EXPERT SYSTEM BASED APPROACH FOR MATERIAL SELECTION OF AUTOMOBILE BODY-IN-WHITE STRUCTURAL PANELS USING NUMERICAL RANKING AND SUSTAINABILITY INDICES

The goal of this work is to establish a set of quantifiable measures for design for sustainability (DFS) that can be applied to automotive applications in terms of environmental, social, economic and technical aspects. In this study, a comprehensive analysis was made in order to develop a methodology that can evaluate different body-in-white designs in terms of major sustainability aspects. Besides the complete life cycle analysis, environmental impacts and cost factors will be analyzed over vehicle\u27s entire life-cycle (fuel extraction and refining, Pre-manufacturing, Manufacturing, Use, and Post-use stages). The considered material options include: conventional steel, high strength steel, aluminum, magnesium, titanium and composites that are currently used in body-in-white (BIW) structures and exterior body panels. Sustainability scoring method was developed and used to decide on how using lighter materials in auto body applications is beneficial or not. The proposed major sustainable factors are categorized into four major groups: environmental, economical, social and technical groups. Also, each group has corresponding factors which were chosen by extensive search and screening, so only important sustainability aspects for auto body design have been selected in this study. Then the dissertation proceeds to show some sustainability scoring methods in order to get better understanding as well as relative ranking for different materials from sustainability point of view. Moreover, this work discusses the role and application of some multi-criteria decision making methods in materials selection, namely quality function deployment (QFD) and analytic hierarchy process (AHP). However, multi-criteria decision making methods are efficient tools to choose alternative from large set of alternatives, especially when two or more conflicting goals are present. Besides that, knowledge based system (KBS) was established for eco-material selection for auto-body structural panels. The goal behind using KBS is to help designers in material selection process which usually needs experience, time and effort

A review of composite material applications in the automotive industry for the electric and hybrid vehicle

A review is made of the state-of-the-art in regard to the use of composite materials for reducing the structural mass of automobiles. Reduction of mass provides, in addition to other engineering improvements, increased performance/range advantages that are particularly needed in the electric and hybrid vehicle field. Problems encountered include the attainment of mass production techniques and the prevention of environmental hazards

An Energy Efficient Turning Process for Hardened Material with Multi-Criteria Optimization

This paper presents a systematic procedure for the optimization of machining parameters such as cutting speed, feed rate, nose radius, edge radius, and rake angle to reduce specific material removal energy and improve energy efficiency in the hard turning of AISI 4140 steel. A simulation approach was applied in conjunction with the design of experiment (DOE), mathematical approximation with a meta-model to develop specific energy as well as an energy efficiency model in terms of cutting parameters. A hybrid approach that combines the Multi-Objective Particle Swarm Optimization (MOPSO) and the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) using entropy weights was adopted to determine the best solution from the Pareto set. The results showed that energy efficiency could be improved by 11%, whereas specific energy decreased by approximately 15% compared to a non-optimal case. Therefore, this study is expected as a contribution to making the turning process of hardened materials greener and more efficient

Material selection processes in the automotive industry

http://deepblue.lib.umich.edu/bitstream/2027.42/1034/2/85481.0001.001.pd

A study of optimal automotive materials choice given market and regulatory uncertainty

Thesis (S.M. in Technology and Policy)--Massachusetts Institute of Technology, Engineering Systems Division, Technology and Policy Program, 2008.Includes bibliographical references (p. 183-185).This present thesis hypothesized that the increasing demand for fuel-efficient vehicles, recently updated Corporate Average Fuel Economy (CAFE) regulation, and volatile U.S. sales markets may foreshadow a shift in the competitiveness of lightweight alternative materials relative to incumbent steels. To test this hypothesis, a novel automotive materials selection methodology was developed which evaluates the net present value (NPV) of vehicle projects by incorporating five integrated models: (1) an ADVISORbased vehicle performance model, (2) a market model that predicts expected annual sales, (3) a cost model that maps technology decisions and sales levels to fixed and variable costs, (4) a binomial lattice model of demand uncertainty, and (5) a regulatory model that mimics CAFE. The integrated model solves materials selection problems by optimization, using explicit simulation to find the set of materials choices for which the NPV of a vehicle project is maximized. A case study was developed to illuminate the competitive dynamics between incumbent steel and lightweight composite materials in two vehicle subsystems (body-in-white, closure set) and three vehicle markets (small car, mid-size car, luxury car). The results suggest that the value of acceleration improvements due to a lightweight materials enabled vehicle mass reduction is greater than the value of concurrent fuel economy improvements. When the value of acceleration improvements and fuel economy improvements are considered, the production volume at which it becomes economically efficient to switch from using composites to using steel shifts from the cost-competitive production volume to a higher one. The magnitude of this shift depends on the degree to which the car market values performance improvements and the rate at which composites become more costly than steel. Generally, more stringent CAFE policies were found to improve composite materials' competitiveness to a greater degree than the effects of demand uncertainty.by Robert Joseph Cirincione, Jr.S.M.in Technology and Polic

Study on feasibility and viability of applying eco-friendly material for the “be”-car bonnet for a sustainable automotive part

The usage of plastic parts and metals parts in automotive industries is causally related to the negative impact on the environment. The fact behind using plastic auto parts is that they give the same strength as metal parts in minimal weight. However, the plastic parts are nonbiodegradable, and the extraction of mineral ores lead to the polluted environment, physical landscape disturbances, and substantial harms. Thus, this research is to find an alternative solution for such kind of problems. To begin with, attempts were performed in order to analyze the feasibility and viability of using natural fiber composites for a semi-structural or small structural auto part. In this study, the part to be studied is an automotive bonnet. Two significant parts comprise the bonnet system, the skin and the supporting frame. The objective is to replace the plastic/metal bonnet skin with an NFRP (Natural Fiber Reinforced Plastic) so that the part can be sustainable and eco-friendly. The bonnet is one of the critical components in an automobile. They have to fulfill many pedestrian safety requirements in order to successfully be certified by the NCAP, apart from being an engine cover. This research is concerned about the bonnet of a new car called “Be”, which CEIIA is developing for a sustainable automotive future. Based on brief studies on the bonnet system, the NFRPs, and the safety requirements for the bonnet system, the use of sustainable materials and corresponding manufacturing process selection was carried out. Using the selected material, a composite laminate is manufactured using a suitable manufacturing process to produce a sustainable and eco-friendly composite. To answer many of the significant questions such as strength and the sustainability of the composite part, various mechanical testing and numerical simulations were performed and checked with the requirement matrix. Two kinds of the recycling process are carried out, and the composite was successfully recycled to prove its sustainability. This investigation has been performed as a “CEIIA - Product Development Project,” and as a master thesis for “Instituto Superior de Engenharia do Porto,” during February-October 2018

Innovative composite materials application in the design of seats and interior parts

The constant increase of petroleum price and the always more strict regulations regarding the emissions level and environmental impact are today the main leading factors that drive worldwide car makers to make efforts in the research of lightweight solutions in order to decrease the fuel consumption and, as a consequence, to reduce the CO 2 amount released in the atmosphere. In this work the attention is focused on innovative materials, such as thermoplastic composites due to their low density, easiness of manufacturing and possibility to be recycled. The case study is geared towards the design of interior components, and in particular to the substitution of a current rear seat back steel structure, meeting stringent weight and stiffness requirements. Abaqus software is used in the conduction of Finite Element Analysis of the component. Cost and manufacturing aspects of the proposed design solution are investigated on order to provide a detailed feasibility overview

Prospective Environmental Analyses of Emerging Technology: A Critique, a Proposed Methodology, and a Case Study on Incremental Sheet Forming

Peer Reviewedhttps://deepblue.lib.umich.edu/bitstream/2027.42/154436/1/jiec12748-sup-0001-SuppMat.pdfhttps://deepblue.lib.umich.edu/bitstream/2027.42/154436/2/jiec12748_am.pdfhttps://deepblue.lib.umich.edu/bitstream/2027.42/154436/3/jiec12748.pd

Metodología para el análisis de la sostenibilidad de piezas de plástico inyectadas

Esta tesis se centra en el análisis de la sostenibilidad de las piezas de plástico inyectadas, considerando dos dimensiones, el impacto ambiental y económico y focalizándose especialmente en el análisis del proceso de fabricación de la inyección de plásticos, dentro del análisis de ciclo de vida completo. Los datos utilizados en el inventario del ciclo de vida suponen la clave para la obtención de unos resultados precisos en la evaluación del impacto ambiental o económico de una pieza. Esta conclusión se obtuvo del análisis de sensibilidad realizado sobre el dataset de EcoInvent, donde por ejemplo se identificó que los aditivos considerados, específicos del procesado del PVC; suponían más de un 13% del impacto ambiental.Estos resultados indican la necesidad de realizar un estudio en detalle que permita identificar de manera correcta acciones de mejora. El entender en qué se basan los datos utilizados para el cálculo de impacto ambiental, mediante metodologías como ReCiPe, permite a su vez evitar errores en análisis de ciclo de vida completosLas medidas experimentales realizadas durante la investigación reflejaron una alta variabilidad (0,3 a 2,6 kWh/kg), en función del tipo de pieza, material y máquina de inyección utilizada, mostrando una clara tendencia descendente a mayor valor de kg/h inyectados. Del total de piezas medidas se ha obtenido una media de consumo eléctrico de 1,056 kWh/kg, un 28,2% menor que el valor constante proporcionado por EcoInvent.Los valores mínimos de consumo se registraron en el procesado de piezas con máquina eléctrica (con un consumo mínimo de 0,375 kWh/kg), por lo que invertir en esta tecnología es una gran acción de mejora.Otra de las tendencias detectadas es la relación entre el consumo y el porcentaje de utilización de la máquina, siendo éste menor cuanto más optimizado esté la relación pieza/máquinaA lo largo de esta tesis, se ha revisado el estado del arte para identificar los potenciales de mejora en este ámbito de investigación. El estudio de la sostenibilidad se ha convertido, debido a la situación de la sociedad actual, en un tema relevante a estudio. Los procesos de fabricación, a gran escala, requieren un análisis en detalle que permita identificar acciones de reducción del impacto. Mediante el uso de sistemas de monitorización de energía, el modelo empírico presentado, o la metodología implementada en la aplicación informática, se permite calcular de forma más precisa la influencia que puede tener cambios en el proceso, sobre el impacto ambiental y económico de una pieza de plástico inyectada, proporcionando información novedosa ta<br /

Manufacturing of coir fibre-reinforced polymer composites by hot compression technique

This present chapter describes the manufacturing technique and properties of coir fibre-reinforced polypropylene composites manufactured using a hot press machine. The effects of basic chromium sulphate and sodium bicarbonate treatment on the physical and mechanical properties were also evaluated. Chemical treatment and fibre loading generally improved the mechanical properties. Five-hour basic chromium sulphate and sodium bicarbonate-treated coir-polypropylene had the best set of properties among all manufactured composites. Chemical treatment also improved water absorption characteristics. This proves that chemical treatment reduced the hydrophilicity of the coir fibre. Overall the hot compression technique was proved to be successful in manufacturing good quality coir reinforced polypropylene composites