Lightweighting

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Materials info consultancy private
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• Reducing the weight of the vehicle

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Reducing Weight of the Vehicle

• UNSPRUNG MASS
• In a ground vehicle with a suspension, the
  unsprung mass is
• The mass of the suspension, wheels or tracks (as
  applicable)
• Other components directly connected to them,
  rather than supported by the suspension.
• Components coming under this include suspension
  springs, wheel rims, other chassis components
  like wishbone, traiing arm etc

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Reducing Weight of the Vehicle

• UNSPRUNG MASS REDUCTION
• Vehicle weight reduction particularly unsprung
  mass reduction
• Saves energy, minimizes brake and tire wear,
• Cuts down emissions. Lightweighting of vehicles
  is directly linked to lower CO2 emissions
• Results in Improved fuel economy.
• The benefits of even modest vehicle weight
  reduction are significant. Reducing an
  automobiles weight by a mere 50 kg (110 lbs)
  reduces up to 5 g of CO2 /km and increases fuel
  economy by up to 2.
• The reduction of unsprung mass can also benefit
  in performance, ride and handling of vehicles
  particularly passenger cars and utility vehicles

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Reducing Weight of the Vehicle

• LIGHTWEIGHTING STRATEGY
• Various approaches for weight reduction could be
  
• Use of polymer or engineering plastics, Aluminum
  or hybrid constructions ( combination of
  different materials)
• Downgauging or reducing thickness of body steel
  components by increasing usage of advanced high
  strength steels for body as well as chassis parts
• With development of hot stamping the strength
  levels upto 1400 Mpa could be achieved in steel
  sheets with a defined chemistry.
• Use of composite/engineering plastics for body
  panels and less load bearing components can be
  done.

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Reducing Weight of the Vehicle

• LIGHTWEIGHTING STRATEGY
• Tubular construction /design can be an option in
  place of a solid section
• The lightweghting in case of castings and
  forgings can be achieved by optimization ,
  thereby weight reduction.
• For autoelectricals the weight reduction can be
  achieved by reducing solenoid weight through use
  of advanced thermoplastics
• Reduction of weight for battery cables and
  wiring harness assemblies by using a hybrid
  construction of Copper and Aluminum.

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Reducing Weight of the Vehicle

• ANALYSIS AND VALIDATION
• All the above weight reduction approaches need to
  be studied carefully
• Through load analysis/CAE , stress levels
  experienced by the part under the various loading
  conditions,
• Manufacturing feasibility, freedom from defects
  through use of advanced simulation software in
  castings and forgings .
• Also it is important to use a proper problem
  solving/failure analysis technique in case of any
  failures in usage to find out the real root
  cause and addressing the same. Normally with
  initial failure such ideas are abandoned

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Reducing Weight of the Vehicle

• OUR SUPPORT
• We at materials info can help you to take through
  this journey of lightweighting of your components
  /aggregates thus achieving the final goal of
  reducing environmental burden