Simplified modelling of joints and beam-like structures for BIW optimization in a concept phase of the vehicle design process

The paper proposes an engineering approach for the replacement of beam-like structures and joints in a vehicle model. The final goal is to provide the designer with an effective methodology for creating a concept model of such automotive components, so that an NVH optimization of the body in white (BIW) can be performed at the earliest phases of the vehicle design process. The proposed replacement methodology is based on the reduced beam and joint modelling approach, which involves a geometric analysis of beam-member cross-sections and a static analysis of joints. The first analysis aims at identifying the beam center nodes and computing the equivalent beam properties. The second analysis produces a simplified model of a joint that connects three or more beam-members through a static reduction of the detailed joint FE model.In order to validate the proposed approach, an industrial case-study is presented, where beams and joints of the upper region of a vehicle's BIW are replaced by simplified models. Two static load-cases are defined to compare the original and the simplified model by evaluating the stiffness of the full vehicle under torsion and bending in accordance with the standards used by automotive original equipment manufacturer (OEM) companies. A dynamic comparison between the two models, based on global frequencies and modal shapes of the full vehicle, is presented as well.