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Lightweight Electric Hybrid Vehicle Design Episode 12

Tham khảo tài liệu 'lightweight electric hybrid vehicle design episode 12', kỹ thuật - công nghệ, cơ khí - chế tạo máy phục vụ nhu cầu học tập, nghiên cứu và làm việc hiệu quả | Lightweight construction materials and techniques 193 While it was decided to stay with more traditional concepts known manufacturing and design technology was taken to its limits by combining the unibody structure with hydroforming and maximum use of structural adhesives as well as laser welding tailor-welded steel blanks and roll forming. The process was computer interactive all along optimizing sections improving joints and using different steel qualities and material thicknesses at appropriate points in the design to create the optimum structure. A number of parts that would traditionally be created by sheet metal stampings were replaced by one-piece hydroformed tubes. This required tight control during design of section perimeters and transitions and some unique joint designs. To attach other body-in-white components to the tube requires a one-sided attachment method and in this case laser welding was chosen. The view at c shows the hydroformed side roof rail. Particular attention was also paid to the connection from the A- B- and C- pillars and to the integration of the rear shock towers into the rear rail in order to provide optimal load transfer into the structure d . a b c d e g g - enlarged Fig 7.12 ULSAB steel weight-reduction project a body shell b monoside panel c hydroformed side roof rail d principal application areas for bonding e integration of rear shock absorber tower f running the lower cowl through the A-pillar g integration of front shock absorber tower. 194 Lightweight Electric Hybrid Vehicle Design To improve the rigidity of the ULSAB the body side inner assembly is weld bonded to the body side outer assembly. Combined use of welds and high temperature adhesive provides continuous bonding. The view at e shows the two principal application areas for bonding. For structural efficiency reasons a non-traditional approach to the cowl to the A-pillarjoint was taken by running the lower cowl section through the A-pillar inner and outer creating a .