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The Development of a Lightweight Electric Vehicle Chassis and Investigation Into the Suitability of Tial for Automotive Applications

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The Development of a Lightweight Electric Vehicle Chassis and Investigation Into the Suitability of Tial for Automotive Applications http://waikato.researchgateway.ac.nz/ Research Commons at the University of Waikato Copyright Statement: The digital copy of this thesis is protected by the Copyright Act 1994 (New Zealand). The thesis may be consulted by you, provided you comply with the provisions of the Act and the following conditions of use: Any use you make of these documents or images must be for research or private study purposes only, and you may not make them available to any other person. Authors control the copyright of their thesis. You will recognise the author’s right to be identified as the author of the thesis, and due acknowledgement will be made to the author where appropriate. You will obtain the author’s permission before publishing any material from the thesis. i The Development of a Lightweight Electric Vehicle Chassis and Investigation into the Suitability of TiAl for Automotive Applications A thesis submitted in partial fulfilment of the requirements for the degree of Masters of Engineering in Mechanical Engineering By Ryan Lovatt Hamilton, New Zealand March 2008 ii Abstract A lightweight chassis for a battery electric vehicle being developed at the University of Waikato was required. The chassis was designed around a predetermined body shape and suspension setup. A chassis, built from 20mm thick aluminium honeycomb sandwich panel, was designed and built to LVVTA standards allowing the car to be driven on public roads. The chassis weighs a little over a third the mass of a mass production car chassis. The car has been driven over 1800km with only one minor problem, indicating the chassis is reliable and well suited to its purpose. Titanium aluminide properties were researched to identify where titanium aluminides could be used in an automobile. Titanium aluminides have a specific strength and stiffness near to steel yet only half the density making it an ideal replacement for steel components. Automotive applications identified that could benefit from the use of TiAl include valves, brake rotors and inside „in-wheel‟ electric motors. iii Acknowledgements I would like to thank; Page Macrae Engineering for undertaking the TIF and providing funding to undertake this project and associated research. Dr. Mike Duke for his leadership and inspiration Norm Stannard for sharing his experience and help in making the car a reality Ian Macrae for having the foresight and belief in new technology and wanting to get hands during the WSC Travis de Fluiter for being a great friend and someone to bounce ideas off for the last two years Matthew Greaves, Ben Guymer and Bernie Walsh from HybridAuto, Australia and the previous Ultracommuter team for what they achieved Nigel Burgess from South Bank University, England Colin Ayres from Ayres Composite panels for their guidance in the use of aluminium honeycomb The University of Waikato Ultracommuter team through which many lessons were learnt and great times had The University of Waikato staff for their support Finally, I would like to thank my family and friends for their help and support. iv Table of Contents Abstract ................................................................................................ ii Acknowledgements ............................................................................. iii Table of Contents ............................................................................... iv List of Figures ..................................................................................... vi List of Tables ...................................................................................... xi Glossary .............................................................................................. xii Chapter 1 Introduction ..................................................................... 13 1.1 Lightweight components in modern day cars ............................................. 13 1.2 Reducing vehicle mass ................................................................................ 14 1.3 Titanium aluminide ..................................................................................... 16 1.4 Research objective ...................................................................................... 16 Chapter 2 Literature review ............................................................ 17 2.1 Introduction ................................................................................................. 17 2.2 Automotive Chassis .................................................................................... 17 2.3 Types of chassis .......................................................................................... 20 2.3.1 Ladder frame ........................................................................................ 20 2.3.2 Backbone (Torque Tube) chassis ......................................................... 22 2.3.3 Space frame .......................................................................................... 23 2.3.4 Monocoque/ Uni-body ......................................................................... 25 2.4 Chassis materials ......................................................................................... 27 2.5 Titanium aluminides .................................................................................... 38 2.5.1 Introduction .......................................................................................... 38 2.5.2 Titanium ............................................................................................... 39 2.5.3 Titanium Production ............................................................................ 43 2.5.4 Titanium aluminides ............................................................................ 45 2.5.5 Alloying ............................................................................................... 46 2.5.6 Mechanical properties .......................................................................... 48 2.5.7 Thermal Properties ............................................................................... 52 2.5.8 Physical properties ............................................................................... 54 2.5.9 Processing/manufacturing .................................................................... 57 v 2.5.10 Current Automotive applications ....................................................... 58 Chapter 3 Ultracommuter Chassis design ...................................... 63 3.1 Introduction ................................................................................................. 63 3.2 Previous concept ......................................................................................... 63 3.3 Chassis selection ......................................................................................... 65 3.4 Material selection ........................................................................................ 65 3.5 Specifications and constraints ..................................................................... 70 3.6 Design ......................................................................................................... 73 3.6.1 Safety ................................................................................................... 73 3.6.2 Computer Aided Drawing .................................................................... 75 3.6.3 FEA Analysis ....................................................................................... 77 3.6.4 Design .................................................................................................. 81 3.6.5 The Final Design .................................................................................. 97 Chapter 4 Manufacture .................................................................. 101 4.1 Introduction ............................................................................................... 101 4.2 Water jet cutting ........................................................................................ 101 4.3 Construction .............................................................................................. 103 4.4 Finishing .................................................................................................... 106 4.5 Top-hats..................................................................................................... 106 4.6 Chassis testing ........................................................................................... 108 Chapter 5 Economics ...................................................................... 110 Chapter 6 Titanium aluminide properties for automotive applications ...................................................................................... 111 6.1 Manufacturing processes ........................................................................... 112 6.2 Areas for TiAl application ........................................................................ 115 6.3 Specific Applications ................................................................................ 115 Chapter 7 Conclusions and Recommendations ............................ 119 7.1 Conclusions ............................................................................................... 119 7.2 Recommendations ..................................................................................... 119 References ........................................................................................ 121 Appendix 1 ......................................................................................
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