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Purdue School of Engineering and Technology

Purdue School of Engineering and Technology

Design and Analysis of Lightweight Vehicles

ME 59700 / 3 Cr.

This course would focus on design and analysis of lightweight vehicles and will cover the following two main subjects:MATERIALS FOR LIGHTWEIGHT VEHICLE STRUCTURES, DESIGN AND ANALYSIS OF VEHICLE STRUCTURES
Textbooks

Materials, Design and Manufacturing for Lightweight Vehicles by P. K. Mallick and Design and Analysis of Vehicle Structures by R.G. Budynas

Outcomes

After completing this course a student should be able to:

  • Discuss materials, their properties, processing technology and design and materials selection issues pertinent to designing lightweight vehicles.
  • Select the materials and describe considerations for lightweight structures.
  • Describe advanced steels, aluminum alloys, magnesium alloys and polymer matrix composites along with information on material properties, processing characteristics and application examples.
  • Explain structural configuration of modern vehicles and vehicle design requirements
  • Explain symmetric and unsymmetric beams; single and multicell thin-walled tubes; skin stiffened construction; shear flow; shear lag; finite element analysis
  • Perform design projects.
Topics
  • Advanced steels for lightweight automotive structures
    • History of steel in automobiles
    • Types of high strength steels
    • Third generation advanced high strength steels
    • Manufacturing and forming high strength steels
    • Designing with steels for light weighting automotive structures
  • Aluminum alloys for lightweight automotive structures
    • International designation systems for aluminum alloys
    • International temper designations for aluminum alloys
    • Aluminum alloys used in lightweight automotive vehicles
    • Substituting aluminum alloys for competitive materials
  • Magnesium alloys for lightweight powertrains  and automotive  structures
    • Cast magnesium, Sheet magnesium, Extruded magnesium
  • Thermoplastics and thermoplastic-matrix composites for lightweight
    automotive structures 
    • Thermoplastics used in automobiles
    • Thermoplastic matrix composites for automobiles
    • Joining of thermoplastic matrix composites
  • Thermoset-matrix composites for lightweight automotive structures
    • Manufacturing processes
    • Carbon fiber reinforced thermoset-matrix composites
  • Introduction to design, design requirements, and the design process
  • Review of classical beam theory
  • Design and analysis of symmetric beams subjected to static axial and/or
    bending loads
  • Material selection, design allowables, and MIL-HDBK-5
  • Fatigue of materials and structures
  • Design and analysis of unsymmetric beams
  • Stress at a point and failure under multi-axial states of stress
  • Shear stresses in single and multi-cell beams subjected to bending and/or
    torsional loadings
  • Structural configurations of modern automobiles
  • Analysis and design methods for typical automotive structural elements