POLITEKNIK KESELAMATAN TRANSPORTASI JALAN

TEGAL
• FUNCTION • SHAPE

Truck
Alat
Bus
Tranpotasi
Sedan

Metal Stamp
Non Metal Joining
Composite Painting
• MATERIAL • PROCESS
DESAIN/REKAYASA
 Product requirements
 Structural dynamics
Improvements in performance including significant
weight savings in the steel body achieved over
recent model generations are described in the
following sections and these are attributed to the
effective application of FEM analysis and the
interrelationship with material properties.
Structural dynamics is described as the achievement
of the desired level of comfort in terms of noise,
vibration and harshness (NVH)
 Static stiffness
 Crashworthiness
 Weight efficiency
DESAIN/REKAYASA
 Product requirements
 Static stiffness
Static design entails the optimization of
torsional stiffness and strength under
quasistatic loading conditions and good static
stiffness values are fundamental requirements
for target dynamic characteristics
 Crashworthiness
 Weight efficiency
DESAIN/REKAYASA
 Product requirements
 Crashworthiness
All vehicle manufacturers are placing continued
emphasis on occupant passive safety and here
FEM simulation is of special importance,
avoiding the need for expensive vehicle
compliance tests during development.
 Weight efficiency
DESAIN/REKAYASA
 Product requirements
 Weight efficiency
Although a basic design requirement previously,
the drive for lower weight vehicles, in the
knowledge that 10 per cent reduction in vehicle
mass leads to fuel savings of up to 6–7 per cent
has intensified over the last 20 years.
DESAIN/REKAYASA
 Product requirements
 Weight efficiency
.
KEY DESIGN PARAMETER AND RELEVANT PROCESSING
MAIN CRITERIA AND RATINGS OF VEHICLE BODY MATERIAL

 Product requirements
 Weight efficiency
Although a basic design requirement previously,
the drive for lower weight vehicles, in the
knowledge that 10 per cent reduction in vehicle
mass leads to fuel savings of up to 6–7 per cent
has intensified over the last 20 years.
STEEL
 Advantages
 Low cost
 Ease of forming
 Consistensy of Supply
 Corrosion resistance with coatings
 Ease of joining
 Recyclable
 Good crash energy absorption

 DisAdvantages
 Heavier than alternative materials
 Corrosion if uncoated
STAINLESS STEEL 18%CR 8%NI
 Advantages
 Corrosion resistance
 Excellent formability
 Use of similar manufacturing
infrastructure as mild steel
 DisAdvantages
 High cost
 Limited supply sources for automotive
applications
ALUMUNIUM
 Advantages
 Low density
 Corrosion resistance
 Strong supply base
 Recyclability
 DisAdvantages
 High cost and fluctuating cost
 Poorer formability than steel
 Less readily welded than steel
MAGNESIUM
 Advantages
 Very low density
 Ability to be thin cast
 Possible to integrate components in castings
 DisAdvantages
 Only viable as cast components (sheet and
extruded magnesium not readily available)
 High cost at medium to high volume
THERMOPLASTICS
 Advantages
 Very low density
 Ability to be thin cast
 DisAdvantages
 Poor wear abrasion and repeated impact
 Poor fatigue resistance
 Potentially high and variable shrinkage
 Higher creep
THERMOSETS
 Advantages
 Lower sensitivity to temperature than
thermoplastics
 Good dimensional stability
 Harder and more scratch resistant than
thermoplastics
 DisAdvantages
 Low toughness and strain at fracture
 Difficulties in recycling
MATERIAL SELECTION
 When selecting the materials for car
body construction other factors such as
environmental acceptability and ease of
manufacture (‘process chain effects’)
must now be considered alongside cost
and the physical and mechanical
properties traditionally used for
engineering design.
EXAMPLE MATERIAL SELECTION
Strategic Selection of Alternative Material
for Automotive Roof to Improve
Crashworthiness in Rollover Accidents


EXAMPLE MATERIAL SELECTION
Abstract

With the developments in automobile technologies;

more focus is given to the vehicle weight reduction.
About 30 % weight is contributed by the automobile
body. Now a days, plastic composites are used to
manufacture automobile bodies as they are strong,
light, corrosion resistant and easy to use. This paper
represents the selection of plastic composites to build
vehicle roof as a replacement of conventional metal
roof. Different types of plastics and plastic composites
were studied and their mechanical properties and cost
were compared with steel and aluminum.
EXAMPLE MATERIAL SELECTION
Introduction

As the roof and pillars

protects the occupant
from the head and neck
injuries, these sections
must be strong enough
to withstand in rollover
accidents.
EXAMPLE MATERIAL SELECTION

A. Mechanical Strength

 The mechanical strength of roof material of a

vehicle is the most important criteria since it
directly related to occupant safety.
EXAMPLE MATERIAL SELECTION
EXAMPLE MATERIAL SELECTION
EXAMPLE MATERIAL SELECTION

B. Light weight (Density)

 The Weight reduction of automobile parts may

lead to higher fuel economy. Among all the
techniques related to increased fuel economy,
weight reduction plays a major role since 30%
weight reduction gives 15-20% greater fuel
economy. It is based on simple logic that an
engine has to work less to accelerate and move
the light parts.
EXAMPLE MATERIAL SELECTION
EXAMPLE MATERIAL SELECTION

C. Cost and Ease in Manufacturing

 The cost is an important parameter in selection

of alternative material from composites.
Composite materials are very emerging field so
far and day by day new inventions and
techniques arrived for their mass production that
minimizes the production cost per unit. Making a
perfect composite is not an easy task for
manufacturers since various complicated process
were involved.
EXAMPLE MATERIAL SELECTION
EXAMPLE MATERIAL SELECTION

D. Shock/Energy absorption capability

 While replacing existing materials of automobile

roof, the main aspect is its crashworthiness. The
crashworthiness is defined as an ability of vehicle
of a component to protect an occupant from
serious injuries at a time of accidents.
 Selection of material with high energy absorption
capability is the base of crashworthiness design.
The amount of energy or impact absorbed by a
material is given by EA (Energy Absorption) is
the area under the load vs. displacement.
EXAMPLE MATERIAL SELECTION
EXAMPLE MATERIAL SELECTION

RESULT
EXAMPLE MATERIAL SELECTION

RESULT
EXAMPLE MATERIAL SELECTION

RESULT
EXAMPLE MATERIAL SELECTION

RESULT

 For roof application plastic composite has enough

strength to pass strength criteria and weight
reduction.
MATERIAL SELECTION
MATERIAL SELECTION
 When selecting the materials for car
body construction other factors such as
environmental acceptability and ease of
manufacture (‘process chain effects’)
must now be considered alongside cost
and the physical and mechanical
properties traditionally used for
engineering design.