This book is focused on the use of plastics in automobiles for traditional applications, as well as for more advanced uses such as under-the-hood components. Engineering thermoplastics offer the ability to tailor-make components from polymers, and to design parts for enhanced performance, new functionality, part integration, and elimination of secondary operations. Parts made from engineering thermoplastics can be manufactured within specified cost constraints, and using manufacturing methods that offer a wide range of production flexibility. A decade of research and real-world applications is presented by the authors on application technology development for various aspects of automotive design – concept design, CAD modeling, predictive engineering methods through CAE, manufacturing method simulation, and prototype and tool making. Additional advantages of plastics are covered and include greater styling, improved energy absorption, and enhanced performance over traditional materials, all while fostering environmental sustainability and reducing overall vehicle weight for next generation automobiles.

This book is focused on the use of plastics in automobiles for traditional applications, as well as for more advanced uses such as under-the-hood components. Engineering thermoplastics offer the ability to tailor-make components from polymers, and to design parts for enhanced performance, new functionality, part integration, and elimination of secondary operations. Parts made from engineering thermoplastics can be manufactured within specified cost constraints, and using manufacturing methods that offer a wide range of production flexibility. A decade of research and real-world applications is presented by the authors on application technology development for various aspects of automotive design – concept design, CAD modeling, predictive engineering methods through CAE, manufacturing method simulation, and prototype and tool making. Additional advantages of plastics are covered and include greater styling, improved energy absorption, and enhanced performance over traditional materials, all while fostering environmental sustainability and reducing overall vehicle weight for next generation automobiles.

Automotive manufacturers are required to decrease CO2 emissions and increase fuel economy while assuring driver comfort and safety. In recent years, there has been rapid development in the application of lightweight and sustainable materials in the automotive industry to help meet these criteria. This book provides critical reviews and the latest research results of various lightweight and sustainable materials in automotive applications. It discusses current applications and future trends of lightweight materials in the automotive area. While there are a few books published mainly focusing on automotive applications of metallic lightweight materials, to date there is no available book focusing on a broad spectrum of lightweight materials, including metal, plastic, composites, bio-fiber, bio-polymer, carbon fiber, glass fiber, nanomaterials, rubber materials, and foaming materials, as this work does. The book also includes case studies of commercial lightweight automotive parts from sustainable lightweight materials, providing an invaluable resource to those involved in this in-demand research and commercialization area.

Today's automotive industry is challenged by ever more stringent demands to reduce fuel consumption and exhaust emissions. Lightweight design and increased use of advanced plastic components will be crucial for the next generation of cars complying with legislation. Engineers and manufacturers who develop and produce polymer-based components for automotives are under pressure to reduce developing times and to optimize production processes for quality and economic viability. Tools of choice are computer-aided selection of polymers in combination with mathematical simulation for both, material properties and production processes. They provide crucial help in finding innovative and economical solutions when designing polymer applications for modern cars. This unique and timely book provides theoretical as well as practical reviews of novel polymer applications for automotive engineering, covering material selection, simulation, prototyping and manufacturing. Nineteen industrial case studies illustrate current polymer applications for the exterior of passenger cars and commercial vehicles made in Europe. These studies describe component-specific and vehicle-specific solutions, providing expert insights into current developments in the polymer industry as well as novel component production and, most importantly, their innovative implementation into industrial practice.

The desire for greater fuel efficiency and reduced emissions have accelerated a shift from traditional materials to design solutions that more closely match materials and their properties with key applications. The Multi-Material Lightweight Vehicle (MMLV) Project presents cutting edge engineering that meets future challenges in a concept vehicle with weight and life-cycle assessment savings. These results significantly contribute to achieving fuel reduction and to meeting future Corporate Average Fuel Economy (CAFÉ) regulations without compromising vehicle performance or occupant safety. The MMLV Project presents: • Lightweight materials applications. • Body in white design and computer aided engineering • Engine and transmission design and lightweighting. • Full vehicle test results that are specific to the MMLV subsystems including crash, corrosion, durability and Noise Vibration and Harshness (NVH). • The Life Cycle Analysis (LCA) for the MMLV The aluminum-intensive structure, combined with carbon fiber, magnesium, and titanium results in full vehicle mass reduction of a C/D class family sedan to that of a subcompact B-car (two vehicle segments lighter). The MMLV Project presents engineering solutions that frame materials selection and applications for the future.

Future Trends in MODERN PLASTICS The prolific author and polymer scientist discusses the current topics in the plastics industry and recommends future research in sustainable polymers and the recycling routes of plastic waste. The book opens with a chapter discussing newly developed monomers such as alkylene-based monomers, epoxide monomers, diol-based monomers, bio-based monomers, and several other types, Modern polymerization methods are then explained, such as ionic polymerization, plasma polymerization, and ring-opening polymerization. The book moves on to special issues and some future trends in the plastics industry with recommendations for future research. Plastics have given society enormous benefits because of their versatility, light weight, durability, and low costs. However, these properties have come with negative impacts because these persistent materials are leaked into the environment during their entire life cycle. Therefore, critical chapters report on the future directions for sustainable polymers, the valorization of plastic waste, and the recovery, treatment and recycling routes of plastic waste. The book concludes with chapters on the usage of plastics in medical devices, as well as the use of plastics in restoration, food applications, additive classes, and manufacturing. Audience The book will be used by plastics engineers, chemists, polymer and materials scientists in both academia and the plastics industry.

Research into the manufacture of lightweight automobiles is driven by the need to reduce fuel consumption to preserve dwindling hydrocarbon resources without compromising other attributes such as safety, performance, recyclability and cost. Materials, design and manufacturing for lightweight vehicles will make it easier for engineers to not only learn about the materials being considered for lightweight automobiles, but also to compare their characteristics and properties.Part one discusses materials for lightweight automotive structures with chapters on advanced steels for lightweight automotive structures, aluminium alloys, magnesium alloys for lightweight powertrains and automotive structures, thermoplastics and thermoplastic matrix composites and thermoset matrix composites for lightweight automotive structures. Part two reviews manufacturing and design of lightweight automotive structures covering topics such as manufacturing processes for light alloys, joining for lightweight vehicles, recycling and lifecycle issues and crashworthiness design for lightweight vehicles.With its distinguished editor and renowned team of contributors, Materials, design and manufacturing for lightweight vehicles is a standard reference for practicing engineers involved in the design and material selection for motor vehicle bodies and components as well as material scientists, environmental scientists, policy makers, car companies and automotive component manufacturers. - Provides a comprehensive analysis of the materials being used for the manufacture of lightweight vehicles whilst comparing characteristics and properties - Examines crashworthiness design issues for lightweight vehicles and further emphasises the development of lightweight vehicles without compromising safety considerations and performance - Explores the manufacturing process for light alloys including metal forming processes for automotive applications

The automotive industry is under constant pressure to design vehicles capable of meeting increasingly demanding challenges such as improved fuel economy, enhanced safety and effective emission control. Drawing on the knowledge of leading experts, Advanced materials in automotive engineering explores the development, potential and impact of using such materials.Beginning with a comprehensive introduction to advanced materials for vehicle lightweighting and automotive applications, Advanced materials in automotive engineering goes on to consider nanostructured steel for automotive body structures, aluminium sheet and high pressure die-cast aluminium alloys for automotive applications, magnesium alloys for lightweight powertrains and automotive bodies, and polymer and composite moulding technologies. The final chapters then consider a range of design and manufacturing issues that need to be addressed when working with advanced materials, including the design of advanced automotive body structures and closures, technologies for reducing noise, vibration and harshness, joining systems, and the recycling of automotive materials.With its distinguished editor and international team of contributors, Advanced materials in automotive engineering is an invaluable guide for all those involved in the engineering, design or analysis of motor vehicle bodies and components, as well as all students of automotive design and engineering. - Explores the development, potential and impact of using advanced materials for improved fuel economy, enhanced safety and effective mission control in the automotive industry - Provides a comprehensive introduction to advanced materials for vehicle lightweighting and automotive applications - Covers a range of design ideas and manufacturing issues that arise when working with advanced materials, including technologies for reducing noise, vibration and harshness, and the recycling of automotive materials

The automotive sector is looking for lighter-weight materials for improved fuel economy and post-consumer recyclability to foster environmental sustainability. Engineering thermoplastics offer the ability to tailor-make components from polymers, and to design parts for enhanced performance, new functionality, part integration, and elimination of secondary operations. Parts made from engineering thermoplastics can be manufactured within specified cost constraints, and using manufacturing methods that offer a wide range of production flexibility. Additionally, plastics offer greater styling, improved energy absorption for pedestrian and occupant safety, and enhanced performance over traditional materials, all while reducing overall vehicle weight. This book is focused on the use of plastics in automobiles, not just for traditional applications such as interiors and body panels, but for more advanced uses such as under-the-hood components. It provides application technology development for various aspects of automotive design-concept design, CAD modeling, predictive engineering methods through CAE, manufacturing method simulation, and prototype and tool making.

Various combinations of commercially available technologies could greatly reduce fuel consumption in passenger cars, sport-utility vehicles, minivans, and other light-duty vehicles without compromising vehicle performance or safety. Assessment of Technologies for Improving Light Duty Vehicle Fuel Economy estimates the potential fuel savings and costs to consumers of available technology combinations for three types of engines: spark-ignition gasoline, compression-ignition diesel, and hybrid. According to its estimates, adopting the full combination of improved technologies in medium and large cars and pickup trucks with spark-ignition engines could reduce fuel consumption by 29 percent at an additional cost of $2,200 to the consumer. Replacing spark-ignition engines with diesel engines and components would yield fuel savings of about 37 percent at an added cost of approximately $5,900 per vehicle, and replacing spark-ignition engines with hybrid engines and components would reduce fuel consumption by 43 percent at an increase of $6,000 per vehicle. The book focuses on fuel consumption-the amount of fuel consumed in a given driving distance-because energy savings are directly related to the amount of fuel used. In contrast, fuel economy measures how far a vehicle will travel with a gallon of fuel. Because fuel consumption data indicate money saved on fuel purchases and reductions in carbon dioxide emissions, the book finds that vehicle stickers should provide consumers with fuel consumption data in addition to fuel economy information.