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The demand for improved fuel economy in both cars and trucks has emphasized the need for lighter weight components. The application of high strength steel to wheels, both rim and disc, represents a significant opportunity for the automotive industry. This paper discusses the Ranger HSLA wheel program that achieved a 9.7 lbs. per vehicle weight savings relative to a plain carbon steel wheel of the same design. It describes the Ranger wheel specifications, the material selection, the metallurgical considerations of applying HSLA to wheels, and HSLA arc and flash butt welding. The Ranger wheel design and the development of the manufacturing process is discussed, including design modifications to accommodate the lighter gage. The results demonstrate that wheels can be successfully manufactured from low sulfur 60XK HSLA steel in a conventional high volume process (stamped disc and rolled rim) to meet all wheel performance requirements and achieve a significant weight reduction.

The Clean Air Act Amendments of 1990 have brought about wholesale changes in the mandated requirements for the EPA and states to bring clean air to the country. Of particular interest to the light and heavy duty truck and bus industry are the requirements for VOC reductions in Title I, the hazardous pollutant reductions requirements in Title III, and the new permitting scheme required under Title V of the Act. The inter-relationship of lower VOC coatings, hazardous pollutant reduction, and permitting requirements will be presented. Since the Act does not fully mesh these requirements, the pathways that coating suppliers and coating application facilities can use to come into compliance will be explored. Specific VOC content of conforming coatings will be presented, how they will impact application processes, and how hazardous air pollutant reductions can be achieved is explored.

EXCLUSIVE MEMBER BENEFIT: 2016 MOBILITY ENGINEERING PROFESSIONAL SALARY SURVEY AND CALCULATOR Gain better insight into compensation practices: this salary survey is the only study its kind to explore levels and changes in compensation and employment for engineers and technical employees in the automotive, aerospace, and commercial vehicle industries. It benchmarks compensation levels based by geography, education, industry sector, experience, and managerial and budgetary responsibility. The full report is available to SAE International members by signing into your My SAE account and downloading it into your My Library area. Members also have full access to the updated online interactive salary calculator by visiting SAE’s website. Become a member of SAE International to access this exclusive benefit for free, or purchase it today. YOU BELONG HERE. Membership helps you succeed both personally and professionally. Join us today.

Engine mounts are an integral part of the vehicle that helps in reducing the vibrations generated from the engine. Engine mounts require a simple yet complicated amalgamation of two very different materials, steel and rubber. Proper adhesion between the two is required to prevent any part failure. Therefore, it becomes important that a comprehensive study is done to understand the mating phenomenon of both. A good linking between rubber and metal substrate is governed by surface pretreatment. Various methodologies such as mechanical and chemical are adopted for the same. This paper aims to present a comparative study as to which surface pretreatment has an edge over other techniques in terms of separation force required to break the bonding between the two parts. The study also presents a cost comparison between the techniques so that the best possible technique can be put to use in the commercial vehicle industry.

This paper describes the results of a series of fatigue studies relating the lives of several weld geometries. Rotating beam and axially loaded specimens were used. A comparison between steel and plastic (polyvinylchloride scale models is made. Using plastic scale models of welded structures for fatigue life determination is the ultimate goal of this work.

“Today, wearing parts are regularly subjected to abnormal loading conditions. They must be able to accept these conditions without failure. In continuous operations, unscheduled downtime greatly increases maintenance costs, not to mention the cost of lost production. White iron castings offer premium abrasion resistance for many of these applications, but are often not used due to the possibility of brittle failure and the difficulty of mechanical attachment. This paper discusses the properties and applications of a composite of martensitic white iron and mild steel. This laminate will accept medium to high impact without loss of service failure, and can be installed by mechanical means or with welded attachment.”

This paper describes the simulation model of a backhoe excavator. The model uses a prescribed motion cycle and the objective of the program is to determine the power requirements for each of the cylinders as well as the total engine power requirement. Most computer simulations are developed by expressing the differential equations of motion for the system being studied. The known force inputs to the system are applied and the time response of the system is then obtained by numerically integrating the governing differential equations. This paper on the other hand develops the reverse of this. Utilizing a prescribed geometry and trajectory cycle for a linkage system as the input, the program solves for the types of force inputs that are required to achieve that trajectory. With the time dependence of the trajectory known, the total power required and the power required of each cylinder is also evaluated. A typical excavator linkage is shown in Fig. 1.

Current trends in environmental and emissions regulations are driving changes in new engine systems, and increasing the need for more effectively sealed joints in exhaust systems. At the high temperatures in these exhaust systems it is difficult for traditional gaskets to provide an effective seal, as they degrade at high operating temperatures. This paper introduces a coating that has both excellent temperature stability and good compliance, thus forming an excellent sealing enhancement for metallic layers in exhaust system gaskets. Temperature stability data is presented along with sealing data, which illustrate the superior performance of this material compared to current systems.

This dictionary of terms was prepared for use by those with a need to describe and understand the dynamics and handling of two-wheeled, single track vehicles. It is intended to span the gap between vehicle dynamics specialists and those with a more general interest. This report is pertinent to such areas as vehicle design and development, the description of two-wheeler properties, rider training and education, and the preparation of standards and regulations. This report was prepared by the SAE Motorcycle Committee, which solicits suggestions for improvements and additions to be considered in future revisions. Comments should be directed to SAE Headquarters.

The automobile industry is seeing an increased need for the application of plastics and their derivatives in various forms such as fiber reinforced plastics, in the design and manufacture of various automotive structural components, to reduce weight, cost and improve fuel efficiency. A lot of effort is being directed at the development of structural plastics, to meet specific automotive requirements such as stiffness, safety, strength, durability and environmental standards and recyclability. This paper presents the concept of reinforcing large injection molded fiber reinforced body panels with structural uni-directional fibers (carbon, graphite, kevlar or fiber glass) wound in tension around the body panels by filament winding technique. Structural uni-directional fibers in tension wound around the fiber reinforced plastic inner body panels would place these body panels under compression.

This paper presents some of the history of the Spacemetal process development; a discussion of the core forming machine, a description of the welder where corrugated core and facing sheets are joined; the quality control process employed for inspecting the finished product; and some of the material properties and applications. FOREWORD Development of a production process and the machines for fabrication of a resistance welded steel sandwich was made by Missile Division, North American Aviation, Inc. Development was carried forward under contract AF 33(600)-26154 from the Manufacturing Methods Branch, Industrial Resources Division of the Air Materiel Command USAF.

A new bumper system which provides 8 kph (5 mph) vehicle protection with superior quality, outstanding durability and high value is in production. The system includes five new technologies: Hot stamped, ultra high strength front beam, 970 N/mm2 (160 KSI) which also is the #1 body structure crossmember. Ultra high strength roll formed rear beam 1150 N/mm2 (190 KSI). polypropylene foam isolators designed for controlled energy management Thermoplastic olefin (TPO), injection molded fascias Two component urethane paint for long term color, gloss and scratch resistance. This bumper system, installed on over 100,000 vehicles so far, meets both MPV and passenger car 8 kph standards. Consumer and insurance industry trends indicate increasing demand for Multi Purpose Vehicle (MPV) bumper systems which meet 8 kph criteria. The major competitors in the MPV market (Aerostar, Grand Caravan, Toyota Previa, GM APV's, and Mazda MPV) have either 0 kph or at best 4 kph systems.

Developed to cut down on maintenance costs and increase the earning power of the vehicle, this family of suspensions provides for improved vehicular behavior - items such as stability, braking, cornering, and overall ride. The suspensions utilize a principle of providing a cushioned variable rate ride through the use of molded rubber springs. Floating walking beams distribute weight equally on both axles in the case of tandems. The axles are positively located by upper wishbones and lower torque rods. The parallelogram thus formed prevents windup and axle hop. The correct use of metals shows a substantial weight saving in the entire model range.

Liquid Crystal Display is in the process of achieving the supreme position as an automotive instrument panel; it will replace all other existing automotive displays on dashboards. However, a number of problems on technical support remain to be solved. Focused the most among them is the strong demand of a highly reliable connection method. The new connection technique by soldering was presented in the previous paper. This paper describes the reliability and fabrication process of the new connection and its application to Driver IC on flexible P.C.B. and Chip on Glass instrument panels.

Review of various construction, equipment and organization factors considered in the design of new plant facility for fabrication of prototype earthmoving vehicles. Emphasis on eliminating existing problems and maximizing plant efficiency.

The new Series 600 John Deere Disks are designed for optimum disking performance in primary and secondary tillage conditions. The tandem design retains the performance characteristics of double offset configurations due to an exclusive rolling disk middlebreaker. Welded main and wing frames feature large square and rectangular tubes which are manufactured on common weld fixtures, providing a strong “family” appearance as well as reduced factory setups and inventories. These disks provide farmer-customers with many options and features necessary to operate in varying soil types and conditions while achieving level disking performance and uniform cutting action.

A new method to predict brake squeal occurrence was developed by MSC under contract to Ford Motor Company. The results indicate that the stability characteristics of this disc brake assembly are governed mainly by the frictional properties between the pads and rotor. The stability is achieved when the friction coefficient of the pads is decreasing as the contact force increases. Based on the results, a stable brake system can be obtained without changing the brake structure by incorporating the appropriate frictional coefficient in the brake system. The method developed here can be also used as a tool to test the quality of any brake design in the early design stage.

Presenting a brand new approach to heat exchangers for engines, transmissions, hydraulic systems, etc. This new heat exchanger is made of only two pieces of circular extruded aluminum profiles: Core and shell. No soldering: The core and the shell is assembled by a minimum of automated work. In an oil to water cooling application, the active surface on the oil side of the core is enlarged by fins 0.2 mm thick, 0.3 mm spacing, and 3 mm high. The fins are made in unique production machines and enlarge the active surface area approximately five times compared to a conventional heat exchanger of the same dimensions. The principle utilizes the low pressure drop at laminar flow and avoids the disadvantage of low heat transfer after a certain laminar flow length. The result is approximately three times higher oil heat dissipation, combined with very low oil pressure drop, compared to conventional technique.

Underwater bulldozers have been built for development of the ocean floor. Yet it is impractical for a diver to operate an underwater bulldozer from within the vehicle. Remote control of a bulldozer is extremely difficult due to complicated relationships between vehicle inclination, blade cylinder deflection, and the terrain profile in front of the bulldozer. In this paper a nonlinear automatic feedback blade control system is designed to replace direct operator control of the blade. To accomplish this design, mathematical models were developed for the vehicle dynamics and the hydraulic system dynamics of a typical bulldozer. Since both subsystem models are complicated nonlinear ones, the blade control system was designed using only a simplified hydraulic system model. The performance of the complete nonlinear system with the blade feedback control system added was then investigated using a hybrid computer simulation compared to available experimental data using a skilled operator.

A farm tractor protection cab made of thin steel sheet pressings is described. The cab is designed and produced using entirely automotive-type procedures. Curved glasses and a dampening suspension of the glasses are found to be an important means of achieving a low noise level in the cab. Using the pressing technique when producing a steel cab makes it possible to give the various cab details rigidity with a minimum of material. When welded together, these details form a very stiff cab body, which gives the necessary mechanical strength. The curved surfaces, the radii, and the round forms, which from a tooling point of view are natural for pressed steel parts, also have a vibration-dampening effect on the entire cab construction, thus making it easier to design a quiet tractor cab. Mounted on a farm tractor of conventional design, the cab meets the noise rating number ISO N85.