Light trucks, SUVs and passenger vehicles face increasing requirements for improved rigidity, increased strength with the constraints of reducing mass, the cost of manufacturing and increasing production flexibility. The ULSAB (UltraLight Steel AutoBody) project has demonstrated optimized vehicle design and manufacturing methodologies for passenger vehicle frames. This has moved forward with the ULSAB-AVC (Advanced Vehicle Concepts) to encompass closures, suspensions, engine cradle and all structural and safety relevant components.
The introduction of hydroformed rails for Light Truck and SUV frames has moved this manufacturing segment forward with providing increased structural performance. The challenge is still present to reduce the cost of manufacturing such frames while improving the flexibility of the manufacturer to meet product design changes.
A new design approach for passenger truck and SUV frames could possibly help manufacturers realize the strength gains of hydroformed assemblies through more efficient utilization of laser welded steel assemblages. Orthotropic frame design, using the laser welding process could provide the next generation of Light Truck and SUV frames. As a manufacturing solution, this would represent an alternative to the use of hydroformed rails by optimizing the integration and utilization of steel for the frame. An orthotropic frame would reduce the cost of manufacturing such frames and improve the manufacturer’s ability to bring new product designs swiftly to market.