Recent regulations for reducing the carbon footprints in the world has also forced the automotive industry to take an action. Automotive Original Equipment Manufacturers (OEMs) aim to reduce the total carbon footprint of vehicles by creating weight and fuel consumption reductions on their vehicles. Composite Lightweight Front-End module (FEM) is one of the developments according to these studies. In this study, Literature research and benchmark activities provided for the FEM system. Accordingly, the design of the FEM system and design parameters has been analyzed, comparison held between conventional sheet metal structures and composite material properties are provided. Some critical points and design inputs are examined. Based on the design inputs preliminary design and fixation methodology on the FEM body is optimized. Furthermore, design feed-back are used to improve the preliminary FEM design as well as mold design. According to feedback, the mold and the preliminary FEM design are optimized. Finally, a unique part is achieved in the front end of vehicles with the advantages of less carbon emission, and less weight while maintaining stiffness requirements.Within the scope of the project, to provide cost and weight reductions, it is aimed to design the FEM in vehicles with long glass fiber reinforced composite material instead of metal. Study is started with literature research and preliminary design studies for the FEM system. Subsequently, the connection status of the FEM with the peripheral parts, fastener types and assembly operations are determined. Accordingly, final design is optimized with moldability and manufacturability feedbacks from the supplier. Detailed information regarding FEM and further studies are provided in the following methodology and findings sections.
Anahtar Kelimeler: Front-End Module, weight reduction, composite, vehicle