Altair > Case Studies > LEIBER Group's Innovative Approach to Lightweight Automotive Component Design

LEIBER Group's Innovative Approach to Lightweight Automotive Component Design

Technology Category

Analytics & Modeling - Digital Twin / Simulation
Functional Applications - Manufacturing Execution Systems (MES)

Applicable Industries

Automotive
Life Sciences

Applicable Functions

Product Research & Development
Quality Assurance

Use Cases

Additive Manufacturing
Manufacturing Process Simulation

Services

Testing & Certification

About The Customer

LEIBER Group is a company that specializes in the design and production of lightweight metal components. With over 750 employees at its two locations in Europe, LEIBER works with many customers worldwide to use groundbreaking new methods to create lighter parts and products. The company is known for its innovative approach to design and manufacturing, and it has a strong commitment to meeting the evolving needs of the automotive industry. A recent project required LEIBER to redesign a component for a commercial vehicle, demonstrating the company's ability to respond to specific customer requirements and industry trends.

The Challenge

LEIBER Group, a company specializing in the design and production of lightweight metal components, faced a challenge in redesigning a suspension beam for a commercial vehicle. The original part was made of cast iron, but the customer required a lighter yet equally strong component. This challenge was set against the backdrop of the automotive industry's conflicting demands: vehicles need to be lighter to reduce fuel consumption and CO2 emissions, but they also need to be safe, reliable, and competitively priced. For many years, weight reduction was not a primary development goal, leading to heavier vehicles due to new systems that increase safety, comfort, and driving experience. The industry is now seeking new approaches and methodologies to realize optimal lightweight structures.

The Solution

LEIBER Group used solidThinking Inspire and a new material, AluXtrem®, a high tensile forgeable alloy, to design the new component. The engineers defined a design space, added load and boundary conditions, and ran an optimization to generate the ideal structural part. This simulation-driven design process allowed them to create structurally efficient concepts quickly and easily, using material only where it was actually needed. The resulting components were lighter and stiffer than traditionally designed components. To further improve the component’s performance and especially its weight, LEIBER combined the simulation-driven design approach with the use of new materials. AluXtrem® was used in the development and production of the new suspension beam, which was 50 percent lighter than the previously used cast iron component.

Operational Impact

The use of solidThinking Inspire and AluXtrem® in the design process led to significant operational benefits. The new component was not only lighter but also stiffer than the previously used cast iron component, contributing to the overall performance of the vehicle. The design process was also streamlined, with fewer iterations between design and engineering departments. This led to a shorter time frame and less effort to create the final solution. The new material also guaranteed better fatigue characteristics of the component, enhancing its durability and reliability. The project was recognized with the EUROPEAN ALUMINIUM AWARD, highlighting the innovative and effective approach taken by LEIBER Group.

Quantitative Benefit