Optimizing Body Structures Designs to Minimize Environmental Impact

Abstract

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