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In the automobile industry, many parts are manufactured by applying aluminum materials to improve fuel efficiency and reduce vehicle weight. In particular, in order to design and manufacture future electric vehicles, the weight reduction of vehicles is receiving more and more challenges. In the case of a suspension part, since it is located in the lower part of the vehicle, it has a great advantage of improving fuel economy due to weight reduction. This paper describes the development stage of a front wheel subframe with a welded structure of aluminum high vacuum die casting method and extrusion method. The result of the aluminum subframe study showed that the weight was reduced by 5.6㎏ and natural frequency was improved by 16㎐ compared with the steel subframe.
In the automotive industry, the high strength steel offers the possibility to obtain significant reduction of weight without affecting the structural performances of final products. The hot stamping represents an innovative manufacturing process for forming of high strength steels, implying a sheet at austenite temperature being rapidly cooled down and formed into a die at the same time(quenching). This forming process is used for the manufacturing of automobile structural components with a strength of up to 1,500㎫, thus enabling extensive cost saving and good crash performance. In this study thermal-mechanical coupled simulation with PAM-STAMP™ was carried out for forming and cooling of a hot stamped part. Moreover, mechanical properties of front cross member with hot stamping.
In the case of a suspension part, since it is located in the lower part of the vehicle, it has a great advantage of improving fuel economy due to weight reduction. In order to reduce the weight of vehicles, there are increasing cases of applying aluminum to suspension parts. This paper describes the stages of development of a rear cross member with a welded aluminum low pressure hollow casting method and extrusion method. The result of the aluminum cross member study showed that the weight was reduced by 6.3㎏ and natural frequency was improved by 46.7㎐ compared with the steel cross member.
An Automotive front cross member supports many crucial components and systems, such as an engine, transmission, and suspension. Important performance measures for the design of a front cross member include durability, stiffness, and NVH, while minimizing weight of primary concern. This paper presents an effective and efficient methodology for front cross member design from conceptual design to detailed design using design optimization.
The most important point in the future automotive industry is about managing the enhanced environmental regulation. To meet them, companies are trying to increase fuel efficiency and ligten weight. Subframe that is located under the body delivers the noise and vibration and endures fatigue. In this reason, normally steel is used in many subframes, but it has high weight. Substituting steel with aluminum is able to lighten weight at a high ratio. This study will introduce the method how to develop an aluminum die-casting bracket, which is able to lighten weight and cost reduction by substituting steel with aluminum. By developing this bracket, we achieved the result that is weight reduction by 8% and the decrease in the number of parts by 20%.