SuperLIGHT-CAR - die Multi-Material-Karosserie

Over the last years, total vehicle weights have risen significantly. With their direct influence on the power demand of vehicles, the reduction of weight is one among other measures in order to decrease the fuel consumption and CO2 emissions. The European project SuperLIGHT-CAR is aiming at a weight reduction for the body in white of a compact class passenger car, following the multi-material approach. By this, the perfect material is chosen for every component of the body structure, based on criteria such as energy absorption, structural integrity, stiffness etc. A comparison between the com- ponent requirements and the material capabilities, the selection is made and the development of the multi-material-body begins. In order to assess the concept and to show further potential for improvement, simulation is required. LS-Dyna is used in this project to a large extent as it offers excellent opportunities for both static and dynamic loadcases that are regarded. The model is therefore built-up from different include files which offer the capability to quickly change between loadcases and concept versions. In addition, a multi- disciplinary optimisation based on LS-Opt reveals further potential for weight reduction. The main goal of the project, a weight reduction of 30 % for the body-in-white, is overachieved while the structural performance of the reference vehicle is maintained or even improved. The fact, that only one-model had to be used for all simulations, decreased the required time for a full analysis run and hence accelerated the development process.