Design of lightweight multi-material automotive bodies using new material performance indices of thin-walled beams for the material selection with crashworthiness consideration

Currently, automotive bodies are constructed usually using a single material, e.g. steel or aluminum. Compared to single-material automotive bodies, multi-material automotive bodies allow optimal material selection in each structural component for higher product performance and lower cost. This paper presents novel material performance indices and procedures developed to guide systematic material selection for multi-material automotive bodies. These new indices enable to characterize the crashworthiness performance of complex-shaped thin-walled beams in multi-material automotive bodies according to material types. This paper also illustrates the application of these performance indices and procedures by designing a lightweight multi-material automotive body. These procedures will help to design a lightweight and affordable body favored by the automotive industry, thus to reduce fuel consumption and greenhouse gas emissions.

[1]  Arno Jambor,et al.  New cars — new materials , 1997 .

[2]  Zhong-qin Lin,et al.  Experimental study of glass-fiber mat thermoplastic material impact properties and lightweight automobile body analysis , 2004 .

[3]  Anindya Deb,et al.  Design of an aluminium-based vehicle platform for front impact safety , 2004 .

[4]  S. Jack Hu,et al.  A method for optimal design of automotive body assembly using multi-material construction , 2008 .

[5]  Jan L. Spoormaker,et al.  Materials selection combined with optimal structural design: concept and some results , 2002 .

[6]  Noboru Kikuchi,et al.  First Order Analysis - New CAE Tools for Automotive Body Designers , 2001 .

[7]  Richard Patton,et al.  Estimating Weight Reduction Effects of Material Substitution on Joints with Constant Stiffness , 2002 .

[8]  M. Ashby.  MULTI-OBJECTIVE OPTIMIZATION IN MATERIAL DESIGN AND SELECTION , 2000 .

[9]  T. Wierzbicki,et al.  On the Crushing Mechanics of Thin-Walled Structures , 1983 .

[10]  Richard Patton,et al.  Causes of weight reduction effects of material substitution on constant stiffness components , 2004 .

[11]  Tongxi Yu,et al.  Energy Absorption of Structures and Materials , 2003 .

[12]  Gordon Blount,et al.  The suitability of aluminium as an alternative material for car bodies , 1999 .

[13]  David Cebon,et al.  Materials Selection in Mechanical Design , 1992 .

[14]  M. B. G. Castro,et al.  Materials selection for an automotive structure by integrating structural optimization with environmental impact assessment , 2004 .

[15]  G. Lu,et al.  Quasi-static axial compression of thin-walled circular aluminium tubes , 2001 .

[16]  Ali Limam,et al.  Experimental and numerical investigation of static and dynamic axial crushing of circular aluminum tubes , 2004 .

[17]  Joel P. Clark,et al.  Automobile bodies: Can aluminum be an economical alternative to steel? , 2001 .

[18]  Mahmoud M. Farag,et al.  Materials selection for engineering design , 1997 .

[19]  Robert Koehr.  ULSAC - Lightweight Steel Automotive Closures , 2001 .

[20]  Z. Jiang,et al.  Optimization of a fender structure for the crashworthiness design , 2010 .

[21]  S. M. Sapuan,et al.  A knowledge-based system for materials selection in mechanical engineering design , 2001 .

[22]  Guanlong Chen,et al.  Use of high strength steel sheet for lightweight and crashworthy car body , 2003 .

[23]  Helen N. Han,et al.  Lifetime costing of the body-in-white: Steel vs. aluminum , 1995 .

[24]  Kamran Behdinan,et al.  Numerical simulation of the axial collapse of thin-walled polygonal section tubes , 2005 .