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Kumbhar Appaso L.ME103506

M Tech- I, Auto.Engg.

SUPER LIGHT CAR DESIGN

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Content

� Objective

� Reasons for lightweight design

�

Superlight car project� Virtual development(material selection

methodology and simulation)

� SLC concept

� Conclusion

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Objectives

� Multi-material philosophy

� Lightweight structure

� Fuel saving

� Co2 emission reduction

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Light weight construction achieved through

� Materials

� Construction principles

� Manufacturing� Joining technologies

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Virtual development

y Material Selection Methodology

-Energy absorption

-Structural integrity

-Stiffness-Formability

-Surface quality

-NVH

y Other criteria

Costs, Life Cycle Analyses, Simulation,

Corrosion, joining, Producibility

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Motivation and challenge

� CO2 emissions (23%) being caused Global

warming by the vehicle traffic

�

Reducing weight by 100 kg leads to a fuelsavings of 0.35 l/100 km and 8.4 g CO2/km

with gasoline engines

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Fig. Approach and schedule of SLC

Lightweight vehicle project phases

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Design Concepts

� Construction,

� Simulation,

�Evaluation and

� Optimisation of the front end, floor and

structural modules

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Development & simulation

� Detail development took place over

several development software (CATIAV5)

� Simulation by (LS-Dyna)

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SLC front end

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SLC front end - Details

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SLC floor

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Results of final SLC body concept

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Advantages

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Crash behaviour of the magnesium

component

Fig. crash of the SLC vehicle

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Fig. Analyse of the plastic strain of the reference

(right) and SLC concept (left)

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Crash test analysis

� First, the crash behaviour of the magnesium

component is optimised for the crash load

�

The component was improved geometricallyand with regard to wall thickness distribution

� The surrounding steel structure was replaced

with a lighter aluminium structure

� By reducing the weight of the front end by 24

kg, goal of more than 30% can reached

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Fig. Main challenge in body design: the multi material concepts

Main challenge in body design

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Fig. Result of Super Light Car (SLC)

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Conclusion

� By multi-material lightweight construction

vehicle body with a 35% reduction in weight

will be possible

� Material, design and manufacturing

technologies remain key technologies in

vehicle development

� Multi-Material-Concepts promise costeffective light weight solutions.

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References

� Http://www.springerlink.com

� Www.superlightcar.com

� Materials for automobiles Bodies by Geoff Davies.

� Goede M (2006) Super light car

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Thank U