Design and Optimization of Body in White of a Four-Wheel Vehicle

The Body in White (BIW) is an important component in an automobile, which should have structural integrity to bear various loads and stresses during the working of vehicle operation. This paper demonstrates a BIW chassis analysis of a Bolero vehicle using the Finite Element (FE) method to evaluate its performance under various loading and boundary conditions. The study focuses on structural and crashworthiness to ensure sufficient protection for passengers in vehicles during accidents.<br /> A geometrical model of the BIW chassis was developed using CATIA software, and analyses were carried out using Ansys Workbench. The deformations and stresses developed during side and frontal impacts were analysed. The materials considered for the BIW structure are CP Steel, Duralumin, and a combination of both. A parametric study on weight optimization was conducted by varying the thickness of the structural members according to allowable stresses and deformations to ensure structural integrity and performance.<br /> The results for the vehicle weight reduction are presented by using a combination of Duralumin (dominating in reinforcement parts) and CP Steel (in remaining areas). The combined material structure is analysed for deformation and stress levels in static structural, side crash, and frontal impact scenarios, and the results are compared with both materials individually. The combination of Duralumin for reinforcement and CP Steel for other structural members is analyzed, as well as the optimal thickness for the required design criteria.