Abstract: A method of conducting fatigue analysis of a plurality of spot welds of a vehicle that may include selecting a target fatigue life for the plurality of spot welds, testing each of the spot welds using a mesh independent linear computer aided engineering (CAE) model, determining a number of the spot welds that did not reach the target fatigue life, and testing the number of spot welds that did not reach the target fatigue life using a mesh dependent linear CAE model.

Abstract: A cargo box (10) reinforcement system (20) includes an upper front panel reinforcement (22) securable to a cargo box front panel (18) and side wall panels (14, 16). The system (20) including a pair of side reinforcements (24, 26). Each side reinforcement (24, 26) is securable to one side of the pair of side panels (14, 16) of the cargo box (10). Each side reinforcement (24, 26) is secured with an end (40) of the upper front panel reinforcement (22). Also, the system (20) includes a pair of gussets (28, 30). Each gusset (28, 30) is coupled with the upper front panel reinforcement (22) and one of the pair of side reinforcements (24, 26).

Abstract: A vehicle cross member has a beam with an overall U-shape cross-section. A pair of legs are connected, via rounded portions, with a web. A series of aperture is formed on the legs along a longitudinal axis of the beam. A flange is formed at a free end of the legs. The flange enables securement of the beam with a vehicle. The legs are angled with respect to one another so that the web has a width less than a width of the beam at the flange. The web has an arcuate portion along the longitudinal axis of the beam aligned with the series of apertures in the legs.

Abstract: A cargo box (10) reinforcement system (20) includes an upper front panel reinforcement (22) securable to a cargo box front panel (18) and side wall panels (14, 16). The system (20) including a pair of side reinforcements (24, 26). Each side reinforcement (24, 26) is securable to one side of the pair of side panels (14, 16) of the cargo box (10). Each side reinforcement (24, 26) is secured with an end (40) of the upper front panel reinforcement (22). Also, the system (20) includes a pair of gussets (28, 30). Each gusset (28, 30) is coupled with the upper front panel reinforcement (22) and one of the pair of side reinforcements (24, 26).

Abstract: A vehicle cross member has a beam with an overall U-shape cross-section. A pair of legs are connected, via rounded portions, with a web. A series of aperture is formed on the legs along a longitudinal axis of the beam. A flange is formed at a free end of the legs. The flange enables securement of the beam with a vehicle. The legs are angled with respect to one another so that the web has a width less than a width of the beam at the flange. The web has an arcuate portion along the longitudinal axis of the beam aligned with the series of apertures in the legs.