Abstract
Lightweight design is one of the current key drivers to reduce the energy consumption of vehicles. Design methodologies for lightweight components, strategies utilizing materials with favorable specific properties and hybrid materials are used to increase the performance of parts for automotive applications. In this paper, various forming processes to produce light parts are described. Material lightweight design is discussed, covering the manufacturing processes to produce hybrid components like fiber–metal, polymer–metal and metal–metal composites, which can be used in subsequent deep drawing or combined forming processes. Approaches to increasing the specific strength and stiffness with thermomechanical forming processes as well as the in situ control of the microstructure of such components are presented. Structure lightweight design discusses possibilities to plastically form high-strength or high-performance materials like magnesium or titanium in sheet, profile and tube forming operations. To join those materials and/or dissimilar materials, new joining by forming technologies are shown. To economically produce lightweight parts with gears or functional elements, incremental sheet-bulk metal forming is presented. As an important part property, the damage evolution during the forming operations will be discussed to enable even lighter parts through a more reliable design. New methods for predicting and tailoring the mechanical properties like strength and residual stresses will be shown. The possibilities of system lightweight design with forming technologies are presented. A combination of additive manufacturing and forming to produce highly complex parts with integrated functions will be shown. The integration of functions by a hot extrusion process for the manufacturing of shape memory alloys is presented. An in-depth understanding of the newly developed processes, methodologies and effects allows for a more accurate dimensioning of components. This facilitates a reduction in the total mass and an increasing performance of vehicle components.
Highlights
Lightweight design is a key driver to reduce CO2 emissions in transportation and automotive industries
Material lightweight design can be done by the use of a single material with a high specific property or by a combination of materials to utilize the best of different materials which are combined to a composite or hybrid
Structures to an assembly can lead to a light system; structure lightweight design is a subset of system lightweight design
Summary
Lightweight design is a key driver to reduce CO2 emissions in transportation and automotive industries. The increasing demand for electric and hybrid powered cars requires new concepts and development of lightweight technologies and processes to produce light parts and automotive components. Hahn et al [1] developed a new concept to evaluate the design and level of lightweight—the true lightweight degree This new factor overcomes the current industrial practice, where a new component is typically associated with lightweight design, if it is lighter than the previous version of the part. Damage is an important property when dealing with lightweight design and is defined as the void evolution inside a part during or after a forming operation It enables the knowledge of process-induced void growth, which weakens. This paper focuses on processes and material concepts to produce light parts for the automotive industry using forming technologies
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