Lightweighting of a Recreational Vehicle Frame Structure using Advanced High Strength Materials and Joining Processes

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Erwin Hymer Group North America (EHGNA) is a major manufacturer of Class B motor homes and trailers with a production**facility in Cambridge, Ontario. To increase their market, there is a clear need to reduce vehicle weight so that a larger range of**passenger vehicles can tow the trailers. To achieve this goal, the weight of the existing structure must be reduced from**approximately 2600 lbs, to 2000 lbs. High strength light metals will be required to reach this target which inevitably leads to**complications in the manufacturing process. The selection and optimization of the joining processes of dissimilar materials is**critical to ensure that the new frame design is feasible from the perspective of assembly and in-service performance. The present**work will investigate lightweighting of the frame structure with an emphasis upon light metals including high strength 6xxx-series**aluminium extrusions and sandwich structures with a novel aluminium foam core. Numerical models of the foam and extrusions**will be generated and used to re-design the frame and achieve part consolidation. An emphasis will be placed upon the**development of the appropriate joining methodology for the aluminium foam to steel and aluminium as well as joining of the**fiberglass shell to the frame