Weight reduction analysis of a four-door passenger car using computer-aided modelling and experimental investigation

  • Faraz Akbar Department of Automotive & Marine Engineering, NED University of Engineering & Technology, Karachi, Pakistan http://orcid.org/0000-0003-4495-1150
  • Zia ur Rahman In-Charge Aircraft Ground Support Equipment (GSE) Maintenance, Munawala Ground Services, Abu Dhabi Airports, UAE


The door of a passenger car is one of the key components used for the safety of passengers from side collisions. Mostly car doors are made of Steel that increase the overall weight of the vehicle since steel is the primary metal used for the construction of door. The main objective of this research is to replace Steel material of a car door with low-cost automotive materials such as aluminium alloy, magnesium alloy, and carbon fibre material to perform weight reduction analysis without compromising the strength and safety. A comprehensive theoretical study of the existing car door has been performed with 3D Computer-Aided Design (CAD) models through commercially available software SolidWorks. Results of this research work revealed that by selecting the appropriate engineering materials of the doors for a commercially available passenger car, the overall weight reduced to 45% when used aluminium material and 64% when used magnesium and carbon-fibre materials compared to the total weight of four doors made of typical steel material. Furthermore, reduction in fuel consumption and CO2 emission was also obtained by reducing the overall weight of the passenger car doors. Lastly, the performance was measured through power-to-weight ratio (PWR) analysis for steel and aluminium which revealed that the latter material was more economical and lighter in weight than the former material.

Apr 6, 2024
How to Cite
AKBAR, Faraz; RAHMAN, Zia ur. Weight reduction analysis of a four-door passenger car using computer-aided modelling and experimental investigation. Mehran University Research Journal of Engineering and Technology, [S.l.], v. 43, n. 2, p. 91-102, apr. 2024. ISSN 2413-7219. Available at: <https://publications.muet.edu.pk/index.php/muetrj/article/view/3002>. Date accessed: 24 may 2024. doi: http://dx.doi.org/10.22581/muet1982.3002.
This is an open Access Article published by Mehran University of Engineering and Technolgy, Jamshoro under CCBY 4.0 International License