Future vehicles could see reduction in front end parts
As OEMs face increasing pressure to streamline vehicle design, particularly for battery electric vehicle (BEV) platforms, the feasibility of parts consolidation at scale is no longer a question.
A new study from WorldAutoSteel, conducted in collaboration with automotive technology development firm Ricardo, aims to provide a practical answer to this industry challenge. Using a virtual front body structure based on the Steel E-Motive vehicle concept, the study shows how greater use of Advanced high-strength steels (AHSS) combined with modest assembly line changes, can deliver measurable reductions in part count, weight and manufacturing investment.
The study found that front body structure part count can be reduced by up to 34 per cent. Starting from a baseline of 38 components, the redesigned structure achieved a reduction of 13 parts, bringing the total down to 25.
This was achieved by consolidating multiple individual components into larger single hot and cold stamped parts, often incorporating more complex geometry. The consolidation approach simplifies tooling and assembly fixtures while retaining manufacturability.
In addition to reducing part count, the study identified an eight per cent weight saving and a 10 per cent reduction in piece cost for the front body structure.
WorldAutoSteel said these savings were realised through the use of advanced high-strength steels that offer high strength and formability, supporting the production of larger, more integrated components without loss of structural performance.
Structural performance was maintained in the consolidated design. The study found no differences anticipated in terms of ease of repair compared with the original architecture.
High strength and formability were achieved using hot stamped press hardened steel. The study also indicated that further improvements in cost and weight could be achieved through the incorporation of tailor welded blanks into consolidated parts.
According to WorldAutoSteel, a $21 million reduction in total manufacturing investment costs could be achieved for the front body structure through simplified tooling and assembly fixtures.
If a similar consolidation approach were applied across the complete body-in-white and closures, WorldAutoSteel said the total reduction in manufacturing investment could be in the region of $112 million, when considering buildings, assembly equipment and tooling costs.
Ingo Olschewski, director, WorldAutoSteel, said the study demonstrates “the potential of AHSS to address key challenges facing next-generation vehicle architectures”.
He highlighted steel as a “sustainable, safe and scalable structural material” that supports parts consolidation, assembly line efficiency and cost efficiency as well as high-performance engineering solutions.