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An outlook on multi material body solutions in the automotive industry – possibilities and manufacturing challenges
Linköping University, Department of Management and Engineering, Machine Design. Linköping University, Faculty of Science & Engineering.ORCID iD: 0000-0002-4170-8860
Linköping University, Department of Management and Engineering, Machine Design. Linköping University, Faculty of Science & Engineering.ORCID iD: 0000-0003-1646-5817
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 [en]
Multi material bodies, Production development, Product development
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:liu:diva-127319DOI: 10.4271/2016-01-1332OAI: oai:DiVA.org:liu-127319DiVA: diva2:921397
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
In thesis
1. Introducing New Materials in the Automotive Industry: Managing the Complexity of Introducing New Materials in Existing Production Systems
Open this publication in new window or tab >>Introducing New Materials in the Automotive Industry: Managing the Complexity of Introducing New Materials in Existing Production Systems
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. 135 p.
Series
Linköping Studies in Science and Technology. Thesis, ISSN 0280-7971 ; 1793
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:liu:diva-142873 (URN)10.3384/lic.diva-142873 (DOI)9789176853979 (ISBN)
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

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Henriksson, FredrikJohansen, Kerstin
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