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A method to predict gap distribution, can deformation and mounting force of catalytic converter during assembling and operation cycles has been developed using ABAQUS contact algorithm with user subroutine for material properties. Inherent in the methodology is the constitutive model for both vermiculite mat and wire mesh mounting materials, which is able to describe their nonlinear and thermal behaviors and shows good agreement with test results. A design optimization procedure is presented to achieve uniform gap design of can and substrate. The technology will enable engineers to generate robust converter can designs, substrate shape and stamping tools for minimum manufacturing failure rate and maximum durability performance once a mounting material is selected.

This reearch presents a concept using effective road profile to calculate road loads. The method uses existing vehicle road load data, simplified vehicle dynamic model and simple tire model to create effective road profile. Then the simplified vehicle model is updated to reflect the vehicle changes of a new vehicle. Run the simplified new vehicle model to calculate road loads. The application of effective road profile in laboratory simulation is introduced. Preliminary CAE road load simulation using the effective road profile is presented.