Transcript of Introduction to Automotive materials
- 1. Automotive Materials-Current Trends and Futuristic
Perspectives Dr. K. Padmanabhan Professor Manufacturing Division
School of MBS and Asst Director, CENC VIT-University Vellore 632014
August, 2010
- 2. About VITs Initiatives The School of Mechanical and Building
Sciences with a faculty strength of over 120 has taken initiatives
in Automotive and Manufacturing Research. The Automotive Research
Centre and the Manufacturing Programme have been established under
two separate Funds for Infrastructure Development of Science and
Technology (FIST) Programmes funded by DST. Established a
collaborative learning centre with ARAI, Pune. In addition to
research projects, the Centre also executes consultancy projects
for the automotive and allied industries. Our partners include
ARAI, Pune; Turbo-Energy Limited, Sholinghur; KEMM, Bangalore; and
CVRDE, Ahmed Nagar A TIFAC-CORE Centre in Automotive Infotronics
and some projects with our own TBI are operational
- 3. Contents History of Automobile Frames Structures and Types
Design Requirements Materials and Processes Selection, Weight and
Cost Future Directions
- 4. Focal Areas
- 5. History of Frames
- 6. History of Frames
- 7. History of Frames
- 8. X Frames
- 9. Tubular Frames
- 10. Platform Type Frames
- 11. Monocoque Frames
- 12. Monocoque Frames
- 13. Design Requirements Design- Complete information required
to produce a product or to render service - Anonymous
- 14. The Titanic .. .. And Tragedy
- 15. Liberty Ships : The first all-welded pre-fabricated cargo
ships mass produced in the United States. 2,751 Liberty Ships were
built between 1941 and 1945. Only two now remain afloat. Many of
the remaining were destroyed by cracking of the type shown.
- 16. Ductile-to-Brittle Transition 1. FCC materials do not show
DBT Good for cryogenic applications Stainless steel (austenite:
fcc) containers for Liq O2 rocket fuel mild steel not good (: bcc)
2. Fine grain size give lower transition temperature 3. High strain
rate increase the transition temperature 4. Notches increase the
transition temperature
- 17. Charpy Impact Test ductile brittle
- 18. Plot temperature vs. absorbed energy Draw a curve through
the points DBTT is mean of upper and lower shelf energy Design
Requirements
- 19. Ductile-to-Brittle Transition y (bcc) TTDBTT y (fcc) T f f
y < f ductilebrittle y > f
- 20. Design Requirements
- 21. Design Requirements
- 22. Design Requirements
- 23. Material Property Charts: Modulus - Density 0.1 10 1 100
Metals Polymers Elastomers Ceramics Woods Composites Foams 0.01
1000 1000.1 1 10 Density (Megagrams/m3 ) YoungsmodulusE,(GPa)
- 24. Design Requirements Ashby Maps
- 25. Design Requirements -Materials Material Index Merit Index
Structural Index Shape Factors Mechanically Efficient Shapes
Specific Properties
- 26. Design Requirements
- 27. Design Requirements - FRP Composites Specific Stiffness and
Strength Fracture Toughness Dynamic Fracture Toughness Damage
Tolerance Hygrothermal Durability Overall Reliability ( Hot Wet
Fatigue) Disposability and Safety Recycleability, Recoverability
and Reuse Plastics Waste to Fuel Conversion
- 28. General Design Requirements Plastic Strain Modularity and
Flexibility Multi Functionality Crumple Zones Collapsibility
Ductility Crashworthiness Dynamic Fracture Energy Impact Toughness
Fatigue ( Esp. Suspension, Stabilizer bars) Vehicle dynamics Noise
Vibrations and Harshness
- 29. Materials and Processes
- 30. Materials and Processes
- 31. Materials and Processes
- 32. Materials and Processes
- 33. Materials and Processes
- 34. Materials and Processes
- 35. Automobile Engines Aluminium Composite Engine Composite
Engine Manifold Using Glass Fibre/PA Matrix Materials
- 36. Engine Materials Grey Cast Irons Compacted Graphitic Cast
Iron Al-alloys, Ni-resist Iron Nodular Cast Iron White (Chilled)
Cast Iron Cr and Mo Steels
- 37. Engine Materials Magnesium alloys are in their research
stage For a 1.5 L engine, the peak firing pressure is about 160
bars CGI can withstand 235 Bars Mg Alloys can withstand only 120
bars of PFP.
- 38. Engine Materials Austenitic SS for gaskets (304) Valves-Ti
Alloys Exhaust manifolds: Ceramic bonded or painted cast irons or
SS. Cr coating on piston rings to wear against cast iron. Liner
materials: CI or Aluminium Connecting rods: forged CT or forged SS,
They are drop or powder forged or die cast using C70 S6 Steel or
Micro-alloyed steel
- 39. Engine Materials Crankshaft: Forged steel alloy, 38MnVS6
Micro-alloyed forged steel Bearing Materials: Babbit metal and
Al-Si alloy Turbochargers: Max pressure ratio now is 4 , Uses
Ductile Iron, Si-Mo Alloy or 440 C SS Compressor: Titanium blades
An All Reinforced Ultra-light Efficient Plastic Engine ?
- 40. Materials and Processes
- 41. Materials and processes Suspensions can be made of spring
steel or even GFR Plastic structures
- 42. Materials and Processes Stabilizer bars must have good
fatigue life and design must take care of DBT. Suitable steels
starting from PCS are used. Tubular structures fare better.
- 43. Materials and Processes Elastomers
- 44. Fibre Reinforced Plastics
- 45. Ford Soybean FRP Car Picture shows Henry Ford I trying to
break The Soybean with a sledgehammer, rather unsuccessfully.
Soybean was made of steel tubular frame and 14 panels containing
phenolic resin. It was worlds first car with an FRP body courtesy
Ford Motors
- 46. Materials and Processes BMC Composite Bumper and SMC
underbody panels, Glass Mat Thermoplastics (GMT) are also
favourites. The condenser lens assembly is made from acrylics or
high impact resistance PC
- 47. Functional Design with FRPs Complex injection moulding
through multiple gating for the instrument panel with PP, ABS/PC,
PPS and PPO blends
- 48. Materials and Processes
- 49. Europe is ahead of North America in its use of natural
fibre composite automotive applications by approximately 5 years.
The global vision of the bio-economy foresees an annual revenue
growth for biofuels of 15%, biochemicals 12%and biomaterials 14%
for the year 2010,and by 2030 biomaterials projected growth was
25%. Mercedes-Benz automobiles have more than 30 parts made of
natural fibres
- 50. FRP BODY CARS- Indian Experience
- 51. Composites in Automobiles Italian automobile with carbon
fibre composite chassis
- 52. Selection, Weight and Cost
- 53. Materials and Processes
- 54. Weight Reduction and Cost
- 55. Main Challenge in Body Design Multi-Material Concepts
Advanced Composites (FRP) Steel Spaceframe MultiMulti
MaterialMaterial ConceptConcept Composites Advanced Steel body
Coil-coated shell Steel thin wall casting High strength Steels
Al-Spaceframe SteelSteel UnibodyUnibody Stainless Steel Spaceframe
Affordabilityofweightreduction Design Materials Processes Approach
Advanced LM-Spaceframe > 2012
- 56. Futuristic Directions
- 57. Waste to Fuel Car Back to the Future II Drive to an organic
waste dust bin and fill your car with waste fuel and drive away !
It is not pulp fiction or celluloid dream anymore !
- 58. Ancient Engines Sakuna Vimana s Ion Mercury Vortex Engine -
Rg Veda- Baradwaja Vimanika Shastra
- 59. Thank you and Questions ?