The multi-material concepts development approach enhances mono-material driven design methodologies:
it puts the overall vehicle’s functionalities first, and then deploys
them into sub-modules and parts, selecting the optimal
material on a part-by-part basis based on overall vehicle
performances. This is the driving force steering the research on the
other areas, favoring functional requirements-based competition among different materials and technologies.
SLC is structured around 4 technical subprojects
covering the following research and technological domains: SP1 vehicle
design and engineering, SP2 forming and joining technologies, SP3
design and simulation tools and other enabling technologies/methods
(life cycle and cost analysis, recycling technologies) and SP4 the
actual development of a front-end structure demonstrator and virtual
car body (VR BIW).
- SP1 (Concepts
& Design): defines the overall research targets and
proposes innovative solutions. Multidisciplinary experts have convened regularly during the first 9 months of the project to determine the best
compromise between suitable alternatives. From month 10 to
36, the selected concepts are detailed and optimised regarding SLC
relevant features. CAx environment enable
multi-parameter optimisation at the vehicle and sub-assemblies level.
- SP2 (Manufacturability):
the concepts for multi-material light weight design of
compact class vehicles are enlarged by the development of advanced
forming processes of available materials (e.g.: Mg/Al hot and cold
forming, Long Fibre reinforced Thermoplastic, Resin-Transfer Moulding
for Thermosets and Thermoplastics, Al/Steel tailored welded blanks,
etc.) and multi-material joining technologies (e.g. laser and friction
stir welding, adhesive bonding, etc.). Surface-related aspects are
integrated in forming technologies development.
The available
technologies will be monitored and benchmarked form the start,
providing important information for steering SP2 developments and the
possibility to adopt external technologies in the SLC demonstrator.
Based on the chosen technologies, the assembly line will be
pre-designed.
- SP3
(Enabling Technologies/Tools): started with the characterisation of
advanced materials and multi-material joints and develops reliable
simulation tools to fill up the toolbox for the simulation of future
multi-material lightweight vehicle designs performance regarding
aspects where methods are missing/unreliable today. Missing blocks like
data for new materials or (joints) failure prediction are addressed.
An
inventory of existing solutions for reuse, recycling and disassembly
will be made and ways to apply them in multi-material SLC concepts will
be sought. This will be turned into the development of a decision
support system to guide automotive designers towards
more sustainable concepts from the very beginning of the design
process.
The SLC front structure demonstrators will be tested
regarding all performances, costs and environment-related parameters,
which will be compared with the SLC goals and with the values predicted
by the simulation tools developed thus enabling their validation and
final optimisation.
- SP4 (Demonstration): In
order to demonstrate with real tests the feasibility to produce and
assemble complex multifunctional parts fulfilling SLC requirements,
front structure demonstrators will be built up. The technologies used
will allow the verifications of cost effectiveness, performance,
sustainability and manufacturability but will of course not be at the
level required for mass production processes (the costs would be by far
prohibitive).
In SP5 (Education and Training, Innovation-related and Management&Coordination activities), the objective is to facilitate SLC
results exploitation. Therefore, several innovation-related activities
have been planned. These include, among others, the analysis of
different scenarios for SLC results exploitation (in other vehicles’
classes as well as in related sectors), SME-targeted workshops
identifying specific exploitation opportunities, technology transfer
events to different transport sectors (rail, aerospace, automotive,
buses) and activities intended to duly protect the generated IPR and to
inform the different project stakeholders (E.C., industry, research
communities, citizens, etc.) on achieved progress.
Highly related to innovation activities, education and training activities
will ensure that a suitable workforce will be ready for results
implementation in industry and that future professionals will be at the
edge of knowledge in lightweight, multi-material concepts development
and realisation.
From the overall management and coordination
point of view, specific activities have been defined covering aspects
such as strategic and day-to-day management, accounting,
administration, setting the IT infrastructure, conflict
prevention/resolution, etc.
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