To demonstrate the use of the SSS method on

a real vehicle body

To ensure the structure has satisfactory load-
path continuity path continuity
To determine load in beams, panels, and
subassemblies
The SSS method is most effectively applied
during the conceptual state, and also used to
help resolve issues on existing structure.
The base existing platform will need to be The base existing platform will need to be
idealized.
The baseline load paths for both bending and
torsion load cases are determined.
Structure of medium size saloon car
(Courtesy of General Motors)
SSS model of structure (right-hand half
only shown)
The side-frame (1)
The front suspension tower (2)
The engine rail-Z shape (3)
The dash (4)
The cowl (5)
The windscreen frame (6)
The centre floor (7)
The centre longitudinal beam (8) The centre longitudinal beam (8)
The floor cross-beams (9), (10)
The rear floor (11)
The rear longitudinal (12)
The rear cross-beam (13)
The angled beam (14)
The rear panel (15)
The boot top (16)
The backlight frame (17)
The roof (18)
A total of 18 SSSs for only half model
Typical load distribution for a medium size passenger car Typical load distribution for a medium size passenger car Typical load distribution for a medium size passenger car Typical load distribution for a medium size passenger car
Using the factor 10
simplifies the arithmetic
(9.81 m/s
2
)
SF and BM diagram SF and BM diagram Slope and Deflection Slope and Deflection
SSS model-bending loads
(right-hand only shown for clarity)
Point load (single load) Point load (single load) Point load (single load) Point load (single load)
- Suspension reactions (F/SUSP, R/SUS)
- bumpers (F/Bumper, R/Bumper)
Distributed load Distributed load Distributed load Distributed load
-Power train (Power-train)
-Passengers (F/Pass, R/Pass) at Z, T, G
-Fuel tank (F/Tank)
-Exhaust (Exhaust)
Center of gravity: x = Mx / Mass
= 3,682,981/ 1,706.75
= 2157.9 mm
Moment equilibrium
Rear axle load = 825.7 kg
Front axle load = 881 kg
Front suspension tower
Has high shear loads
Good shear connection must be made to the
engine rail & the upper fender rail engine rail & the upper fender rail
Bending loads are not significant
The tower is not very wide but very deep
Front Bulkhead
Bending moment on the dash panel is a hogging
moment
It is not a severe condition as the dash panel is very It is not a severe condition as the dash panel is very
deep
Side shear force is significant
May indicate the need of stiffeners (swaging)
Rear seat cross-beam
Bending moment on the dash panel is a sagging
moment
It is significant as the rear seat cross-beam is not It is significant as the rear seat cross-beam is not
deep
Side shear force is significant
Good shear connections are required to the rockers
Applying equal and opposite wheel loads
Pure torsion moment
Assuming , the track is 1.45 m
The Applied load at node O
Front suspension towers and engine rails Front suspension towers and engine rails Front suspension towers and engine rails Front suspension towers and engine rails
The main torsion box The main torsion box The main torsion box The main torsion box
Torsion case edge loads Torsion case edge loads Torsion case edge loads Torsion case edge loads
q = Q / L
High forces and moments occur at the rear
suspension mounting point (node O)
The SF and BM are different and higher than
for the bending case for the bending case

The loading on engine rail shows much

higher SF and BM than bending case
On the main torsion box, it shows the
importance of maintaining a continuous shear importance of maintaining a continuous shear
path.
The windscreen and backlight frames must
have adequate section stiffness and good
corner joints. (max bending)
Require a good shear connection between the
inner wing and dash panel.
Require a stiffening member between the top
of the suspension tower and the cowl. of the suspension tower and the cowl.
The cowl carries a significant BM including
the SF transferred between the dash panel
and the windshield frame.
At the real panel acts as beam is not require
to carry shear between the floor and boot top
frame.
Similarly, the boot top frame does not Similarly, the boot top frame does not
required carry shear between the rear panel
and the backlight frame.
The alternative model has shear flow values
higher than in the original model because of
the reduced area main torsion box.