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22 Autocar Professional 1 May 2010 www.autocarpro.in

AUTOMOTIVE LIGHTWEIGHTING SPECIAL

www.autocarpro.in 1 May 2010 Autocar Pro

AUTOMOTIVE LIGHTWEIGHTING SPEC

When TataMotors

launchedthe much-awaited

Nano at the Auto Expoin 2008, the industry and observers alike wereimpressed with the way thatthe carmaker had kept toits promise of an aesthetic-looking car that didn’t costthe earth.

But while the hypefocused on price, the fact isthat the company’s vendors

worked round the clock to think innovatively todevelop components that

were light in terms of costsand weight as well. This fact

was crucial to the success of the company.

That among otherreasons is why ProfessorCharles Fine, co-directorof the International Motor

Can Inia take the lea to euce vehicle weight?With the accent on reducing weight and improving fuel economy, OEMs and component manufacturers are using new materials and designs to gain a strategic advantage

Maruti Suzuki’s mantra has

been to make small cars that

are lighter and fuel efficient.

It all began with its debutante

model the Maruti 800

launched in 1983, which was

then the smallest car in terms

of size and engine capacity.

The legacy continues and the

recently launched new WagonR

has several weight-reduction

initiatives.

Speaking to Autocar

Professional , executive officer

(production engineering)

of Maruti Suzuki, R Dayal

says tailored welded blanks

(TWB) have been used in the

new WagonR in the doors

and tailgate. “We began

introducing TWB in the Estilo

and later introduced it in the

SX4. TWB is a manufacturing

method in which steel parts of

different thickness and tensile

strength are laser welded in

sheet condition and pressed

together. This enables partial

part reinforcement, avoiding

the need for additional parts,

thus, keeping the weight under

control."

Chief general manager

(engineering, research, design

& development) C V Raman

says the new WagonR is

heavier by 35kg (VXi model)

than the earlier model as the

car is built on a new platform.

Its overall length has been

increased by 75mm to 3595mm

against the old version. The

wheelbase has been increased

to 2400mm besides becoming

wider (1495mm) and taller

(1700mm). Given the

increased dimensions, the

weight of the car should

have increased significantly

but for the use high-tensile

steel and TWB. By using high

tensile steel, Maruti was

able to achieve the same

performance at

lower thickness and thus,

reduce overall body weight.

In the A-star and the new

WagonR, the company

has used high tensile steel

to reduce weight. All the

load bearing and structure

members of the A-star body

are made of 440 or 590 high

tensile steel grade.

The impact of adopting

TWB technology and use of

high tensile steel is reflected

in improved fuel efficiency.

Raman says about 20kg of high

tensile steel has been used in

the new WagonR.

Maruti has focused on

weight reduction through its

three-pronged strategy of

'Reduce, Reuse and Recycle'

(3R) in all its manufacturing

facilities, supply chain and

logistics operations.

30 SECONDS ON . . . MARUTI SUZUKI'S EFFORTS IN LIGHTWEIGHTING

TATA MOTOrsTata Motors has usedcomputer aidedengineering (CAE), early vendor involvement, andleveraged the findings of its materials technology research programmesin order to achieve itslightweighting objectives.

At the product conceptand strategic intent stageitself, weight objectivesand targets are setto complement fuelefficiency, performanceand durability. CAE toolsare used to optimise weightto maximise performanceof the systems andcomponents for NVH,fatigue durability, customertouch points, and ride andhandling.

As far as early supplierinvolvement is concerned,

Tata Motors says i

help the companyidentify the latestin weight reductiotechnologies thatbenefit Tata prod

The company’sengineers and sciconstantly look foexplore new matprocessing technolightweighting cothe basis of whichinnovate during tproduct developmprocess.

In the recent paTata Motors has ualternate materiaas high strength saluminium alloysplastic composite

weighting.Going forward,

exploring several measures includi

Lightweight engine

The company’s K-series

lightweight aluminium engine

has been designed to be

environment friendly and

fuel-efficient. This engine,

introduced in the A-star, is a

significant initiative towards

offering customers the latest

technology. The new WagonR

is the third model (after the A-

star and Estilo) in Maruti's line-

up to use the K-series engine.

Maruti engineers have put

together a host of innovative

technologies such as the use

of plastic parts, reduction in

piston skirt area to reduce

weight, and resin-coated

piston to minimise friction,

enhance performance and

provide high acceleration.

Besides reducing emissions,

the engine offers improved

fuel efficiency and help

achieve better Noise, Vibration

and Harshness (NVH)

characteristics.

Employee involvement

Maruti has also initiated

several projects on

minimisation and utilisation.

Every year, the company

celebrates Value Analysis

– Value Engineering (VA-VE)

month aimed at involving

employees and suppliers

in design improvements

that reduce weight and

cost without compromising

on quality. In 2008-09, it

launched the 'One Gram One

Component' weight reduction

scheme to reinforce the need

to use resources prudently.

As a Suzuki subsidiary, it

follows its parent company’s

basic philosophy of 'Smaller,

Fewer, Lighter, Shorter

and Neater' in its

manufacturing facilities.

This philosophy has helped

it in optimal utilisation of

resources and cost saving.

Through various kaizen

activities, efforts are made

to reduce not only the

weight of car components

but also equipment used in

manufacturing.

The Maruti Center

of Excellence (MACE),

created for vendor s

upgradation organi

programmers for su

on several topics inc

component weight

yield improvement

productivity improv

In 2008-09, Maru

consumed 279,085

tonnes (MT) of steel

24,389 MT of ferrou

11,619 MT of non-fe

casting and 3,998 M

paints. It has undert

various activities to

material consumptio

improvement is one

activity it has prom

its inception, as par

3R programme. Dur

initial phase, it focu

steel coil blank size

by changing the rad

blank, and modifyin

design, die face and

profile.

MURRALI THALOR

New WagonR uses high-tensilesteel, TWB and lightweightK-series engine.

The world’s largestauto companieshave sunk so muchinto heavy-steel-based vehicles thatthey cannot lead

the way to makinglight vehicles. Indiatherefore has anadvantage here.

Vehicle Program at the

Massachusetts Instituteof Technology, seesautomotive lightweightingas a strategic opportunity for India’s auto sector.

We at Autocar Professional decided tospeak with key players inthe sector and ask them

what their companies were doing to make theirvehicles lighter. We spoke

with OEMs and componentmakers alike who saidnew materials includingengineering plastics andnew technologies were

what they are looking atto produce vehicles thatare lighter, safer and eco-friendly.

Interestingly, the journey towards lightweightingbegins even before a car isactually made. New product

and design software means

that at the conceptualphase itself, weight targetsand objectives can bedefined and worked on.

Professor Fine saysautomotive lighweightingis an opportunity for Indiabecause fuel demand andprices will remain on anupward trend.

The world’s largest autocompanies have sunk somuch into heavy-steel-based vehicles that they cannot lead the way inmaking light vehicles.

Above all, lightweightingrequires a redesign of theentire automotive supply chain.

With India’s automotivesupply chain still relatively

young, it can mould itself to being a pioneer inlightweighting.

Tata Motors uses alternate materials such as

high strength steels, aluminium alloys andplastic composites for lightweighting.

All the load bearing and structure members of the A-starbody are made of 440 or 590 high tensile steel grade.







hollow constructionusing high-strength tubesand hot stamped parts,greater harnessing of lightweighting potential of aluminium and its MMC as

well as plastic compositesand nanoclay plasticcomposites.

Tata says that goingforward, the cost of

materials like magnesium,titanium and carbon fibrecomposites will reach levels

where their lightweightingpotential can be put to useeconomically. Vehicles of the future will be of multi-material construction,

where each materialperforms several roles inaddition to offering light

weighting advantage.

GENErAL MOTOrsGM India is evaluatingalternate lightweightmaterials for variousapplications in its vehicles.Many of its new productsin the US, for example, usealuminium for the bonnetsand rear tailgate. Its R&Dfacilities are developingparts that are expectedto be much lighter thanexisting products. GMalso uses state-of-the-artsimulation tools early inthe design phase to reduceand optimise weight. Withincreasing application of plastics, SMC, magnesiumand aluminium, GM hopesto develop lighter vehiclesin the future as technologiesevolve.

HONdA sIEL CArs INdIAThe carmaker useshigh-tensile steel in themanufacturing of its carsfor lightweight yet high-strength and enhancedsafety. Also, high-quality materials like magnesium,aluminium and high quality plastic are used to ensurethat its vehicles are notheavy.HSCI has also restrictedthe use of hazardousmaterials such as asbestos,crome6, lead, cadmiumand mercury to ensure itsvehicles are safe and eco-friendly.

VOLVO-EICHEr CVThe commercial vehiclemanufacturer has usedmaterials like composites,aluminium and high-strength low alloy steelscoupled with extensive

weight optimisationtechniques that havehelped it to continuemaking lighter vehicles,thereby enabling customersto carry more payload forthe same gross vehicle

weight.

INdIA YAMAHAMOTOrLightweighting isconsidered to be very important aspect at

Yamaha and is directly related to improving fuelefficiency. The steps thebike maker has taken tolightweight its vehiclesinclude re-engineering of parts and careful selectionof materials that help itimprove the power-to-massratio. Going forward, India

Yamaha says it is focusingon re-engineering of partsand taking other weightreduction measures such asusing superior raw materialand increasing the numberof plastic parts.

WEIGHT rEdUCTIONbY PArTs MAKErs

MUTUAL INdUsTrIEsMumbai-based MutualIndustries designs andmanufactures parts usinglow-weight plastics.However, it says, these

materials have yet to beexplored to contribute on alarger scale to automotivelightweighting.

As automotive plasticsspecialists, the company believes that there are many more potential applicationsthan the established onesthat could contributetowards lightweighting.Such applications callfor development activity

which involves design andengineering resources.

Therefore, Mutit prefers to particnew product deverather than secludpart developmenre-engineering folightweighting. Thcompany says it hcapability to handproduct developma knowledge base

covers the complfrom prototype topart production.

While a range opolypropylenes a

ASA have been usmanufacturing auexteriors and intepainted or textureand trim to substpressed sheet-mepolyamides and ahave been substitfor cast metals forand noise reductimaterial propertiefamily of plastics tuned into the coto cater to the sperequirement of thand its structure. plastics and reinfadditives and its aappropriate enginand design are limin lightweighting by the creativity odevelopment team

One product thhas progressively

weight over a peris the oil sump whtraditionally builtmetal diecast, andmade of polyamiis a basic design inplastics applicatioan estimated 4kg10kg in metal diec

ZOOM AUTOMThis Mumbai-basmakes plastic fuefor passenger cars

Automotive tied u YAPP AutomotiveCompany of Chintechnical assistanmake plastic fuel plant at Maraimanear Chennai.

To make these tanks, it has beenHDPE sourced frKorea. The compasupplied its first l

Zoom Automotive suppliesplastic fuel tanks to theFord Fiesta and the newlylaunched Figo.

Mutual Industries'oil sump made usingpolyamide is 6kg lighterthan a metal diecast one.

Yamaha plans to increasethe number of plastic partsin its bikes to reduce weight.

Honda Siel uses high-tensile steelin its cars as also magnesium,aluminium and high quality plastic.







plastic fuel tank to FordIndia for the Fiesta saloon.The Figo, Ford’s small caroffering for India, also hasa Zoom-made plastic fueltank.

According to Zoom, if an OEM wants to reducethe weight of the fuelsystem, then the entire

system comprising tanks,filler pipes, fuel lines andengine would have to bemade of plastic for thereto be significant weightreduction. It currently supplies the fuel tank andfiller pipes dependingon the OEM and theirrequirements.

The company usesthe co-ex blow mouldingprocess to make its tanks

which are either monolayer(used in diesel cars) andmultilayer (for petrol cars).

dsM ENGINEErINGPLAsTICsThis company, whichprovides a range of engineering plastics toTier I and Tier II suppliers,has been working withmany OEMs to convertcomponents made withmetals to plastics with high-performance engineeringthermoplastics. Thematerials used withstandhigh temperatures, high

wear and tear and frictionresistance and haveenabled DSM to reduce part

weights by upto 70 percent.

These materialscan have mechanicalproperties that are ascomparable if not betterthan diecast aluminium.The alternatives that DSMprovides OEMs includeparts integration anddesign flexibility, apart from

weight and cost reduction.

DSM also provides CAEservices to auto companiesto help them evaluatethe conversion of partscurrently made from steelinto plastics with the aim of

weight reduction. As far as alternative

materials go, the company uses Akulon Ultraflow – PA6– from unfilled upto 60percent glass filling, Stanyl– PA46 – a high temperature,high wear and friction-resistant material, Arnitel– TPE-E for metal tubingsto plastic tubings and

Arnite – PBT / PET. Thereare several applicationsand these include Akulon– PA6 – that has been usedto lower the weight of autoapplications for productssuch as air intake manifoldsand cylinder head covers.DSM Engineering Plasticshas also used Arnite – PETto reduce the weight forapplications such aspulleys. The company hasalso used Stanyl – PA46 tolower the weight of va riousgears and Arnitel –TPE andStanyl PA 46 to reduce the

weight of air ducts.

ALKrAfTTHErMOPLAsTICsThis Chennai-basedmanufacturer hasdeveloped a plasticheader for intercoolersin commercial vehicles.Samples have beensupplied to few OEMsand clearances are

awaited. The genesisof the development wasdriven by value engineeringand productivity. Whilecost savings were anestimated five percent,final assembly productivity improved about fivetimes.

While plastic tank technology is already available for intercoolers,this was restricted topassenger cars. However,operating temperaturesin CVs are high. Forinstance, the operatinginlet temperature foran intercooler can be ashigh as 180deg C. Theexisting plastic materialcannot withstandtemperatures beyond130deg C. Therefore, thechallenge was to sourcethe right material whichcould withstand highertemperatures. Alkraft wasable to achieve this by using specially developedengineering plastics. Thenext challenge was tofinetune the manufacturingprocess as this type of special engineering plastic

is not commonly The newly deve

plastic header tanabout 1kg less thaconventional tankintermediate CVs

weight reductionin the range of 2.5M&HCVs. In addithe plastic tanks a

better aesthetics aimproved producassembly comparconventional welassembly processnormal tanks.

IsPAT INdUsTrThe steel manufahot-rolled steel thin the automotiveutilises the compsteel-making tech- CONA RC - Thin- CSP - that providseveral benefits toThese include vercarbon content inenhances weldabincreases ductilityformability, and ltogether with micalloying induced

which provides chigher strength. Tmakes steel that istrong.

The key benefiIspat's steel is theto-weight ratio. Itclients for auto-grinclude componeattached to leadinTata Motors and Suzuki.

Nitin Kothari, MD - DSMEngineering Plastics saysits products can helpautomakers reduce partweights by upto 70 percent.

DSM Engineering Plastics has awide portolio o products thatcan help OEMs replace metal.

Vinod Mittal, vice-chairmanand managing director,Ispat Industries: "The keybeneft o our steel is thestrength-to-weight ratio."

Alkrat has developed a plastic headeror intercoolers in CVs.







dELPHI TECHNICALCENTrE INdIAComponent manufacturerDelphi has undertakenseveral steps to reduce the

weight of its components.It cut the weight of EngineManagement Systems by optimising the design of

enclosure and reducingthe board size by usingcompact electronicspackaging. Delphi’s safety sensors are moulded inplastic, which help reducethe weight by almost 30percent as compared toconventional sensors.

The company is atpresent experimenting withpotentially high strengthplastics which help reducecomponent and vehicle

weight.As regards productsthat it has worked on,Delphi has reduced weightin powertrain controllers,infotainment products,body control modules,safety sensors and hybridvehicle electronics. Theinfotainment product ismoulded in plastic thereby replacing the conventionalsteel packaging. This hasreduced the weight of the product by almost50 percent, which hashelped in delivering betterperformance. Delphi hasalso used integrated high-end technologies like ‘jetimpingement cooling inhybrid vehicle electronics,

which has helped inreducing weight.

Delphi says it developstechnologies and productsin line with its core theme of safety and eco-friendliness.

With regard to its plans,they are integration of multiple body control

modules into singleproduct; optimising andreplacing steel structure inhybrid vehicle electronicsmodule with high strengthplastics and developingsolutions to expel heatthrough plastics.

As far as the integrationof multiple body controlmodule goes, this helpsin consolidating differentcomponents into onemodule. For example,

window lifters, headlightlevelers, wipers and otherelectronic switches. Apartfrom reducing the weightof the vehicle, it providesthe OEMs a complete andsingle-box solution insteadof having to purchasedifferent electronics boxesfrom different suppliers.

As far as optimising andreplacing steel structures,Delphi uses light weightsteel – 2mm steel (insteadof 3mm steel) – withadditional design featureslike stiffeners and ribsto provide strength tothe plastic. This helps inreducing the weight of thecomponent. For example,

the battery disconnect unitholding structure is madeof plastic, which can evensurvive a mild crash.

VArrOC GrOUPThe Aurangabad-basedcomponent manufacturer'smetallic division is

equipped with cold, warm and hot forgingfacilities and supported

with dedicated facilities tosupply gearbox assembliesstarting from 100cc to750cc for all two-wheelersegments.

The basis of all productsit manufactures is theforging process. As aresult of increasing raw material cost, there hasbeen pressure on thebottomline. To compensatefor increasing input costs,

weight reduction andprocess improvements arethe key objectives at Varroc.

The company says ithas used state-of-the-artmetal flow simulation forthe forging process, so alliterations of process designstart with 100 percent

yield. Its design engineersoptimise the tool design toachieve flash-less forgings.

As Varroc has both hot andcold forging manufacturingfacilities in-house, thecombination of hot andcold forging is used tominimise component

weight.

Examples incluless forging develfor gear blanks up2kg weight, Varrodeveloped the flaforging concept, wis being deployednew componentstechnology has h

up to 300 grams oper part.

Also, critical co which can be mamachining proceincreased input whave been develoThe shapes generforging are near-nlittle machining ato meet surface firequirements.

The company works closely withOEMs to reduce wright from the constage. This resultsoptimised weightand low cost to boplayers. Examplesthe kick gear and internal faces of gblanks. One examproduct that it haable to reduce wesignificantly isthe component fo

which was reduc2.06kg to 1.6kg. Thhas been done thprototype sampleuse of flashless dehelped eliminate trimming operatireduce machining

Varroc works closely with OEMs to cut component where are a camshat, spindle steering and a ront w

Delphi has reduced weightin a number o componentslike powertrain coolingmodules.

Tarak Balaji, director,Delphi Technical CentreIndia: "We will continue toimprovise our products tomake the vehicles lighter,saer and greener."

Delphi’s Bussed Electrical Centers (BEC) simpliy Electronic/Electricalarchitecture. The company has reduced weight in this key component.

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