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2015-06-22
Event
This session covers static and dynamic issues in the body and chassis that contribute to noise and vibration problems in vehicles. Included in this session are modal studies, measurement and analysis methods, transfer path analysis, design guidelines, and recommended practices for noise and vibration control of the body and chassis.
2015-06-22
Event
This session focuses on the development and application of analytical methods for characterizing the dynamic behavior of structural systems. Analysis methods for all structural components, subsystems and complete systems found in automotive vehicles will be considered, except for powertrain and driveline which are covered in Powertrain Structural Analysis session. Examples include (but are not limited to) body structure, chassis structure, seats and interior structures.
2015-06-22
Event
The focus of the Structural Analysis session is to share experiences on analyzing, testing, and developing solutions to structural noise and vibration problems from powertrain sources. Analytical modeling, experimental testing and predictive correlation are just a few of the tools used in this endeavor.
2015-04-21
Event
This symposium provides a forum for researchers and application engineers to disseminate the knowledge and information gained in the area of advanced high-strength and press-hardening steel development and applications in automotive structures, enabling light-weight and durable vehicles with improved safety.
2015-04-21
Event
Body Engineering & Design papers cover several important areas that are related to vehicle body, including its components such as instrument panel, steering column and wheel, seats, hood, decklid, transmission cross-member, hard mounted chassis, CRFM, etc. The topics included are: Novel concepts, Analysis, Design, Testing, Predictions of strength, stiffness, and fatigue life, Various welding methods, Improvement in vehicle body quality, durability, reliability, and Performance of safety, ride & handling, NVH, aerodynamics, mass reduction, as well as fuel economy.
2015-04-14
Technical Paper
2015-01-1737
Jean-louis Ligier, Mathieu Benoit, Sylvain Damaz
Today new automotive engine design is optimized in term of mass. However, in term of stiffness, optimizations mainly consider eigenfrequency criteria. But in assembly components with quite low stiffness cumulated microslip phenomena can occur when the structures are subject to cyclic loadings. After a while, macro-displacements will be observed and then failures of the assembly will take place. Bush, plain bearing, roller bearing in conrod or in gearbox can be subject to this kind of problem. In this paper, after a short description of various mechanisms which can cause microreptation phenomena, two types of cumulated microslip occurring in engine and gearbox are presented. Behavior specifities will be highlighted to remind how particular are cumulated microslip. From the field, it appears that both phenomena arise with a low probability of occurrence. It implies not to use the devices concerned by this problem to investigate the phenomenon.
2015-04-14
Technical Paper
2015-01-0368
Janampally Sandeep Kumar Reddy, Shailendra Deopa, Abhay Sharma, Piyush Aggarwal
The condenser opening area plays a vital role in the A/C Performance of the vehicle particularly during the idling. This paper presents the detail study on the effects of the condenser opening area on the A/C performance. Based on the theory, the effect of the condenser opening area is studied and it is validated by the experimental results. Based on these results an optimum value of the condenser opening area required for the best A/C performance is concluded.
2015-04-14
Technical Paper
2015-01-1312
MyoungKwon Je
The power sliding door system(PSD) is being equipped in the MPV(Multi-Purposd Vehicle) vehicle for convenience in the door operation. This study will be done to optimize package for interior design and package in the vehicle which equips PSD system. To optimize the package, investigation for PSD's structure need to be done and the examples of other vehicle maker will be investigated and compared. And the study to reconcile between the performance and good package of PSD system made the unique PSD design method in this study. And finally, this study will show the result vehicle in which the optimized mechanism is applied. So we will realize the effect from this study.
2015-04-14
Technical Paper
2015-01-1319
Eitaro Koya, Yukihide Fukuda, Shinya Kitagawa, Mitsunori Murakami, Atsushi Kawauchi, Sadanori Furue
Weight reduction is a key measure to enhance fuel economy of a vehicle. When a weight reduction is applied to suspension parts, high stiffness is also required. To achieve both high stiffness and light weight, it is effective to adopt a hollow structure to the main structure. For manufacturing of a hollow structure by aluminum casting, Gravity Die Casting (GDC) has been widely applied because of its slow charging speed contributing to avoid high pressure to the foundry sand core. In GDC, the molten metal is generally charged at a speed of 1 m/s or slower and this low speed keeps the pressure low. However, in this method, the charging time is prolonged and the wall thickness reduction is restricted. Accordingly, it was needed to establish a method of hollow structure casting that can be implemented to HPDC, because HPDC is capable of thin wall casting and realizing a short process time. However, in HPDC, the injection speed is usually 30 to 40 m/s.
2015-04-14
Technical Paper
2015-01-1314
Max Sardou, Patricia Djomseu
STATE OF THE ART. The weight of the unsprungs components cost a lot of energy and damage roads. Almost all OEM are planning to reduce weight of their vehicles up to 350 kg by using carbon-epoxy composite. The target is to save: • 1.2 litter/100 km of fuel consumption , • 3 g of CO2/km. The paper presents a tough solution in order to produce high performance carbon-epoxy composite parts. SARDOU SAS SOLUTIONS. In order to save weight car manufacturers are considering replacing metal by a composite carbon epoxy. Replacing metal by a composite is a smart solution: • Offering the capacity to address a lot of metal parts on a car and for instance to split by two the weight of aluminium forged components like: o Suspension wishbone o Suspension link o Cradle o Sub frame o Rack and pinion casing • Offering the capacity to produce light and low cost “high pressure vessels” for hydrogen and NGV storage. • Offering the capacity to produce light and low energy savings “composite valve springs”.
2015-04-14
Technical Paper
2015-01-1317
Golam Mainuddin, Mohamad Qatu
Rotating machinery vibration is an interesting subject, particularly in automotive engineering. Every rotating component has vibration issues. This typically results from issues of balancing, run-out and others. Automotive industries are interested in minimizing noise and vibration to comfort levels. This is a main attribute for automotive customers. Noise and vibration issues also impact warranty claims, which are important to the auto industry as well. Light electric vehicles (EV) show different levels of NVH. The usual abrupt vibration and noise issues typically recorded for internal combustion engine (ICE) do not exist for EV. This research is intended to get an overall idea about NVH levels in EV and to show the differences between internal combustion engine and electric vehicle during cruising mode. Several tests were conducted with a light electric vehicle. Vibration signatures were recorded during cruising (in low speeds) of the electric truck.
2015-04-14
Technical Paper
2015-01-0358
Praveen Balaj Balakrishnan, Xiaoyong Yu
An adsorption air conditioning system is proposed to provide cabin comfort cooling for automotives. This report is focused on the development of a compact adsorption cooling system for automobile applications and its experimental performance. This system uses AQSOA – Z01, an adsorbent material that adsorbs and regenerates water efficiently at low temperature ranges. A water circulation system was specially built to simulate the process of obtaining heat from exhaust gas heat and provide low-grade thermal energy for the adsorption cooling system. As this system does not need to be powered by engine as in the conventional system, it can improve fuel efficiency of the engine up to 10% which also results in reduction of pollutants due to combustion. The prototype is capable of producing up to 1310 Watts of cooling power and achieved 650 W/kg as the value for the specific cooling power (SCP) and coefficient of performance (COP) value of 0.45.
2015-04-14
Technical Paper
2015-01-1308
Rajiv Hiralal Pant, Vyankatesh Govind Naidu
There has been global trend on BIW light weighting using advanced materials like AHSS, DP, and TRIP etc. This articles questions this approach and puts light on other side of BIW light weighting to make us think whether use of AHSS is always lighter on pocket? This also provides an overview of some of the enabling strategies for robust BIW design using low cost conventional material. The strategies make use of the latest practices like upfront CAE and BOK (Book of Knowledge). Earlier studies indicated that in order to reduce BIW weight, it is necessary to reduce sheet metal thicknesses using advanced materials. However thickness reduction using AHSS is not always beneficial from cost point of view. Also less thickness affects BIW performance considerably. The easiest approach in BIW design to gain higher strength is to change material to higher yield strength.
2015-04-14
Technical Paper
2015-01-1310
Rama Subbu, Baskar Anthonysamy, Piyush Mani Sharma, Prasanna Mahendiran
The main challenge that arise in the design of a motorcycle frame is its effect on the functioning of the vehicle, ride comfort and durability. While functionality and ride comfort can be evaluated before the product reaches customer, evaluation of its durability is a complex process. This work is an investigation of the frame body of a lower cc vehicle. These vehicles are subjected to endurance tests on a rough road to quantitatively evaluate their frame durability. However, such tests require significant time and cost, so we have attempted to develop a virtual rough road simulator and frame test rig, in which the frame body durability of a two wheel vehicle can be evaluated. Also durability results were compared and analyzed among the track data, road simulator and frame test rig. This paper presents an approach for efficiently evaluating motorcycle frame body durability using external loads predicted from measured strain data from test track.
2015-04-14
Technical Paper
2015-01-1316
Hwawon Lee, Parvath Police, Lisa Koch, Rajmouli komarivelli, Brice Willis
Spot weld separation in vehicle development stage is one of the critical phenomena in structural analyses regarding quasi-static test condition, like roof strength or seat/belt pull. It directly reduces structural performance by losing connected load path and occasionally introduces tearing on surrounding sheet metals. Traditionally many efforts have been attempted to capture parent metal ductile fracture, but not applied to spot weld separations in automotive FEA simulations. [1][2][3] There are two analytical methods that have been widely used in the automotive industry. One is force-based approach. This approach is represented by mesh-independent beam or hex weld with contact definitions to sheet metal. Weld separation is predicted by utilizing developed force and moment criteria, but is limited to capturing interfacial weld fracture mode only. The other approach is strain-based spot weld.
2015-04-14
Technical Paper
2015-01-0702
Bita Ghaffari, Jonathan Dekam, Kevin Haddix, Kimberly Lazarz, Roman Maev, Sergey Titov
Adhesive bonding technology has gained increased significance in automotive industry, especially with the growing use of aluminum alloy body structures. The variability in thicknesses of the metal and adhesive layers, as well as the variability in joint geometry, of automotive components has presented challenges in nondestructive evaluation of adhesive joints. These issues have recently been resolved for steel-adhesive joints through the use of an ultrasonic pulse-echo technique. The difference in acoustic impedance of steel and Al, however, leads to a lack of robustness in using the same technique for Al-adhesive joints. In this paper, we present the results from utilizing a modified version of this pulse-echo algorithm to inspect Al-adhesive joints in both laboratory and production environments. A 52-element, 10 mm X 10 mm, 15-MHz matrix array of ultrasonic transducers was used to obtain the echotrains, analysis of which produced a C-scan image of the adhesive bead.
2015-04-14
Technical Paper
2015-01-1318
Mohammad Muneer, Yogesh Sharma
The door performance of an automobile is gauged not only by its function but also the “feel” of operating a door which majorly depends upon opening /closing force and closing velocity. This feel is in direct relation to soundness of design and build quality which the customer experiences even before driving the vehicle. The above mentioned performance parameters depend largely on the following factors: 1. Door structure and weight 2. Hinge Axis inclination 3. Body/panel Accuracy 4. Check link/stop comp design 5. Latch mechanism 6. Compression resistance force from sealing 7. Air binding effect 8. Frictional forces (both part and component level) For a sliding door, along with above mentioned factors following also play a major role. 9. Rail design/ door closing/opening locus 10. Door support structure (Hinges) Several studies have been conducted for door open/close performance for a conventional swing door, however little has been done for sliding door.
2015-04-14
Technical Paper
2015-01-0532
Mingchao Guo, Weidong Zhang, Dajun Zhang, Ram Bhandarkar
A tailgate on cargo box is a typical closure with dynamic mechanical connections to box body structure: the pivot joints at lower corners of both left and right hand sides not only rotate free around the lateral axes but also travel free away from the box body structure along the lateral axes within certain range. This causes modeling difficulties for the tailgate to box body connections in durability analysis when a linear static based stress and fatigue damage linear accumulation approach is employed. Any assumptions in the connection modeling will results in inaccurate stresses at the pivot joint areas, both tailgate and box body sides. In this paper, a developed new technique with measured acceleration input is described in details. The acceleration time histories in x, y and z directions at three corners of the tailgate are collected first.
2015-04-14
Technical Paper
2015-01-1309
Hyunggyung Kim
This paper describes about the development of new concept’s rear wheel guards for the reduction of Road Noise in the passenger vehicle using test. The new wheel guards are proposed by various frequency chamber concept and different textile layers concept. Two wheel guards were verified by small cabin resonance test and vehicle test. Through new developing process without vehicle test, Result of road noise will be expected when new concepts and materials of wheel guard is applied into automotive vehicle. As this concept consider tire radiation noise frequency and multilayers sound control multilayers, 2 concepts reduced road noise from 0.5 to 1.0 dB The suggested Estimation method of part reverberant absorption method is similar to result of vehicle tests by part absorption index. Furthermore, optimization of frequency band to wheel guards will reduce more 0.5 dB noises in vehicle.
2015-04-14
Technical Paper
2015-01-0550
Wenxin Qin
Substructure Stiffness Synthesis for Fatigue Analysis of Automotive Structure Wenxin Qin (Chrysler Group, LLC, USA) Abstract In automotive chassis, body and powertrain durability fatigue analysis, FEA model becomes bigger and bigger and close to adopt a full vehicle as computer hardware and software improved. However, due to a huge amount of components (more than 20,000 parts in a vehicle), there are still too much computational time needed and a lot of pre/post process works to do for using full car FEA model. Therefore, for saving time and cost it is desirable to reduce the number of subsystems, and getting an effective subsystem model which keeps the main features of the mechanics of a whole vehicle system. In this paper, authors present a useful and effective substructure FEA model: Substructure Stiffness Synthesis (SSS) method in the automotive durability analysis.
2015-04-14
Technical Paper
2015-01-1340
Yoichi Toyooka, Kiyoshi Hasegawa
Warping the exteriors of outer panels happens during the application of heat for hardening structural adhesives. Using aluminum and resin promote warping. Simulation of warping at the design stage and evaluating warping during mass-production require us to quantify the degree of warping to evaluate absolute values. These analytic values correspond to values from warping in panels, and display a correlation with visual examinations. Degree of displacement was an evaluative indicator for the quantification of warping. However, warping will not always be recognized due to gradual change in areas of the panel and cases where it will be recognized due to sudden change, despite that the absolute value of the degree of displacement might be the same. This research considered a warping simulation and evaluation using curvature as the evaluative indicator. Curvature is the gradient of change of the curved surface.
2015-04-14
Technical Paper
2015-01-1370
Mehran Ebrahimi, Kamran Behdinan
Energy consumption is one of the most significant challenges in the world today, and has been the source of many struggles in international level. The future of human’s generations is in serious danger because of energy related issues such as resources shortage and global warming. Hence, responsible governments have codified some policies to reduce fuel consumption in energy-dependent industries and their products. Automobile industries as the manufacturers of fuel consumer products are not exempt from these rules, and are always looking for more lightweight industrial designs. In order to achieve more lightweight solutions, changing the material of an available part to a lower density one is the first option in many applications, and aluminum as an accessible material with acceptable mechanical properties can be a suitable replacement for steel in the majority of industrial demands.
2015-04-14
Technical Paper
2015-01-1311
Leland Decker, James Truskin
As CAFE requirements increase, automotive OEMs are pursuing innovative methods to lightweight their Body In Whites (BIWs). Within Chrysler, this lightweighting research and development activity often occurs through Decoupled Innovation projects. A Decoupled Innovation team comprised of engineers from Chrysler’s BIW Structures Group, in collaboration with Tier 1 supplier Magna Exteriors, sought to re-design a loadbearing component on the BIW that would offer significant weight savings when the current steel component was replaced with a carbon fiber composite. This paper describes the design, development, physical validation and partnership that resulted in a composite Rear Package Shelf Assembly solution for a high-volume production vehicle. As the CAFE requirements loom closer and closer, these innovation-driven engineering activities are imperative to the successful lightweighting of Chrysler vehicles.
2015-04-14
Technical Paper
2015-01-1321
Shigetaka Kameyama
Body development efficiency should be improved to reduce rework; designing a sufficiently stiff body model from the beginning becomes the key. A body designer studies the space available, which is judged by styling, design, and packaging; based on experience. The first model seldom reaches the targets of body stiffness, so improvements are required. We want to make a sufficiently stiff body model by building a simple and easy-to-use analysis method to help the designers’ understanding. In early stages of body development, there are more opportunities to study and propose design space for a stiff body structure. Because of the design flexibility at early stages, the information is easy to change, but there is little information to know how much space is available. Requirements analysis should be minimized. Designers should obtain the appropriate targets for each body part because each part has a different designer.
2015-04-14
Technical Paper
2015-01-1324
Guangtian Gavin Song, Chin-An Tan
In automotive industry, door slam CAE fatigue life analysis is very important in door durability evaluation and optimization to dramatically reduce the design cycle and minimize the expensive durability testing. Couple of linear stress based methodologies, such as inertia relief method, direct transient response solution, or local strain approach, have been applied in CAE. Linear material properties are used in these linear stress based methodologies. In local strain approach, contact surface could be defined in the necessary area. Then the stress time history is retrieved and input to further fatigue life analysis or firstly converted to nonlinear stress with Neuber’s rule to consider plastic deformation effect. But under some circumstances, the structure may have large local area plastic deformation. So the linear stress based methodology can’t precisely predict the load path, and further affect the accuracy of fatigue analysis.
2015-04-14
Technical Paper
2015-01-0723
Sebastian Bender, Markus Lienkamp, Raymond Khoo, Christoph Große, Heong Wah Ng, Felix M. Wunner
Upcoming stringent regulations on emissions and fuel efficiency are driving the automotive industry towards light-weight vehicle design. A higher share of carbon fiber composite materials in vehicle structures is expected. Current literature addresses development processes of composite components under a limited scope but the considerations of design parameters used in these studies are inadequate for the realistic development of a full vehicle structure, especially in a resource-constrained development project. In addition, existing vehicle structure design philosophies used for metallic structures cannot be directly ported over for composites design due to the differences in material properties, failure modes and design for manufacturing limitations.
2015-04-14
Technical Paper
2015-01-1352
Suhas Kangde, Abhijit Londhe, Ashish Kumar Sahu
Body in White (BIW) is one of the major mass contributors in a full vehicle. Bending stiffness, Torsional stiffness, durability and modal characteristics are the basic performances for which BIW is designed. Usually while meeting these performances, a lot of weight is added to BIW. Sensitivity analysis helps to identify the critical panels contributing to the performance while BIW optimization helps to reduce the overall mass of the BIW without compromising on the basic performances. This paper highlights the optimization study carried out on the BIW of a Sports Utility Vehicle (SUV) for mass reduction. This optimization was carried out considering all the basic performance parameters. In the initial phase of BIW development, optimization helps to ensure minimum BIW weight rather than carrying out mass reduction post manufacturing and testing.
2015-01-14
Technical Paper
2015-26-0171
Niraj Singh, Ruhi Thakur, Mathew Cyriac
Abstract With the change in the perspective of the Customers towards safer vehicles, most of the Vehicle manufacturers in India are making their vehicles Crash compliant. According to the accidental data collection, Side crashes are second leading cause of death after Frontal crash. Currently sub system level tests are done for evaluating the side impact safety performance of the vehicle. One of such sub system level test is Quasi-static side door intrusion Test. The primary purpose of this testing is to measure the Force-deflection characteristics by intrusion of the impactor into the vehicle. These characteristics are controlled by various door components like door beam, latch & striker, hinge etc. This article studies the relation between Side door intrusion and Side collision, effect of above mentioned components on this relation. A theoretical study is done to study this relationship and it is substantiated with experimental data.
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