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22 Autocar Professional 1 May 2010 www.autocarpro.in
AUTOMOTIVE LIGHTWEIGHTING SPECIAL
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AUTOMOTIVE LIGHTWEIGHTING SPEC
When TataMotors
launchedthe much-awaited
Nano at the Auto Expoin 2008, the industry and observers alike wereimpressed with the way thatthe carmaker had kept toits promise of an aesthetic-looking car that didn’t costthe earth.
But while the hypefocused on price, the fact isthat the company’s vendors
worked round the clock to think innovatively todevelop components that
were light in terms of costsand weight as well. This fact
was crucial to the success of the company.
That among otherreasons is why ProfessorCharles Fine, co-directorof the International Motor
Can Inia take the lea to euce vehicle weight?With the accent on reducing weight and improving fuel economy, OEMs and component manufacturers are using new materials and designs to gain a strategic advantage
Maruti Suzuki’s mantra has
been to make small cars that
are lighter and fuel efficient.
It all began with its debutante
model the Maruti 800
launched in 1983, which was
then the smallest car in terms
of size and engine capacity.
The legacy continues and the
recently launched new WagonR
has several weight-reduction
initiatives.
Speaking to Autocar
Professional , executive officer
(production engineering)
of Maruti Suzuki, R Dayal
says tailored welded blanks
(TWB) have been used in the
new WagonR in the doors
and tailgate. “We began
introducing TWB in the Estilo
and later introduced it in the
SX4. TWB is a manufacturing
method in which steel parts of
different thickness and tensile
strength are laser welded in
sheet condition and pressed
together. This enables partial
part reinforcement, avoiding
the need for additional parts,
thus, keeping the weight under
control."
Chief general manager
(engineering, research, design
& development) C V Raman
says the new WagonR is
heavier by 35kg (VXi model)
than the earlier model as the
car is built on a new platform.
Its overall length has been
increased by 75mm to 3595mm
against the old version. The
wheelbase has been increased
to 2400mm besides becoming
wider (1495mm) and taller
(1700mm). Given the
increased dimensions, the
weight of the car should
have increased significantly
but for the use high-tensile
steel and TWB. By using high
tensile steel, Maruti was
able to achieve the same
performance at
lower thickness and thus,
reduce overall body weight.
In the A-star and the new
WagonR, the company
has used high tensile steel
to reduce weight. All the
load bearing and structure
members of the A-star body
are made of 440 or 590 high
tensile steel grade.
The impact of adopting
TWB technology and use of
high tensile steel is reflected
in improved fuel efficiency.
Raman says about 20kg of high
tensile steel has been used in
the new WagonR.
Maruti has focused on
weight reduction through its
three-pronged strategy of
'Reduce, Reuse and Recycle'
(3R) in all its manufacturing
facilities, supply chain and
logistics operations.
30 SECONDS ON . . . MARUTI SUZUKI'S EFFORTS IN LIGHTWEIGHTING
TATA MOTOrsTata Motors has usedcomputer aidedengineering (CAE), early vendor involvement, andleveraged the findings of its materials technology research programmesin order to achieve itslightweighting objectives.
At the product conceptand strategic intent stageitself, weight objectivesand targets are setto complement fuelefficiency, performanceand durability. CAE toolsare used to optimise weightto maximise performanceof the systems andcomponents for NVH,fatigue durability, customertouch points, and ride andhandling.
As far as early supplierinvolvement is concerned,
Tata Motors says i
help the companyidentify the latestin weight reductiotechnologies thatbenefit Tata prod
The company’sengineers and sciconstantly look foexplore new matprocessing technolightweighting cothe basis of whichinnovate during tproduct developmprocess.
In the recent paTata Motors has ualternate materiaas high strength saluminium alloysplastic composite
weighting.Going forward,
exploring several measures includi
Lightweight engine
The company’s K-series
lightweight aluminium engine
has been designed to be
environment friendly and
fuel-efficient. This engine,
introduced in the A-star, is a
significant initiative towards
offering customers the latest
technology. The new WagonR
is the third model (after the A-
star and Estilo) in Maruti's line-
up to use the K-series engine.
Maruti engineers have put
together a host of innovative
technologies such as the use
of plastic parts, reduction in
piston skirt area to reduce
weight, and resin-coated
piston to minimise friction,
enhance performance and
provide high acceleration.
Besides reducing emissions,
the engine offers improved
fuel efficiency and help
achieve better Noise, Vibration
and Harshness (NVH)
characteristics.
Employee involvement
Maruti has also initiated
several projects on
minimisation and utilisation.
Every year, the company
celebrates Value Analysis
– Value Engineering (VA-VE)
month aimed at involving
employees and suppliers
in design improvements
that reduce weight and
cost without compromising
on quality. In 2008-09, it
launched the 'One Gram One
Component' weight reduction
scheme to reinforce the need
to use resources prudently.
As a Suzuki subsidiary, it
follows its parent company’s
basic philosophy of 'Smaller,
Fewer, Lighter, Shorter
and Neater' in its
manufacturing facilities.
This philosophy has helped
it in optimal utilisation of
resources and cost saving.
Through various kaizen
activities, efforts are made
to reduce not only the
weight of car components
but also equipment used in
manufacturing.
The Maruti Center
of Excellence (MACE),
created for vendor s
upgradation organi
programmers for su
on several topics inc
component weight
yield improvement
productivity improv
In 2008-09, Maru
consumed 279,085
tonnes (MT) of steel
24,389 MT of ferrou
11,619 MT of non-fe
casting and 3,998 M
paints. It has undert
various activities to
material consumptio
improvement is one
activity it has prom
its inception, as par
3R programme. Dur
initial phase, it focu
steel coil blank size
by changing the rad
blank, and modifyin
design, die face and
profile.
MURRALI THALOR
New WagonR uses high-tensilesteel, TWB and lightweightK-series engine.
The world’s largestauto companieshave sunk so muchinto heavy-steel-based vehicles thatthey cannot lead
the way to makinglight vehicles. Indiatherefore has anadvantage here.
Vehicle Program at the
Massachusetts Instituteof Technology, seesautomotive lightweightingas a strategic opportunity for India’s auto sector.
We at Autocar Professional decided tospeak with key players inthe sector and ask them
what their companies were doing to make theirvehicles lighter. We spoke
with OEMs and componentmakers alike who saidnew materials includingengineering plastics andnew technologies were
what they are looking atto produce vehicles thatare lighter, safer and eco-friendly.
Interestingly, the journey towards lightweightingbegins even before a car isactually made. New product
and design software means
that at the conceptualphase itself, weight targetsand objectives can bedefined and worked on.
Professor Fine saysautomotive lighweightingis an opportunity for Indiabecause fuel demand andprices will remain on anupward trend.
The world’s largest autocompanies have sunk somuch into heavy-steel-based vehicles that they cannot lead the way inmaking light vehicles.
Above all, lightweightingrequires a redesign of theentire automotive supply chain.
With India’s automotivesupply chain still relatively
young, it can mould itself to being a pioneer inlightweighting.
Tata Motors uses alternate materials such as
high strength steels, aluminium alloys andplastic composites for lightweighting.
All the load bearing and structure members of the A-starbody are made of 440 or 590 high tensile steel grade.
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AUTOMOTIVE LIGHTWEIGHTING SPECIAL
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AUTOMOTIVE LIGHTWEIGHTING SPEC
hollow constructionusing high-strength tubesand hot stamped parts,greater harnessing of lightweighting potential of aluminium and its MMC as
well as plastic compositesand nanoclay plasticcomposites.
Tata says that goingforward, the cost of
materials like magnesium,titanium and carbon fibrecomposites will reach levels
where their lightweightingpotential can be put to useeconomically. Vehicles of the future will be of multi-material construction,
where each materialperforms several roles inaddition to offering light
weighting advantage.
GENErAL MOTOrsGM India is evaluatingalternate lightweightmaterials for variousapplications in its vehicles.Many of its new productsin the US, for example, usealuminium for the bonnetsand rear tailgate. Its R&Dfacilities are developingparts that are expectedto be much lighter thanexisting products. GMalso uses state-of-the-artsimulation tools early inthe design phase to reduceand optimise weight. Withincreasing application of plastics, SMC, magnesiumand aluminium, GM hopesto develop lighter vehiclesin the future as technologiesevolve.
HONdA sIEL CArs INdIAThe carmaker useshigh-tensile steel in themanufacturing of its carsfor lightweight yet high-strength and enhancedsafety. Also, high-quality materials like magnesium,aluminium and high quality plastic are used to ensurethat its vehicles are notheavy.HSCI has also restrictedthe use of hazardousmaterials such as asbestos,crome6, lead, cadmiumand mercury to ensure itsvehicles are safe and eco-friendly.
VOLVO-EICHEr CVThe commercial vehiclemanufacturer has usedmaterials like composites,aluminium and high-strength low alloy steelscoupled with extensive
weight optimisationtechniques that havehelped it to continuemaking lighter vehicles,thereby enabling customersto carry more payload forthe same gross vehicle
weight.
INdIA YAMAHAMOTOrLightweighting isconsidered to be very important aspect at
Yamaha and is directly related to improving fuelefficiency. The steps thebike maker has taken tolightweight its vehiclesinclude re-engineering of parts and careful selectionof materials that help itimprove the power-to-massratio. Going forward, India
Yamaha says it is focusingon re-engineering of partsand taking other weightreduction measures such asusing superior raw materialand increasing the numberof plastic parts.
WEIGHT rEdUCTIONbY PArTs MAKErs
MUTUAL INdUsTrIEsMumbai-based MutualIndustries designs andmanufactures parts usinglow-weight plastics.However, it says, these
materials have yet to beexplored to contribute on alarger scale to automotivelightweighting.
As automotive plasticsspecialists, the company believes that there are many more potential applicationsthan the established onesthat could contributetowards lightweighting.Such applications callfor development activity
which involves design andengineering resources.
Therefore, Mutit prefers to particnew product deverather than secludpart developmenre-engineering folightweighting. Thcompany says it hcapability to handproduct developma knowledge base
covers the complfrom prototype topart production.
While a range opolypropylenes a
ASA have been usmanufacturing auexteriors and intepainted or textureand trim to substpressed sheet-mepolyamides and ahave been substitfor cast metals forand noise reductimaterial propertiefamily of plastics tuned into the coto cater to the sperequirement of thand its structure. plastics and reinfadditives and its aappropriate enginand design are limin lightweighting by the creativity odevelopment team
One product thhas progressively
weight over a peris the oil sump whtraditionally builtmetal diecast, andmade of polyamiis a basic design inplastics applicatioan estimated 4kg10kg in metal diec
ZOOM AUTOMThis Mumbai-basmakes plastic fuefor passenger cars
Automotive tied u YAPP AutomotiveCompany of Chintechnical assistanmake plastic fuel plant at Maraimanear Chennai.
To make these tanks, it has beenHDPE sourced frKorea. The compasupplied its first l
Zoom Automotive suppliesplastic fuel tanks to theFord Fiesta and the newlylaunched Figo.
Mutual Industries'oil sump made usingpolyamide is 6kg lighterthan a metal diecast one.
Yamaha plans to increasethe number of plastic partsin its bikes to reduce weight.
Honda Siel uses high-tensile steelin its cars as also magnesium,aluminium and high quality plastic.
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plastic fuel tank to FordIndia for the Fiesta saloon.The Figo, Ford’s small caroffering for India, also hasa Zoom-made plastic fueltank.
According to Zoom, if an OEM wants to reducethe weight of the fuelsystem, then the entire
system comprising tanks,filler pipes, fuel lines andengine would have to bemade of plastic for thereto be significant weightreduction. It currently supplies the fuel tank andfiller pipes dependingon the OEM and theirrequirements.
The company usesthe co-ex blow mouldingprocess to make its tanks
which are either monolayer(used in diesel cars) andmultilayer (for petrol cars).
dsM ENGINEErINGPLAsTICsThis company, whichprovides a range of engineering plastics toTier I and Tier II suppliers,has been working withmany OEMs to convertcomponents made withmetals to plastics with high-performance engineeringthermoplastics. Thematerials used withstandhigh temperatures, high
wear and tear and frictionresistance and haveenabled DSM to reduce part
weights by upto 70 percent.
These materialscan have mechanicalproperties that are ascomparable if not betterthan diecast aluminium.The alternatives that DSMprovides OEMs includeparts integration anddesign flexibility, apart from
weight and cost reduction.
DSM also provides CAEservices to auto companiesto help them evaluatethe conversion of partscurrently made from steelinto plastics with the aim of
weight reduction. As far as alternative
materials go, the company uses Akulon Ultraflow – PA6– from unfilled upto 60percent glass filling, Stanyl– PA46 – a high temperature,high wear and friction-resistant material, Arnitel– TPE-E for metal tubingsto plastic tubings and
Arnite – PBT / PET. Thereare several applicationsand these include Akulon– PA6 – that has been usedto lower the weight of autoapplications for productssuch as air intake manifoldsand cylinder head covers.DSM Engineering Plasticshas also used Arnite – PETto reduce the weight forapplications such aspulleys. The company hasalso used Stanyl – PA46 tolower the weight of va riousgears and Arnitel –TPE andStanyl PA 46 to reduce the
weight of air ducts.
ALKrAfTTHErMOPLAsTICsThis Chennai-basedmanufacturer hasdeveloped a plasticheader for intercoolersin commercial vehicles.Samples have beensupplied to few OEMsand clearances are
awaited. The genesisof the development wasdriven by value engineeringand productivity. Whilecost savings were anestimated five percent,final assembly productivity improved about fivetimes.
While plastic tank technology is already available for intercoolers,this was restricted topassenger cars. However,operating temperaturesin CVs are high. Forinstance, the operatinginlet temperature foran intercooler can be ashigh as 180deg C. Theexisting plastic materialcannot withstandtemperatures beyond130deg C. Therefore, thechallenge was to sourcethe right material whichcould withstand highertemperatures. Alkraft wasable to achieve this by using specially developedengineering plastics. Thenext challenge was tofinetune the manufacturingprocess as this type of special engineering plastic
is not commonly The newly deve
plastic header tanabout 1kg less thaconventional tankintermediate CVs
weight reductionin the range of 2.5M&HCVs. In addithe plastic tanks a
better aesthetics aimproved producassembly comparconventional welassembly processnormal tanks.
IsPAT INdUsTrThe steel manufahot-rolled steel thin the automotiveutilises the compsteel-making tech- CONA RC - Thin- CSP - that providseveral benefits toThese include vercarbon content inenhances weldabincreases ductilityformability, and ltogether with micalloying induced
which provides chigher strength. Tmakes steel that istrong.
The key benefiIspat's steel is theto-weight ratio. Itclients for auto-grinclude componeattached to leadinTata Motors and Suzuki.
Nitin Kothari, MD - DSMEngineering Plastics saysits products can helpautomakers reduce partweights by upto 70 percent.
DSM Engineering Plastics has awide portolio o products thatcan help OEMs replace metal.
Vinod Mittal, vice-chairmanand managing director,Ispat Industries: "The keybeneft o our steel is thestrength-to-weight ratio."
Alkrat has developed a plastic headeror intercoolers in CVs.
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dELPHI TECHNICALCENTrE INdIAComponent manufacturerDelphi has undertakenseveral steps to reduce the
weight of its components.It cut the weight of EngineManagement Systems by optimising the design of
enclosure and reducingthe board size by usingcompact electronicspackaging. Delphi’s safety sensors are moulded inplastic, which help reducethe weight by almost 30percent as compared toconventional sensors.
The company is atpresent experimenting withpotentially high strengthplastics which help reducecomponent and vehicle
weight.As regards productsthat it has worked on,Delphi has reduced weightin powertrain controllers,infotainment products,body control modules,safety sensors and hybridvehicle electronics. Theinfotainment product ismoulded in plastic thereby replacing the conventionalsteel packaging. This hasreduced the weight of the product by almost50 percent, which hashelped in delivering betterperformance. Delphi hasalso used integrated high-end technologies like ‘jetimpingement cooling inhybrid vehicle electronics,
which has helped inreducing weight.
Delphi says it developstechnologies and productsin line with its core theme of safety and eco-friendliness.
With regard to its plans,they are integration of multiple body control
modules into singleproduct; optimising andreplacing steel structure inhybrid vehicle electronicsmodule with high strengthplastics and developingsolutions to expel heatthrough plastics.
As far as the integrationof multiple body controlmodule goes, this helpsin consolidating differentcomponents into onemodule. For example,
window lifters, headlightlevelers, wipers and otherelectronic switches. Apartfrom reducing the weightof the vehicle, it providesthe OEMs a complete andsingle-box solution insteadof having to purchasedifferent electronics boxesfrom different suppliers.
As far as optimising andreplacing steel structures,Delphi uses light weightsteel – 2mm steel (insteadof 3mm steel) – withadditional design featureslike stiffeners and ribsto provide strength tothe plastic. This helps inreducing the weight of thecomponent. For example,
the battery disconnect unitholding structure is madeof plastic, which can evensurvive a mild crash.
VArrOC GrOUPThe Aurangabad-basedcomponent manufacturer'smetallic division is
equipped with cold, warm and hot forgingfacilities and supported
with dedicated facilities tosupply gearbox assembliesstarting from 100cc to750cc for all two-wheelersegments.
The basis of all productsit manufactures is theforging process. As aresult of increasing raw material cost, there hasbeen pressure on thebottomline. To compensatefor increasing input costs,
weight reduction andprocess improvements arethe key objectives at Varroc.
The company says ithas used state-of-the-artmetal flow simulation forthe forging process, so alliterations of process designstart with 100 percent
yield. Its design engineersoptimise the tool design toachieve flash-less forgings.
As Varroc has both hot andcold forging manufacturingfacilities in-house, thecombination of hot andcold forging is used tominimise component
weight.
Examples incluless forging develfor gear blanks up2kg weight, Varrodeveloped the flaforging concept, wis being deployednew componentstechnology has h
up to 300 grams oper part.
Also, critical co which can be mamachining proceincreased input whave been develoThe shapes generforging are near-nlittle machining ato meet surface firequirements.
The company works closely withOEMs to reduce wright from the constage. This resultsoptimised weightand low cost to boplayers. Examplesthe kick gear and internal faces of gblanks. One examproduct that it haable to reduce wesignificantly isthe component fo
which was reduc2.06kg to 1.6kg. Thhas been done thprototype sampleuse of flashless dehelped eliminate trimming operatireduce machining
Varroc works closely with OEMs to cut component where are a camshat, spindle steering and a ront w
Delphi has reduced weightin a number o componentslike powertrain coolingmodules.
Tarak Balaji, director,Delphi Technical CentreIndia: "We will continue toimprovise our products tomake the vehicles lighter,saer and greener."
Delphi’s Bussed Electrical Centers (BEC) simpliy Electronic/Electricalarchitecture. The company has reduced weight in this key component.
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