automakers to invest in advanced safety technologies. The result will be improved vehicle safety, reduced road accidents, and a more competitive and innovative automotive industry. All cars undergo front. and side impact testing, which includes 64kmph Front impact test 50kmph Side impact test 29kmph optional Pole impact test 40kmph child and adult pedestrian impact tests. 2.4 FE Analysis 2.4.1 Parametric Study in Ansys A parametric study in ANSYS is a method used to explore how changes in design variables affect performance. Instead of creating and testing multiple models, this approach allows you to define a range of values for parameters like material types or dimensions and let ANSYS automatically run simulations for each variation. For example, in this project I have made thickness as a varying parameter and analysis has been done accordingly. This process provides valuable insights into design trends and relationships, helping to optimize the design efficiently while saving time and resources. 2.4.2 Static structural Analysis In static structural analysis, we focus on bending and torsional stiffness. Bending stiffness measures how well a structure resists deformation under load, crucial for ensuring components like beams and shafts don't bend excessively. Torsional stiffness evaluates a structure's resistance to twisting, important for elements such as drive shafts and frames where twisting loads are significant. By using tools like ANSYS to simulate these conditions, engineers can predict a structure's behaviour, identify potential weaknesses, and refine designs to enhance safety and reliability. Boundary condition for static structural Table 3 boundary condition for static structural condition Front End Rear End Loads Bending (Pitching) • Rotation about x is free • Remaining DOF are constrained • Rotation about x and translation about y is free. • Remaining DOF are constrained. 10kN Rotation about z (Steering) • Rotation about z is free • Remaining DOF are constrained • Rotation about z and translation about x is free. • Remaining DOF are constrained. 2000Nm is applied in y direction Rotation about y (Rolling) • Rotation about y is free • Remaining DOF are constrained • Rotation about y and translation about xis free. • Remaining DOF are constrained. 2000Nm is applied in z direction. 2.4.3 Explicit Dynamic Analysis In this, the explicit dynamic analysis results are discussed mainly focussing on side crash and frontal crash analysis. 2.4.3.1 Side Crash analysis I conducted an explicit dynamic crash analysis using ANSYS to simulate a collision, where a point mass traveling at 50 km/h impacts a stationary car over a brief 0.01-second interval. I set up the boundary conditions to reflect the impact velocity and monitored key indicators like equivalent stress, average stress, and total deformation throughout the simulation. This analysis helps assess the car's structural integrity and safety during a collision, providing valuable data for design improvements and enhancing vehicle safety. Table 4 Side crash analysis setting Definition Pre.Stress Environment None Available Pressure Initialization From Deformed State Input Type Velocity Define By Components Coordinate System Global Coordinate System X Component 13888.9 mm/s Y Component 0 mm/s Z Component 0 mm/s 2.4.3.2 Frontal Crash analysis I performed an explicit dynamic analysis to simulate a frontal crash, where a car traveling at 65 km/h impacts a stationary vehicle over 0.01 seconds. In ANSYS, I set the boundary conditions with the stationary car's base fixed and applied the specified velocity to the moving car. During the simulation, I tracked key metrics like equivalent stress, average stress, and total deformation to assess the vehicle's structural integrity and safety. The results will help in refining the design and improving overall vehicle safety. Table 5 Frontal crash analysis setting Definition Pre.Stress Environment None Available Pressure Initialization From Deformed State Input Type Velocity Define By Components Coordinate System Global Coordinate System X Component 0 mm/s Y Component 18055.6 mm/s Z Component 0 mm/s 3. RESULT AND DISCUSSIONS 3.1 Variation of weight with change in thickness. I have applied varying thicknesses from 2mm to 0.8mm for CP Steel, Duralumin and combination of both to the Body-in-White (BIW) structure, leading to notable changes in weight. The adjustments in thickness have resulted in a clear variation in the overall weight of the structure, the variation of mass is tabulated in Table 6 . Table 6 Mass reduction as change in thickness Weight in kg CPSTEEL DURALUMIN COMB OF BOTH 2mm 315.864 112.6648585 257.1005299 1.8mm 284.2776 101.3983727 231.3904769 1.5mm 236.898 84.49864388 192.8253974 1.2mm 189.5184 67.5989151 154.2603179 1mm 157.932 56.33242925 128.5502649 0.8mm 126.3456 45.0659434 102.8402119 3.2 Static structural analysis 3.2.1 Bending (Pitching) The analysis of CP Steel, Duralumin, and a combination of both materials under bending load conditions was conducted using Ansys software. The study varied thicknesses from 2mm to 0.8mm, assessing total deformation, and maximum stress. The results, summarized in Table 7 , reveal how each material deforms under the given conditions, providing a clear comparison across the different thicknesses. Table 7 Total deformation for bending Deformation (mm) CP Steel Duralumin Combination of both 2mm 0.8775 2.388634171 1.049233348 1.8mm 1.185819 3.227001644 1.407095332 1.5mm 2.005707 5.455960493 2.348646613 1.2mm 3.839159 10.43943711 4.424161001 1mm 6.545312 17.79411534 7.450294072 0.8mm 12.60255 34.25507069 14.15051038 The maximum stress for CP Steel, Duralumin and Combination of both in static structural analysis under bending load conditions by varying thickness from 2mm to 0.8mm are listed in the Table 8 . Table 8 Maximum stress for Bending Max Stress (Mpa) CP Steel Duralumin Combination of both 2mm 22.70126 22.85937188 24.94743685 1.8mm 28.02854 28.22079869 30.39742833 1.5mm 40.33882 40.60889322 42.67111655 1.2mm 62.94133 63.35190375 64.39314061 1mm 90.54058 91.12081964 89.97158158 0.8mm 141.3649 142.256114 135.3640232 3.2.2 Steering (Rotation about z) Analysis has been done for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about y axis load conditions by varying thickness. These are analysed through parametric study in Ansys software and plotted all result, which are Total deformation, Maximum stress and Average stress in a graphical representation as well as in tabular form. The total deformation for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about z axis load conditions by varying thickness from 2mm to 0.8mm are listed in the Table 9 . Table 9 Total deformation for Rotation about z axis ROTATION ABOUT Z Deformation (mm) CP Steel Duralumin Combination of both 2mm 20.07795 55.39735367 52.10037661 1.8mm 21.33344 58.85605692 55.64801785 1.5mm 24.49789 67.58789224 46.56010163 1.2mm 29.14195 80.4032136 55.2564273 1mm 33.59551 92.69643285 63.5911821 0.8mm 40.09192 110.6305623 75.71754466 The maximum stress for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about z axis load conditions by varying thickness from 2mm to 0.8mm are listed in the Table 10 . Table 10 Maximum stress for Rotation about z axis Max Stress (Mpa) CP Steel Duralumin Combination of both 2mm 130.4015 128.1626981 253.4962005 1.8mm 135.9969 133.6726651 275.6989505 1.5mm 157.1254 155.7858887 228.2523635 1.2mm 194.0688 192.4508286 268.1012484 1mm 227.7074 225.8216056 312.5809553 0.8mm 273.3145 271.0252927 370.7805166 3.2.3 Rolling (Rotation about y) Analysis has been done for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about y axis load conditions by varying thickness. These are analysed through parametric study in Ansys software and plotted all result, which are Total deformation, Maximum stress and Average stress in a graphical representation as well as in tabular form. The total deformation for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about y axis load conditions by varying thickness from 2mm to 0.8mm are listed in the Table 11 . Table 11 Maximum deformation of rotation about y (Rolling) ROTATION ABOUT y (Rolling) Deformation (mm) CP Steel Duralumin Combination of both 2mm 11.77348 29.75209807 22.08315848 1.8mm 12.89021 32.31088027 23.32235212 1.5mm 15.1929 37.64866816 20.28585349 1.2mm 18.42821 46.99982189 24.06677257 1mm 21.38353 56.34652809 28.77808738 0.8mm 25.44515 69.76991037 35.6883689 The maximum stress for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about y axis load conditions by varying thickness from 2mm to 0.8mm are listed in the Table 12 . Table 12 Maximum stress of rotation about y axis Max Stress (Mpa) CP Steel Duralumin Combination of both 2mm 274.6353 237.5129713 286.486481 1.8mm 297.6943 260.927732 298.1722309 1.5mm 343.2804 308.3221869 292.1252619 1.2mm 403.1502 374.0838345 362.2351629 1mm 453.0608 431.8912222 429.0661908 0.8mm 514.877 506.3631836 529.0803833 3.3 Modal Analysis Modal analysis is performed in Ansys workbench and natural frequencies are extracted for three types of modes. The extracted modes are tabulated for CP Steel, Duralumin and Combination of both. 3.3.1 Bending Mode Bending mode also known as pitching. The natural frequencies are tabulated in Table 13 for three various materials. Analysis has been done for three different materials. These are analysed in Ansys workbench and plotted result, which is natural frequencies and also modal description. Table 13 Bending Mode modal frequencies Materials Mode Natural Frequencies (Hz) Modal Description CP Steel 16 21.869 Bending Duralumin 16 22.109 Bending Combination of both 18 23.843 Bending 3.3.2 Steering Mode Analysis has been done for three different materials. These are analysed in Ansys workbench and plotted result, which is natural frequencies and also modal description. The results are tabulated in Table 14 . Table 14 Steering mode modal frequencies Materials Mode Natural Frequencies (Hz) Modal Description CP Steel 11 7.49115 Steering Duralumin 11 7.4918 Steering Combination of both 14 7.9942 Steering 3.3.2 Rolling Mode Analysis has been done for three different materials. These are analysed in Ansys workbench and plotted result, which are natural frequencies and also modal description. The results are tabulated in Table 15 . Table 15 Rolling mode modal frequencies Materials Mode Natural Frequencies (Hz) Modal Description CP Steel 11 7.4115 Rolling Duralumin 11 7.4918 Rolling Combination of both 11 7.9942 Rolling 3.4 Explicit Dynamic Analysis 3.4.1 Side crash analysis I conducted an explicit dynamic analysis using different materials at varying thicknesses of 2mm, 1.5mm, 1.2mm, 1.8mm, 1mm, and 0.8mm. The results of these analyses have been compiled into a comprehensive table. The total deformation values are tabulated in Table 16 for varying thickness Table 16 Total deformation for side crash analysis Deformation (mm) CP Steel Duralumin Combination of both 2mm 124.93 137.8366295 122.8562679 1.8mm 127.31 138.9759051 125.4886494 1.5mm 132.31 140.1870148 130.7853561 1.2mm 135.53 139.15 133.9845041 1mm 137.47 141.0099563 136.1400028 0.8mm 137.82 140.9546731 139.8573798 Maximum stress for side crash analysis is obtained through parametric study in Ansys software, where analysis is done on various thickness starting from 2mm to 0.8mm and the results are tabulated in Table 17 . Table 17 Maximum deformation for side crash analysis Max Stress (Mpa) CP Steel Duralumin Combination of both 2mm 4798.1 1783.6 4437.643431 1.8mm 4722.3 1757.1 4413.196683 1.5mm 4610.1 1742.5 4688.699731 1.2mm 4408.6 1632.3 4400.708374 1mm 4136.8 1537 4032.630629 0.8mm 3735.1 1323.2 3500.445659 3.4.2 Frontal crash analysis I performed a frontal explicit dynamic analysis using various materials at thicknesses of 2mm, 1.2mm and 0.8mm. The findings from these analyses have been organized into a detailed Table 18 . Table 18 Total deformation for frontal impact Total Deformation (mm) CP Steel Duralumin Combination of both 2mm 204.18 208.63 196.04 1.2mm 194.2 204.55 186.59 0.8mm 192.45 195.24 189.8 The maximum stress for CP Steel, Duralumin and Combination of both in static structural analysis under bending load conditions by varying thickness 2mm, 1.2mm and 0.8mm are listed in the Table 19 Table 19 Maximum Stress for frontal impact Maximum Stress (MPa) CP Steel Duralumin Combination of both 2mm 6603.3 2658.3 4953.5 1.2mm 6553.3 1733.5 3099.1 0.8mm 3305.1 1592.1 2800.5 4 CONCLUSIONS The Body in White (BIW) structure of the Bolero vehicle was analyzed under static structural, modal, and crashworthiness conditions, varying thicknesses from 2mm to 0.8mm. The static structural analysis showed that for CP Steel, deformation ranged from 0.897mm to 12.602mm with stresses from 22.71MPa to 141.36MPa. For Duralumin, deformation ranged from 2.388mm to 34.255mm with stresses from 22.55MPa to 142.25MPa. The combination of both materials showed deformations from 1.049mm to 14.150mm and stresses from 24.94MPa to 135.36MPa. Modal analysis identified bending, steering, and rolling modes with frequencies of 25.399 Hz, 29.39 Hz, and 8.32 Hz, respectively. In explicit analysis for crashworthiness, CP Steel showed deformations from 124.93mm to 137.82mm and stresses from 4798.1 MPa to 3735.1MPa for side impacts, while frontal impacts ranged from 204.18mm to 192.45mm with stresses from 6603.3MPa to 3305.1MPa. Duralumin exhibited deformations from 137.83mm to 140.95mm and stresses from 1783.6MPa to 1323.2MPa for side impacts, with frontal deformations from 208.63mm to 195.24mm and stresses from 2658.3MPa to 1592.1MPa. The combination material had deformations from 122.85mm to 139.85mm and stresses from 4437.1MPa to 3500.44MPa for side impacts, and from 196.04mm to 180.8mm with stresses from 4953.5MPa to 2800.5MPa for frontal impacts. The combination of CP Steel and Duralumin with a thickness of 1.2mm proved most effective in reducing deformation and stress in both side and frontal impacts. This configuration was found to be optimal for weight reduction, lowering the vehicle's weight from 189.51kg to 154.26kg, a reduction of 18.6%. Therefore, it is recommended to use Duralumin for reinforcement and CP Steel for other structural members at 1.2mm thickness to achieve a lighter and adequately strong vehicle structure. References Nikhade A (2014) Modal Analysis of Body in White. Int J Innovative Res Sci Eng, ISSN (Online), 2347–3207 Liu B, Zhan Z, Zhao X, Chen H, Lu B, Li Y, Li J (2014) A research on the body-in-white (BIW) weight reduction at the conceptual design phase. SAE Technical Paper , No. 2014-01-0743 Sahu AK, Londhe A, Kangde S, Shitole V (2015) Body in white mass reduction through Optimization. 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Int J Veh Des 67(3):219–236 Christensen J, Bastien C, Blundell M, Gittens A, Tomlin O (2011) Lightweight hybrid electrical vehicle structural topology optimization investigation focusing on crashworthiness. Int J Veh Struct Syst 3(2):113 Mahindra Bolero Single Cab Turbo (2006) / Double Cab Turbo - LHD Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-4832694","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":346277801,"identity":"d609a8e3-c093-4ac7-bf68-a2581d1f5568","order_by":0,"name":"Mohammed Sadiq Mohiuddin","email":"data:image/png;base64,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","orcid":"","institution":"Vasavi College of Engineering","correspondingAuthor":true,"prefix":"","firstName":"Mohammed","middleName":"Sadiq","lastName":"Mohiuddin","suffix":""},{"id":346277802,"identity":"4ca62bec-f0a0-4449-bbfb-37efb461ba19","order_by":1,"name":"Anjaneyulu Jalleda","email":"","orcid":"https://orcid.org/0000-0002-9238-4237","institution":"Vasavi College of Engineering","correspondingAuthor":false,"prefix":"","firstName":"Anjaneyulu","middleName":"","lastName":"Jalleda","suffix":""}],"badges":[],"createdAt":"2024-07-31 05:53:45","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-4832694/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-4832694/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":65440102,"identity":"3c24b95d-7077-4d96-a790-d2a28b7049c6","added_by":"auto","created_at":"2024-09-27 12:42:58","extension":"png","order_by":1,"title":"Figure 1","display":"","copyAsset":false,"role":"figure","size":38772,"visible":true,"origin":"","legend":"\u003cp\u003eDimension specification (height)\u003c/p\u003e","description":"","filename":"image1.png","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/ec4deda42804c5fc2a3f24f7.png"},{"id":65439253,"identity":"4d32661c-6e36-4d84-ab63-74fac7fc0556","added_by":"auto","created_at":"2024-09-27 12:34:58","extension":"png","order_by":2,"title":"Figure 2","display":"","copyAsset":false,"role":"figure","size":67887,"visible":true,"origin":"","legend":"\u003cp\u003eDimension specification (Lenght)\u003c/p\u003e","description":"","filename":"image2.png","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/9a188a71d731e935df5d6c21.png"},{"id":65440101,"identity":"bb601947-e679-4526-ab57-fbf5661be631","added_by":"auto","created_at":"2024-09-27 12:42:58","extension":"png","order_by":3,"title":"Figure 3","display":"","copyAsset":false,"role":"figure","size":165463,"visible":true,"origin":"","legend":"\u003cp\u003eDimension specification (width)\u003c/p\u003e","description":"","filename":"image3.png","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/40ca49adad83d878fdf6d3c3.png"},{"id":65440438,"identity":"e67eed7b-e71e-4896-8217-5e6607cac81a","added_by":"auto","created_at":"2024-09-27 12:50:58","extension":"png","order_by":4,"title":"Figure 4","display":"","copyAsset":false,"role":"figure","size":108095,"visible":true,"origin":"","legend":"\u003cp\u003eBending boundary condition\u003c/p\u003e","description":"","filename":"image5.png","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/22a1291f74f873c666bb7b87.png"},{"id":65440107,"identity":"48e85bf6-2047-4b8d-b67e-34077715fda8","added_by":"auto","created_at":"2024-09-27 12:42:58","extension":"png","order_by":5,"title":"Figure 5","display":"","copyAsset":false,"role":"figure","size":84202,"visible":true,"origin":"","legend":"\u003cp\u003eSteering boundary condition\u003c/p\u003e","description":"","filename":"image6.png","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/49a9697209edac7bc272059e.png"},{"id":65439261,"identity":"1d0e0c13-38ca-4bfd-9432-316cafdcc610","added_by":"auto","created_at":"2024-09-27 12:34:58","extension":"png","order_by":6,"title":"Figure 6","display":"","copyAsset":false,"role":"figure","size":97174,"visible":true,"origin":"","legend":"\u003cp\u003eRolling boundary condition\u003c/p\u003e","description":"","filename":"image7.png","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/b39b3d79fd1d2d775252d5cf.png"},{"id":65440105,"identity":"ce652fdb-dc50-4011-83b7-0ee1ddbb9d31","added_by":"auto","created_at":"2024-09-27 12:42:58","extension":"png","order_by":7,"title":"Figure 7","display":"","copyAsset":false,"role":"figure","size":72951,"visible":true,"origin":"","legend":"\u003cp\u003eBoundary condition for side crash 1\u003c/p\u003e","description":"","filename":"image8.png","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/8b7f422d5bb8c2de4b4734ac.png"},{"id":65439257,"identity":"5da50ede-aadb-4111-b3c7-62a73a52aae8","added_by":"auto","created_at":"2024-09-27 12:34:58","extension":"png","order_by":8,"title":"Figure 8","display":"","copyAsset":false,"role":"figure","size":96126,"visible":true,"origin":"","legend":"\u003cp\u003eBoundary condition for side crash 2\u003c/p\u003e","description":"","filename":"image9.png","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/ab16224e14fb12d80eedcfb8.png"},{"id":65440104,"identity":"d59ce65d-7158-4e5e-9f99-bd556c9e6540","added_by":"auto","created_at":"2024-09-27 12:42:58","extension":"png","order_by":9,"title":"Figure 9","display":"","copyAsset":false,"role":"figure","size":79779,"visible":true,"origin":"","legend":"\u003cp\u003eFrontal crash boundary condition 1\u003c/p\u003e","description":"","filename":"image10.png","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/1b14f301f595729c5040d5c2.png"},{"id":65440437,"identity":"54a63e1c-6039-473b-8d08-04c73d95b3c4","added_by":"auto","created_at":"2024-09-27 12:50:58","extension":"png","order_by":10,"title":"Figure 10","display":"","copyAsset":false,"role":"figure","size":104576,"visible":true,"origin":"","legend":"\u003cp\u003eFrontal crash boundary condition 2\u003c/p\u003e","description":"","filename":"image11.png","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/87414bdf1c617fff66f55d03.png"},{"id":65439255,"identity":"7589de06-5df7-472d-8757-cefda34e02bc","added_by":"auto","created_at":"2024-09-27 12:34:58","extension":"png","order_by":11,"title":"Figure 11","display":"","copyAsset":false,"role":"figure","size":22902,"visible":true,"origin":"","legend":"\u003cp\u003eUnnumbered image in the METHODOLOGY section.\u003c/p\u003e","description":"","filename":"image4.png","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/3589d45c848c0fdde2a761d3.png"},{"id":73091484,"identity":"6706dd4a-78ed-44c7-937b-5aefe718ad45","added_by":"auto","created_at":"2025-01-06 15:44:35","extension":"pdf","order_by":0,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1915949,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-4832694/v1/cac55a68-43eb-4924-a2e2-67d832c55b24.pdf"}],"financialInterests":"","formattedTitle":"Design and Optimisation of Body in White of a four-wheel vehicle","fulltext":[{"header":"1. INTRODUCTION","content":"\u003cp\u003e\"Body in White\" (BIW) is a key stage in car manufacturing where the vehicle's sheet metal components are assembled using welding, riveting, and adhesives before painting. This phase is crucial as it establishes the vehicle's structural integrity, safety, and quality. Mastering BIW can significantly enhance vehicle performance, manufacturing efficiency, and cost-effectiveness [\u003cspan citationid=\"CR1\" class=\"CitationRef\"\u003e1\u003c/span\u003e][\u003cspan citationid=\"CR2\" class=\"CitationRef\"\u003e2\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eTraditionally, BIW focused on creating a strong and rigid structure to handle driving stresses and protect passengers in a collision. Nowadays, there is a greater emphasis on reducing the weight of the BIW to improve fuel efficiency and lower emissions while maintaining safety and durability. This shift is driven by environmental regulations, high fuel costs, and consumer demand for efficient vehicles.\u003c/p\u003e \u003cp\u003eOptimizing BIW involves balancing material selection, design, manufacturing processes, and cost. Each factor critically influences the final BIW characteristics and overall vehicle performance. For example, choosing the right materials can affect the BIW's weight, strength, and cost, while its design impacts aerodynamics, crashworthiness, and manufacturability [\u003cspan citationid=\"CR3\" class=\"CitationRef\"\u003e3\u003c/span\u003e].\u003c/p\u003e \u003cp\u003eMaterial choice is vital for BIW optimization. Although steel has traditionally been used for its strength and affordability, new materials like high-strength steel, aluminum, magnesium, and composites offer benefits such as reduced weight and improved strength. These materials, however, introduce new manufacturing and cost challenges.\u003c/p\u003e \u003cp\u003eAdvanced computer-aided engineering (CAE) tools help in BIW design optimization by simulating and analyzing various design alternatives. These tools enable engineers to assess different design parameters, such as geometry, material properties, and joining methods, to find the best design that meets performance criteria while minimizing weight and cost. New manufacturing technologies like laser welding, adhesive bonding, and 3D printing also enhance precision and flexibility but require investment in new equipment and workforce training. Balancing these factors with cost considerations ensures that the BIW is efficient, sustainable, and cost-effective.\u003c/p\u003e"},{"header":"2. METHODOLOGY","content":"\u003cdiv id=\"Sec3\" class=\"Section2\"\u003e \u003ch2\u003e2.1 Modelling\u003c/h2\u003e \u003cp\u003eThe modelling project undertaken involves the BIW structure for a vehicle using CAD software, CATIA V5. \"Body in White\" refers to the stage in automotive manufacturing where a car's sheet metal components are welded together before adding moving parts, paint, trim, and other elements. The Mahindra Bolero, a popular SUV [\u003cspan citationid=\"CR4\" class=\"CitationRef\"\u003e4\u003c/span\u003e] known for its robust build and practicality, served as the primary reference for this model.\u003c/p\u003e \u003cp\u003eThe initial step in the project was to gather precise dimensions of the Bolero, including its length, width, and height. These dimensions are crucial as they form the foundational framework upon which the entire BIW structure is built. Incorporating the Bolero's overall dimensions into the CATIA V5 environment ensured that the model's proportions and scale were accurate.\u003c/p\u003e \u003cp\u003eBy accurately modelling the BIW structure using the specifications of the Mahindra Bolero, this project aims to achieve a balance between weight reduction and maintaining the necessary strength and stiffness. This balance is essential for ensuring the vehicle's safety and performance while also enhancing fuel efficiency and reducing emissions.\u003c/p\u003e \u003cp\u003eBelow are the specifications such as height, length, and width of the components, along with an isometric view in the CATIA V5 software interface, providing a comprehensive understanding of the model's design and scale.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003eIn CATIA V5, I started modelling the pillars. A, B, and C which are integral for maintaining the structural integrity of the vehicle. These pillars were placed at precise intervals, correlating with the specified dimensions and ensuring they provided adequate support and rigidity to the structure.\u003c/p\u003e \u003cp\u003eFollowing the pillars, I designed the roof structure. Given that the Bolero is known for its rugged design, it was essential to replicate the roof's sturdy characteristics. The roof beams and cross-members were designed to not only provide support but also to distribute the load effectively in case of a rollover, thereby enhancing the safety of the vehicle. Throughout the modelling process, I paid special attention to the joints and weld points. These are crucial in real-life manufacturing as they ensure the components are securely attached, providing overall rigidity and durability to the vehicle. In CATIA V5, I simulated these joints to ensure they would perform as expected under various stress conditions.\u003c/p\u003e \u003cp\u003eThe use of CATIA V5 allowed for precise control over the design process, enabling me to create a highly detailed and accurate representation of the BIW structure. This model serves as a crucial step in understanding and analysing the vehicle's design, providing insights that are essential for further development and optimization.\u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec4\" class=\"Section2\"\u003e \u003ch2\u003e2.2 MATERIAL SELECTION\u003c/h2\u003e \u003cp\u003eThe selection of materials for Body in White (BIW) is crucial for a vehicle's performance, safety, and efficiency. Historically, steel, particularly mild steel, dominated BIW due to its strength, durability, and low cost, providing essential structural support. However, as the demand for lighter, more fuel-efficient vehicles increased, the limitations of mild steel became evident. This shift has driven the automotive industry to explore modern materials such as high-strength steel, aluminum, magnesium, and composites, which offer better strength-to-weight ratios but also present new manufacturing and cost challenges.\u003c/p\u003e \u003cdiv id=\"Sec5\" class=\"Section3\"\u003e \u003ch2\u003e2.2.1 C P Steel\u003c/h2\u003e \u003cp\u003eComplex phase steels, similar to TRIP steels but with less retained austenite, feature fine precipitates and a high volume of hard phases within a fine microstructure of ferrite. These steels are precipitation-hardened using niobium, titanium, and/or vanadium, achieving very high strengths of 800 MPa and above. While not as formable as TRIP steels, they offer better weldability and lower costs due to reduced alloy content. This development marks a significant evolution in automotive steel, with most steels used in new vehicles today being unavailable a decade ago. The automotive and steel industries are rapidly advancing in steel manufacturing, with no signs of slowing down.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab1\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 1\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eMaterial properties of CP Steel\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"2\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e \u003cp\u003eProperty\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eValue\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003eDensity (kg^m3)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e7850\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003eYoung\u0026rsquo;s modulus (Pa)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e2.1E\u0026thinsp;+\u0026thinsp;11\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003ePoisons ratio\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e0.33\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003eTensile strength (MPa)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e800 .1200\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec6\" class=\"Section3\"\u003e \u003ch2\u003e2.2.2 Duralumin\u003c/h2\u003e \u003cp\u003eDuralumin is a notable aluminum alloy, first developed in the early 20th century by the German company D\u0026uuml;rener Metallwerke AG, that combines aluminum with copper, and sometimes magnesium and manganese, to create a lightweight yet strong material. Its introduction revolutionized aircraft construction by significantly reducing weight without sacrificing strength or durability. Known for its high tensile strength, corrosion resistance, and machinability, Duralumin was crucial in early aviation and remains widely used today in modern aircraft, automotive parts, and some sporting goods. Its impact on materials science and engineering underscores its ongoing relevance and influence across various industries.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab2\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 2\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eMaterial properties of Duralumin\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"2\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e \u003cp\u003eProperty\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eValue\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003eDensity (kg^m3)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e2800\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003eYoung\u0026rsquo;s modulus (Pa)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e7.6E\u0026thinsp;+\u0026thinsp;10\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003ePoisons ratio\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e0.33\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003eTensile strength (MPa)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e730\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003eCompressive strength (MPa)\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e460\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003c/div\u003e \u003cdiv id=\"Sec7\" class=\"Section2\"\u003e \u003ch2\u003e2.3 Regulatory Standards\u003c/h2\u003e \u003cdiv id=\"Sec8\" class=\"Section3\"\u003e \u003ch2\u003e2.3.1 Initial design\u003c/h2\u003e \u003cp\u003eIn body-in-white (BIW) design, vehicle dimensions are crucial for determining the overall structure and layout. The Mahindra Bolero, with its length of 3995 mm and width of 1745 mm, offers key reference points for designers. These dimensions provide ample interior space and allow for the integration of essential components like the powertrain and safety systems, while also ensuring stability and handling. By incorporating the Bolero\u0026rsquo;s specifications, BIW designers can address packaging challenges, integrate necessary parts, and maintain the vehicle's aesthetic and performance goals, making these dimensions a valuable guide in creating efficient and effective BIW designs.\u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec9\" class=\"Section3\"\u003e \u003ch2\u003e2.3.2 Crashworthiness standards\u003c/h2\u003e \u003cp\u003eThe Bharat New Car Assessment Program (Bharat NCAP) is set to significantly enhance automotive safety standards in India by compelling manufacturers to prioritize safety in their designs. This initiative involves rigorous testing of vehicles, providing consumers with clear safety ratings to make informed choices and driving automakers to invest in advanced safety technologies. The result will be improved vehicle safety, reduced road accidents, and a more competitive and innovative automotive industry.\u003c/p\u003e \u003cp\u003eAll cars undergo front. and side impact testing, which includes\u003c/p\u003e \u003cp\u003e \u003cul\u003e \u003cli\u003e \u003cp\u003e64kmph Front impact test\u003c/p\u003e \u003c/li\u003e \u003cli\u003e \u003cp\u003e50kmph Side impact test\u003c/p\u003e \u003c/li\u003e \u003cli\u003e \u003cp\u003e29kmph optional Pole impact test\u003c/p\u003e \u003c/li\u003e \u003cli\u003e \u003cp\u003e40kmph child and adult pedestrian impact tests.\u003c/p\u003e \u003c/li\u003e \u003c/ul\u003e \u003c/p\u003e \u003c/div\u003e \u003c/div\u003e \u003cdiv id=\"Sec10\" class=\"Section2\"\u003e \u003ch2\u003e2.4 FE Analysis\u003c/h2\u003e \u003cdiv id=\"Sec11\" class=\"Section3\"\u003e \u003ch2\u003e2.4.1 Parametric Study in Ansys\u003c/h2\u003e \u003cp\u003eA parametric study in ANSYS is a method used to explore how changes in design variables affect performance. Instead of creating and testing multiple models, this approach allows you to define a range of values for parameters like material types or dimensions and let ANSYS automatically run simulations for each variation. For example, in this project I have made thickness as a varying parameter and analysis has been done accordingly. This process provides valuable insights into design trends and relationships, helping to optimize the design efficiently while saving time and resources.\u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec12\" class=\"Section3\"\u003e \u003ch2\u003e2.4.2 Static structural Analysis\u003c/h2\u003e \u003cp\u003eIn static structural analysis, we focus on bending and torsional stiffness. Bending stiffness measures how well a structure resists deformation under load, crucial for ensuring components like beams and shafts don't bend excessively. Torsional stiffness evaluates a structure's resistance to twisting, important for elements such as drive shafts and frames where twisting loads are significant. By using tools like ANSYS to simulate these conditions, engineers can predict a structure's behaviour, identify potential weaknesses, and refine designs to enhance safety and reliability.\u003c/p\u003e \u003cp\u003e \u003cb\u003eBoundary condition for static structural\u003c/b\u003e \u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab3\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 3\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eboundary condition for static structural condition\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eFront End\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eRear End\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eLoads\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eBending (Pitching)\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e\u0026bull; Rotation about x is free\u003c/p\u003e \u003cp\u003e\u0026bull; Remaining DOF are constrained\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e\u0026bull; Rotation about x and translation about y is free.\u003c/p\u003e \u003cp\u003e\u0026bull; Remaining DOF are constrained.\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003e10kN\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eRotation about z (Steering)\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e\u0026bull; Rotation about z is free\u003c/p\u003e \u003cp\u003e\u0026bull; Remaining DOF are constrained\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e\u0026bull; Rotation about z and translation about x is free.\u003c/p\u003e \u003cp\u003e\u0026bull; Remaining DOF are constrained.\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003e2000Nm is applied in y direction\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eRotation about y (Rolling)\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e\u0026bull; Rotation about y is free\u003c/p\u003e \u003cp\u003e\u0026bull; Remaining DOF are constrained\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e\u0026bull; Rotation about y and translation about xis free.\u003c/p\u003e \u003cp\u003e\u0026bull; Remaining DOF are constrained.\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003e2000Nm is applied in z direction.\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec13\" class=\"Section3\"\u003e \u003ch2\u003e2.4.3 Explicit Dynamic Analysis\u003c/h2\u003e \u003cp\u003eIn this, the explicit dynamic analysis results are discussed mainly focussing on side crash and frontal crash analysis.\u003c/p\u003e \u003cdiv id=\"Sec14\" class=\"Section4\"\u003e \u003ch2\u003e2.4.3.1 Side Crash analysis\u003c/h2\u003e \u003cp\u003eI conducted an explicit dynamic crash analysis using ANSYS to simulate a collision, where a point mass traveling at 50 km/h impacts a stationary car over a brief 0.01-second interval. I set up the boundary conditions to reflect the impact velocity and monitored key indicators like equivalent stress, average stress, and total deformation throughout the simulation. This analysis helps assess the car's structural integrity and safety during a collision, providing valuable data for design improvements and enhancing vehicle safety.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab4\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 4\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eSide crash analysis setting\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"2\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"2\" nameend=\"c2\" namest=\"c1\"\u003e \u003cp\u003eDefinition\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003ePre.Stress Environment\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eNone Available\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003ePressure Initialization\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eFrom Deformed State\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eInput Type\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eVelocity\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eDefine By\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eComponents\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eCoordinate System\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eGlobal Coordinate System\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eX Component\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e13888.9 mm/s\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eY Component\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e0 mm/s\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eZ Component\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e0 mm/s\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec15\" class=\"Section4\"\u003e \u003ch2\u003e2.4.3.2 Frontal Crash analysis\u003c/h2\u003e \u003cp\u003eI performed an explicit dynamic analysis to simulate a frontal crash, where a car traveling at 65 km/h impacts a stationary vehicle over 0.01 seconds. In ANSYS, I set the boundary conditions with the stationary car's base fixed and applied the specified velocity to the moving car. During the simulation, I tracked key metrics like equivalent stress, average stress, and total deformation to assess the vehicle's structural integrity and safety. The results will help in refining the design and improving overall vehicle safety.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab5\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 5\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eFrontal crash analysis setting\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"2\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"2\" nameend=\"c2\" namest=\"c1\"\u003e \u003cp\u003eDefinition\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003ePre.Stress Environment\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eNone Available\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003ePressure Initialization\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eFrom Deformed State\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eInput Type\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eVelocity\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eDefine By\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eComponents\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eCoordinate System\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003eGlobal Coordinate System\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eX Component\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e0 mm/s\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eY Component\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e18055.6 mm/s\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eZ Component\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c2\"\u003e \u003cp\u003e0 mm/s\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003cp\u003e \u003c/p\u003e \u003c/div\u003e \u003c/div\u003e \u003c/div\u003e"},{"header":"3. RESULT AND DISCUSSIONS","content":"\u003cdiv id=\"Sec17\" class=\"Section2\"\u003e \u003ch2\u003e3.1 Variation of weight with change in thickness.\u003c/h2\u003e \u003cp\u003eI have applied varying thicknesses from 2mm to 0.8mm for CP Steel, Duralumin and combination of both to the Body-in-White (BIW) structure, leading to notable changes in weight. The adjustments in thickness have resulted in a clear variation in the overall weight of the structure, the variation of mass is tabulated in Table \u003cspan refid=\"Tab6\" class=\"InternalRef\"\u003e6\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab6\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 6\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eMass reduction as change in thickness\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eWeight in kg\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eCPSTEEL\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eDURALUMIN\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eCOMB OF BOTH\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e315.864\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e112.6648585\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e257.1005299\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e284.2776\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e101.3983727\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e231.3904769\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.5mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e236.898\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e84.49864388\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e192.8253974\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e189.5184\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e67.5989151\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e154.2603179\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e157.932\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e56.33242925\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e128.5502649\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e0.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e126.3456\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e45.0659434\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e102.8402119\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec18\" class=\"Section2\"\u003e \u003ch2\u003e3.2 Static structural analysis\u003c/h2\u003e \u003cdiv id=\"Sec19\" class=\"Section3\"\u003e \u003ch2\u003e3.2.1 Bending (Pitching)\u003c/h2\u003e \u003cp\u003eThe analysis of CP Steel, Duralumin, and a combination of both materials under bending load conditions was conducted using Ansys software. The study varied thicknesses from 2mm to 0.8mm, assessing total deformation, and maximum stress. The results, summarized in Table\u0026nbsp;\u003cspan refid=\"Tab7\" class=\"InternalRef\"\u003e7\u003c/span\u003e, reveal how each material deforms under the given conditions, providing a clear comparison across the different thicknesses.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab7\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 7\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eTotal deformation for bending\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eDeformation (mm)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eCP Steel\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eDuralumin\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eCombination of both\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e0.8775\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e2.388634171\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e1.049233348\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e1.185819\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e3.227001644\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e1.407095332\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.5mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e2.005707\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e5.455960493\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e2.348646613\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e3.839159\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e10.43943711\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e4.424161001\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e6.545312\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e17.79411534\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e7.450294072\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e0.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e12.60255\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e34.25507069\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e14.15051038\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003cp\u003eThe maximum stress for CP Steel, Duralumin and Combination of both in static structural analysis under bending load conditions by varying thickness from 2mm to 0.8mm are listed in the Table\u0026nbsp;\u003cspan refid=\"Tab8\" class=\"InternalRef\"\u003e8\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab8\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 8\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eMaximum stress for Bending\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eMax Stress (Mpa)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eCP Steel\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eDuralumin\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eCombination of both\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e22.70126\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e22.85937188\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e24.94743685\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e28.02854\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e28.22079869\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e30.39742833\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.5mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e40.33882\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e40.60889322\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e42.67111655\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e62.94133\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e63.35190375\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e64.39314061\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e90.54058\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e91.12081964\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e89.97158158\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e0.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e141.3649\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e142.256114\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e135.3640232\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec20\" class=\"Section3\"\u003e \u003ch2\u003e3.2.2 Steering (Rotation about z)\u003c/h2\u003e \u003cp\u003eAnalysis has been done for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about y axis load conditions by varying thickness. These are analysed through parametric study in Ansys software and plotted all result, which are Total deformation, Maximum stress and Average stress in a graphical representation as well as in tabular form.\u003c/p\u003e \u003cp\u003eThe total deformation for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about z axis load conditions by varying thickness from 2mm to 0.8mm are listed in the Table\u0026nbsp;\u003cspan refid=\"Tab9\" class=\"InternalRef\"\u003e9\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab9\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 9\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eTotal deformation for Rotation about z axis\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eROTATION ABOUT Z\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eDeformation (mm)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eCP Steel\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eDuralumin\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eCombination of both\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e20.07795\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e55.39735367\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e52.10037661\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e21.33344\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e58.85605692\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e55.64801785\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.5mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e24.49789\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e67.58789224\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e46.56010163\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e29.14195\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e80.4032136\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e55.2564273\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e33.59551\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e92.69643285\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e63.5911821\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e0.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e40.09192\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e110.6305623\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e75.71754466\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003cp\u003eThe maximum stress for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about z axis load conditions by varying thickness from 2mm to 0.8mm are listed in the Table\u0026nbsp;\u003cspan refid=\"Tab10\" class=\"InternalRef\"\u003e10\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab10\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 10\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eMaximum stress for Rotation about z axis\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eMax Stress (Mpa)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eCP Steel\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eDuralumin\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eCombination of both\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e130.4015\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e128.1626981\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e253.4962005\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e135.9969\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e133.6726651\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e275.6989505\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.5mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e157.1254\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e155.7858887\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e228.2523635\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e194.0688\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e192.4508286\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e268.1012484\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e227.7074\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e225.8216056\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e312.5809553\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e0.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e273.3145\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e271.0252927\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e370.7805166\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec21\" class=\"Section3\"\u003e \u003ch2\u003e3.2.3 Rolling (Rotation about y)\u003c/h2\u003e \u003cp\u003eAnalysis has been done for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about y axis load conditions by varying thickness. These are analysed through parametric study in Ansys software and plotted all result, which are Total deformation, Maximum stress and Average stress in a graphical representation as well as in tabular form.\u003c/p\u003e \u003cp\u003eThe total deformation for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about y axis load conditions by varying thickness from 2mm to 0.8mm are listed in the Table\u0026nbsp;\u003cspan refid=\"Tab11\" class=\"InternalRef\"\u003e11\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab11\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 11\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eMaximum deformation of rotation about y (Rolling)\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eROTATION ABOUT y (Rolling)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eDeformation (mm)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eCP Steel\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eDuralumin\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eCombination of both\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e11.77348\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e29.75209807\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e22.08315848\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e12.89021\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e32.31088027\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e23.32235212\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.5mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e15.1929\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e37.64866816\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e20.28585349\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e18.42821\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e46.99982189\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e24.06677257\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e21.38353\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e56.34652809\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e28.77808738\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e0.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e25.44515\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e69.76991037\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e35.6883689\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003cp\u003eThe maximum stress for CP Steel, Duralumin and Combination of both in static structural analysis under rotation about y axis load conditions by varying thickness from 2mm to 0.8mm are listed in the Table\u0026nbsp;\u003cspan refid=\"Tab12\" class=\"InternalRef\"\u003e12\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab12\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 12\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eMaximum stress of rotation about y axis\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eMax Stress (Mpa)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eCP Steel\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eDuralumin\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eCombination of both\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e274.6353\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e237.5129713\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e286.486481\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e297.6943\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e260.927732\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e298.1722309\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.5mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e343.2804\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e308.3221869\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e292.1252619\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e403.1502\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e374.0838345\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e362.2351629\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e453.0608\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e431.8912222\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e429.0661908\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e0.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e514.877\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e506.3631836\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e529.0803833\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003c/div\u003e \u003cdiv id=\"Sec22\" class=\"Section2\"\u003e \u003ch2\u003e3.3 Modal Analysis\u003c/h2\u003e \u003cp\u003eModal analysis is performed in Ansys workbench and natural frequencies are extracted for three types of modes. The extracted modes are tabulated for CP Steel, Duralumin and Combination of both.\u003c/p\u003e \u003cdiv id=\"Sec23\" class=\"Section3\"\u003e \u003ch2\u003e3.3.1 Bending Mode\u003c/h2\u003e \u003cp\u003eBending mode also known as pitching. The natural frequencies are tabulated in Table\u0026nbsp;\u003cspan refid=\"Tab13\" class=\"InternalRef\"\u003e13\u003c/span\u003e for three various materials. Analysis has been done for three different materials. These are analysed in Ansys workbench and plotted result, which is natural frequencies and also modal description.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab13\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 13\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eBending Mode modal frequencies\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e \u003cp\u003eMaterials\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eMode\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eNatural Frequencies (Hz)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eModal Description\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eCP Steel\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e16\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e21.869\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003eBending\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eDuralumin\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e16\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e22.109\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003eBending\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eCombination of both\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e18\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e23.843\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003eBending\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec24\" class=\"Section3\"\u003e \u003ch2\u003e3.3.2 Steering Mode\u003c/h2\u003e \u003cp\u003eAnalysis has been done for three different materials. These are analysed in Ansys workbench and plotted result, which is natural frequencies and also modal description. The results are tabulated in Table\u0026nbsp;\u003cspan refid=\"Tab14\" class=\"InternalRef\"\u003e14\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab14\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 14\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eSteering mode modal frequencies\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e \u003cp\u003eMaterials\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eMode\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eNatural Frequencies (Hz)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eModal Description\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eCP Steel\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e11\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e7.49115\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003eSteering\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eDuralumin\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e11\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e7.4918\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003eSteering\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eCombination of both\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e14\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e7.9942\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003eSteering\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec25\" class=\"Section3\"\u003e \u003ch2\u003e3.3.2 Rolling Mode\u003c/h2\u003e \u003cp\u003eAnalysis has been done for three different materials. These are analysed in Ansys workbench and plotted result, which are natural frequencies and also modal description. The results are tabulated in Table\u0026nbsp;\u003cspan refid=\"Tab15\" class=\"InternalRef\"\u003e15\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab15\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 15\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eRolling mode modal frequencies\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e \u003cp\u003eMaterials\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eMode\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eNatural Frequencies (Hz)\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eModal Description\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eCP Steel\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e11\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e7.4115\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003eRolling\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eDuralumin\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e11\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e7.4918\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003eRolling\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003eCombination of both\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e11\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e7.9942\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c4\"\u003e \u003cp\u003eRolling\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003c/div\u003e \u003cdiv id=\"Sec26\" class=\"Section2\"\u003e \u003ch2\u003e3.4 Explicit Dynamic Analysis\u003c/h2\u003e \u003cdiv id=\"Sec27\" class=\"Section3\"\u003e \u003ch2\u003e3.4.1 Side crash analysis\u003c/h2\u003e \u003cp\u003eI conducted an explicit dynamic analysis using different materials at varying thicknesses of 2mm, 1.5mm, 1.2mm, 1.8mm, 1mm, and 0.8mm. The results of these analyses have been compiled into a comprehensive table.\u003c/p\u003e \u003cp\u003eThe total deformation values are tabulated in Table \u003cspan refid=\"Tab16\" class=\"InternalRef\"\u003e16\u003c/span\u003e for varying thickness\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab16\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 16\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eTotal deformation for side crash analysis\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eDeformation (mm)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eCP Steel\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eDuralumin\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eCombination of both\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e124.93\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e137.8366295\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e122.8562679\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e127.31\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e138.9759051\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e125.4886494\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.5mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e132.31\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e140.1870148\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e130.7853561\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e135.53\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e139.15\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e133.9845041\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e137.47\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e141.0099563\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e136.1400028\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e0.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e137.82\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e140.9546731\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e139.8573798\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003cp\u003eMaximum stress for side crash analysis is obtained through parametric study in Ansys software, where analysis is done on various thickness starting from 2mm to 0.8mm and the results are tabulated in Table\u0026nbsp;\u003cspan refid=\"Tab17\" class=\"InternalRef\"\u003e17\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab17\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 17\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eMaximum deformation for side crash analysis\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eMax Stress (Mpa)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eCP Steel\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eDuralumin\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eCombination of both\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e4798.1\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e1783.6\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e4437.643431\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e4722.3\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e1757.1\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e4413.196683\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.5mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e4610.1\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e1742.5\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e4688.699731\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e4408.6\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e1632.3\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e4400.708374\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e4136.8\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e1537\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e4032.630629\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e0.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e3735.1\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"left\" colname=\"c3\"\u003e \u003cp\u003e1323.2\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e3500.445659\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003cdiv id=\"Sec28\" class=\"Section3\"\u003e \u003ch2\u003e3.4.2 Frontal crash analysis\u003c/h2\u003e \u003cp\u003eI performed a frontal explicit dynamic analysis using various materials at thicknesses of 2mm, 1.2mm and 0.8mm. The findings from these analyses have been organized into a detailed Table \u003cspan refid=\"Tab18\" class=\"InternalRef\"\u003e18\u003c/span\u003e.\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab18\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 18\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eTotal deformation for frontal impact\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eTotal Deformation (mm)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eCP Steel\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eDuralumin\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eCombination of both\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e204.18\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e208.63\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e196.04\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e194.2\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e204.55\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e186.59\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e0.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e192.45\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e195.24\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e189.8\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003cp\u003eThe maximum stress for CP Steel, Duralumin and Combination of both in static structural analysis under bending load conditions by varying thickness 2mm, 1.2mm and 0.8mm are listed in the Table\u0026nbsp;\u003cspan refid=\"Tab19\" class=\"InternalRef\"\u003e19\u003c/span\u003e\u003c/p\u003e \u003cp\u003e \u003cdiv class=\"gridtable\"\u003e\u003ctable float=\"Yes\" id=\"Tab19\" border=\"1\"\u003e \u003ccaption language=\"En\"\u003e \u003cdiv class=\"CaptionNumber\"\u003eTable 19\u003c/div\u003e \u003cdiv class=\"CaptionContent\"\u003e \u003cp\u003eMaximum Stress for frontal impact\u003c/p\u003e \u003c/div\u003e \u003c/caption\u003e \u003ccolgroup cols=\"4\"\u003e \u003cdiv align=\"left\" class=\"colspec\" colname=\"c1\" colnum=\"1\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c2\" colnum=\"2\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c3\" colnum=\"3\"\u003e\u003c/div\u003e \u003cdiv align=\"char\" char=\".\" class=\"colspec\" colname=\"c4\" colnum=\"4\"\u003e\u003c/div\u003e \u003cthead\u003e \u003ctr\u003e \u003cth align=\"left\" colspan=\"4\" nameend=\"c4\" namest=\"c1\"\u003e \u003cp\u003eMaximum Stress (MPa)\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003ctr\u003e \u003cth align=\"left\" colname=\"c1\"\u003e\u0026nbsp;\u003c/th\u003e \u003cth align=\"left\" colname=\"c2\"\u003e \u003cp\u003eCP Steel\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c3\"\u003e \u003cp\u003eDuralumin\u003c/p\u003e \u003c/th\u003e \u003cth align=\"left\" colname=\"c4\"\u003e \u003cp\u003eCombination of both\u003c/p\u003e \u003c/th\u003e \u003c/tr\u003e \u003c/thead\u003e \u003ctbody\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e6603.3\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e2658.3\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e4953.5\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e1.2mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e6553.3\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e1733.5\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e3099.1\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003ctr\u003e \u003ctd align=\"left\" colname=\"c1\"\u003e \u003cp\u003e\u003cb\u003e0.8mm\u003c/b\u003e\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c2\"\u003e \u003cp\u003e3305.1\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c3\"\u003e \u003cp\u003e1592.1\u003c/p\u003e \u003c/td\u003e \u003ctd align=\"char\" char=\".\" colname=\"c4\"\u003e \u003cp\u003e2800.5\u003c/p\u003e \u003c/td\u003e \u003c/tr\u003e \u003c/tbody\u003e \u003c/colgroup\u003e \u003c/table\u003e\u003c/div\u003e \u003c/p\u003e \u003c/div\u003e \u003c/div\u003e"},{"header":"4 CONCLUSIONS","content":"\u003cp\u003eThe Body in White (BIW) structure of the Bolero vehicle was analyzed under static structural, modal, and crashworthiness conditions, varying thicknesses from 2mm to 0.8mm. The static structural analysis showed that for CP Steel, deformation ranged from 0.897mm to 12.602mm with stresses from 22.71MPa to 141.36MPa. For Duralumin, deformation ranged from 2.388mm to 34.255mm with stresses from 22.55MPa to 142.25MPa. The combination of both materials showed deformations from 1.049mm to 14.150mm and stresses from 24.94MPa to 135.36MPa. Modal analysis identified bending, steering, and rolling modes with frequencies of 25.399 Hz, 29.39 Hz, and 8.32 Hz, respectively. In explicit analysis for crashworthiness, CP Steel showed deformations from 124.93mm to 137.82mm and stresses from 4798.1 MPa to 3735.1MPa for side impacts, while frontal impacts ranged from 204.18mm to 192.45mm with stresses from 6603.3MPa to 3305.1MPa. Duralumin exhibited deformations from 137.83mm to 140.95mm and stresses from 1783.6MPa to 1323.2MPa for side impacts, with frontal deformations from 208.63mm to 195.24mm and stresses from 2658.3MPa to 1592.1MPa. The combination material had deformations from 122.85mm to 139.85mm and stresses from 4437.1MPa to 3500.44MPa for side impacts, and from 196.04mm to 180.8mm with stresses from 4953.5MPa to 2800.5MPa for frontal impacts.\u003c/p\u003e \u003cp\u003eThe combination of CP Steel and Duralumin with a thickness of 1.2mm proved most effective in reducing deformation and stress in both side and frontal impacts. This configuration was found to be optimal for weight reduction, lowering the vehicle's weight from 189.51kg to 154.26kg, a reduction of 18.6%. Therefore, it is recommended to use Duralumin for reinforcement and CP Steel for other structural members at 1.2mm thickness to achieve a lighter and adequately strong vehicle structure.\u003c/p\u003e"},{"header":"References","content":"\u003col\u003e\u003cli\u003e\u003cspan\u003eNikhade A (2014) Modal Analysis of Body in White. Int J Innovative Res Sci Eng, ISSN (Online), 2347\u0026ndash;3207\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eLiu B, Zhan Z, Zhao X, Chen H, Lu B, Li Y, Li J (2014) A research on the body-in-white (BIW) weight reduction at the conceptual design phase. \u003cem\u003eSAE Technical Paper\u003c/em\u003e, No. 2014-01-0743\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eSahu AK, Londhe A, Kangde S, Shitole V (2015) Body in white mass reduction through Optimization. \u003cem\u003eSAE Technical Paper\u003c/em\u003e, No. 2015-01-1352\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eLee MS (2020) A study on collision characteristic of center-pillar with CR420 and hot stamped steel during side crash simulation. Int J Crashworthiness 27(2):554\u0026ndash;564\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eLesch C, Kwiaton N, Klose FB (2017) Advanced high strength steels (AHSS) for automotive applications\u0026thinsp;\u0026ndash;\u0026thinsp;tailored properties by smart microstructural adjustments. Steel Res Int 88(10):1700210\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eBabalu Kumar SS, Gupta R, Kumar AK, Om Prakash (2021) Verma, \u0026amp;. Crash Evaluation of a Composite Car Body using Ansys Workbench 16.2. \u003cem\u003eInternational Journal of Creative Research Thoughts (IJCRT)\u003c/em\u003e, 9(8), August 2021, ISSN: 2320\u0026ndash;2882\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eOuissi T, Collaveri G, Sciau P, Olivier JM, Brunet M (2019) Comparison of aluminum alloys from aircraft of four nations involved in the WWII conflict using multiscale analyses and archival study. Heritage 2(4):2784\u0026ndash;2801\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eVishnu S, Avinash D, Patil G, Suhas P, Bhattacharyya I (2018) Body in White Weight Optimization Using Equivalent Static Loads. \u003cem\u003eSAE Technical Paper\u003c/em\u003e, No. 2018-01-0482\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eHorvath CD (2021) Advanced steels for lightweight automotive structures. In \u003cem\u003eMaterials, Design and Manufacturing for Lightweight Vehicles\u003c/em\u003e, Woodhead Publishing, pp. 39\u0026ndash;95\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eKiani M, Gandikota I, Rais-Rohani M, Motoyama K (2014) Design of lightweight magnesium car body structure under crash and vibration constraints. J Magnesium Alloys 2(2):99\u0026ndash;108\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003ePatil S, Wani R, Umale S (2022) Explicit Dynamics Crash Analysis of Car for Different Materials using Ansys. 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Int J Veh Des 67(3):219\u0026ndash;236\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eChristensen J, Bastien C, Blundell M, Gittens A, Tomlin O (2011) Lightweight hybrid electrical vehicle structural topology optimization investigation focusing on crashworthiness. Int J Veh Struct Syst 3(2):113\u003c/span\u003e\u003c/li\u003e \u003cli\u003e\u003cspan\u003eMahindra Bolero Single Cab Turbo (2006) / Double Cab Turbo - LHD\u003c/span\u003e\u003c/li\u003e\u003c/ol\u003e"}],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":true,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":false,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":false,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"BIW, FE Analysis, Crash Simulation, CATIA V5, Ansys Workbench, Weight Optimization","lastPublishedDoi":"10.21203/rs.3.rs-4832694/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-4832694/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThe Body in White (BIW) is a critical component in automobile design, providing essential structural integrity to withstand various loads and stresses during vehicle operation. This paper presents the simulation and analysis of a BIW chassis for a Bolero vehicle using finite element (FE) analysis to evaluate its performance under different loading and boundary conditions. The study focuses on structural and crash analysis to ensure high-quality vehicles that offer adequate protection to passengers during accidents.\u003c/p\u003e \u003cp\u003eA geometrical model of the BIW chassis was designed using CATIA V5 software, and simulations were conducted using Ansys Workbench. Modal analysis was performed to observe natural frequencies and mode shapes, while the deformation and stress induced during side and frontal impacts were analyzed. The materials considered for the BIW structure included CP Steel, Duralumin, and a combination of both. A parametric study on weight optimization was conducted, determining the thickness of structural members based on allowable stress and deformation to ensure structural integrity and performance.\u003c/p\u003e \u003cp\u003eThe results showed an 18.6% reduction in vehicle weight using a combination of Duralumin (dominating in reinforcement parts) and CP Steel (in other areas). The combined material structure demonstrated less deformation in static structure, side crash, and frontal impact scenarios compared to using either material individually at 1.2mm thickness. Additionally, stress levels were observed to be comparatively lower.\u003c/p\u003e","manuscriptTitle":"Design and Optimisation of Body in White of a four-wheel vehicle","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2024-09-27 12:34:53","doi":"10.21203/rs.3.rs-4832694/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"67cfdae2-5b97-4afc-88cb-04583ff25698","owner":[],"postedDate":"September 27th, 2024","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-01-06T15:36:27+00:00","versionOfRecord":[],"versionCreatedAt":"2024-09-27 12:34:53","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-4832694","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-4832694","identity":"rs-4832694","version":["v1"]},"buildId":"qtupq5eGEP_6zYnWcrvyt","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}