6AAD0023 Vehicle Structure Analysis and Manufacture - University of Hertfordshire

Assignment - Materials and manufacturing strategy for the development a small sports car

Learning Outcome 1: Describe typical automotive forming, joining and finishing processes;
Learning Outcome 2: Identify the principal forms of automotive corrosion;
Learning Outcome 3: Identify the techniques used to analyse automotive sheet formability.

Assignment Brief:
You are asked to write an individual report of not more than eight (8) pages long on the materials and manufacturing changes that need to be considered by an automotive company (experienced in the manufacture of aluminium-intensive vehicle body structures) in the development of a small, all-electric sports car. Please refer to the next page for full details.

Assignment Title: Materials and manufacturing strategy for the development a small sports car

Traditionally, vehicle body structures have been mild steel-based, as steel is relatively cheap and formable. However, demands for lighter, stronger, stiffer and (sometimes) cheaper vehicles have encouraged manufacturers to consider different body materials over the past 20 years which have required the development of alternative manufacturing processes. The options available to OEMs can be summarised as:

1. High volume, small and medium-sized vehicles with conventional powertrains are likely to focus on steel-intensive bodies but with greater use of high-strength steels;

2. Medium volume vehicles and electric vehicles are likely to seek multi-material solutions, using a mix of aluminium alloys, high-strength steels, magnesium and fibre composites;

3. Low volume, niche vehicles will also use a mix of materials, but with greater use of carbon-fibre composites (luxury end) and glass-fibre composites (non-luxury end).

This movement to alternative materialshas necessitated the development of:
• different component forming processes;
• alternative assembly processes, particularly in relation to the joining of components made of different materials;
• adapted paint shop processes, again to accommodate different materials in the body and to combat the additional body corrosion challenges.

You are the Senior Design Manager for a high-end passenger car manufacturing company, specialising in medium volume, aluminium-intensive vehicles. The company is at the feasibility stage fora smallsports car (high-end, but not luxury). The manufacturer is aware of the fact that this low-volume model will necessitate a review of its all-aluminium strategy, and consideralternative metals and fibre-reinforced composites for the body.

Having relied on an aluminium-intensive monocoque design for many years, the company has little retained experience in the use ofalternative materials such as high strength steels, magnesium alloys orfibre composites. To explore these alternative technologies and process conditions, a short review is required to inform the company of the processes, their advantages and disadvantages (including data on the materials, manufacturing technologies, the costs, economic benefits and challenges) and make recommendations on how the company should move forward.

Your Manager has asked you to prepare a summary report of not more than EIGHT pages (inclusive of figures, tables but exclusive of references) in which you should:

1. Provide an argument for considering alternative materialsand associated manufacturing processes for the vehicle body, including the advantages of doing so;

2. Identify any manufacturing problems that might arise. You must give reasons why these problems may occur in terms of forming, joining and finishing;

3. Where possible, suggest solutions to the problems identified in 2, above.

4. Include a list of references (Harvard referencing style).

Attachment:- Vehicle Structure Analysis.rar