Salt Lake City, Utah
June 23, 2018
June 23, 2018
July 27, 2018
College Industry Partnerships
The Deep Orange initiative is an integral component of the graduate program in the Department of Automotive Engineering at Clemson University. The ultimate goal of Deep Orange is to place automotive engineering knowledge into context to tackle complex vehicle development problems through collaboration among students and colleagues whose perspectives are shaped by radically different experiences. During the 2-year MS program, students, faculty, and participating industry partners develop and manufacture a vehicle prototype providing the students with experience in marketing, design, engineering, systems integration, prototyping, and validation. For the third edition of Deep Orange, the goal was to develop a blank sheet, fully functional, hybrid mainstream sports car concept targeted towards Generation Y with Mazda North American Operations as the primary sponsor and the Art Center College of Design as the styling partner.
The objective of this paper is to present a case study for the development of the unique Deep Orange 3 body-in-white (BIW) prototype vehicle structure. The size and proportions of the BIW concept were developed based on the requirements derived from a marketing study based on 70,000 surveys completed by owners of new cars and light trucks in the United States. Based on the findings of the marketing study, a sports car concept was derived for a 6-seat interior configuration and a body architecture packaging a dual-mode hybrid all-wheel drive powertrain. In addition to developing an efficient body structural lay-out, an additional objective of the program was to develop and showcase a BIW concept that would eliminate metal stamping and the associated high investment costs associated with this technology (such as stamping tools and dies). It was chosen to investigate and apply Industrial Origami’s patented technology that incorporates light-gauge metal folded into complex, high load-bearing structure, formed with simple, low-cost fixtures at the location of BIW assembly.
Developing the geometry, topology, and functionality of the BIW based on these design and manufacturing requirements required intensive collaboration among design students and chassis, vibration, powertrain, and packaging engineering students, while at the same time integrating functional properties, weight, cost, and design space. The BIW engineering discussed in this paper focused on defining relevant load cases (such as static/dynamic stiffness properties), developing a structural configuration to efficiently transfer BIW loads, creating occupant accommodation space, packaging of powertrain and chassis components, and conducting computational analyses to assess BIW stiffness and strength. Once the structural performance targets were met, the final sheet metal folded design was realized using aluminum in combination with adhesives and rivets. In addition to describing the conceptual structural analysis, the paper elaborates on the team collaboration required to achieve the final realization of the BIW structure.
Schmueser, D., & Brooks, J. O., & Prucka, R. G., & Pisu, P. (2018, June), Innovative Graduate Engineering Education Implemented with Project-focused Learning: A Case Study—The Clemson University Deep Orange 3 Vehicle Prototype Program Paper presented at 2018 ASEE Annual Conference & Exposition , Salt Lake City, Utah. 10.18260/1-2--30668
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