A Study of Automotive Composites and Optimisation for Chassis Implementation
Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
In the quest of reducing emissions of passenger cars a trend in the car industry has recently been tointroduce lightweight composite materials to replace steel which has been the otherwise main materialto use. In this report the weight-optimising of a structural underbody for a passenger car using twodifferent manufacturing methods is described. The two methods are Advanced Sheet MouldingCompound (A-SMC) and Resin Transfer Moulding (RTM). A-SMC is characterised by a low cycle time andfast layup of the material resulting in lower cost. RTM is slower and thus more expensive but has bettermaterial properties which results in lower weight. The novel approach is to use A-SMC to construct thecomplete underbody as one piece which has not been done before. The geometry is FEM -optimised forminimum material thickness under a standard load case for torsional stiffness.The simulations showed that the underbody was not possible to be manufactured using A-SMC in itsoriginal shape without being reinforced. When reinforcing the structure it met the design constraintsand the weight was optimised to 53.9 kg with the possibility for further improvements. The RTMmethod resulted in 25.83 kg without any reinforcements but showed potential for further weightreduction by changing the geometrical design. A final analysis of the underbody combined the twomanufacturing methods and the weight was here optimised to 25.27 kg without any reinforcements.
Place, publisher, year, edition, pages
2013. , 39 p.
Trita-AVE, ISSN 1651-7660 ; 2013:08
Engineering and Technology
IdentifiersURN: urn:nbn:se:kth:diva-121508OAI: oai:DiVA.org:kth-121508DiVA: diva2:618592