LIGHTWEIGHT DESIGN: A LIGHTWEIGHT APPROACH TO HYBRID SAFETY FRAMES

Lightweight frame design with integrated shear-stress fields across the entire load-bearing structure, an enhancement of the "Spaceframe" concept.

Stress-optimized design of the load-bearing frame and joint connections.

Functionally integrated exploitation of all available space.

Taking the concept one step further: vehicle bodies made of synthetic material or GRP.

The use of shear-stress fields is extended to the entire vehicle.

As part of the “ebase” network project “Innovative Floor Assembly for New Drive Technologies”, TGM has developed a novel, structural body design tailor-made to the requirements of battery-powered drive systems.

TOPOLOGICAL OPTIMIZATION AND ANALYSIS

The topological optimization analysis provided by TGM offers many possibilities – at first it implements an optimal lightweight design in early project phases – a major influence on the targeted weights. On the other hand this method reveals optimized load paths depending on the special mechanical boundary conditions. The required result is to reach a maximum usage of the given structures or to remove unnecessary areas. Our goal is to develop structures which achieve the required boundary conditions while being as light as possible.

TGM analyzed and optimized with support of full version Altair HyperWorks

Car shell structure

  • FE-structural analysis & FE-optimization
  • Topology optimization
  • Identification of weight saving potentials

Benefit

  • Identification of 600 kg weight saving potentials
  • 56 FE-optimization loops
  • Increased material usage and efficiency
  • Wall thickness optimized lightweight design
  • Duration: 8 weeks

Electrical component housing

  • FE-structural analysis
  • Potential- and risk identification
  • Analysis of natural frequencies

Benefit

  • Identification of natural frequencies
  • Identification of critical areas
  • Work out of 10 % weight saving potentials
  • Implementation of 6 % weight saving potentials
  • Wall thickness optimized lightweight design
  • Duration: 9 days

Cladding (outside)

  • FE-structural analysis & FE-optimization
  • Potential- and risk identification
  • Lightweight design

Benefit

  • Work out of 40 % weight saving potentials
  • Development of wall thickness optimized lightweight design
  • Mitigation of weight risks
  • Increased material usage and efficiency
  • Duration: 3 days

TECHNOLOGY CONSULTING: A LIGHTWEIGHT APPROACH TO BIONIC BASED VAULT STRUCTURING

As a development partner of Dr. Mirtsch Wölbstrukturierung GmbH, TGM has the exclusive right to exploit the jointly developed analytical know-how for its own weight-analysis techniques and calculation software.

As part of an R&D project funded by the German government through the German Federation of Industrial Research Associations (AiF), Dr. Mirtsch Wölbstrukturierung GmbH and TGM have jointly developed methodology for the weight analysis of vault-structured materials and reference bodies, as well as for the evaluation of weight-saving potentials.

The corresponding vault-structuring technology as well as the manufacturing process for vault-structured sheet metals are patented worldwide by Dr. Mirtsch Wölbstrukturierung GmbH, Germany.

Dr. Mirtsch Wölbstrukturierung GmbH - Mühlenstraße 62, 13187 Berlin

These innovations offer better fatigue behavior thanks to the higher plastic reserves of vault-structured hexagons as compared with embossed hexagons featuring similar stiffness but lower vault-structure depth.