Lightweight Design for the Future Steel Vehicle

Broek, Cees Ten; Singh, Harry; Hillebrecht, Martin

doi:10.1365/s40112-012-0171-0

Cited by 7 publications

(4 citation statements)

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“…In large-scale automotive manufacturing, lightweight structures have mainly been implemented using advanced designs based on steel. This includes new alloys, topologies as well as adapted manufacturing processes [30]. One example is the introduction of shell designs instead of frame constructions.…”

Section: Automotivementioning

confidence: 99%

“…These are enabled through the use of stamping and welding, which still represents the state-of-the art for large-scale manufacturing [1]. Recent innovations include the application of high-strength and ultra-high strength steels [30,31] as well as new manufacturing processes like tailor-rolled blanks [32].…”

Section: Automotivementioning

confidence: 99%

“…In steel manufacturing, alloying elements such as chromium, nickel, manganese, silicon, and molybdenum influence properties such as strength, corrosion resistance and formability as well as trade-offs between these properties [71]. Innovations in manufacturing process routes and alloying have led to a number of high performance steels such as high strength steel (HSS) and advanced high strength steel (AHSS), which have enabled a decrease of product weight of products by reducing the sheet metal thickness [30,76]. Kelly et al calculated GHG emission reductions for HSS and AHSS for different vehicle body and chassis structures, showing the highest reduction of around 20 % for AHSS applied to door frames [77].…”

Section: Steel Magnesium and Aluminium In Lightweight Structuresmentioning

confidence: 99%

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Life cycle engineering of lightweight structures

et al. 2018

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Lightweight structures are increasingly necessary to meet current engineering requirements. Weight reduction in diverse applications such as automobiles or machine tools is achieved either by using less material or by substituting material with a lighter one, which provides more functionality per unit of weight. To be an effective enabler for sustainability, lightweight structures should result in lower environmental impacts per functional unit when compared to conventional structures on a life cycle basis. However, applying new materials and manufacturing processes often leads to an increase in environmental impacts from the raw materials and production stage of the life cycle. Furthermore, end-of-life disassembly and recycling may become more difficult. In addition, the expected efficiency gains from the use of lightweight structures depend on how the overall market and technical systems respond to them. Consequently, the environmental evaluation of lightweight structures in engineering entails various methodological challenges. Organised around a life cycle engineering framework with a focus on eco-effectiveness, this paper provides a comprehensive review of lightweight structure applications and the challenges and opportunities they present in a life cycle engineering context.

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Section: Automotivementioning

confidence: 99%

Section: Automotivementioning

confidence: 99%

Section: Steel Magnesium and Aluminium In Lightweight Structuresmentioning

confidence: 99%

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Life cycle engineering of lightweight structures

et al. 2018

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“…In addition to the shape of cross-section, the selection of material and thickness also determines the collision safety and lightweight level of the autobody, 3 but in the traditional autobody design process, the cross-section design is usually separated from the optimization of material and thickness, and the coupling effect between different types of variables is not considered which cannot realize the lightweight potential fully. 4 For this problem, 3G-optimization is proposed, which can simultaneously consider the cross-section (Geometry), structure thickness (Gauge), and material grade (Grade) in structure optimization.…”

Section: Introductionmentioning

confidence: 99%

3G-optimization of multi-cell crash box cross-section of autobody based on crashworthiness

Zhang

Wang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part D:

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The cross-section, thickness, and material of the autobody structure determine the crashworthiness and lightweight level. Different from the variables in traditional autobody design that are considered separately, the basic theory of 3G-optimization is to simultaneously consider geometric shape (Geometry), the thickness of structure (Gauge), and material grade (Grade) in structural optimization design, which is conducive to maximizing the lightweight potential of the structure. This paper presents a cross-section optimization method for multi-cell thin-walled structures based on 3G-optimization, which is used in the structural design of crash box. Based on full width frontal collision condition, the cross-section shape, thickness, and material variables of the multi-cell crash box are optimized simultaneously. Multiple sets of optimization schemes show obvious weight reduction effect while ensuring safety. Besides, the sub-system decoupling method and hybrid cellular automaton (HCA) method are applied to 3G-optimization process, which is beneficial to improve the calculation efficiency and provide a theoretical basis for the definition of the initial design space for 3G-optimization.

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