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A desktop study, carried out in collaboration with a European Vehicle manufacturer, was undertaken to assess the feasibility of developing a hydroformed B Pillar. An existing vehicle structure having class leading side impact performance characteristics was used for this study. The goal of the project was, without modification to the existing structure, to demonstrate equivalent or superior side impact performance at reduced mass and assess manufacturing and economic feasibility.By using a conical Tubular Blank, advanced CAE and a design process driven by Hyfo’s innovative Knowledge Based Engineering tools a fully integrated solution was delivered, achieving improved performance and a significant reduction in mass. Manufacturing feasibility was classed as satisfactory for a design constrained by the existing body structure. Minor modifications to the structure (generally less than 5mm surface displacements on no-critical surfaces) were identified to increase manufacturing robustness. Economically, this solution yields an on-cost, although the cost per kilo saved was well inside generally agreed acceptable limits. | ||||||
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