Abstract
KEYWORDS – Lightweight, Engine Room Bracket, EV, SMC
ABSTRACT –
The use of composite materials is very important to electric vehicles (EV) to substantially reduce vehicle weight. However, the most important challenge is to apply composite materials in structural applications in vehicles. This paper shows that SMC (Sheet Molding Compound) is used to develop lightweight weight Engine Room Bracket Assembly, which is a structural component. SMC offers greater styling freedom, so that the component can be integrated to three parts, and then improve the manufacturing process. CAE-based design methodologies were utilized to assess the strength, stiffness and impact performance. Then various tests including environmental test, NVH test, bench vibration and vehicle four channel test have been executed to check if the SMC component can meet the performance requirement. Change of material can get 36% weight reduction versus conventional steel component. Moreover, the cost of the SMC component is a little higher than that of the steel part, and can be accepted for mass production.