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Impact resistance of plastic underbody parts was studied using simulated injection-molded specimen which can be tested according to different types of material used, injection molding variants like position and number of injection molding gates, and features of ribs. Material applied was glass fiber reinforced polyamide which can be used in underbody parts. Test was performed using several combinations of injection molding gates and rib types. From the test result, optimal design guide for plastic underbody parts was determined. Also, new high impact resistant plastic material made of glass fiber reinforced polyamide 66 (PA66) and polyamide 6 (PA6) alloy was developed and the material properties useful for CAE were determined. As a case study, oil pan and muffler housing were designed following the optimal design guide and CAE. And the reliability of the sample muffler housing designed was verified.

As petroleum prices experience record volatility, automotive OEMs are seeking advanced materials that permit the development of more light weight, fuel efficient vehicles. Thermoplastics are a natural solution since they provide the combination of structural properties with lower material density, along with ease of forming geometrically complicated parts with rapid cycles and with minimal finishing operations. However, new automotive applications are becoming increasingly demanding with regard to chemical exposure, environmental exposure, thermal environment, and load bearing requirements. Addressing these challenges requires a thorough understanding of the application in order to identify appropriate thermoplastic resins and to develop novel resin technologies to extend the performance of structural engineering thermoplastics.

As the global automotive industry continues to strive for improved performance at lower costs, the use of blow-molded thermoplastics in underhood components offers a wide range of benefits, including: 1. Cost reduction 2. Weight reduction 3. Improved recyclability 4. Multi-functional part design opportunities 5. Reduction in number of parts and materials in the engine compartment 6. Greater temperature resistance to handle increasing powertrain temperatures 7. Easier assembly/disassembly for productivity improvements and cost savings in the manufacturing process 8. Reduced noise 9. Improved engine performance (up to 2 percent) Underhood applications where blow-molded technology can provide these advantages include turbo- charge ducts, air ducts, crankcase venting hoses, resonators, coolant reservoirs, and pipes and hoses for oil cooling, air conditioning and coolant systems. This technology is now used in the European automotive market and in Japan.

A method and equipment for the determination of material limits for polymeric thrust elements is presented along with initial data based on the system. Methods are presented to better simulate drive train thrust element operation on equipment that utilizes production ready mating components under actual load, speed, and lubrication conditions. Initial results for limited materials are presented. This study allows for a more complete understanding of the effects of the product of pressure and velocity (PV) on material wear and frictional behavior for drive train applications of thrust elements.

Environmental and fuel economy regulations (Eu 6d and WLTP RDE) on automobiles have been tightened recently. To counter this regulation, the global automobile industry is focusing on weight reduction, fuel efficient turbo charger, cooled EGR, thermal management, low friction and so on. However, the high-speed turbocharger makes turbulence, and resulting in airflow noise. This noise is transmitted indoor through the air intake system, which adversely affects the vehicle's competitiveness. Therefore, for turbo engine, it is essential to reduce the noise of the air intake system. The air intake system consists of air cleaner, air filter, air intake hose and air duct. The air flow noise of turbo-engine is mainly the emission noise emitted from the walls of air intake system. And the transfer path of turbo noise is in order of air intake hose, air cleaner and air duct. Therefore, it is effective to reduce the noise of the air intake hose located at the beginning of noise transfer path.