Title: Evolution FP7 funded project: body structure design strategies using new composite and aluminium materials and enabled technologies

Authors: Elena Cischino; Cristina Elizetxea; Iratxe Lopez; Zina Vuluga; Mikelis Kirpluks; Peteris Cabulis; Jesper DeClaville Christiansen; Catalina-Gabriela Sanporean; John P. Deverill; Francesca Di Paolo; César Maestro; Estibaliz Alcalde; Enrico Mangino

Addresses: Pininfarina S.p.A., Via Nazionale 30, Cambiano 10020, Italy ' Fundacion Tecnalia Research and Innovation, Mikeletegi Pasalekua 2, Donostia-San Sebastián E-20009, Spain ' FPK – Batz S. Coop. Torrea, 2, 48140 Igorre (Bizkaia), Spain ' ICECHIM – Institutul Na?ional de Cercetare – Dezvoltare pentru Chimie si Petrochimie, Splaiul Independen?ei 202, Bucure?ti 060021, Romania ' IWC – Latvijas Valsts Koksnes Kimijas Instituts, Dzerbenes st. 27, LV-1006, R?ga, Latvija ' RITOLS, Dz?rbenes iela 27, LV-1006, R?ga, Latvija ' Aalborg University, Fibigerstraede 16, Aalborg 9220, Denmark ' Aalborg University, Fibigerstraede 16, Aalborg 9220, Denmark ' AMRC with Boeing, University of Sheffield, Advanced Manufacturing Park, Wallis Way, Catcliffe, Rotherham, S60 5TZ, UK ' Soc. Cons. Innovazione Automotive e Metalmeccanica a r.l., Via Nazionale snc, Santa Maria Imbaro 66030, Italy ' Cidaut Fundación para la Investigación y Desarrollo en Transporte y Energía Aleixandre Campos 2, Boecillo 47151, Spain ' Cidaut Fundación para la Investigación y Desarrollo en Transporte y Energía Aleixandre Campos 2, Boecillo 47151, Spain ' Centro Ricerche Fiat S.C.p.A., Strada Torino 50, Orbassano 10043, Italy

Abstract: Based on Pininfarina Nido EV concept, EVolution aims to reduce the vehicle weight through new materials and process technologies, focused on five demonstrators: underbody, front crossbeam, mechanical subframe, shotgun system and door. This paper refers to body structure design strategies using new composite, Al materials and enabled technologies, focusing in particular on demonstrators design and manufacturing. The new front crossbeam geometry of the front shell is adapted starting from the Nanotough design, while the rear shell is specific for EVolution. The subframe demonstrator is redesigned to fulfil mechanical requirements of the part and manufacturing feasibility either. The EVolution door concept consists of two semistructural composite skins including a structural Al frame. The underbody is conceived through an integrated approach, optimising each element for its function. The shotgun component is designed to link parts obtained with different manufacturing technologies and several aluminium alloys in one single component: the structural node demonstrator.

Keywords: body in white; lightweighting; composites; aluminium; electric vehicles.

DOI: 10.1504/IJAUTOC.2017.091422

International Journal of Automotive Composites, 2017 Vol.3 No.2/3/4, pp.251 - 275

Received: 14 Jan 2017
Accepted: 10 Oct 2017
Published online: 30 Apr 2018 *

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