Reduce Vehicle Weight Research Articles

Editorial

Editorial Innovations in Automotive Materials and Processing - The automotive industry is undergoing a profound transformation, another revolution, moving towards Electric Vehicles (EVs). From lightweight composites to sustainable alternatives, advancements in automotive materials are driving improvements in performance, efficiency, and sustainability. The materials we use and how we process them are becoming more important than ever. Lightweighting for Efficiency and Sustainability - Light weighting is a significant trend in automotive materials. As automakers aim to meet stringent fuel efficiency standards and improve the range of electric vehicles, reducing vehicle weight has become a top priority. Materials, such as aluminium, carbon fiber, and advanced high-strength steels, are now integral to the design of modern vehicles. Aluminium continues to dominate in the automotive industry, with its high strength-to-weight ratio making it a preferred material for body panels, frames, and even electric vehicle (EV) batteries. This trend is set to continue, as automakers look to reduce the overall weight of EVs and extend their driving range. Carbon fiber-reinforced polymers (CFRP) are being increasingly used in high-performance vehicles, but their cost and manufacturing complexity have limited adoption. Sustainable and Green Materials - Sustainable materials are at the forefront of this transformation. Bio-based plastics, natural fiber composites, and recycled materials are being incorporated into vehicle interiors, trims, and structural components. There is a need for developing alternative materials like hemp-based composites and biodegradable polymers that reduce reliance on petroleum-based plastics. Smart Materials for the Future of Mobility - Beyond traditional applications, the future of automotive materials is also being shaped by smart technologies. Materials that can adapt to changing conditions—such as shape-memory alloys, self-healing coatings, and conductive polymers—are paving the way for the next generation of vehicles. For instance, self-healing materials can automatically repair cracks or scratches in the vehicle’s body, reducing the need for repairs and extending the overall lifespan of the vehicle. Innovations in Manufacturing and Processing Techniques - Advances in material science go together with cutting-edge manufacturing and processing technologies making new materials viable for mass production. One area is additive manufacturing (3D printing). Which allows automakers to create intricate components with minimal waste and at lower costs. New forming and welding techniques are improving the processing of lightweight materials. For example, friction stir welding (FSW) and laser welding are increasingly being used for joining aluminium and other materials. Advanced coatings and surface treatments are helping to enhance the durability and performance of materials. These innovations are particularly critical for protecting lightweight metals and composites from corrosion, wear, and environmental degradation—ensuring that vehicles remain safe and functional for longer periods. The Road to 2030 and Beyond - As we enter this exciting new chapter in the automotive world, one thing is clear: the road to the future is electric. This will require collaboration, innovation, and bold thinking from automakers, policymakers, and consumers. In the coming years, we will undoubtedly see materials that were once thought to be the stuff of science fiction become common place in the vehicles of tomorrow. The next wave of automotive innovation will be shaped, by the materials we use and the ways we process them. Achieving these advancements requires collaboration across industries—material scientists, engineers, manufacturers, and environmentalists—working together to push the boundaries of what’s possible. The ARAI Journal of Mobility Technology has been fostering automotive fertility keeping them updated on the latest technologies and innovations. The current issue covers topics on EVs, Battery technologies, Mechanical Dynamics, Simulation Techniques, Virtual Reality, as well as IC Engine technology.

Control Strategies for Steer-By-Wire Systems: An Overview

Steer-by-wire (SbW) is the latest steering evolution, providing many benefits, such as reduced vehicle weight and enhanced steering capability. While reliability is one of the main concerns hindering its widespread application, the potential of this technology to revolutionize the automotive industry is huge. Control techniques play an important part in achieving the full potential of SbW by focusing on the development of its performance and safety aspects. This paper provides a review of the control techniques that are being used in SbW technology to achieve better performance and enhance safety. Various control techniques for SbW exist to serve different purposes when dealing with the non-linear nature of the SbW dynamics. Although there is no one-size-fits-all control technique for all the requirements of the SbW, this study highlights that the non-linear controllers based on the sliding mode control (SMC) are a popular option for enhancing the accuracy of SbW systems. However, these controllers often suffer from a downside known as chattering. In contrast, robust controllers like Model Predictive Controllers (MPCs) can effectively manage uncertain dynamics and eliminate chattering, although they pose challenges due to their high computational costs.

Advancements in Nanotechnology for Vehicle Frames: Enhancing Safety and Performance

In recent years, the automotive industry, especially the electric vehicle sector, has made considerable strides with the integration of advanced materials. Nanotechnology, a key player in material science, offers significant potential for improving vehicle performance, with safety being one of the most critical aspects of automotive design. This review examines the utilization of nanomaterials such as carbon nanofibers (CNF) and carbon nanotubes (CNT) in vehicle frames, emphasizing their ability to enhance structural strength, reduce vehicle weight, and improve crash resilience. By leveraging these materials, manufacturers can create lighter, stronger, and more energy-efficient vehicles. This paper also explores recent breakthroughs in nanotechnology applied to automotive frames, discusses the challenges faced in large-scale implementation, and outlines potential future research directions that could further optimize vehicle performance and safety. Through this comprehensive review, the author aims to provide a clear understanding of the current landscape and future potential of nanotechnology in vehicle frame design.

Numerical investigation on bending characteristic and ductile fracture of AA7075 thin-walled beam using advanced orthotropic plasticity and fracture models

Thin-walled structures manufactured from the 7075 aluminum alloy are gaining tremendous attention in the automotive industry for their potential to reduce vehicle weight. However, the bending characteristics and rupture behavior of the AA7075 thin-walled beams under unexpected collision events have not been extensively studied. This study aims to fill that gap through a detailed numerical investigation of the bending deformation and failure mechanism of AA7075 thin-walled beams under quasi-static three-point bending at room temperature. Full-size, three-dimensional numerical simulations of laboratory-scale AA7075-T6 hat-shaped beam were conducted using the ABAQUS/Explicit solver. The material elastic–plastic response is described by a rate-independent constitutive description, incorporating advanced non-quadratic orthotropic plasticity and anisotropic ductile fracture criteria via VUMAT subroutines. Results indicate that the simulations accurately reproduced experimental observations, including the loading-displacement curves and deformation patterns. The bending behavior of the AA7075-T6 thin-walled beams aligns with typical bending collapse mechanisms, consistent with Kecman’s theory. The rupture process exhibits ductile fracture characteristics, with heterogeneous stress distribution across the material thickness affecting crack initiation rates between the upper and lower surfaces. Notably, the stress state at the fracture’s half-thickness section approximates an equi-biaxial tension condition. These findings provide essential insights into the bending deformation and failure mechanisms of AA7075 thin-walled structures under unexpected impact loading.

(Invited) Mild Anodization of Aluminum: From Fundamentals to Industrial Applications

Considering the recent energy crisis and global environmental pollution, the weight reduction of vehicles through the modification of several parts (e.g., engines and wheels) is emerging as an important research area. One strategy for achieving this is the use of aluminum. Aluminum, a lightweight material with excellent recyclability, is widely used in various industrial fields. There are various surface treatment methods for aluminum, depending on the purpose of use in each operating environment. Corrosion resistance and hardness of native oxides are not enough under some environment.To improve the surface properties of aluminum, anodic oxidation of aluminum (so-called anodizing or anodization), is generally applied. The surface treatment has a history of nearly 100 years. In Japan, anodization using oxalic acid was first patented in 1923. A porous-type oxide film formed on aluminum by anodization, or a product covered with the porous alumina film, is industrially called alumite in Japan. The structure of a porous-type oxide film (alumite) determines the various surface properties of aluminum. For instance, to increase the hardness of anodic films on aluminum, the anodization is industrially carried out at low temperature to avoid chemical dissolution of the formed oxide film during anodization.Here, I present an overview of the progress of anodization in common acidic electrolytes (e.g., sulfuric acid, oxalic acid, or phosphoric acid) containing alcohol as an additive [1-6]. Anodization was mainly conducted using various alcohols with different physical properties under mild anodization conditions with a constant current of 100 A·m−2 at 20 °C. The effects of alcohol addition in electrolytes on the anodization behavior of aluminum, the coating ratio, the porosity, the maximum attainable film thickness, and the hardness of anodic films will be discussed in terms of both basic research and commercial applications. H. Asoh, M. Matsumoto, H. Hashimoto, Surf. Coat. Technol., 378, 124947 (2019).M. Matsumoto, H. Hashimoto, H. Asoh, J. Electrochem. Soc., 167, 041504 (2020).H. Asoh, T. Sano, J. Electrochem. Soc., 168, 103506 (2021).H. Asoh, H. Kadokura, R. Murohashi, M. Matsumoto, J. Electrochem. Soc., 169, 073510 (2022).T. Sano, Y. Wakabayashi, H. Asoh, Surf. Coat. Technol., 459, 129399 (2023).H. Asoh, S. Ota, K. Hagiwara, J. Electrochem. Soc., 171, 033502 (2024).

Comparison of Experimental and Numerical Investigation of Mono-Composite and Metal Leaf Spring

The automotive industry is increasingly focused on reducing vehicle weight, leading to the widespread adoption of composite materials with high strength-to-weight ratios in both aviation and automotive sectors. These materials are gradually replacing traditional options like steel. Leaf springs, one of the oldest and most common suspension components, continue to be widely used in vehicles. This study aims to replace conventional multi-leaf steel springs with mono-composite leaf springs while preserving the same load-carrying capacity and stiffness. Composite materials, such as glass fiber and epoxy resin, provide advantages including higher elastic strain energy storage, superior strength-to-weight ratios, and enhanced corrosion resistance compared to steel. Consequently, the weight of leaf springs can be reduced without sacrificing performance. The steel and mono-composite leaf springs were modeled using Catia software, and their performance was evaluated using ANSYS 15.0 software.

Achieving Superior Ductility at High Strain Rate in a 1.5 GPa Ultrahigh-Strength Steel without Obvious Transformation-Induced Plasticity Effect

The development of ultrahigh-strength steels with good ductility is crucial for improving the crashworthiness of automobiles. In the present work, the mechanical responses and deformation behaviors of 1.5 GPa ultrahigh-strength steel were systematically investigated over a wide range of strain rates, from 10−3 s−1 to 103 s−1. The yield strength and tensile elongation at quasi-static strain rate (10−3 s−1) were 1548 MPa and 20%, respectively. The yield strength increased to 1930 MPa at an extremely high strain rate (103 s−1), and the steel maintained excellent ductility, with values as high as 17%. It was found that the prevailing of the transformation-induced plasticity (TRIP) effect at quasi-static condition resulted in the formation of fresh martensite. This produced strong hetero-deformation-induced (HDI) stress and strain partitioning, contributing to the enhancement of strain hardening. The TRIP effect is remarkably suppressed under high strain rates, and thus the retained austenite with excellent deformation ability sustains the subsequent deformation, leading to superior ductility when the TRIP effect and HDI strengthening are retarded. Ultrahigh-strength steel with great strength–ductility combination over a wide range of strain rates has great potential in improving component performance while reducing vehicle weight.

Friction stir processing on a strontium modified, thin-wall, vacuum-assisted high-pressure die-cast Aural-5 alloy to improve tensile and fatigue performance

This study explores the application of friction stir processing (FSP) to enhance the material properties of Sr-modified Aural-5 alloy, with a focus on improved tensile and fatigue properties. Aural-5 is a well-known vacuum-assisted high-pressure die-cast (HPDC) Al–Si7–Mg alloy used in the automotive industry to reduce vehicle weight, enhance fuel efficiency, and lower carbon emissions. This alloy modifies its material chemistry with Sr for fine fibrous networks of eutectic silicon and manganese (Mn) to reduce die soldering. It has significantly less iron (Fe) content resulting in the elimination of detrimental needle-shaped Fe-bearing β-phase intermetallic and improving ductility. The initial microstructure of as-received HPDC Aural-5 exhibits shrinkage porosity in the middle section, a dendritic microstructure with fibrous Al–Si eutectic colonies, a shear-band structure beneath the die-wall, large dendritic externally solidified crystals (ESCs), needle-shaped Mg2Si phase and significant second-phase particulates. Some of those microstructural features, such as porosity, ESCs, needle-shaped Mg2Si phase, and large second-phase particles, serve as initiation sites for cracks under mechanical loading, resulting in adverse effects on tensile properties, particularly ductility. FSP effectively transforms the microstructure into a wrought configuration with uniform particle distribution by eliminating porosity and disintegrating dendrites, eutectic colonies, ESCs, second-phase particles, and shear-band structures. FSP-driven microstructure modification enhances yield strength and tensile ductility by ∼30 % and ∼35 %, respectively. The fatigue life of the material in a bending mode configuration (stress ratio R = 0.1) after FSP exhibits enhancements ranging from 2.0 to 3.9 times that of the original HPDC Aural-5 alloy, depending on the applied stress level.

استكشاف تعدد استخدامات الألمنيوم في الهندسة الميكانيكية

Aluminum, known for its lightweight, high strength, and excellent corrosion resistance, is a critical material in mechanical engineering. Its unique properties make it indispensable in various industries, including aerospace, automotive, construction, and packaging. This research paper explores the fundamental properties of aluminum that contribute to its widespread use. It discusses the metal's high strength-to-weight ratio, excellent thermal and electrical conductivity, and significant ductility and malleability. These characteristics allow aluminum to be formed into complex shapes and structures, essential for advanced engineering applications. In the aerospace industry, aluminum alloys are extensively used in manufacturing aircraft frames and components, contributing to improved fuel efficiency and performance. In the automotive sector, aluminum's lightweight nature helps reduce vehicle weight, enhancing fuel efficiency and lowering emissions. The construction industry benefits from aluminum's strength and corrosion resistance, making it ideal for building durable infrastructure. Additionally, aluminum's high thermal conductivity makes it suitable for heat exchangers in HVAC systems, automotive radiators, and electronic cooling systems. Recent advancements in aluminum technology have further expanded its applications. The development of aluminum-lithium alloys offers higher strength and lower density than traditional aluminum alloys, making them particularly suitable for aerospace applications. Recycling advancements have made aluminum production more sustainable, reducing environmental impact and energy consumption. Research into nanostructured aluminum shows promise for creating materials with enhanced properties, such as increased strength and improved resistance to wear and corrosion. Additive manufacturing with aluminum alloys allows for the creation of complex and lightweight components, previously challenging to produce with traditional methods. In conclusion, aluminum's versatile properties make it an essential material in mechanical engineering. Its applications across various industries demonstrate its critical role in advancing technology and improving performance. Ongoing research and technological advancements continue to enhance aluminum's capabilities, ensuring its significance in the field of mechanical engineering.

Statistical analysis of trends in Battery Electric Vehicles: Special reference to vehicle weight reduction, electric motor, battery, and interior space dimensions

Electric vehicles (EVs) are increasingly being used, as they are more environmentally friendly than conventional vehicles with internal combustion engines (ICE). Battery electric vehicles (BEVs) can be said to have zero exhaust emissions only if the electricity used to drive these vehicles is obtained in an environmentally friendly way. It is common knowledge that BEVs have a significantly higher overall mass than conventional vehicles. The significantly higher total vehicle weight of BEVs can have various adverse effects on energy consumption during movement and the vehicle's dynamics. In contrast to the negative aspects of BEVs, there are also positive aspects that are primarily related to the comfort of drivers and passengers, considering the main fact that they do not require the presence of a floor tunnel. In this paper, trends related to BEVs in the previous five years were statistically analysed. Changes in average sizes related to BEVs are shown, primarily internal dimensions that can be of crucial importance when deciding between BEVs and conventional vehicles. In the paper itself, other important trends are presented, both for the electric motor itself and for the batteries used in BEVs.

Recent Progress in Creep-Resistant Aluminum Alloys for Diesel Engine Applications: A Review.

Diesel engines in heavy-duty vehicles are predicted to maintain a stable presence in the future due to the difficulty of electrifying heavy trucks, mine equipment, and railway cars. This trend encourages the effort to develop new aluminum alloy systems with improved performance at diesel engine conditions of elevated temperature and stress combinations to reduce vehicle weight and, consequently, CO2 emissions. Aluminum alloys need to provide adequate creep resistance at ~300 °C and room-temperature tensile properties better than the current commercial aluminum alloys used for powertrain applications. The studies for improving creep resistance for aluminum casting alloys indicate that their high-temperature stability depends on the formation of high-density uniform dispersoids with low solid solubility and low diffusivity in aluminum. This review summarizes three generations of diesel engine aluminum alloys and focuses on recent work on the third-generation dispersoid-strengthened alloys. Additionally, new trends in developing creep resistance through the development of alloy systems other than Al-Si-based alloys, the optimization of manufacturing processes, and the use of thermal barrier coatings and composites are discussed. New progress on concepts regarding the thermal stability of rapidly solidified and nano-structured alloys and on creep-resistant alloy design via machine learning-based algorithms is also presented.

Multifunctional nanocomposite coating for aluminium alloy: Corrosion resistance, flame retardancy, and mechanical enhancement for automotive components

Aluminium alloys are utilized in the automotive industry for components such as engine blocks, wheels, chassis, and body panels. Their lightweight nature helps reduce vehicle weight, leading to improved fuel efficiency and lower emissions. The development of nanocomposites incorporating impermeable two-dimensional materials holds significant promise for safeguarding metals against corrosion. By introducing N-aminoethyl-3-aminopropyltrimethoxysilane (AAMS) functionalized molybdenum nitride (MoN) into a coating matrix, the barrier effect can be significantly enhanced owing to its remarkable chemical and thermal stability. This enhancement is further amplified through the incorporation of functionalized MoN into graphitic carbon nitride (GCN) within a polyurethane (PU) matrix, resulting in improved corrosion protection and fire-retardant properties. Through electrochemical techniques conducted in marine environments, the protective efficacy of aluminium coated with polyurethane, alongside varying concentrations of functionalized MoN/GCN, was assessed. The resulting PU composite exhibited superior flame-retardant capabilities, manifesting in substantial reductions in peak heat release rate (PHRR), total heat release (THR), and total smoke production (TSP) compared to pure PU formulations. Electrochemical impedance spectroscopy (EIS) measurements revealed a notable enhancement in coating resistance (5.65 × 1011 Ω. cm2), even following 500 h of exposure to the electrolyte. Furthermore, the newly formulated PU composite, featuring functionalized MoN/GCN, demonstrated exceptional water repellency with a water contact angle (WCA) of 157°. This remarkable hydrophobicity underscores its potential for applications requiring protection against moisture ingress. Additionally, the PU composite exhibited commendable mechanical properties, boasting an adhesive strength of 19.1 MPa within the PU substrate. This enhanced adhesive strength ensures the coating's integrity even after prolonged immersion periods. Given its multifaceted benefits, the PU composite incorporating functionalized MoN/GCN emerges as a promising candidate for integration into automotive industries as a viable coating component. Its ability to concurrently provide corrosion protection, flame retardancy, water repellency, and mechanical robustness underscores its potential to enhance the durability and longevity of automotive components, thereby contributing to improved performance and longevity in harsh operating environments.

Energy absorption characteristics of a bio-inspired prepreg carbon fiber crash box under quasi-static axial compression

Reducing vehicle weight is crucial for enhancing fuel efficiency and reducing emissions in transportation. Traditional composite materials offer improved energy absorption over metals yet are limited by brittleness. This study introduces an innovative approach, inspired by the mantis shrimp's natural defense mechanisms, to enhance the crashworthiness and energy absorption of composite structures, optimizing safety and performance. Utilizing a bio-inspired design, we developed corrugated Carbon Fiber Reinforced Polymer (CFRP) crash box structures, aiming to optimize their energy absorption capabilities and crash force efficiency (CFE) for potential applications in transportation safety. Through a series of quasi-static axial compression tests, the corrugated structures' performance was evaluated against traditional crash box designs. The experimental results demonstrate that the bio-inspired configurations improved crashworthiness characteristics. Strategic manipulation of layer numbers and corrugations led to superior CFE values, indicative of safer, more controlled collision behavior. The “7N-6L” configuration featuring seven corrugations with six layers of CFRP demonstrated the highest efficacy, achieving an optimal CFE of 1.08. This configuration demonstrated a Specific Energy Absorption (SEA) of 1.56 J/g and an Energy Absorption (Ea) of 42.56 J. Furthermore, compared to conventional steel crash boxes, the CFRP crash box with 7N-6L corrugated structure showcased competitive energy absorption capabilities with significantly reduced mass, absorbing 2850 J with a CFE of 0.91, nearly matching the ideal CFE and highlighting its superior lightweight performance. These results underline the potential of integrating bio-inspired designs to develop robust, lightweight structures for improved crashworthiness, paving the way for safer and more sustainable transportation solutions.

A computational framework for probabilistic modeling of galvanic corrosion for automotive applications

Abstract To address the need for reduced vehicle weight and improved environmental sustainability, the automotive industry has increasingly turned to mixing lightweight materials and alloys with metal alloys. However, this integration of dissimilar materials has heightened the risk of galvanic corrosion. This study addresses the gap in modeling of galvanic corrosion under dynamic thin film electrolyte by incorporating data derived from real-world weather conditions and finite element simulations. The presented model successfully captures the trend of galvanic corrosion rate for a given atmospheric environmental condition. The model predictions are compared with experimental data in the literature. Good agreements are observed. The model is further used for prediction of galvanic corrosion of two identical vehicles located in two different geographic locations (i.e., Miami Beach in Florida and Wendover in Nevada) in the year 2021 leveraging weather station data. Additionally, a Bayesian estimation method is used to account for uncertainties in the model parameters and estimation of the probability of failure.

Studies on the Quality of Joints and Phenomena Therein for Welded Automotive Components Made of Aluminum Alloy—A Review

To fulfill the need to limit automotive emissions, reducing vehicle weight is widely recommended and achieved in many ways, both by the construction of individual elements of the vehicle and by the selection of light materials, including Al alloys. Connecting these elements with each other and with elements made of iron alloys can be realized, inter alia, by welding or stir welding. However, the quality of the welds obtained varies widely and depends on many design, operational, and environmental factors. The present study focused on a review of various welding techniques used to join both similar and dissimilar Al alloys utilized in the automotive industry, the effect of various process parameters on weld quality, and the phenomena observed in such welds. The research methodology was based on the analysis of the content of articles from main databases. Apart from capturing the current state of the art, this review evaluates reaching the possible highest joint quality and welding process disadvantages such as porosity, poor surface quality, a tendency toward hot cracking, and low ductility for the Al alloys applied in the automotive industry.

Applicability of the formability evaluation method for advanced high strength steels

The use of high strength and ultra-high strength steels has become the main technical solution for reducing vehicle weight and improving safety. It is more complicated to evaluate the formability of advanced high strength steels with different microstructure and deformation characteristics. In this paper, the applicability of existing formability evaluation methods for advanced high strength steels has been verified by experiment and theoretical analysis. The experiment and data analysis of conventional formability evaluation methods, such as strain hardening index, forming limit curve and hole expansion ratio, were carried out on advanced high strength steels, such as dual-phase steel, complex-phase steel, quenched and tempered steel and dual-phase steel with high formability, which are widely used in automotive industry. It is found that due to the complex work hardening characteristics of advanced high strength steels, the work hardening homogenization and forming limit cannot be characterized by a single work hardening index or forming limit diagram, and the standard hole expansion method cannot reflect the quality sensitivity of the formed edge. A new formability evaluation index is proposed and discussed, which can be used to more accurately compare the formability of advanced high strength steels and provide a reference for material evaluation and part selection.

Simulation of calculation of combat vehicle fuel efficiency by reducing vehicle weight using aluminum material

In the contemporary landscape, combat vehicles are tasked with meeting multifaceted demands, ranging from fortified defense capabilities to enhanced operational versatility and lethal efficacy. At the crux of these requirements lies the pivotal challenge of managing vehicular weight, a parameter that profoundly impacts endurance, agility, and speed. Extensive research endeavors have shed light on aluminum as a compelling solution to mitigate this weight burden while ensuring the requisite durability in combat vehicles. Through the utilization of MATLAB simulations, this study endeavors to elucidate the correlation between mass reduction and fuel efficiency, culminating in the creation of a comparative graph. The findings of this research make a significant contribution by demonstrating that a 15% reduction in vehicle mass, equivalent to 324 kilograms through the substitution of conventional materials with aluminum, yields substantial fuel savings amounting to 13.36%, or 1.3 liters. Such insights underscore the pivotal role of material selection in optimizing fuel efficiency in combat vehicle design

The environmental impact of lightweight body in white structures in vehicle manufacturing

The quest for sustainability and reduction of human impact on the planet has led to discussions about environmental efficiency in the manufacture and use of automotive vehicles. The advancement of environmental and government laws has encouraged the automotive industry to seek constant improvements in safety, fuel economy and reduction of greenhouse gas emissions. To achieve these goals, reducing the weight of vehicles has been considered a relevant strategy, with several research and development efforts in search of high-tech materials and innovative design. The assessment of the life cycle of vehicles, from the extraction of raw materials to the end of their useful life, is essential for estimating environmental impacts. In this context, this paper focuses on the life cycle analysis of vehicles with new generation steel structures (Body in White Solution) compared to current steels (Body in White Baseline), aiming at reducing greenhouse gas emissions by reducing of the thickness of the steel plates, maintaining the mechanical properties necessary to guarantee the safety of the vehicle. The methodology of this study was divided into the evaluation of Body in White (BIW) mass in current steels (Baseline) and in advanced high resistance steels (Solution); detailing the vehicular life cycle from the extraction of materials to its end of life; in the estimation of greenhouse gas emissions through simulation and in the comparison of vehicle emissions with BIW in current steels and in advanced high resistance steels. As a result, it was possible to observe that, in the comparison of the CO2 footprint, modeled in the Eco Audit, there is a 15% reduction in emissions in the CO2 footprint for the BIW solution, as well as a 7% reduction in the Ceq total, in the on-site test and a saving of 260.40 L in fuel consumption, that is, the reduction in vehicle weight plays a significant role in reducing CO2 emissions, providing a mitigation factor for global warming.

Finite Elements Analysis and Topology Optimization of Parking Brake Lever and Ratchet

Topology optimization is known as one of the basic categories of structural optimization. Topology optimization is received increasing attention in many engineering disciplines. Topology optimization contributes to minimizing emissions and environmental effects by increasing material utilization efficiency and manufacturing sustainability. The mechanical parking brake is still used in many vehicles. This study aims to contribute to the reduction in vehicle weight by applying topology optimization. In addition, it also purposes to promote sustainability in manufacturing by reducing material usage and energy consumption. A CAD model was created by considering the existing mechanism element dimensions. The parking brake lever mechanism component was evaluated using topology optimization and finite element analysis methods. Static analyses were performed using a finite element analysis program. The results of this analysis were used as input data for topology optimization. In the topology optimization, the response constraint mass was increased by 5 increments from 50% to 95%. As a result, the maximum equivalent (von Mises) stress for the parking brake lever is 230,29 MPa, and for the ratchet is 11,559 MPa. The maximum total deformation value for the brake lever is 0,95853 mm and for the ratchet is 0,0079482 mm. The parking brake lever mass decreased by 18,48% from 0.27751 kg to 0.22622 kg. The ratchet mass decreased from 0.095042 kg to 0.061911 kg by 34.85%.

İki Farklı Reçine Kullanılarak Oluşturulan Hibrit Kompozit Malzemelerin Araç Tamponlarında Kullanımının Araştırılması

As efforts to reduce vehicle weight in today's vehicles accelerate, efforts to find new types of materials that can replace traditional materials have accelerated. In this study, carbon fiber was used as a reinforcement element together with glass fiber for lightening in vehicle bumpers. While vinyl ester and polyester were chosen as the matrix material for the piece to be produced, production was made by the hand lay-up method. The produced samples were first subjected to tensile test and their mechanical values were determined. The mechanical test results were introduced to the ANSYS program, and separate analyzes were made for the materials produced on the same bumper design and the results were compared. According to the results of the analysis, there was 2.13 times decrease in total deformations in glass fiber/carbon fiber/Vinyl ester hybrid composites compared to glass fiber/vinyl ester homogeneous composites. In terms of equivalent stresses, 8% reduction was achieved in the carbon fiber /glass fiber/Vinyl ester hybrid composite compared to the carbon/Vinyl ester homogeneous composite. It was concluded that the choice of reinforcement and matrix is important for creating bumper material and improving the mechanical values of the bumper