Super Light Car design

8/7/2019 Super Light Car design

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Kumbhar Appaso L.ME103506

M Tech- I, Auto.Engg.

SUPER LIGHT CAR DESIGN



Content

� Objective

� Reasons for lightweight design

�

Superlight car project� Virtual development(material selection

methodology and simulation)

� SLC concept

� Conclusion



Objectives

� Multi-material philosophy

� Lightweight structure

� Fuel saving

� Co2 emission reduction



Light weight construction achieved through

� Materials

� Construction principles

� Manufacturing� Joining technologies



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



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





Fig. Approach and schedule of SLC

Lightweight vehicle project phases



Design Concepts

� Construction,

� Simulation,

�Evaluation and

� Optimisation of the front end, floor and

structural modules



Development & simulation

� Detail development took place over

several development software (CATIAV5)

� Simulation by (LS-Dyna)



SLC front end



SLC front end - Details



SLC floor



Results of final SLC body concept





Advantages



Crash behaviour of the magnesium

component

Fig. crash of the SLC vehicle



Fig. Analyse of the plastic strain of the reference

(right) and SLC concept (left)



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



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

Main challenge in body design



Fig. Result of Super Light Car (SLC)



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.



References

� Http://www.springerlink.com

� Www.superlightcar.com

� Materials for automobiles Bodies by Geoff Davies.

� Goede M (2006) Super light car



Thank U

Super Light Car design

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