SUPER LIGHT CAR DESIGN

Kumbhar Appaso L.
ME103506
M Tech- I, Auto.Engg.
 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
Material Selection Methodology
-Energy absorption
-Structural integrity
-Stiffness
-Formability
-Surface quality
-NVH
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 fuel
savings of 0.35 l/100 km and 8.4 g CO2/km
with gasoline engines
Lightweight vehicle – project phases

Fig. Approach and schedule of SLC

 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 (CATIA
V5)
• 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 geometrically
and 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
 Main challenge in body design

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

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 cost
effective 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