Automakers are pursuing a variety of vehicle lightweighting strategies in their efforts to meet the challenging new footprint-based fuel economy standards for 2025. Chassis and suspension systems need to answer to these lightweighting activities taking into account the technical and cost requirements. This study demonstrates the mass reduction potential of current and next generation steel grades for a mid-size multi-link rear chassis module. Extensive benchmarking data were used to develop a generic baseline design for the module that represents current state-of-the-art in terms of steel grades and gauges used. Comprehensive performance criteria for the rear chassis module were established by performing kinematic and compliance testing of five popular North American mid-size vehicles. Finite element analysis (FEA) was used for gauge and grade optimization of the design using advanced high strength steel (AHSS) grades available today as well as next generation steel grades. Using currently available AHSS grades, a new steel solution with equivalent system performance was achieved at a weight savings of 20% with no cost penalty. An additional 9% weight savings potential was realized when next generation steel grades were considered.
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