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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