Optimization of the Production Process of an A-Pillar using a Differential Thickness Profile Approach via FEA

Energy efficiency of car body structures includes, in addition to the obvious aspect of fuel consumption, an ultra-high level of passenger safety. However, with traditional manufacturing processes, an acceptable level of passenger safety results in an increased car body weight. The realization of ultra-high strength properties and, at the same time, improved structural weight could be achieved through different tailoring routes such as: Tailor-Rolling, Tailor-Welding, and differential thermomechanical processes. In this technological context, an FE model is developed for the improvement of tailored-rolled technology through which an optimization of state of the art thickness can be realized by using different high-strength materials in the proposed FE model of an existing A-Pillar geometry.