Year: 2017 Volume: 1 Issue: 3 Page: 137-143
A NEW HYBRID REAR CRASH BEAM DEVELOPMENT PHASE FOR LIGHTENING OF BODY STRUCTURE WEIGHT INSTEAD OF CONVENTIONAL STEEL SOLUTIONS
LEVENT AKSEL, SEMRA AKBULUT, HÜSEYİN YILDIZ, OSMAN SAKLI, SERKAN A. ALTINEL
Lightening studies of the vehicles are becoming more and more important with the increase of performance and comfort level requirements. But it is not so easy to adapt the light solutions on the vehicles when thinking material conformity of the parts to each other. So the material selection and definition of the correct material on related body structure is the key parameter for a lightweight vehicle design. The designers are struggling for lightening the total vehicle weight by using alternative materials like aluminum, magnesium, advanced plastics or steels. On this direction a new hybrid rear crash beam is designed by using advanced plastic and steel materials. In this hybrid solution are being used very different design parameters like honeycomb plastic crash box design, like double layered crushing system (softer plastic box + steel travers + rigid plastic box) and also production methods like, plastic injection, steel stamping, welding, riveting etc. All design and production methods have to show a very good harmony during crushing verification of the structure. Gradual energy absorbing, acceleration of the crash beam in to the vehicle structure, interference values into the rear panel and rails are being measured to check this harmony which means that good energy absorbing and protection of the vehicle structure, combustion system etc. Rear rails water infiltration and rear tow hitch performances are controlled for conforming of the rear beam. At the end of the study hybrid rear rail part is confirmed with all aspect and used on serial production with 3.94 kg total weight and gained circa 1.5 kg vs steel rear beam.
Anahtar Kelimeler (Keywords): Hybrid Rear Crash Beam, Lightweight Vehicle, Vehicle Rear Crash, Honeycomb design, Tow Hitch