Optimizing the Weight of Chassis for Autonomous Vehicles using Advanced Reinforced Materials

                                               Mahmoud R    Sandus L

  Cite As : 

 Mahmoud, R & L, Sandous ." Optimizing the  Weight of  Chassis for Autonomous Vehicles using Advanced Reinforced Materials ".Machinery Manufacture and Reliability ,Allerton.Press, Vol,49, No1, pp1052-1063( 2019)
 

  The transportation sector forms one of the main concerns in accordance of the mechanical engineering. Satisfying the daily complex requirements in the transportation sector had not become simple, as the vehicle consists of countable number of systems that cooperate to achieve a desired performance. In addition, the demand of timesaving had become vital nowadays, applying these requirements needs to increase the acceleration’s magnitude especially for passenger cars. This project takes under research the possibility of replacing the conventional materials such as carbon steel that is used in the chassis manufacturing process. Firstly, a literature review on the autonomous electric vehicles is carried out in order to know the historical background of them then, an illustration of the traction forces required to be satisfied. The traction force recognition allows engineers to predict the different road scenarios, which enhance the vehicle’s performance significantly. Actually, the autonomous electric vehicle is considered being a complex system that requires to be designed by experts and experienced engineers. In addition, the electrical powering concept adds a higher complexity level due to the low capacities of the utilized batteries. Hence, decreasing the overall weight of the vehicle is predicted to enhance their performance in accordance of the economy and reliability. The project is directed to select the BYD autonomous electrical vehicle to be studied. CES material selector software is used in predicting the materials provide the highest performance index determined according to the favorable and unfavorable characteristics. The price, density, and yield strength constraints have been specified in order to increase the economic benefits, decrease the overall weight of the vehicle, and providing the carbon steel stress resistivity. Results suggested using PA6/E-glass fiber, E-glass fiber or Aluminum7055 instead of carbon steel. The aforementioned materials are then simulated using SolidWorks, the modelled ladder frame chassis has payed an attention during solving the simulation study by defining the mesh type to be fine. The simulation study decided to be applied on the original material (carbon steel) and each suggested material (PA6/E-glass fiber, E-glass fiber and Aluminum7055). The study intended to compared the three suggested materials and carbon steel to investigate the higher performance, the E-glass fiber material is predicted to be the best. The material decision is based upon the high ability of E-glass fiber to meet the assumed duties accompanied with a higher safety factor. In addition, using E-glass fiber is lighter, less expensive, and its manufacturing process is predicted to consume less energy and emit less toxic gasses.