Conceptual Development of Hybrid Structures Towards Eco-Efficient Vehicle Lightweighting

Abstract

Lightweight design is a major strategy in automotive development. The dominant motivation is a reduction of use-phase energy demands while retaining or improving technical performance. The application of new materials is the prevalent lightweighting strategy. Modern vehicle concepts extend material substitution up to the combination of different materials on a component level, so called hybrid designs. While engineering processes, methods and tools in design and production engineering are well established for conventional designs, hybrid designs pose new challenges. Lightweight materials as well as new manufacturing and recycling processes may cause increased environmental impacts. In order to achieve eco-efficient lightweight structures, energy savings from the vehicles’ use phase need to compensate additional burdens in other lifecycle stages. The current work presents findings gained in a public-private research collaboration. Its starting point is the understanding of the role of life cycle engineering towards its impact on overall sustainability goals. Based on derived key requirements, an integrated life cycle engineering approach is developed. Activities and interfaces between life cycle engineering, component design and manufacturing are elaborated. A special focus is set on the conceptual design stage, as emerging materials and manufacturing technologies lead to a broader concept variety. This stage presents also a major lever for shaping the life cycle environmental impact of components.