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Introducing New Materials in the Automotive Industry: Managing the Complexity of Introducing New Materials in Existing Production Systems
Linköping University, Department of Management and Engineering, Machine Design. Linköping University, Faculty of Science & Engineering.ORCID iD: 0000-0002-4170-8860
2017 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Passenger vehicles are central to Western society, and contribute to a significant part of our greenhouse gas emissions. In order to reduce emissions, the automotive industry as a whole is working to reduce mass in passenger vehicles in order to reduce energy consumption. One way to reduce mass is to introduce lightweight materials in the body of the vehicle. This research aims to explore the relationship between product and production system when introducing new materials.

Besides a theoretical review and an industry-centered technological mapping, four case studies have been conducted during the course of this licentiate thesis. Two case studies were conducted with engineering design students working as development teams, one case study with the author as the developer and finally one case study in an industrial environment at a product owning company with in-house production. The goal of the case studies has been to increase the collective knowledge of how product development decisions affect production development decisions, and vice versa, when developing passenger vehicles in new materials.

In the following analysis of case study outcomes, a number of factors important for introducing new materials are discussed. The relationship between product and production is investigated, both in terms of how the production system affects the product and how the product affects the production system. The outcome from this analysis is a mapping of important factors for automotive industry companies to understand and identify when looking at introducing new materials in existing production systems. Finally, a suggestion for future research efforts is presented.

Place, publisher, year, edition, pages
Linköping: Linköping University Electronic Press, 2017. , p. 135
Series
Linköping Studies in Science and Technology. Thesis, ISSN 0280-7971 ; 1793
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:liu:diva-142873DOI: 10.3384/lic.diva-142873ISBN: 9789176853979 (print)OAI: oai:DiVA.org:liu-142873DiVA, id: diva2:1155571
Presentation
2017-11-09, ACAS, A-huset, Campus Valla, Linköping, 09:15 (English)
Opponent
Supervisors
Available from: 2017-11-08 Created: 2017-11-08 Last updated: 2017-11-20Bibliographically approved
List of papers
1. An outlook on multi material body solutions in the automotive industry – possibilities and manufacturing challenges
Open this publication in new window or tab >>An outlook on multi material body solutions in the automotive industry – possibilities and manufacturing challenges
2016 (English)In: SAE Technical Paper Series, Detroit (MI), USA: Society of Automotive Engineers, 2016Conference paper, Published paper (Refereed)
Abstract [en]

In the automotive industry, mass reduction and lightweight design is a continuing trend that does not show signs of declining. When looking at where to reduce weight in a vehicle, the body is a preferential subsystem due to its large contribution to overall mass and the stability of body composition over a specific model range. The automotive industry of today moves toward a greater differentiation in materials that compose a car, which can be seen in the several different multi material vehicle bodies that have been introduced by manufacturers in recent years. But while mixing materials may contribute to a good compromise between weight reduction and vehicle cost, it also proposes a number of challenges that need to be addressed. Among other material factors, the different coefficients of thermal expansions might introduce new stresses during painting and curing. Joining processes and possible chemical reactions between materials also needs to be taken into account, the same with the question of whether to integrate or differentiate different functions in a system. If the manufacturing plant uses mixed model assembly lines, design of end effectors for gripping multiple different materials is another challenge not previously encountered in this context. In this paper, a number of production and manufacturing related challenges are discussed, and the authors highlight different areas where the requirements of design engineering tools needs to be evaluated for these new multi material concepts and design decisions in order for automotive manufacturers to ensure future market competitiveness.

Place, publisher, year, edition, pages
Detroit (MI), USA: Society of Automotive Engineers, 2016
Keyword
Multi material bodies, Production development, Product development
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:liu:diva-127319 (URN)10.4271/2016-01-1332 (DOI)
Conference
SAE 2016 World Congress and Exhibition
Projects
Produktion2030 - Storskalig tillverkning av produkter i flera material
Funder
VINNOVA
Available from: 2016-04-20 Created: 2016-04-20 Last updated: 2017-11-08Bibliographically approved
2. On Material Substitution in Automotive BIWs – From Steel to Aluminum Body Sides
Open this publication in new window or tab >>On Material Substitution in Automotive BIWs – From Steel to Aluminum Body Sides
2016 (English)In: 26TH CIRP DESIGN CONFERENCE / [ed] Wang, Lihui; Kjellberg, Torsten, Elsevier, 2016, Vol. 50, p. 683-688Conference paper, Published paper (Refereed)
Abstract [en]

Weight reduction and material substitution are increasing trends in the automotive industry. In this project, the task of substituting the steel body side in the monocoque of a large SUV towards an aluminum body side was investigated through a design engineering approach adopting a breadth-first analysis method. One conclusion based on the analysis is that the choice of joining technology would become arbitrary due to the breadth-first approach. In this paper, the authors present their findings from the aforementioned case, including the challenges with switching between materials with fundamentally different properties when performing material substitution projects. The possibility of having taken a depth-first analysis approach, and the possible effects on the project result, is discussed.

Place, publisher, year, edition, pages
Elsevier, 2016
Series
Procedia CIRP, ISSN 2212-8271 ; 50
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:liu:diva-130510 (URN)10.1016/j.procir.2016.05.028 (DOI)000387666600115 ()
Conference
26th CIRP Design Conference
Projects
Produktion 2030 - Storskalig tillverkning av produkter i flera material
Funder
VINNOVA
Available from: 2016-08-11 Created: 2016-08-11 Last updated: 2017-11-08
3. Including Student Case Projects in Integrated Product and Production Development Research – Methodology Description and Discussion
Open this publication in new window or tab >>Including Student Case Projects in Integrated Product and Production Development Research – Methodology Description and Discussion
2016 (English)Conference paper, Oral presentation only (Other academic)
Abstract [en]

Within integrated product and production development research, casestudies needto be performed for data gathering purposes. Today, there are two commonly used ways to perform this research; observingindustry projects orhaving the researchers perform the projects themselves. The first option can pose data access and IPRissues, and the second optioncomes with biasing risks. Another approach is to work with studentcaseprojects, givingstudents interesting projects and findinga solution to mediate both data gathering opportunity and biasing risks. This approach has been tested at Linköping University, with students performing projects in the Vinnovafunded Production 2030 –Large Scale Production in Mixed Materials project. Two larger student case projects have been performed on the topic of material substitution and mixed material solutions within the automotive industry.In this paper, the method used to include student projects is presented along with identified benefits and drawbacks. Including student case projects in research have shown to be beneficial in research on processes, projects and methodology, but needs to be complemented by data fromindustry projects and the researcher ́s own work within integrated product and production development in order to create a more reliable analysis with high level of detail.

Keyword
Case studies, Integrated product and production development, mixed material solutions
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:liu:diva-142930 (URN)
Conference
7th Swedish Production Symposium, SPS, Lund, October 25-27, 2016
Funder
VINNOVA
Note

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Available from: 2017-11-13 Created: 2017-11-13 Last updated: 2017-11-20

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