Optimizing Body Structures Designs to Minimize Environmental Impact
Typ
Examensarbete för masterexamen
Master's Thesis
Master's Thesis
Program
Mobility engineering (MPMOB), MSc
Publicerad
2024
Författare
Kulkarni, Aditya
Vishwanath, Anirudh Mosale
Modellbyggare
Tidskriftstitel
ISSN
Volymtitel
Utgivare
Sammanfattning
Industries emitted a record 36.2 billion tons of CO2e emissions in 2022, highlighting
the need for sustainable products and manufacturing processes. In view of this,
the study was aimed at enhancing the sustainability of automotive Body In White
(BIW) structures by exploring alternative designs.
Hence, this thesis aims to investigate and provide insights into the feasibility and
advantages, if any, of transitioning from presently used materials and manufacturing
process at Zeekr, to an alternative option for sustainable component development.
The study enlists comparative solutions to enhance sustainability in BIW structures,
with a central focus on mitigating CO2 emissions. The core proposal involves
redesigning of existing automotive body structure components using alternative materials
and suitable manufacturing processes.
The thesis is divided into two phases; Phase 1 and Phase 2. Phase 1 begins with
theoretical calculations and Euro NCAP-based and RCAR load cases, followed by
Computer Aided Drawing (CAD) in Catia V5, Computer Aided Engineering (CAE)
simulations (in Ansys, Abaqus and LS-Dyna), and finally Life Cycle Inventory (LCI)
analysis. These were carried out for two existing simplified geometries of body structure
components; side sill/ rocker and front crash box. The aim here was to better
understand the affecting parameters and their effects on predefined performance
standards. This serves as a stepping stone for Phase 2.
In Phase 2, we strategically re-designed the front Crash Management System (CMS)
to reduce CO2 impact while maintaining structural performance, guided by Phase
1 insights.CAE simulations were employed to refine the designs, allowing for a thorough
assessment of materials and manufacturing processes. Through Life Cycle
Assessment (in OpenLCA), resulting CO2e emissions from current and re-designed
parts were studied and the better option among the two was recommended for possible
vehicle integration
Beskrivning
Ämne/nyckelord
sustainability , body structure designs , steel , aluminium , biw , manufacturing processes , life cycle assessment