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This paper presents a methodology developed using Design of Experiments to predict the maximum temperature of an automotive headlamp reflector for the given geometry of the headlamp components and heat source. The proposed approach has been validated through comparison with three-dimensional Computational Fluid Dynamics simulation. The final out come of this study is a set of transfer functions, which can predict the maximum temperature of a reflector, positioned either in horizontal or vertical configuration.

This book is focused on the use of plastics in automobiles for traditional applications, as well as for more advanced uses such as under-the-hood components. Engineering thermoplastics offer the ability to tailor-make components from polymers, and to design parts for enhanced performance, new functionality, part integration, and elimination of secondary operations. Parts made from engineering thermoplastics can be manufactured within specified cost constraints, and using manufacturing methods that offer a wide range of production flexibility. A decade of research and real-world applications is presented by the authors on application technology development for various aspects of automotive design – concept design, CAD modeling, predictive engineering methods through CAE, manufacturing method simulation, and prototype and tool making.