techview
The Auto Industry’s Loss Leaders
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n collaboration with the Center for Automotive Research (CAR; Ann Arbor, MI), Altair (Troy, MI) created the Enlighten Award in 2013 to recognize achievements in weight reduc- tion in the auto industry. This year’s winner is Ford Motor Co. for the 2015 F-150. Through an unprecedented use of aluminum in a mass-produced vehicle a weight saving of 700 lb (315 kg) or more per vehicle has been achieved. Ford’s well-documented efforts illustrate the importance of lightweighting today. So too does the fact that the number of contest entrants jumped from 10 in 2013 to 17 in 2015. A brief description of the 2015 runners-ups’ efforts fol- lows. A more complete description may be found at http://
tinyurl.com/poundfree. First Runner-Up, General Motors: Used CAE development methods to achieve 163.1-lb (73.4-kg) weight reduction on the architecture of the Cadillac CTS and ATS models while still providing mass effi ciency, stiffness, safety, and structural feel without degrading on-road performance characteristics. Second Runner-Up, Automotive Performance Materials
and Faurecia: Brought sustainable design to interior panels of the Peugeot 308 by integrating a hemp-based fi ber with polypropylene, which allows for complex shapes and archi- tectures along with a weight savings of 20–25%. Lightweighting an Off-Road Vehicle: BAIC Group saved 40 kg in its new model BJ40 using CFRP, magnesium, aluminum and optimized structuring of the hood, lower control arm, frame, roof, and seat frame.
Carbon Composite Grille Opening Reinforcements: BASF,
Ford and Magna Exteriors increased the overall front stiffness of the Mustang GT 350 for a 24% weight reduction. Composite Body Structure and Panels: Continental Structural Plastics and GM created a composite material that forms most of the upper body of the 2016 Chevrolet Corvette C7. The system saved 9 kg. Victor Reinz Thermoplastic Cylinder Head Cover with
MuCell: Dana Holding Corp. reduced cylinder head cover weight by 29% in the 2015 Ford F-250 through F-550, while maintaining durability and stability by using MuCell, a mold- ing technology licensed from Trexel Industries.
James D. Sawyer Yearbook Editor
Betaforce Structural Polyurethane-based Adhesives for Lightweight Automotive Applications: Dow Automotive Systems created an adhesive for the 2014 BMW i3. Weight savings can range from 79 to almost 198 kg per vehicle. Exhaust System for GM K2xx Light Duty Truck: Faurecia Emissions Control Technologies implemented an analysis-led design and virtual validation process of the 2014 Chevrolet Silverado and GMC Sierra, which reduced the exhaust sys- tem weight 1.125 kg.
Hydraulic Gear Shift Actuator Module: FTE Automotive USA Inc. designed a 35% lighter gear shift actuator module for double clutch transmissions to shift in between gears by converting hydraulic pressure into a mechanical stroke. Steel Wheels for Commercial Vehicles: Maxion Wheels applied a new design process leveraging simulation and opti- mization processes for a 4.5-kg weight reduction. Renault Espace Lift Gate: Trinseo developed a full thermo- plastic lift gate for the 2015 Renault Espace that combines LGF-PP and TPO compounds for a 10% weight savings over the previous metallic version.
Ultra High Modulus Adhesive for Mixed Material Bonding: Sika Automotive developed a high-viscosity semi-structural adhesive with high elongation and ultra-high modulus, used for bonding mixed materials for the chassis of the BMW i3. Front Axle for Low and Medium Duty Trucks: Volvo-Eicher
Commercial Vehicle Ltd. used material removal techniques to reduce the weight of the axle by 9 kg. Cargo Body: Volvo-Eicher Commercial Vehicle Ltd. used design optimization, integrated brim type panels and rearranging the base frame crossmember pitches and side structure pitches to save 180 kg per vehicle. Cabin Wind Defl ector: Volvo-Eicher Commercial Vehicle Ltd. achieved a 25% weight reduction for a wind defl ector by utilizing a design optimization process. Transmission Housing for Commercial Vehicles: Volvo- Eicher Commercial Vehicle Ltd. cut weight by 30% while improving the performance, reliability, durability, and safety of the product by using a new process of design, CAE, proto- typing, validation and line improvements.
31 — Motorized Vehicle Manufacturing 2015
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