Reducing the weight of vehicle

In a ground vehicle with a suspension, the unsprung mass is the mass of the suspension, wheels or tracks (as applicable), and other components directly connected to them, rather than supported by the suspension.

 Vehicle weight reduction particularly unsprung mass reduction saves energy, minimizes brake and tire wear, and, perhaps most welcome, it cuts down emissions. Lightweighting vehicles is directly linked to lower CO2 emissions and improved fuel economy. The benefits of even modest vehicle weight reduction are significant. Reducing an automobile’s weight by a mere 50 kg (110 lbs) reduces up to 5 g of CO2 /km and increases fuel economy by up to 2%.

The reduction of unsprung mass can also benefit in performance, ride and handling of vehicles particularly passenger cars and utility vehicles

Various approaches for weight reduction could be use of polymer or engineering plastics, Aluminum or hybrid constructions ( combination of different materials)

While downgauging or reducing thickness of body steel components can be attempted by increasing usage of advanced high strength steels for body as well as chassis parts , use of composite/engineering plastics for body panels and less load bearing components can be done. .Also the tubular construction /design can be an option in place of a solid section.

With development of hot stamping the strength levels upto 1400 Mpa could be achieved in steel sheets with a defined chemistry.

The lightweghting in case of castings and forgings can be achieved by optimization , thereby weight reduction.

Even for autoelectricals the weight reduction can be achieved by reducing solenoid weight through use of advanced thermoplastics, reduction of weight for battery cables and wiring harness assemblies by using a hybrid construction of Copper and Aluminum.

All the above weight reduction approaches need to be studied carefully through load analysis/CAE , stress levels experienced by the part under the various loading conditions, manufacturing feasibility, freedom from defects through use of advanced simulation software in castings and forgings . Also it is important to use a proper problem solving/failure analysis techniques in case of any failures in usage to find out the real root uase and addressing the same. Normally wth initial failure such ideas are abandoned

We at materials info can help you to take through this journey of lightweighting of your components/aggregates thus achieving the final goal of reducing the environmental burden .