Design Optimization of the Cowl Cross Bar - Light Cowl Cross Bar Satisfying 5 Performances -
- 29 Downloads
Nowadays, more lightweight designs is the key goal of all major automotive industries. One of the main sections for more lightweight automotive area is the Cowl cross bar (CCB) assemblies. A cowl cross bar supports a steering system, airbag module, audio, instrument panel and air conditioning system. The CCB integrates these components into the cockpit module and connects to the body. So the CCB must meet the 5 performance requirements, ① NVH requirement to minimize the vibration, ② Crash performance for less deflection, ③ Steering response requirement for steer predictability, ④ Durability performance like the fatigue life and ⑤ Supporting rigidity for the components. In this study, a new methodology for the optimum CCB design is proposed to obtain a more lightweight design considering 5 targeted requirements. At first, for NVH and Steering response performance, 3-steps of optimization was fulfilled in sequence of (1) Size optimization and mounting position, (2) Case studies about the various types of brackets and (3) Shape optimization using the topology. The proposed design and optimization framework was verified whether it could meet the crash, durability and stiffness requirements. The final optimal CCB would be applied to the new platforms of the Hyundai-Kia motors.
Key wordsCowl cross bar Cross car beam NVH Crash Durability Steering response Topology
Unable to display preview. Download preview PDF.
- Danniel, W. (2003). High efficiency energy absorber for knee impact. SAE Paper No. 2003-01-1170.Google Scholar
- Mehran, E. and Kamran, B. (2015). A novel approach for design and optimization of automotive aluminum crosscar beam assemblies. SAE Paper No. 2015-01-1370.Google Scholar
- Patrick, B. (2001). Pyrotechnic knee bolster development and its contribution to car drivers safety. SAE Paper No. 2001-01-1049.Google Scholar
- Srikanth, K., Kumar, B. K., Vikram, N. and Ravi, T. (2003). Occupant knee impact simulations: A parametric study. SAE Paper No. 2003-01-1168.Google Scholar
- Venkat, N. and Thomas, G. (1999). Material characterization and FEA correlation for engineering theromoplastics under high strain loading. SAE Paper No. 1999-01-3175.Google Scholar