Adjustment of Design Limited Imperfections for Transportation Vehicles

The realization of light weight-construction without loss of passive safety in transportation vehicles is a big challenge for the next years. Considering the requirements on an automobile from consumer view a modern car should combine a high quality of comfort and standard with low operating expenses and a high safety standard. The use of lightweight design enables reductions in fuel consumption and CO2 emissions which are leading to a decrease of operating costs. The increase in passive safety is mainly characterized by an increase in strength and weight due to a concerted material selection an enhancement of sheet metal thickness and additional compensating elements e.g. patches. Especially for limited imperfections like cataphoretic drain holes or accesses for joining operations the strength adjustment without additional compensating elements and increasing weight possesses very much potential. The presented research investigate the possibility to reinforce local imperfections considering the material TRIP780 by combining different approaches on light-weight design. The reinforcements are realized by additional forming elements and enhance the moment of inertia. Different investigations were carried out to assess the placement and arrangement of the reinforcements in the deep drawing parts