Design Process of Durable and Lightweight Rally Car Frame from Ultra-High Strength Stainless Steel

Article Preview

Abstract:

To get all outstanding mechanical properties from ultra-high strength steel (UHSS) transformed into a lightweight and durable product, a comprehensive design process must be performed. The general DFMA method has been extended to get good design solutions with limited designer resources and within a relative short time period. Key steps of the extended DFMA design process are innovative brainstorming, the agile utilization of the optimization software, the heavy use of finite element analysis and fast design iteration. In this paper, the modified DFMA design method is described step by step. This method has been successfully used in the design process of the small lightweight rally car frame. The design process of the rally car is introduced as a case example of implementation of the extended DFMA.

You might also be interested in these eBooks

Info:

Periodical:

Pages:

325-332

Citation:

Online since:

October 2018

Export:

Price:

* - Corresponding Author

[1] G. Boothroyd, P. Dewhurst, W. Knight. Product design for manufacture and assembly. New York, 1994. ISBN 0-8247-9176-2.

Google Scholar

[2] I. Bettles, Design for manufacture & assembly (DFMA)-the Boothroyd & Dewhurst approach, Third International Conference on Factory 2000: Competitive Performance Through Advanced Technology, 27-29 July 1992, pp.316-321. ISBN: 978-0852965481.

Google Scholar

[3] G. Boothroyd, W. Knight, Design for assembly, IEEE Spectrum September 1993, pp.53-55.

Google Scholar

[4] G. Boothroyd, Product design for manufacture and assembly, Computer-Aided Design Volume 26, Issue 7, July 1994, Pages 505-520, https://doi.org/10.1016/0010-4485(94)90082-5.

DOI: 10.1016/0010-4485(94)90082-5

Google Scholar

[5] W. ElMaraghy, H. ElMaraghy, T. Tomiyama, L. Monostori, Complexity in engineering design and manufacturing, CIRP Annals - Manufacturing Technology 61 (2012) 793–814, https://doi.org/10.1016/j.cirp.2012.05.001.

DOI: 10.1016/j.cirp.2012.05.001

Google Scholar

[6] G. Boothroyd, P. Dewhurst, W. Knight. Product design for manufacture and assembly, third ed., New York, 2011. ISBN 978-1-42008927-1.

Google Scholar

[7] P. Selvaraj & P. Radhakrishnan & M. Adithan, An integrated approach to design for manufacturing and assembly based on reduction of product development time and cost, The International Journal of Advanced Manufacturing Technology 42 (2009).

DOI: 10.1007/s00170-008-1580-8

Google Scholar

[8] C. Emmelmann, P. Sander, J. Kranz, E. Wycisk, Laser Additive Manufacturing and Bionics: Redefining Lightweight Design, Physics Procedia 12 (2011) 364-368, https://doi.org/10.1016/j.phpro.2011.03.046.

DOI: 10.1016/j.phpro.2011.03.046

Google Scholar

[9] L. Kroll, P. Blau, M. Wabner, U. Frieß, J. Eulitz, M. Klärner, Lightweight components for energy-efficient machine tools, CIRP Journal of Manufacturing Science and Technology 4 (2011) 148-160, https://doi.org/10.1016/j.cirpj.2011.04.002.

DOI: 10.1016/j.cirpj.2011.04.002

Google Scholar

[10] M. Kleiner, S. Chatti, A. Klaus, Metal forming techniques for lightweight construction, Journal of Materials Processing Technology 177 (2006) 2-7, https://doi.org/10.1016/j.jmatprotec. 2006.04.085.

DOI: 10.1016/j.jmatprotec.2006.04.085

Google Scholar

[11] Xintao Cui, Hongwei Zhang, Shuxin Wang, Lianhong Zhang, Jeonghan Ko, Design of lightweight multi-material automotive bodies using new material performance indices of thin-walled beams for the material selection with crashworthiness consideration, Materials & Design 32 (2011).

DOI: 10.1016/j.matdes.2010.07.018

Google Scholar