Program Overview
This program is designed to provide professionals with an in-depth understanding of lightweight materials and their role in automotive design. The training will focus on the fundamentals of lightweight materials like aluminum and composites, explore the functional and technical trade-offs in design decisions, and analyze real-world case studies showcasing the impact of lightweighting on vehicle performance and cost. Through conceptual discussions, situational problem-solving exercises, and expert-led interactive sessions, participants will gain actionable insights into optimizing automotive design for lightweighting.
Features
- Understand the fundamental properties and applications of lightweight materials in automotive design.
- Identify and evaluate functional and technical trade-offs in lightweighting strategies.
- Analyze real-world case studies to derive actionable insights for their roles.
- Apply lightweighting concepts to improve vehicle performance, cost-efficiency, and sustainability.
Target audiences
- Design engineers
- Materials engineers
- Manufacturing & Production engineers
- Vehicle Integration specialists
- Product development teams
- R&D professionals
Curriculum
- 4 Sections
- 17 Lessons
- 1 Day
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- Introduction to Lightweight Materials3
- 1.1Key materials for lightweighting: aluminum, magnesium alloys, high-strength steels, carbon fiber, and thermoplastic composites.
- 1.2Material properties: strength-to-weight ratio, fatigue resistance, thermal properties, and recyclability.
- 1.3Interactive Exercise: Evaluate materials for specific automotive components based on their properties.
- Functional and Technical Trade-Offs in Design Decisions5
- 2.1Functional trade-offs: structural integrity vs. weight reduction, stiffness vs. flexibility.
- 2.2Technical considerations: joining technologies (e.g., adhesive bonding, riveting), manufacturability, and repairability of lightweight materials.
- 2.3Cost-benefit analysis: initial cost vs. long-term benefits (fuel efficiency, lower emissions).
- 2.4Emerging trends: multi-material design and additive manufacturing.
- 2.5Simulation: Solve a lightweighting challenge for a vehicle component (e.g., hood, chassis, or suspension system).
- Case Studies in Lightweighting5
- 3.1Lightweighting success in electric vehicles (e.g., Tesla Model S battery enclosure).
- 3.2Challenges in implementing carbon fiber in high-volume manufacturing (e.g., BMW i3).
- 3.3Role of aluminum in mass-market vehicles (e.g., Ford F-150).
- 3.4Anecdotes from industry projects on overcoming lightweighting challenges.
- 3.5Group discussion: Propose lightweighting solutions for participants’ real-world projects or challenges.
- Future Trends and Wrap-Up4
Instructor
