The reduction of air pollution caused by transports is a current and relevant topic. In this context, the present work focused on the automotive lightweighting of commercial vehicles and buses, which currently is not widely investigated. In particular, aim of this research is to develop a technically reliable and cost effective safety component for Light Commercial Vehicles (LCVs) in aluminum alloy. This solution guarantees a weight saving between about 40 and 50% in comparison with the traditional welded sheet metal structure. In addition, the better corrosion resistance of the selected aluminum alloy that allows to avoid an additional protective treatment gave further environmental benefits. The project was developed with a detailed technical analysis summarized as following: a preliminary examination of the different lightweighting solutions through FEA and laboratory analysis, process features definition, design improvement, life cycle assessment analysis, prototypes production and validation. In particular, the final component was an HPDC AlSi9MnMg with dimensions of about 1260x450 mm and weight of about 15 Kg. The Life Cycle Assessment analysis demonstrated the environmental relevance of the lightweight of these components. Finally, the validation tests were successfully passed.
Analysis and Development of a Safety Relevant Component for Commercial Vehicles
CORNACCHIA, Giovanna;PANVINI, Andrea;
2018-01-01
Abstract
The reduction of air pollution caused by transports is a current and relevant topic. In this context, the present work focused on the automotive lightweighting of commercial vehicles and buses, which currently is not widely investigated. In particular, aim of this research is to develop a technically reliable and cost effective safety component for Light Commercial Vehicles (LCVs) in aluminum alloy. This solution guarantees a weight saving between about 40 and 50% in comparison with the traditional welded sheet metal structure. In addition, the better corrosion resistance of the selected aluminum alloy that allows to avoid an additional protective treatment gave further environmental benefits. The project was developed with a detailed technical analysis summarized as following: a preliminary examination of the different lightweighting solutions through FEA and laboratory analysis, process features definition, design improvement, life cycle assessment analysis, prototypes production and validation. In particular, the final component was an HPDC AlSi9MnMg with dimensions of about 1260x450 mm and weight of about 15 Kg. The Life Cycle Assessment analysis demonstrated the environmental relevance of the lightweight of these components. Finally, the validation tests were successfully passed.I documenti in IRIS sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.
