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Fender Material Systems: A Lifecycle Cost Comparison
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English
Abstract
This paper explores a framework for simulating the lifecycle costs of an automotive component for alternative material systems. The front fender for a midsize sedan is chosen as a case study. The material systems under consideration include the following: stamped steel, stamped aluminum, compression molded SMC, injection molded thermoplastic, and reinforced reaction injection molded polyurethane (RRIM PUR).
The lifecycle for the fender is defined to include manufacturing, operation, and post-use. Using a technique called Technical Cost Modeling, manufacturing costs including fabrication, assembly, and priming are simulated for a range of production volumes. Operation costs are calculated in two areas: fuel consumption and repair. Component weight is examined as it influences fuel consumption (and therefore cost) for varying scenarios of vehicle life and annual mileage. Repair costs are assessed for different collision speeds and directions. Post-use cost (or value) is calculated based on the material type and the operating and investment cost required for the four stage recycling process: dismantling, shredding/ferrous separation, non-ferrous separation, and landfilling.
The aggregate of the three components of lifecycle cost is then summed for the alternative material systems. This collective measure is then used to examine such questions as how much more manufacturers might be willing to pay for a lighter or more durable component.
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Topic
Citation
Mascarin, A. and Dieffenbach, J., "Fender Material Systems: A Lifecycle Cost Comparison," SAE Technical Paper 920373, 1992, https://doi.org/10.4271/920373.Also In
References
- Busch John V. Dieffenbach Jeff R. “Economic Criteria for Sensible Selection of Body Panel Materials” SAE International Congress and Exposition February 1991
- Facts and Figures '91 Motor Vehicle Manufacturers Association Detroit, MI 1991
- 1991 Market Data Book Automotive News Detroit, MI May 1991
- Busch John V. Field Frank “Comparative Economics of Five Body Panel Technologies” Advanced Composites Conference 1987
- Suchar Kimberly J. “Structural Repair of Composites” SPI Composites Institute, 46th Annual Conference February 1991
- Mitchell's Collision Estimating Guides Mitchell International San Diego, CA 1990