F2010B112
Lightweight Design for Efficient Vehicles
Ricardo is a leading provider of technology, product innovation and engineering solutions for the world's automotive and transport industries. Lightweight design is a key facilitator to meeting the future requirements for a number of engineering sectors. In terms of vehicle engineering, the demand for fuel efficient vehicles without compromise to comfort or performance means that novel, lightweight designs are essential. For over 7 years Ricardo have conducted a number of focussed lightweight chassis and body structure studies which aim to utilise novel materials and design ideas to support the short and long term goals of CO2 reduction and the engineering of efficient vehicles. Ricardo have developed a robust lightweight engineering process which has proven successful on a range of applications and continues to evolve. As the process minimises material usage, it supports the product life cycle management drive to reduce a product's environmental footprint.
Many of the design studies have been based on benchmark parts from popular, high volume production vehicles. The aim was to develop novel design solutions to meet the cost, weight and performance aspirations of OEMs within typical vehicle constraints and demonstrate the potential of the Ricardo lightweight engineering process. Simply making components from stronger materials using thinner sections is not always a solution because stiffness, corrosion or other factors may suffer. Therefore, ensuring a good understanding of the functional requirements for a part, and the allowable range for targets is an essential part of the process. Advanced CAE tools are used extensively to investigate new design ideas and materials, optimise concepts, and gain confidence in the performance of a design concept. Benchmarking and validation tests typically conducted include; stiffness, stress, fatigue, modal frequency, non-linear overload and residual displacement, dynamic kerb impact, crash and k&c where appropriate. A technology partner was responsible for the forming analysis to ensure manufacturing feasibility. Lightweight does not necessarily mean more expensive, and this is demonstrated within the case studies.
One study benchmarked 3 vehicles, and then developed 6 front lower control design solutions to replace the existing parts. The resulting control arm designs were optimised to offer attractive mass and cost savings in comparison with the reference arms, while also achieving a high level of structural integrity. The levels of saving offered by the final designs ranged from a weight reduction of up to 42%, and a cost saving of up to 30%.
This abstract is supplemented by a PDF, which can be viewed here.