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An research vision towards future generation of cars using light weight materials

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Title: An research vision towards future generation of cars using light weight materials


1
An research vision towards future generation of
cars using light weight materials
  • Dr. Shankar Kalyanasundaram
  • June 6, 2007
  • DERF seminar Program

2
Some facts about automotive use in U.S.A
  • Employs millions of people
  • A vehicle is sold every two seconds excellent
    for personal mobility
  • Paved area equal to the states of Ohio, Indiana
    and Pennsylvania, requiring maintenance costing
    more than 200 million per day
  • Maimed or injured 250 million people and killed
    more Americans than have died in all wars in
    Americas history
  • 8 million barrels of oil is used every day
  • Creates 7 billion pounds of unrecycled scrap and
    waste every year
  • Emits lots of greenhouse gases (estimate include
    one-fourth of U.S generation of greenhouse gases)
  • Reference Natural Capitalism- The next
    Industrial Revolution P. Hawken, A.B. Lovins,
    L.H Lovins

3
How about efficiency?
  • 80 of the fuel consumption is lost mainly in the
    engines heat and exhaust
  • Of the resulting force 95 is spent on moving the
    car and only 5 is spent on moving the driver
  • 1 of fuel consumed is actually used in moving
    the passengers (1 cent for every dollar that one
    spends on petrol)

4
What should we do?
  • Get rid of cars and use alternate modes of
    transportation
  • Holy Cow!!!!

5
Bullock Cart is the answer!!
6
What is the answer?
  • Needs to be ultra light weight
  • Needs to have ultra-low-drag behavior
  • Need a more efficient propulsion system
  • Hybrid-electric
  • Alternate fuels Fuel Cell Technology
  • Need to be fully recyclable
  • Need to blend in todays best technology
  • Need to be commercially viable to produce and
    provide the customers with a real value for
    money

7
Our research focus
  • Develop a research framework for manufacturing
    light weight materials for mass production (stamp
    forming)
  • Composite materials
  • Sandwich structures
  • Lightweight materials are currently used in low
    volume long production time applications
    (aerospace)

8
STAMP Forming of Metals
  • High volume production
  • 2 minutes for each part
  • couple of hundreds of parts per shift
  • Quality indicators
  • Splitting
  • Wrinkling
  • Spring back (Geometrical tolerance)
  • Generally involves room temperature manufacturing

9
Stamp forming
10
Research challenges on light weight material
forming
  • Develop an unified approach that combines
    numerical (FEA), analytical and experimental work
  • The problem is governed by a large number of
    highly nonlinear coupled equations (FEA)
  • Need realistic mechanics models to characterize
    the material behavior, interfaces and failure
    behaviors
  • We have developed a novel experimental
    methodology to measure deformation behavior real
    time during forming first of its kind in the
    world for light weight materials

11
Strain Measurement
Punch
Sample
Cameras
12
Some results on failure behavior
  • Wrinkle and crack formation
  • Glass-reinforced FML cup

13
Animations of simulations
14
Channel forming
15
Validation of Finite Element Simulations
  • Measurement of surface strain in stamped forms
    used to validate modeling
  • Major strain for top surface of aluminium cup
  • Aramis above
  • LS DYNA (FEA) right

16
Key findings so far
  • Need to heat the samples before forming
  • The material combinations can play a very
    critical role in producing a defect free part in
    addition to process variables
  • Light weight materials can have superior forming
    characteristics compared to their monolithic
    metals --- Yes there is a big future for them in
    commercial productions!!
  • Research is currently underway to produce an
    unified approach (improved and better than
    anyone) to handle this important problem in large
    scale manufacturing

17
Future Challenges
  • Technology Transfer Issues
  • Need a Seamless manufacturing technology (from
    design to production)
  • Cost
  • System Integration
  • Joining
  • Painting
  • Repair and maintenance
  • Organizational behavioral issues
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