5 Reasons Why Your Business Needs Cross Car Beam Assembly？

Nothing new about that, you would say. Magnesium alloys used in die casting applications have density is about two-three of aluminium and a fifth of steel. Magnesium has many applications : as a lightweighting metal in various industries such as the automotive industry, a alloying agent to improve the mechanical properties and corrosion resistance of aluminium alloys, an additive in the steel industry desulfurization process. It features high castability allowing thin-wall casting. It is not a rare element and can be found in seawater, brine, and minerals, mainly dolomite, magnesite, and brucite. And yet, its production is concentrated in China which accounts for more than 70% of the world production. The publications you can read about Magnesium relates to purity improvement, production cost reduction but also greenhouse gas emission and its environment impact.

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Let's take a practical example with the Cross-Car Beam ("CCB"). This assembly holds the dashboard, the steering column, various pieces of equipment such as the infotainment screen, HVAC, instrument cluster, glove box, airbags... and if structural, helps prevent crash intrusion. Die cast CCB are a one-part component instead multiple welded parts. Consequences are significant : high complexity and cost, but also the integration of multiple functions to reduce the amount of the parts, better tolerance control and vibration absorption. Magnesium CCB are typically found on premium brands such as BMW, Jaguar, Mercedes, Alfa Romeo and other high-end products.

A quick look at the data aggregated from the A2Mac1 database and you will notice the great diversity of weights whereas the length of the beam is bounded by the vehicle width, all segments included. The chart conveys two ideas : opportunities for CCB weight reduction exist; Mg-alloy based CCBs tend to be lighter than other materials (aluminium, steel, steel and plastic).

Do you notice anything special ? Four red dots stand out in the lower right corner of the chart, under 4kg and mm long. They turned out to be Chinese vehicles, including a modest Roewe i6 (starting price is 89.800¥ that is €), Roewe ei5 (BEV starting at 128.800¥ or €) and two premium cars, the BYD Han and the NIO ES8. Below the same chart only with cars having a Mg alloy CCB.

Whereas the NIO ES8 features a half-cross car beam and an interesting interior packaging we already addressed ad nauseam, the three other cars use a dual CCB made die-cast AM60B alloy on the driver and a conventional tubular steel assembly on the passenger side. Here is how the BYD Han CCB look like.

How about lightweight design, then ? Indeed, the CCB total weight of the BYD Han is 6.8kg which is slightly below the average of our 900 undiscriminated vehicle selection above. From a lightweighting perspective : low-key "check". How about the benefits of using Magnesium, then ? Safety : "check" as the half-cross car beam of the NIO ES8 led to excellent side-crash test results on China NCAP. NVH merits : a possible "check" on the driver side. Cost-wise : my colleagues in Munich could assess it but I assume only the dominance of the Chinese local Mg alloy production could make this solution cost-effective. It seems as though the NIO or Roewe solution might have inspired BYD, but equipment that makes up the BYD identity such as the central rotating infotainment screen required mounting brackets only an actual beam could hold.

What is the conclusion of this story ? My colleagues and I are working on the Discovery Report & Highlights of the BYD Han and we bumped into such an intriguing design. I once heard that Benchmarking is about discovering crazy ideas that came to smart engineers. I think this might be one of them.

To know more about A2Mac1 and our Benchmarking offering such as Vehicle Discovery Reports, feel free to contact me at .

Opinions are mine and do not express the views of my employer.

 AIM:  To simulate a non-linear transient dynamic problem of a Bird Strike with a Jet Engine Blade and evaluate the results. OBJECTIVES: 1. The given file contains all the 4 parts which as to separate and save part wise. 2. The suitable material is to be created and saved in a subfolder. 3. The…

AIM: To demonstrate spherical, revolute, cylindrical, and translational joints between two rigid bodies and two deformable bodies.  OBJECTIVE: 1. Demonstrate the different types of joints like Spherical, Revolute, Cylindrical & Translational joints. 2. For all the joints simulate with rigid & elastic…

Aim: 1) To calculate the Mooney Rivlin and Ogden material constants and compare both using stress-strain data from a Dogbone specimen tensile test with 100 percent strain. 2) The given material data is the engineering stress-strain in MPa/(mm/mm). 3) The comparison should be shown from the d3hsp file and using simulation.…

AIM : 1) Using the diagram of the true stress-strain curve given for graphite iron casting, creating a material model for the Dogbone specimen.  2) Validating the material model by performing a tensile test on a Dogbone specimen. OBJECTIVE :          By Using the diagram of the true stress-strain curve given for graphite…

 AIM:  To perform the simulation in order to reduce the run time with the help of mass scaling in LS-Dyna.  OBJECTIVE: 1) To learn about the mass scaling Technique to reduce the computational time for the analysis. 2) The limit for the mass scaling is restricted to 8% and simulation has to be completely…

Aim: To perform the Head Impact Simulation and calculate the Head Impact Criterion (HIC) value for the following cases. Objective: To perform head impact analysis and calculate the HIC (Head injury criteria/coefficient) value for the following cases: Case1: Simple head model and rigid wall Case2: Child head-foam and rigid…

Aim:   To perform the simulation using ELFORM = 1, 2, -1, -2 and calculate the stretch ratio.  OBJECTIVE: 1) To Create a block of 10mmx10mmx10mm dimension with 10 elements for each direction and use the material card attached (Ogden_Material.k). 2) Use appropriate boundary conditions to simulate…

AIM :      To create a complete simulation file using Input Parameters from this to perform a Crash Box Simulation using Spotweld Beam & Solid element and Plot the Output results. OBJECTIVE :      --> Input Parameters required for the simulation are listed below,  …

AIM :      To create a complete simulation file using Input Parameters from this to perform a Crash Box Simulation and Plot the Output results. OBJECTIVE :      --> Input Parameters required for the simulation are listed below,                          - Title Card,                          - Section,                  …

AIM :      To create a complete simulation file using Input Parameters from this to perform a drop test and Plot the Output results. OBJECTIVE :      --> Input Parameters required for the simulation are listed below,                          - Title Card,                          - Section,                          - Material…

AIM :      To Solve using both Explicit and Implicit methods using the F(u) = u3+9u2+4u equation. THEORY : Explicit Method :         However, if the nonlinear force versus displacement relationship is not known, but the stiffness is known, it is possible to construct the graph of…

AIM :       To Check for the geometrical errors, take mid-surface and 2D mesh & Volume mesh(tetra mesh) with the given element Quality Criteria for the given Component and perform suitable connections. OBJECTIVE :        For the given assembly, check for the geometrical errors and…

AIM :      To Check for the geometrical errors, take mid-surface and mesh with the given element Quality Criteria for the given Component. OBJECTIVE :      For the given component, check for the geometrical errors and mesh with the given element Quality criteria. After meshing the component…

AIM :       To Check for the geometrical errors, take mid-surface and mesh with the given element Quality Criteria for the given Component and perform suitable connections. OBJECTIVE :        For the given CCB CAD model, Check for the Geometry cleanup (if required), Take the mid…

AIM :     To Perform Morphing for given models and Increase the height of the Dog houses and Ribs. THEORY : Morphing :       Morphing is a special effect in motion pictures and animations that changes (or morphs) one image or shapes into another through a seamless transition.…

 AIM :      For the given Rear door FE model, Create and Apply different PIDs for different components and Perform suitable connections. OBJECTIVE :      By using ANSA Software, Create and apply different PIDs for different components and to perform suitable connections. PROCEDURE : Importing…

AIM :    In the Rearview Mirror model check for the geometrical errors and mesh with volume tetra elements as per the given quality criteria and there should not kinks and dips on the surface of the component. OBJECTIVE :    For the given component, check for the geometrical errors and mesh with…

AIM :   To Check for the geometrical errors and mesh with the given element Quality Criteria for the given Component and to write a detailed report about the mid-surface and meshing Process. PROCEDURE :  IMPORTING CAD MODEL AND GEOMETRY CLEANUP :          1. Import the given Hood Model…

AIM :   To Extract a Mid-Surface and Mesh Component with given Quality Criteria values and assign thickness for the FE Model. OBJECTIVE :   Follow the Quality Criteria and mesh the following component and assign thickness: Target Element Length = 4mm S.N Quality Criteria  Value  1 Aspect Ratio …

AIM :    Create a Mid-Surface and Meshing the Component with given Quality Criteria values.  OBJECTIVE :   Follow the Quality Criteria and mesh the following component and assign thickness: Target Element Length = 5mm S.N Quality Criteria  Value  1 Aspect Ratio  5 2 Skewness 45 3…

AIM :      Mesh the given Component with a Mesh size of 5mm and Create a connector and Attach the various parts of the given model. OBJECTIVE :      Create connector and Attach the various parts of the given model  1. Right_Rail_2 & Front_truss_1:- Seam-Quad(angled+capped+L)…

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AIM :      Create 3D Meshing for the given component as per given Element sizes and Tet collapse values. OBJECTIVE :       1. Create Tetramesh for Housing model with 5mm element size.       2. For the given models, Create a 3D tetra mesh with a 6mm element size. PROCEDURE…

AIM :     Create a Mid-Surface and Meshing the Component with given Quality Criteria values. OBJECTIVE :       Follow the below-mentioned quality criteria, mesh the component given below and assign thickness: Target Element Length = 5mm S.N Quality Criteria  Value  1 Aspect Ratio …

AIM :      To Create 1D elements on the following component with given cross-section and DOF. OBJECTIVE :     a. Rod element:- with only translational DOF and RBE2 link           Cross-Section: BOX- Dimension a= 12 mm            …

AIM :      To test the vehicle crashworthiness by conducting a Roof Crush test as per Standard requirements and evaluate the results by using Radioss in Hypermesh. OBJECTIVE :       - Import the model and transform the impactor into the required position.       - Create…

AIM :      To test the vehicle crashworthiness by conducting a Side pole impact test as per Standard requirements and evaluate the results by using Radioss in Hypermesh. OBJECTIVE : Check unit system and either follow [Mg mm s] or [Kg mm ms]. Create an appropriate interface, friction 0.2, and recommended…

AIM :     To test the vehicle crashworthiness by conducting a frontal crash test into a rigid barrier as per Standard requirements and evaluate the results by using Radioss in Hypermesh. OBJECTIVE :    Check unit system and either follow[Mg mm s] or [Kg mm ms]. Create an appropriate interface,…

AIM :      To create mesh for bumper Assembly and to run the crash tube model as per following conditions and Plot Rigid Wall Force, Contact Forces, Internal Energy and to create TH/PART for all parts and compare results for all cases.   OBJECTIVE : Sudy-1 : Bumper Assembly      1. Creating…

AIM :      To run the simulation for 7 Cases by changing Law1, Law2, Law27, Law36 and Modifying Failure Card, Material Properties and Compare results for all cases. OBJECTIVE :       Compare 7 cases as discussed in last 3 slides, in a tabulated format on the basis of:    …

AIM :     Comparison of results with base simulation(Case-1) and improved shell element properties(Case-2) by using crash beam file as per given run time,animation steps,Shell element properties to recomended properties conditions and running the simulation. Finally check the energy error and mass error and plot…

AIM :      1. To find Speed of sound in steel rail, Time for sound to travel length of rail and to change time frequency to get 20 animation steps.      2. To create 3D Meshing tetra mesh and Hex mesh for the given model as per conditions.   OBJECTIVE :         …

AIM :     To carry out the geometry cleanup operation on the given 3 files.             - Practice             - Clip Repair             - Mounting Bracket    There should not be any free  edges, convert…

AIM :    To parse the Thermodynamic data file and then Calculate the Specific Heat (Cp), Enthalpy(H),Entropy(S) and also calculate the Molecular Weight of each species. OBJECTIVE :   1. To write a program to extracts the 14 co-efficients and calculates the enthalpy, entropy and specific heats for…

AIM :   To Check for the geometrical errors and mesh with the given element Quality Criteria for the given Component and to write detailed report about mid-surface and meshing Process. PROCEDURE :  IMPORTING CAD MODEL AND GEOMETRY CLEANUP :          1. Import the given Hood Model in ANSA…

AIM :    1. To list out the total weight of various types of Aircrafts.    2. To make difference between Ground Speed and Air Speed.    3. To explain Why is it not recommended to use aircraft engine power to move it on the ground at Airport.    4. To explain about how an aircraft…

AIM :    1. To Calculate the energy required for Braking, for a defined drive cycle.    2. To explain that Why electric motor can’t develop braking torque at high speed similar to starting and to explain how electric and mechanical brakes are coordinated.     3. To Make a MATLAB…

AIM :     1. To explain about efficiency of Power Electronics and also types of losses occur in Power Electronic circuits.    2. To generate a duty cycle control signal for simple power converter circuit by using suitable MATLAB model.    3. To make a comparision of square wave inverter…

AIM :     1. To discuss about Equivalent circuit network of Induction motor MATLAB model.     2. To Calculate the ratio of starting torque at half voltage & frequency to rated values by using given Parameters.     3. To Make a MATLAB script file which will plot speed torque characteristics…

AIM :  1. To explain about how Induction motor Operation is similar to clutch.  2. Calculate the starting time of a drive with the following parameters:  3. Obtain the equillibrium points and determine the stability for a drive.    EXPLANATION : STUDY -1 : Induction Motor Operation :  …

AIM :    1. By Modifying "Speed Control of a DC motor BJT H-bridge model" in Run MATLAB demo, such that armature current doesn’t shoot up when motor changes direction from forward to reverse.     2. Four-Quadrant Chopper DC drive (DC7) block is to be compared with H-bridge model.    3.…

AIM :    1. Types of Power Converter Circuits employed in Electric and Hybrid Electric Vehicle.    2. By using the given input parameters for electic vehicle to calculate the Steady state speed if duty cycle is 70%.    3. Brief Explanation about Induction versus DC Brushless motor by Wally…

AIM :    To Prepare a Technical report for BAJA All Terrain Vehicle ATV Model Without Using Look Up Table and Using Look Up Table. OBJECTIVE :     Carry out the System level Simulation of an BAJA All terrain vehicle and prepare the technical report explaining the model properties of Without Using…

AIM :     1. To make a simulink model of Doorbell using solenoid block.    2. To Use a thermistor to sense the temperature of a heater & turn on or turn off the fan as per below conditions.        Given Inputs: Temperature source: 20 °C from 0 to 10 seconds,…

AIM :    1. To Determine the work done as the tool moves through a distance of 100 mm.        2. To Create a Simulink model to implement equation z=3x2-5y+18  Store result values using To File block.       3. To Open the 'Mass-Spring-Damper in Simulink and…

AIM : 1. To Implement control logic of a “washing machine” using Stateflow as per given sequence. 2. Make a Simulink chart for the “Gear shift” logic as per given conditions. OBJECTIVE :     1. In Simulink, Implement the Control Logic of a Washing Machine using State Flow as per given…

AIM :    To Write a code to Calculate the Global Maxima of a stalagmite function using Genetic Algorithm.   OBJECTIVE :    In MATLAB, Using Equation of Stalagmite Function and  Genetic Algorithm Syntax to calculate the Global Maxima.   GENETIC ALGORITHM :    A genetic algorithm is…

AIM :    To Create a program to fit a linear and cubic polynomial for the cp data and plot the linear and cubic fit curves along with the raw data points.   OBJECTIVE :      Creating a Curve Fitting Program for linear polynomial and cubic polynomial  between Temperature vs Specific heat…

AIM :      To simulate the transient behaviour of a simple pendulum and to create an animation of it's motion.   OBJECTIVE :     Solving a Ordinary Second Order ORDINARY Differential Equation (ODE) and applying that ODE in a MATLAB to Simulate Simple Pendulum and creating a animation movie.…

AIM :     To create a PV Diagram for Otto Cycle and also to find out the Thermal Efficiency of the engine.   OBJECTIVE :    By using MATLAB to create a Program for Otto cycle and make plot for it to generate a PV Diagram and also to find the Thermal Efficiency of the engine.   THEORY…

AIM :      To Simulate Forward Kinematics of a 2R Robotic Arm using MATLAB. OBJECTIVE :       By using MATLAB to Create a Program  and Simulate the Forward Kinematics of a 2R Robotic Arm.   THEORY :       Kinemat ics - is the study of object in motion, there Velocity,…