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Institute of Global Innovation Research

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Energy

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[ENERGY] Ogasawara Team

Development of next generation ultra-light mobility

Team Head

Toshio Ogasawara

Affiliation Institute of Engineering
Division / Department Advanced Mechanical Systems Engineering
Position Professor
URL http://web.tuat.ac.jp/~ogasat/

Foreign Researcher(s)

Frédéric Barlat

Affiliation Pohang University of Science and Technology (Korea)
Division / Department Graduate Institute of Ferrous Technology
Position Professor
URL https://sites.google.com/site/mmlpostech/professor-frederic-barlat

Yannis Korkolis

Affiliation The Ohio State University(U.S.A.)
Division / Department Department of Integrated Systems Engineering
Position Associate Professor
URL https://ise.osu.edu/people/korkolis.1

Sam Coppieters

Affiliation KU Leuven (Belgium)
Division / Department Department of Materials Engineering
Position Research Expert
URL https://iiw.kuleuven.be/onderzoek/mem2p/our-team/00058898

Kwek-Tze Tan

Affiliation The University of Akron (U.S.A.)
Division / Department Department of Mechanical Engineering
Position Assistant Professor
URL http://metacomposites.uakron.edu/

Ian Davies

Affiliation Curtin University (Australia)
Division / Department School of Civil and Mechanical Engineering
Position Associate Professor
URL https://staffportal.curtin.edu.au/staff/profile/view/I.Davies

Sanjay Dhakate

Affiliation National Physical Laboratory (India)
Division / Department Advanced Carbon Products group
Position Professor
URL http://www.nplindia.in/users/dhakatenplindiaorg

Erween Abd Rahim

Affiliation Universiti Tun Hussein Onn (Malaysia)
Division / Department Faculty of Mechanical and Manufacturing Engineering
Position Associate Professor
URL https://community.uthm.edu.my/erween

Mathias Lidberg

Affiliation Chalmers University of Technology (Sweden)
Division / Department Department of Mechanics and Maritime Sciences
Position Associate Professor
URL https://www.chalmers.se/en/staff/Pages/mathias-lidberg.aspx

Members

Toshihiko KUWABARA (Institute of Engineering / Professor), Hiroyuki SASAHARA ((Institute of Engineering / Professor), Keiichi NAKAMOTO (Institute of Engineering / Associate Professor), Pongsathorn RAKSINCHAROENSAK (Institute of Engineering / Professor), Akinori Yamanaka (Institute of Engineering / Associate Professor)

Overview

Green mobility technologies such as energy saving, low carbon emission, and safety, are indispensable for sustainable transportation systems such as automobiles, aircraft and others in future. We challenge to establish the fundamental technologies for the development and manufacture of green mobility systems by integrating some academic fields such as material science, material processing science and intelligent control.
For green manufacturing technology, we establish material models for accurately reproducing the deformation behavior of light-weight materials and install them into forming simulation software to realize accurate forming simulations of automotive parts. We challenge new machining technologies by combination of subtractive processing with cutting and grinding and additive processing with metal 3D printing. In addition, we develop design methodology of carbon fiber reinforced plastic composites (CFRP). To enhance the handling and stability of lightweight vehicle, the basic technology for in-wheel-motor torque distribution control is developed and verified via computer simulation and a driving simulator.
Integrating these technologies, we contribute the Green mobility in near future.

Approaches

 In order to realize a sustainable transportation society with Energy saving, Low carbon, Safety, it is indispensable to improve the fuel efficiency of transportation equipment, typified by automobiles and aircraft, and research and development of safety technology. Generally, it is known that if you reduce the weight of a car body by 10%, the fuel efficiency will be improved by 10%. But the weight saving and safety of the car is a trade-off. Therefore, if cars which are capable of autonomously preventing an accident is realized by positively adopting advanced vehicle control technology, it is possible to reduce the weight of the cars to the limit without sacrificing safety, and it is possible to realize safe and highly fuel-efficient automobiles.
In this research, we aim to establish the world's first integrated fundamental technology for the development and manufacture of super fuel-saving automobiles by integrating / fusing academic fields of material science, material processing science and intelligent control. By reducing the weight of the car body by 100 kg, the CO2 reduction of 20 g / km is expected; this means the reduction of fuel consumption by 2 - 5%. On the other hand, in order to protect passengers at the time of a collision and improve ride comfort, there is a limit to weight reduction of the vehicle body. Therefore, development and application of advanced control technology will accelerate R & D of super-fuel-efficient automobiles that guarantee safety and security while improving weight saving. This will become a technology that can be a breakthrough in new automotive engineering field, This technology can be applied not only to automobiles, but also to the body design of railway cars and further to the aircraft fuselage design, which has a large impact on the reduction of energy consumption in the transport sector, which accounts for 30% of the total.

Plan

★Development of ultrahigh precision forming simulation technology
We aim to establish an ultrahigh precision mathematical model for lightweight materials such as high tensile strength steels and aluminum alloys, by measuring their deformation characteristics under biaxial stress states, equivalent to deformation during actual forming processes of automobile bodies. The model will be implemented in computer simulation software. Furthermore, we will perform forming simulations of automotive parts using the software, so that we are able to present cutting-edge design and manufacturing guidelines for further weight reduction of automobile bodies.
Furthermore, we develop crystal plasticity finite element simulation methodology to conduct numerical multiaxial material test and sheet metal forming simulation based on microstructure in lightweight metallic materials. This will enable us to find the optimum microstructure to improve the formability of the materials.

★ Advanced machining and additive manufacturing technology
The target of this study is to develop high precision and high efficiency machining technologies for lightweight thin shape using heat resistant alloy, titanium alloy and carbon fiber reinforced plastic (CFRP) applicable for aerospace field or power generation gas turbine engine . New machining technologies by combination of subtractive processing with cutting and grinding and additive processing with metal 3D printing are investigated.

★Damage simulation technology of CFRP
Furthermore, carbon fiber reinforced plastic composites (CFRP) have been widely applied for automobiles as well as aerospace systems such as aircrafts, because of the excellent specific strength and modulus. We attempt to establish a new rational design methodology for estimating the damage and fracture behaviors of CFRPs under dynamic and static loading conditions. The methodology will be effective for significant weight saving and cost reduction in various kinds of mobility systems.

★ Advanced vehicle dynamics control technology
Lightweight vehicles have significant sensitivity to vehicle handling quality in heavy loading condition. This study aims to enhance the handling and stability of lightweight vehicle by using in-wheel-motor torque distribution control. The effectiveness of the proposed vehicle dynamics control is verified via computer simulation and a driving simulator. Various motor configuration of electric vehicles and use of regenerative braking for safe and energy-efficient driving are investigated.

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