In conjunction with the FutureTruck collegiate design competition, The University of Wisconsin - Madison has integrated an all aluminum frame into their four-wheel drive, charge sustaining, parallel hybrid-electric sport utility vehicle. The base vehicle is a 2000 Chevrolet Suburban nicknamed the “Moollennium” and weighs approximately 2400 kg. The original GMT 830 frame constitutes 10% of the Suburban’s weight and has the largest weight reduction potential. In a cooperative effort with Tower Automotive, the University of Wisconsin-Madison has modeled, stamped and constructed two full aluminum frames using the GMT 430 tooling. The first frame, the UW 430 AL, was assembled to replicate the GMT 430 frame, while the second-generation frame, the UW 830 AL, mimicked the GMT 830 frame. FEA and traditional deflection and bending calculations were used to stiffen and strengthen the aluminum frame to acceptable levels. Front horn crush tests were used to optimize frontal impact energy absorption — the UW 830 AL design absorbs 36% more energy than the original GMT 430 steel frame with a 40% reduction in peak load. The complete aluminum frame weighs 120 kg — 98 kg lighter than the steel GMT 830 frame and 130 kg lighter than the steel GMT 430 frame.
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