A long-term initiative at the Clemson University International Center for Automotive Research (CU-ICAR) is advancing the automotive engineering graduate research and education program. Called "Deep Orange," this framework immerses students in automotive engineering master’s and doctoral degree programs in the world of a future OEM (Original Equipment Manufacturer) and supplier. As part of the 3rd Deep Orange vehicle project, it was decided to engineer, build, and showcase the load bearing structure of the Body-in-White (BiW) based on a novel technology of sheet metal folding developed by Industrial Origami. The approach chosen eliminates metal stamping and high capital investments such as dies and molding presses. The engineering of the BiW involved defining design relevant load cases (such as frontal/side/rear impact and static/dynamic stiffness properties), developing a topology to transfer the loads throughout the BiW, creating design space for occupants, chassis and powertrain components and conduct functional analyses of the BiW in terms of stiffness. This presentation details how Altair HyperMesh, RADIOSS, and HyperView were used for many aspects of this project.

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Application of a Novel Metal
Folding Technology for Automotive
BiW Design
Prathamesh Marathe
June 5, 2012 CUICAR | Deep Orange 3 1

2. 3
CU-ICAR (Clemson University International Center for Automotive Research)
• Advanced-technology research campus in collaboration with academia, industry and
government organizations
• The first and only US Automotive Engineering program so far; Master & PhD program
• State-of-the-art equipment & facilities
• Technology neighborhood
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3. 3
What is Deep Orange
• Vehicle prototype program at CU-ICAR that immerses graduate automotive
engineering students into the world of a future OEM and/or supplier
• Helps students to gain hands on experience
– Students are involved from inception to completion in all phases
– Students get to interact with cross functional faculty members
• Students learn about state of the art technologies and how to integrate these
Deep Orange 1 car Deep Orange 3 Spring – Summer ’12 team
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4. 3
Deep Orange: A New Teaching Paradigm
Product/Production Architectures
Market Analyses System Design
Start: Day 1 Day 193
Annual new Prototype Vehicle releases
from two-year Development Cycles
Target Validation Concept
Graduation Selection
An integral feature of our
MS/PhD Research & Education Program
Validation System Integration
Manufacturing/Assembly Day 523
June 5, 2012
End: Day 712 CUICAR | Deep Orange 3 4

5. 3
The Importance of Industry Participation
• Provide realistic problem statements and challenges that address current
and future (industry) issues.
• Give access to new innovations, materials, technologies and processes.
• Mentor students during regularly scheduled meetings.
• Provide crucial background information on subject matter often not
accessible in an academic setting.
• Fund the overall program.
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6. 3
The Deep Orange 3 Project
• Joint Sponsorship of
– Mazda North American Operations (MNAO)
– Clemson University-International Center for Automotive Research (CU-
ICAR)
– Arts Center College of Design (ACCD)
• Designed to give large scale view of the automobile design and engineering
process
– Marketing Data
– Design and Engineering
– Validation and Testing
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7. 3
IOI Technology
• Conventional Technology: Stamping of sheets
• Drawbacks
– High tooling cost
– Complicated process
Source: http://www.industrialorigami.com/solutions/transportation.cfm
• New Technology: Folding of sheets into simple shapes
• Advantages
– Low cost tooling
– Unskilled labor force can be easily trained (Less complicated)
– Lesser time requirement
– Lower Number of parts
– Accurate laser cut holes for mounting components and riveting
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8. 3
Application of IOI Technology
• Topology of vehicle
• Packaging of other assemblies
• Chassis
• Powertrain
• Occupants
• Analysis of structure for torsion and bending stiffness
• Analysis of structure for dynamic loading
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9. 3
Application of IOI Technology
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Components of BiW
Floor And
Spaceframe
Front Crash Rear Crash
Structure Structure
June 5, 2012 CUICAR | Deep Orange 3 10

11. 3
FEA of IOI Structure
• Use of Hypermesh to generate mesh
– Sheet metal parts and Space frame pipes as 2D shell mesh
– Thicker geometries as 3D tetra mesh
3D Tetra Mesh in
2D Shell Mesh in Floor Assembly Spaceframe Assembly
June 5, 2012 CUICAR | Deep Orange 3 11

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FEA of IOI Structure
• Adhesives used to connect different sheets
• Spot weld connectors used to connect space frame to IOI structure
• Boundary conditions and loads
– For Torsional Stiffness of the BiW
• Loads applied at front strut towers
• Constraints at front and rear with beams to simulate real life situations
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13. 3
FEA of IOI Structure (Contour Plots)
• Use of Hyperview to do post processing of analysis results
– Displacements
– Induced stresses
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14. 3
FEA of IOI Structure (Twist Angle Vs Vehicle Length)
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15. 3
Future Steps
• Carryout Dynamic Loading of the structure
• Test the fold ability of the sheets
• Realize the BiW structure form sheets and spaceframe.
June 5, 2012 CUICAR | Deep Orange 3 15

16. 3
Acknowledgements
• Thanks to Dr Paul Venhovens for support and supervision
• Thanks to DO-3 team for timely help
• Thanks to Altair and Dr David Schmueser for this opportunity to present the
work at this conference
June 5, 2012 CUICAR | Deep Orange 3 16

17. 3
Thank You
June 5, 2012 CUICAR | Deep Orange 3 17