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With the automotive industry moving towards higher durability targets, reduced product development cycle time, and lower design costs, the need for simulation has never been higher. This paper explains the use of simulation techniques in the design and development of door module. A step-by-step approach to simulate a door slam event is proposed. Fatigue life estimation using simulation results is also discussed. Finally, simulation benefits are illustrated with a simulation-test case study completed at ArvinMeritor that resulted in a fatigue life improvement of more than 50%. The scope of this paper is limited to simulation methods for door slam. Test methods to collect data for door slam simulation are not discussed.

Future stringent emission limits both in the European Community and USA require continuously increased conversion efficiency of exhaust after-treatment systems. Besides the obvious targets of fastest light-off performance, overall conversion efficiency and durability, catalytic converters for maximum output engines require highly optimized flow properties as well, in order to create minimum exhaust backpressure for low fuel consumption. This work deals with the design, development and serial introduction of a close coupled main catalyst system using the innovative technology of Perforated Foils (PE). By means of PE-technology, channel-to-channel gas mixing within the metal substrate could be achieved leading to dramatically reduced backpressure values compared with the conventional design.

In the development and manufacture of vehicle components and systems, it is often necessary to quickly identify optimal design modifications for mitigating noise and vibration problems to meet the production schedule. To address this need, experimental techniques for determining the sensitivity of forced vibration response to changes in mass, damping or stiffness properties are of great use. In order to distinguish physical changes in the system from nonlinear input-output distortion, experimental techniques for identifying nonlinear input-output models in mechanical systems are also needed. The use of experimental sensitivity measurements and analyses for studying linear and nonlinear forced vibration data is examined in this work. Embedded sensitivity functions are first used to identify design modifications for reducing a vibration resonant problem.