汽车铝应用手册-AAM-design-2-design-with-aluminium.pdf

Design – Design with Aluminium Table of Contents 2  Design with Aluminium 2  2.1  Introduction 2  2.1.1  Holistic design makes the difference 2  2.1.2  The cost of lightweighting with aluminium 4  2.1.3  Mixed material design 5  2.1.4  The role of production volume 7  2.1.5  Integration of functions and parts integration 9  2.2  Comparison to steel 15  2.2.1  Design criterion: Stiffness 17  2.2.2  Stiffness and elastic energy absorption 22  2.3  Assembly methods and tolerances 27  2.3.1  Joining techniques 28  2.3.2  Assembly process 31  2.3.3  Sources of tolerances 32  2.4  Material selection criteria 33  2.4.1  Automotive sheet products 34  2.4.2  Automotive extrusions 36  2.4.3  Automotive castings 38  2.5  Examples of potential weight savings 40  2.5.1  Design for equivalent strength 40  2.5.2  Design for equivalent stiffness 41  2.5.3  Design for equivalent stiffness – Sheet 42  Version 2011 © European Aluminium Association (auto@eaa.be) 1 2 Design with Aluminium 2.1 Introduction 2.1.1 Holistic design makes the difference The main reason for introducing aluminium into vehicle components, structural modules and full vehicle structures is to achieve a significant weight reduction compared to a conventional design. Depending on the specific application, the weight reduction potential ranges between 25% and over 50%. Significant weight reduction possibilities exist even compared to a modern vehicle body designed using advanced high strength steel grades. In a recent study by ika Aachen “Stiffness and Crash Relevance of Car Body Components”, the strength and stiffness relevance of typical components of a state-of-the-art, reference compact class car body including closures were quantified for