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Viewing 1 to 30 of 2675
2017-04-06
Event
BE & D 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. Topics included are: Novel concepts, Analysis, Design, Testing, Predictions of strength, stiffness, and fatigue life, welding methods, vehicle body quality, durability, reliability, safety, ride & handling, NVH, aerodynamics, mass reduction, as well as fuel economy.
2017-04-06
Event
BE & D 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. Topics included are: Novel concepts, Analysis, Design, Testing, Predictions of strength, stiffness, and fatigue life, welding methods, vehicle body quality, durability, reliability, safety, ride & handling, NVH, aerodynamics, mass reduction, as well as fuel economy.
2017-04-06
Event
Multibody system modeling and simulation, rigid and flexible body modeling, loads predictions for vehicle body, frame/sub-frame, exhaust system, driveline, and powertrain, modeling of vehicle dynamics simulation and durability loads simulation, process considering vehicle dynamics and durability loads, data processing and analysis, loads sensitivity analyses for model parameters, design load minimization, prediction of loads effects, robust design methods, driver modeling, and system modeling.
2017-04-05
Event
Multibody system modeling and simulation, rigid and flexible body modeling, loads predictions for vehicle body, frame/sub-frame, exhaust system, driveline, and powertrain, modeling of vehicle dynamics simulation and durability loads simulation, process considering vehicle dynamics and durability loads, data processing and analysis, loads sensitivity analyses for model parameters, design load minimization, prediction of loads effects, robust design methods, driver modeling, and system modeling.
2017-03-28
Technical Paper
2017-01-1304
Alejandro Rosas Vazquez, Fernando Paisano, Diego Santillan Gutierrez
For many years the use of in-mold fasteners has been avoided for various reasons including: not fully understand the load cases in the part, the fear for quality issues to occur, the need for servicing, or the lack of understanding the complexity of all failure modes. The most common solution has been the use of secondary operations to provide attachments, such as, screws, metal clips, heat staking, sonic welding or other methods which are ultimately a waste in the process and increase manufacturing costs. The purpose of this paper is to take the reader through a design process which allows for the design of in-molded attachment clips on plastic parts. The paper explores the design process for in-molded attachment clips starting with a design concept idea, testing the basic concept using a personal 3D printer, optimizing the design with physical tests and CAE analysis, and finally producing high resolution 3D prototypes for validation and tuning.
2017-03-28
Technical Paper
2017-01-1309
S. M. Akbar Berry, Hoda ElMaraghy PhD, Johnathan Line, Marc Kondrad
Modularity in product architecture and its importance in product development has become a critical discussion topic in the last few decades. Several Product Modularity definitions and prospects were discussed by many researchers, however, most of the definitions and concepts are proliferated such that it is difficult to apply one universal definition to every modular product architecture and in product development. Automotive seat modular design and key factors for consideration towards modular seat design and assemblies are the main objectives of this work. The primary objectives are focused around the most “natural segmentation” of the seat elements (i.e., cushions, backs, trims, plastics, head restraints, etc.) to enable the greatest ease of final assembly and greatest flexibility for scalable feature offerings around common assembly “hard-points.”
2017-03-28
Technical Paper
2017-01-1303
Nobuhisa Yasuda, Shinichi Nishizawa, Maiko Ikeda, Tadashi Sakai
The purpose of this study is to validate a reverse engineering based design method for automotive trunk lid torsion bars (TLTB) in order to determine a free shape that meets a target closed shape as well as a specified torque. A TLTB is a trunk lid component that uses torsional restoring force to facilitate the lifting open of a trunk lid, as well as to maintain the open position. Bend points and torque at a closed trunk position are specified by a car maker. Conventionally, a TLTB supplier determines bend points of the free shape by rotating the given bend points from a closed position around a certain axis to satisfy the specified torque at the closed position. Bend points of a deformed TLTB shape in the closed position often do not match the target bend points given by a car maker when designed by the conventional method, which can potentially cause interference issues with surrounding components.
2017-03-28
Technical Paper
2017-01-0423
Lei Yang, Chuxuan Wang, Yunqing Zhang
The frame is an important subsystem for the FSAE race car, as it supports and connects to other subsystems. The weight, frequency and structure of the frame influence on the race car performances such as acceleration, handling, ride and durability. A rigid-flexible coupling FSAE race car model with flexible frame is implemented in ADAMS/car. By extracting the forces and torques of the joints which connect the frame to other subsystems in various race car extreme conditions, the loads transfer path from road and aerodynamic forces to the frame is discussed. The strength, stiffness and free mode analysis of the frame are carried out by means of Finite Element Analysis (FEA), the stress analysis and checking are under loads extracted from dynamic simulation with the rigid-flexible coupling FSAE race car model. According to the FEA results, an optimization of the frame is implemented by topological and size optimization.
2017-03-28
Technical Paper
2017-01-1305
Yucheng Liu, Jeremy Batte, Zachary Collins, Jennifer Bateman, John Atkins, Madelyn Davis, David Salley, Cindy L. Bethel, John Ball, Christopher Archibald
A robot mining system was designed to traverse the Martian chaotic terrain, excavate a minimum of 10 kg of Martian regolith and deposit the regolith into a collector bin within 10 minutes as part of the competition. A systems engineering approach was employed to conduct this design project. The designed mining robot consisted of two major components: (1) mechanical system and (2) control system. In this paper, design, prototyping, and assessment of the mechanical system are demonstrated. The final mining robot consists of an aluminum frame driven by four motors and wheels, and a scoop and lifting arm subsystem for collecting and depositing Martian regolith, which was powered by two computers and used two commercially-of-the-shelf sensors to navigate the Martian terrain. Engineering students and faculty from different engineering disciplines collaboratively participated in this effort.
2017-03-28
Technical Paper
2017-01-1511
Anton Kabanovs, Graham Hodgson, Andrew Garmory, Martin Passmore, Adrian Gaylard
The motivation for this paper is to consider the effect of rear end geometry on rear soiling using a representative generic SUV body. In particular the effect of varying the top slant angle is considered using both experiment and Computational Fluid Dynamics (CFD). Previous work has shown that slant angle has a significant effect on wake shape and drag and here we extend this to investigate the effect on rear soiling. It is hoped that this work can provide an insight into the likely effect of such geometry changes on the soiling of similarly shaped road vehicles. To increase the generality of results, and to allow comparison with previously obtained aerodynamic data, a 25% scale generic SUV model is used in the Loughborough University Large Wind Tunnel. UV doped water is sprayed from a position located at the bottom of the left rear tire to simulate the creation of spray from this tire.
2017-03-28
Technical Paper
2017-01-1634
Hui Sung Lee
When customers use a tailgate(or trunk), some systems such as power tailgate and smart tailgate have been introduced and implemented for improving convenience. However, they still have some problems in some use cases. Some people have to search for the outside button to open the tailgate, or they should take out the key and push a button. In some cases, they should move their leg or wait a few seconds which makes some people feel that it is a long time. In addition, they have to push the small button which is located on the inner trim in order to close the tailgate. This paper proposes a new tailgate control technology and systems based on acoustic patterns in order to solve some inconvenience. An acoustic user interaction (AUI) is a technology which responds to human's rubbing and tapping on a specific part analyzing the acoustic patterns. The AUI has been recently spotlighted in the automotive industry as well as home appliances, mobile devices, musical instruments, etc.
2017-03-28
Technical Paper
2017-01-0395
Xin Xie, Danielle Zeng, Boyang Zhang, Junrui Li, Liping Yan, Lianxiang Yang
Vehicle front panel is an interior part which have a major impact on the consumers’ experience of the vehicles. To keep a good appearance during long time aging period, most of the front panel is designed as a rough surface. Some types of surface defects on the rough surface can only be observed under the exposure of certain angled sun light. This brings great difficulties in finding surface defects on the production line. This paper introduces a novel polarized laser light based surface quality inspection method for the rough surfaces on the vehicle front panel. By using the novel surface quality inspection system, the surface defects can be detected real-timely even without the exposure under certain angled sun light. The optical fundamentals, theory derivation, experiment setup and testing result are shown in detail in this paper.
2017-03-28
Technical Paper
2017-01-1310
Harihar T. Kulkarni, Yu Wang, James Alanoly
The perceived quality of automotive closures (flushness and margin) is strongly affected by flanging and hemming of the outer panels and assembly respectively. To improve the quality of closures, the traditional hardware approach needs significant amount of time and costly die re-cuts and trials with prototype panels. Thus, such approach may delay the vehicle program and increase the overall investment cost. The proposed CAE methodology approach provides upfront design guidance to dies and panels, reduces time and cost associated with flanging and hemming trials necessary to improve overall quality of the closures. In this approach, as a first step, analytical formulae and design of experiments (DOE) are followed to estimate magnitude of design parameters of panels and dies to provide upfront design guidance.
2017-03-28
Technical Paper
2017-01-1308
Abhishek Softa, Anuj Shami, Rajdeep Singh Khurana
The automotive world is under constant challenge to go green or not harm our planet. Engineers are trying hard every day to meet this challenge. Increase in usage of personal transport is again a question for car producers. Every new car on road is increasing the carbon footprint. High fuel efficiency is one of the answers of this problem. Engineers all over the world are working on alternative and unconventional fuels, hybrid engines, fuel cells etc. As body designers we are solving this problem by new designs and usage of lightweight techniques. Car bodies are made lighter by optimizing old designs and by usage of different lightweight materials. In addition to this approach replacement of conventional material like steel by plastic (PU) is viable solution for this problem. This paper is focusing on the usage of new material and design concept. Areas of usage are roof rails that are used for improving vehicle aesthetics or as a load carrying structure or sometimes as both.
2017-03-28
Technical Paper
2017-01-1463
Feng Zhu, Clifford C. Chou
A new design methodology based on data mining theory has been proposed and used in the vehicle crashworthiness design. The method allows exploring the big crash simulation dataset to discover the underlying complicated relationships between response and design variables, and derive design rules based on the structural response to make decisions towards the component design. An S-shaped beam is used as an example to demonstrate the performance of this method. A large amount of simulations are conducted and the results form a big dataset. The dataset is then mined to build a decision tree. Based on the decision trees, the interrelationship among the geometric design variables are revealed, and then the design rules are derived to produce the design cases with good energy absorbing capacity. The accuracy of this method is verified by comparing the data mining model prediction and simulation data.
2017-03-28
Technical Paper
2017-01-0441
Zhenyu Wang, Mei Zhuang
A numerical study on sunroof noise reduction is carried out. One of the strategies to suppress the noise is to break down the strong vortices impinging upon the trailing edge of the sunroof into smaller eddies. In the current study, a serrated sunroof trailing edge with sinusoidal profiles of wavelengths is investigated for the buffeting noise reduction. A number of combinations of wavelengths and amplitudes of sinusoidal profiles is employed to examine the effects of trailing edge serrations on the noise reduction. A generic vehicle model is used in the study and a straight trailing edge is considered as a baseline. The results indicate that the trailing edge serration has a significant impact on the sound pressure level (SPL) in the vehicle cabin and it can reduce the SPL by up to 10~15 dB for the buffeting frequency.
2017-03-28
Technical Paper
2017-01-0417
Yingjun Li, Yunkai Gao, Gangan Ma, Qianqian DU, Yabin WAN
To solve the problem of serious roller wear and improve the smoothness of the sliding door motion process, the rigid-flexible coupling multi-body model of the vehicle sliding door was built in ADAMS. Force boundary conditions of the model were determined to meet the speed requirement of monitoring point and time requirement of opening-closing process according to the bench test specification. The results of dynamic simulation agreed well with that of test so the practicability and credibility of the model was verified. In the optimization of the ride comfort of the sliding door, the shape parameters of the middle guide and the position of arm-shafts were selected as design variables while the impact load of rollers, the curvature of the trajectory and angular acceleration of the sliding door centroid were taken as optimization objectives.
2017-03-28
Technical Paper
2017-01-0473
Satoshi Nakada, Toru Furusawa, Eiichiro Yokoi, R Carbas, M Costa, E Marques, G Viana, LFM da Silva
In recent years, adhesive bonding is increasingly being applied in the construction of vehicle frames in order to improve stiffness and crash performance. Regarding crash performance, the behavior of impacted components is affected by the fracture energy value of the adhesive. However, for many types of structural adhesives, the relationship between the ductility and fracture energy values under static mixed-mode loading has not been sufficiently evaluated. In this paper, the fracture energy of three structural adhesives in a static mixed-mode loading using Double Cantilever Beam (DCB) specimens is presented. To derive the fracture energy values, the Compliance Based Beam Method (CBBM) was used, which allowed for precise determination of fracture energy values. Static mixed-mode loading tests were performed in six configurations of mixed-mode loading, ranging from pure peel mode state to almost pure shear mode state.
2017-03-28
Technical Paper
2017-01-1298
Kamlesh Yadav, Abhishek Sinha, Rajdeep Singh Khurana
Vehicle Hood being the face of a passenger car poses a challenge to meet the regulatory and aesthetic requirements. However, the urge to make a saleable product makes aesthetics a primary condition. This eventually makes the role of structure optimization much more important. A recent development in the Indian automotive industry, which is known for dynamics of cost competitive cars, has posed the challenge to make passenger cars meeting the regulation and having optimized cost. This work is application of structure optimization of Hood and design of peripheral parts for meeting pedestrian protection performance keeping the focus on having cost-effective solution. This paper discusses Headform compliance of the work done on one of the flagship model of Maruti Suzuki India Ltd., providing detailed analysis of the procedure followed from introduction stage of regulatory requirement in the project to final validation of the engineering intent.
2017-03-28
Technical Paper
2017-01-1453
Sudip Sankar Bhattacharjee, Shahuraj Mane, Harsha Kusnoorkar, Sean Hwang, Matt Niesluchowski
Pedestrian protection assessment methods require multiple head impact tests on a vehicle’s hood and other front end parts. Assessment methods become more complicated for vehicles equipped with pyrotechnic deployment systems, that are typically used to lift up the hood surface for creating more deformation space prior to pedestrian head impact. Estimation of pedestrian head impact time, thus, becomes a critical requirement for performance validation of deployable hood systems. In absence of standardized physical pedestrian models, Euro-NCAP recommends a list of virtual pedestrian models that could be used by vehicle manufacturers, with vehicle FEA models, to predict the potential head impact time along the vehicle front end profile. FEA simulated contact time is used as target for performance validation of sensor and pyrotechnic deployable systems.
2017-03-28
Technical Paper
2017-01-0290
Veera Aditya yerra, Srikanth Pilla
The advancements in automation, big data computing and high bandwidth networking has expedited the realization of Industrial Internet of Things (IIoT). IIoT has made inroads into many sectors including automotive, semiconductors, electronics, etc. Particularly, it has created numerous opportunities in the automotive manufacturing sector to realize the new aura of platform concepts such as smart polylemma of production technologies. The stringent CAFE standards set forth by the Obama administration has pushed the automotive industry to radically revolutionize and design lightweight systems using advanced materials such as composites. Despite several outstanding benefits, advanced materials often come with additional costs. Minimizing physical infrastructure and improving efficiency will make the use of these materials affordable. This paper provides a thought provoking application of IIoT in automotive composites body shop.
2017-03-28
Technical Paper
2017-01-1300
Raj Jayachandran, Bhimaraddi Alavandi, Matt Niesluchowski, Erika Low, Yafang Miao, Yi Zhang
An engine cooling system in an automotive vehicle comprises of heat exchangers such as a radiator, charge air cooler, and oil coolers along with engine cooling fans. Typical automotive engine-cooling fan assembly includes an electric motor mounted on to a shroud that encloses radiator core. Typically a fan shroud is made of plastic material and holds one or two motors and is supported at four corners. One of the main drivers of a fan shroud design is Noise, Vibration, and Harshness requirements, without compromising the main function - airflow requirement for cooling. Usually, stiffness requirement is not given adequate attention in arriving at optimal design of a fan shroud. Research Council for Automotive Repairs (RCAR), based in Europe, issues vehicle ratings on the basis of its performance in Low Speed Damageability (LSD) tests. One such test is a 15kph, 40% offset rigid wall impact to the front of the vehicle.
2017-03-28
Technical Paper
2017-01-0388
Haeyoon Jung, MiYeon SONG, Sanghak kim
This paper proposes the Off-cycle credit alternative test methodology for Semi-transparent solar panel integrated on Automobile roof glass to achieve the CO2 credits from the Environmental Protection Agency (EPA) & the National Highway Traffic Safety Administration (NHTSA). Manufactures offer the option to put solar cells on the roof of a vehicle for reducing cabin ambient temperature. However, Hyundai Motors develops the semi-transparent solar roof with a controller to provide electric energy for vehicles. This electrical energy cannot be accounted for on the current EPA cycles either the two cycle test or the five-cycle test. Therefore, the manufacture has to establish the methodology based on solar system for vehicles. In order to improve the efficiency of our solar system and to calculate reduced CO2 emission, we studied useable solar energy in driving condition other than peak power in standard test condition(@ 25℃, 1Sun).
2017-01-10
Technical Paper
2017-26-0304
P M Aneeth, Rajeev Dave, Manoj Yadav, Shinoy Kattakayam
Abstract The entire commercial vehicle industry is moving towards weight reduction to leverage on the latest materials available to benefit in payload & fuel efficiency. General practice of weight reduction using high strength steel with reduced thickness in reference to Roark’s formula does not consider the stiffness & dent performance. While this helps to meet the targeted weight reduction keeping the stress levels within the acceptable limit, but with a penalty on stiffness & dent performance. The parameters of stiffener like thickness, section & pitching are very important while considering the Stiffness, bucking & dent performance of a dumper body. The Finite Element Model of subject dumper body has been studied in general particularly on impact of dent performance and is correlated with road load data to provide unique solution to the product. The impact of payload during loading of dumper is the major load case.
2017-01-10
Technical Paper
2017-26-0289
H. Rajesh, Mahesh Anand Patwardhan, Nagesh Voderahobli Karanth, Mandar Bhatkhande, R Ramkumar, Ninad Pachhapurkar, M Saraf, Y.P. Reddy
Abstract The design and development of complete vehicle, understanding of chassis system development process is an important task. Chassis frame of a vehicle is supporting member, both structurally and functionally, to all other chassis aggregate systems viz. suspension, steering, braking system etc. In this paper, a methodology for chassis frame model construction and validation is explained. In present work, chassis frame model is validated in terms of modal parameters and also against static loading conditions. Existing chassis 3D Computer Aided Design (CAD) data was generated using scanning and cloud point data conversion technique. FE model was generated and validated through experimental measurements viz. modal testing, vertical bending, lateral bending, and torsional bending test. Loading and boundary conditions were replicated on the complete FE model in CAE domain and test validation was carried out using appropriate mesh biasing and weld modeling techniques.
2017-01-10
Technical Paper
2017-26-0254
Ganesh Krishna Babar
Abstract Canopy design is governed by CPCB regulations. The regulations explicitly tells about noise levels. It’s very important to have the proper ventilation of canopy to ensure the proper working at all climatic conditions. Mostly it is installed at commercial locations & hence the ownership cost matters. Reducing the footprint without affecting the power output is challenging. It implies the need of the CFD simulation to predict the cooling performance of the canopy. The baseline canopy is tested to estimate the performance parameters. It is modelled in CFD with all the minute details. All the parts including engine, alternator, fan, fuel tank are modelled. MRF(Moving Reference Frame) model used to simulate fan performance. The cooling systems like radiator & oil cooler is modelled as porous region. The total flow across canopy & the air velocity across critical regions is used to define the performance.
2017-01-10
Technical Paper
2017-26-0023
Amit Pathak, Anish Kumar, Rahul Lamba
Abstract Risk of injury to occupant in the event of side impact is considerably higher compared to frontal or rear impact as the energy absorbing zones at the front and rear of vehicle is high whereas limited space is available to dissipate the impact energy in the event of side impact. In such scenario strength of side door plays an important role in protecting the occupant. Side door beam in door structure contributes significantly towards the lateral stiffness and plays dominant role in limiting the structural intrusion into passenger compartment. Hence it is interesting to understand the effect of beam specification and orientation on side door strength. Since these factors not only affect the strength but also the cost and weight targets, their study and analysis is important with respect to door design This paper showcases the effect of beam layout and its specifications on the overall strength of the door with an experimental approach using physical test.
2016-11-08
Technical Paper
2016-32-0029
Shohei Suzuki
Abstract One of the issues when developing motocrossers is that, when a motocrosser jumps and lands, the landing applies heavy loads on various parts of the bike, particularly the frame, and produces high stresses. This sometimes causes deformation, cracks, breakage, etc. during strength tests on actual bikes, and it takes much time and money to check the effects and develop solutions. To solve this problem, we have developed a method for simulating the jump-landing of motocrossers.
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