This paper reports the development of the aluminum body for the Honda Insight which achieves an ultra-high fuel efficiency. In developing the new aluminum body, the following objectives were set in order to achieve an ultra-high fuel economy and to keep cost within a feasible level: 1. 50 % reduction in the weight of body in white. 2. High rigidity of the body. 3. Collision safety performance at the top level in its category. 4. Reductions in tooling investments and the number of parts used. An aluminum hybrid body structure was to be developed which would combine the merits of both the monocoque and space frame structure with maximum utilization of the characteristics of aluminium. The general approach was to 1. increase the application of extruded materials, 2. employ cast parts to improve the coupling rigidity, 3. reduce pressed parts and cut costs. The body frame structure is one which receives the suspension input or energy generated during collisions more efficiently and which ensures that the load is distributed over the entire frame. The aluminium hybrid body has 15 % fewer parts and 24 % fewer welding points. The body in white unit weights 47 % less compared with the steel body. The structural improvements help to ensure that the collision safety performance meets Honda's in-company standards which include the head-on 40 % offset impact test at 64 km/h and the head-on full-lap collision test at 55 km/h. In order to develop the aluminum hybrid body, new bending members made of extruded aluminum and new lage-sized aluminum cast parts are developed. Materials and production technology are discussed.


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    Title :

    Development of aluminum body for the most fuel efficient vehicle


    Additional title:

    Entwicklung einer Aluminiumkarosserie für den Honda Insight mit sehr geringem Kraftstoffverbrauch


    Contributors:
    Saito, M. (author) / Iwatsuki, S. (author) / Yasunaga, K. (author) / Andoh, K. (author)

    Published in:

    JSAE Review ; 21 , 4 ; 511-516


    Publication date :

    2000


    Size :

    6 Seiten, 14 Bilder, 2 Tabellen, 1 Quelle




    Type of media :

    Article (Journal)


    Type of material :

    Print


    Language :

    English





    Development of aluminium body for the most fuel efficient vehicle

    Saito,M. / Iwatsuki,S. / Yasunaga,K. et al. | Automotive engineering | 2000




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