Abstract

The main objective of the LIGHTRANS project is the design and development of lightweight multi-material structures, through the development of optimized and low-cost manufacturing and joining processes. Which should allow its application in eco-efficient road transport vehicles. More specifically, within the framework of this project, the redesign  of a bus superstructure as well as an electric three-wheeled  vehicle will      be developed. Within the LIGHTRANS project, due to the needs of the market, it is proposed to strategically combine materials of different nature in such a way that the resulting structures present a weight reduction but without affecting the properties of the final components. The multimaterial structurals developed within the framework of the project, for both study cases, are based on thermosetting and thermoplastic compounds, cellular polymers and steel. Throughout this article, the mechanical characterization of the materials used for the manufacture of the components of both study cases, the manufacture of all the proposed components, as well as the evaluation of each of them in the final structures through tests will be presented. field.

Abstract

The present work addresses different aspects of the manufacturing process optimization of structural components for the automotive sector. More precisley the development of a novel bumper beam is being pursued by combining steel and composite to achieve, ultimatly, a weight reduction of the current component. For this it has been fundamental to consider not only the requirements of the part, specially from the safety prespective, but also manufacturing criteria.

The study carried out has included everything from the design of the component up to the evaluation of a wide range of composite materials, both of thermostable and thermoplastic nature. Thus, different manufacturing technologies together with their process window and tooling desing has been accomplished in this work. In addition, several surface treatment technologies including cutting-edge ones such as laser texturing, have been combined with different strategies to ensure, in this way, the optimal performance of the solution.

Finally, the development of ad-hoc demonstrators has allowed identifying the most suitable design and materials. Also, it has been possible to quantify the performance of the components, process times and final cost. Finally, a 25% weight reduction has been achieved, maintaining the mechanical properties and cycle times down to 5 minutes.