Title: Automotive lightweight engineering: a method for identifying lazy parts

Authors: Benjamin W. Caldwell; Essam Z. Namouz; Jenkins L. Richardson; Chiradeep Sen; Thomas Rotenburg; Gregory M. Mocko; Joshua D. Summers; Andreas Obieglo

Addresses: Clemson Engineering Design Applications and Research (CEDAR) Lab, Department of Mechanical Engineering, Clemson University, 136 Fluor Daniel Building, Clemson, South Carolina 29634-0921, USA ' Clemson Engineering Design Applications and Research (CEDAR) Lab, Department of Mechanical Engineering, Clemson University, 136 Fluor Daniel Building, Clemson, South Carolina 29634-0921, USA ' Clemson Engineering Design Applications and Research (CEDAR) Lab, Department of Mechanical Engineering, Clemson University, 136 Fluor Daniel Building, Clemson, South Carolina 29634-0921, USA ' Clemson Engineering Design Applications and Research (CEDAR) Lab, Department of Mechanical Engineering, Clemson University, 136 Fluor Daniel Building, Clemson, South Carolina 29634-0921, USA ' Clemson Engineering Design Applications and Research (CEDAR) Lab, Department of Mechanical Engineering, Clemson University, 136 Fluor Daniel Building, Clemson, South Carolina 29634-0921, USA ' Clemson Engineering Design Applications and Research (CEDAR) Lab, Department of Mechanical Engineering, Clemson University, 136 Fluor Daniel Building, Clemson, South Carolina 29634-0921, USA ' Clemson Engineering Design Applications and Research (CEDAR) Lab, Department of Mechanical Engineering, Clemson University, 136 Fluor Daniel Building, Clemson, South Carolina 29634-0921, USA ' BMW Manufacturing Co., Greer, South Carolina 29651, USA

Abstract: This paper presents a method for evaluating the lightweightedness of a vehicle, specifically addressing those components whose primary purpose is to aid in manufacturing and assembly rather than to provide end-user function. Seven laziness indicators are described. These indicators are used to evaluate individual vehicle components to aid in identifying mass reduction potential and focus the attention of designers on components or assemblies with high potential for mass reduction. This method is applied to a complete automotive vehicle, demonstrating a mass savings potential of the overall vehicle of approximately 5% of the total mass of the vehicle.

Keywords: automotive engineering; lightweight engineering; mass reduction; vehicle design; design for assembly; DFA; design for manufacturing; DFM; automotive components; component design; assembly design; component laziness indicators; vehicle mass.

DOI: 10.1504/IJVD.2013.057474

International Journal of Vehicle Design, 2013 Vol.63 No.4, pp.364 - 386

Received: 16 Sep 2010
Accepted: 10 Sep 2011
Published online: 16 Oct 2014 *

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