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
Future of lightweighting with electrification and autonomous vehicles.
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