This document discusses strategies for reducing vehicle weight, particularly unsprung mass, through lightweight materials and design optimizations. Reducing unsprung mass can improve vehicle performance, handling, fuel economy and reduce emissions. Various approaches are outlined, including using polymers, aluminum, advanced high-strength steels, composites, downgauged materials, and tubular/optimized designs. Proper analysis, simulation, testing and failure validation is needed to ensure weight reductions do not compromise part strength or reliability.

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Reducing the weight of the vehicle

2. Reducing Weight of the Vehicle
UNSPRUNG MASS
 In a ground vehicle with a suspension, the unsprung mass is
 The mass of the suspension, wheels or tracks (as applicable)
 Other components directly connected to them, rather than
supported by the suspension.
 Components coming under this include suspension springs,
wheel rims, other chassis components like wishbone, traiing
arm etc
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3. Reducing Weight of the Vehicle
UNSPRUNG MASS REDUCTION
 Vehicle weight reduction particularly unsprung mass
reduction
 Saves energy, minimizes brake and tire wear,
 Cuts down emissions. Lightweighting of vehicles is directly
linked to lower CO2 emissions
 Results in Improved fuel economy.
 The benefits of even modest vehicle weight reduction are
significant. Reducing an automobile’s weight by a mere 50 kg
(110 lbs) reduces up to 5 g of CO2 /km and increases fuel
economy by up to 2%.
 The reduction of unsprung mass can also benefit in
performance, ride and handling of vehicles particularly
passenger cars and utility vehicles
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4. Reducing Weight of the Vehicle
LIGHTWEIGHTING STRATEGY
 Various approaches for weight reduction could be
 Use of polymer or engineering plastics, Aluminum or
hybrid constructions ( combination of different materials)
 Downgauging or reducing thickness of body steel
components by increasing usage of advanced high
strength steels for body as well as chassis parts
 With development of hot stamping the strength levels
upto 1400 Mpa could be achieved in steel sheets with a
defined chemistry.
 Use of composite/engineering plastics for body panels
and less load bearing components can be done.
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5. Reducing Weight of the Vehicle
LIGHTWEIGHTING STRATEGY
 Tubular construction /design can be an option in place of a
solid section
 The lightweghting in case of castings and forgings can be
achieved by optimization , thereby weight reduction.
 For autoelectricals the weight reduction can be achieved by
reducing solenoid weight through use of advanced
thermoplastics
 Reduction of weight for battery cables and wiring harness
assemblies by using a hybrid construction of Copper and
Aluminum.
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6. Reducing Weight of the Vehicle
ANALYSIS AND VALIDATION
All the above weight reduction approaches need to be
studied carefully
 Through load analysis/CAE , stress levels experienced by
the part under the various loading conditions,
 Manufacturing feasibility, freedom from defects through
use of advanced simulation software in castings and
forgings .
 Also it is important to use a proper problem
solving/failure analysis technique in case of any failures in
usage to find out the real root cause and addressing the
same. Normally with initial failure such ideas are
abandoned
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7. Reducing Weight of the Vehicle
OUR SUPPORT
We at materials info can help you to take through this
journey of lightweighting of your components
/aggregates thus achieving the final goal of reducing
environmental burden
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