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The ability to introduce new lightweight materials into vehicles is not as simple like “remove and replace”. The direct challenges in light weighting are manufacturing feasibility for design concept and material selection for right application. The execution approaches of automotive lightweight and the design and manufacturing performance of typical parts with the product performance are discussed. Typical case studies and analysis is presented to evaluate the selection and application of the lightweight materials for different application.

Wheel is one of the safety critical components which is being subjected to constant weight reduction but not at the expense of its reliability and durability. The Indian automobiles are subjected to overloading and at the same time endure severe shock loads due to poor road conditions. This forces the vehicle manufacturers to increase the factor of safety on the wheel and also test under severe loading conditions apart from the regulatory requirements and international standard norms. This makes the wheel manufacturers to design not only for the rated or standard load provided by the vehicle manufacturers but also considering the road conditions and OEM torture track testing requirements. Hence, along with the conventional fatigue tests according to the customer requirement, realistic loading conditions needs to be brought in to testing and virtual simulation.