Abstract: A method of producing a vehicle includes determining the performance of aged adhesive coupons, which are subject to a worst-case scenario of manufacturing, aging, and stress testing. Virtual vehicle components are modeled using the performance of the aged adhesive coupons. The virtual vehicle components are then subjected to virtual mechanical forces to determine their virtual performance, which is then validated against the performance of identical real-life aged vehicle components subjected to identical mechanical forces. A virtual vehicle is modeled using the validated virtual vehicle components. The virtual performance of the virtual vehicle when subject to a virtual crash test is then compared against a predetermined standard, and the design of the virtual vehicle is considered feasible if its performance exceeds the predetermined standard. A vehicle is manufactured according to the feasible design of the virtual vehicle.

Abstract: A method of producing a vehicle includes determining the performance of aged adhesive coupons, which are subject to a worst-case scenario of manufacturing, aging, and stress testing. Virtual vehicle components are modeled using the performance of the aged adhesive coupons. The virtual vehicle components are then subjected to virtual mechanical forces to determine their virtual performance, which is then validated against the performance of identical real-life aged vehicle components subjected to identical mechanical forces. A virtual vehicle is modeled using the validated virtual vehicle components. The virtual performance of the virtual vehicle when subject to a virtual crash test is then compared against a predetermined standard, and the design of the virtual vehicle is considered feasible if its performance exceeds the predetermined standard. A vehicle is manufactured according to the feasible design of the virtual vehicle.

Abstract: Crashworthiness designing of a structure using a Hybrid Cellular Automata (HCA) algorithm where field states are computed using finite element analysis (FEA) and the material distribution of the structure is updated at each iteration using cellular automata method. The HCA algorithm optimizes the topology of the structures to achieve certain performance within the limits of various constraints applied to ensure crashworthiness of the structures. The HCA algorithm may also be applied to designing of structures to be fabricated by an extrusion method having the same cross section along the direction of extrusion or stamped structures having thickness varying across the structure.

Abstract: A vehicle body structure includes a floor connected to a main frame assembly. The main frame assembly includes first and second side rails and interconnecting cross-members. A front frame structure located near a forward part of the vehicle body structure is connected to the main frame assembly. The front frame structure includes first and second diagonal members and a laterally extending member. Each of the first and second diagonal members includes a forward end portion connected to the main frame assembly and a rearward end portion connected to the lateral member. The rearward end portions converge toward one another and the lateral member is connected to the first and second side rails. The front frame structure transfers an impact load caused by a narrow offset frontal collision from the first side rail to the second side rail by transferring the load through the front frame structure.

Abstract: A vehicle body structure includes a floor connected to a main frame assembly. The main frame assembly includes first and second side rails and interconnecting cross-members. A front frame structure located near a forward part of the vehicle body structure is connected to the main frame assembly. The front frame structure includes first and second diagonal members and a laterally extending member. Each of the first and second diagonal members includes a forward end portion connected to the main frame assembly and a rearward end portion connected to the lateral member. The rearward end portions converge toward one another and the lateral member is connected to the first and second side rails. The front frame structure transfers an impact load caused by a narrow offset frontal collision from the first side rail to the second side rail by transferring the load through the front frame structure.

Abstract: A vehicle frame structure includes a longitudinal floor frame member and a frame stiffener connected with the floor frame member. The floor frame member connects with a vehicle floor panel to form a substantially closed cross section. The floor frame member includes a lower wall including a lower section, a higher section, and a transition section disposed between the lower section and the higher section. The lower wall transitions upward along the transition section from the lower section to the higher section. The frame stiffener connects with the floor frame member on an exterior of the floor frame member. The frame stiffener has a substantially U-shaped configuration in cross section and includes a bottom wall that is vertically offset below the lower wall of the floor frame member at least along a portion of the transition section.

Abstract: A vehicle frame assembly includes a first frame member and a separate second frame member having an end portion connected to an end portion of the first frame member. A frame patch is interposed between and connected to the respective end portions of the first and second frame members. The frame patch together with the respective end portions of the first and second frame members defines a tri-layer patch configured to divide an input load applied longitudinally to the vehicle frame assembly into multiple force vectors which distribute the input load across a wide area of the vehicle frame assembly.

Abstract: Crashworthiness designing of a structure using a Hybrid Cellular Automata (HCA) algorithm where field states are computed using finite element analysis (FEA) and the material distribution of the structure is updated at each iteration using cellular automata method. The HCA algorithm optimizes the topology of the structures to achieve certain performance within the limits of various constraints applied to ensure crashworthiness of the structures. The HCA algorithm may also be applied to designing of structures to be fabricated by an extrusion method having the same cross section along the direction of extrusion or stamped structures having thickness varying across the structure.