Giuseppe Tomasoni

Lightweighting in light commercial vehicles: cradle-to-grave life cycle assessment of a safety-relevant component

PurposeCurrently, the reduction of weight in automotive is a very important topic in order to lower the air pollution. In this context, the purpose of the present paper was to analyze a real case study through a comparison of the environmental sustainability between a conventional steel crossbeam for light commercial vehicles and an innovative lightweight aluminum one.MethodsFor both scenarios, a cradle-to-grave life cycle assessment methodology and a sensitivity analysis has been used through the study of the following phases: mineral extraction, component manufacturing, use on vehicle, and end of life. In particular, many primary data and a complete vehicle model simulation with three different European driving cycles have been used in order to reach the highest possible level of accuracy during the analysis.Results and discussionRegarding the manufacturing phase, the aluminum component’s production gave the highest impact because of the high energy required in the mineral reduction. Anyway, this stage of the analysis had a low effect on the entire LCA, because the benefit of weight reduction during vehicle use showed a strongly higher contribution. The urban driving cycle had the most relevant impact, as a consequence of the frequent start and stop operations and the longest time with engine at idle speed, while the extra-urban cycle is the less demanding due to its higher average speed and no start and stop.ConclusionsIn conclusion, the present research demonstrated the environmental importance of the lightweight for an actual case study in the commercial vehicles field.

New design concept of a downhill mountain bike frame made of a natural composite material

In this work, the design of a new downhill mountain bike frame, made with an innovative natural composite, is presented. The study is based on an early finite element analysis of the characteristics and performance of a standard frame made of aluminum, allowing to define the loading conditions and to provide a design optimization of the frame in different race situations. The model was later implemented with the properties of a natural reinforced composite. The results obtained show that the new composite allows a weight reduction with a stiffness and a safety coefficient comparable to the standard aluminum frame.