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2016-10-06 ...
  • October 6-7, 2016 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
This seminar provides a functional understanding of the principles involved in conducting a Design for Manufacture/Design for Assembly study. DFM/DFA can support both manual and automated processes resulting in significant cost savings through simpler designs with fewer components. Related topics include workstation layouts, ergonomic considerations and errorproofing. Actual examples from the automotive industry are used to support the lecture and participants complete actual design efficiency using the DFM/DFA worksheet.
2016-08-15 ...
  • August 15-16, 2016 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
Plastic - any class of synthetically-produced organic compounds capable of being molded and hardened into a specific shape or form. This course is designed to offer a basic understanding of plastics and plastic processing. Using plastics can be simple, but there is much more behind producing high performance plastic parts. This seminar will walk you through the molding process, provide a comprehensive look at the variables in the manufacturing mix, and review characteristics of typical automotive plastics such as PP, PVC, ABS, and more.
2016-04-14
Event
This session will feature the latest developments in sheet metal forming technology. We seek contributions in the general areas of forming processes, formability issues and modeling. Topics of particular interest include: • Forming Processes: Stamping, hydroforming, gas forming, high temperature forming, etc. • Formability Issues: Springback, edge cracking, stretch-bend failures and fracture. • Modeling: Material models, forming limits, failure criteria in various deformation modes and process modeling & optimization.
2016-04-14
Event
This session will feature the latest developments in sheet metal forming technology. We seek contributions in the general areas of forming processes, formability issues and modeling. Topics of particular interest include: • Forming Processes: Stamping, hydroforming, gas forming, high temperature forming, etc. • Formability Issues: Springback, edge cracking, stretch-bend failures and fracture. • Modeling: Material models, forming limits, failure criteria in various deformation modes and process modeling & optimization.
2016-04-12
Event
We are seeking papers related to welding and joining of similar or dissimilar materials of plastics, composites, aluminum, magnesium, titanium, and conventional and advanced high strength steels. Papers related to friction stir (spot) welding, ultrasonic welding, resistance welding, arc welding, laser welding, brazing or soldering, riveting and bolting, and adhesive joining are welcome. Papers related to strength, fracture and fatigue of welds, joints and fasteners are also welcome.
2016-04-05
Technical Paper
2016-01-0502
Yuyang Song, Umesh Gandhi
Fiber reinforced thermoplastic composites have great potential as the substitute materials for metals in the automotive industry as for structural applications due to its lightweight. One bottle neck to preventing adoption of advanced lightweight composite materials is the joining of the dissimilar materials. The application of adhesively bonded joints has increased significantly in order to improve the integrity of structural components in vehicle design. In this paper, finite element analysis is used to model the adhesive behavior of the adhesive joining between steel to composite, and composite to composite. The standard lap shear and peeling test are firstly conducted to estimate the adhesive properties using reverse engineering. Next, these adhesive properties are applied and validated on the FE model of a 3D part for complex loading condition.
2016-04-05
Technical Paper
2016-01-1380
S. Khodaygan, Amir Ghasemali, Hamed Afrasiab
One of the most important characteristics of industrial products, especially mechanical set-ups, is considering the tolerances of production and assembly of these set-ups, which it directly influences the products’ operations. In sheet metal structures, due to the high flexibility of the sheets, the errors appeared while assembly will be as highly influential as the errors due to the production tolerance of the sheets. As a result, having a comprehensive model which could analyze the assembly process of these structures and also clarifies the relation between the tolerance of the parts and the ultimate changes of the set-up will be of considerable importance. During the assembly process, the contact effect between the components is inevitable. If such effect is not considered, the contact surfaces will permeate. The purpose of this paper is to present a method to analyze the tolerance of flexible sheet structures, considering the contact effect between surfaces.
2016-04-05
Technical Paper
2016-01-1358
Jerry Lai, Youssef Ziada, Juhchin Yang
During the planetary gear assembly, staking is a widely-used method for affixing pinion shafts into the position. A reliable staking process not only prevents the movement of the shaft during transmission operation, but also minimizes the distortion of the assembly due to the staking process. The quality of staking operations is determined by the component designs, the process parameters, and the staking tool geometry. It would be extremely time-consuming and tedious to evaluate these factors empirically; not to mention the requirement of prototypes in the early stage of a new program. A Non-linear Finite Element methodology has been developed to simulate the complete staking process including shaft press in, staking, and after staking tool release. The critical process parameters, such as staking force, staking length, shaft and holes interference amount, etc., are then evaluated systematically.
2016-04-05
Technical Paper
2016-01-0394
Minghuang Cheng, Norihiko Sawa
This paper describes the development of a fatigue life prediction method for Laser Screw Welding (LSW), which is used to assess the durability of automotive structures in the early design stages to shorten the vehicle development time. The LSW technology is a spot-type joining method such as resistance spot welding (RSW), and has been developed and applied to body-in-white structures in recent years. LSW can join metal panels even when a clearance exists between the panels. However, as a result of this favorable clearance-allowance feature of LSW, a concave shape may occur at the nugget part of the joint. These LSW geometric features, the concavity of nuggets and the clearance between panels, are thought to affect the local stiffness behavior of the joint. Therefore, while assessing the fatigue life of LSW, it is essential to estimate the influence adequately for the representation of the local stiffness behavior of the joint.
2016-04-05
Technical Paper
2016-01-0384
Andrew Cox, Jeong Hong
Lightweight, optimized vehicle designs are paramount in helping the automotive industry meet reduced emissions standards. Self-piercing rivets are a promising new technology that may play a role in optimizing vehicle designs, due to their superior fatigue resistance compared with spot welds and ability to join dissimilar materials. This paper presents a procedure for applying the mesh-insensitive Battelle Structural Stress method to self-piercing riveted joints for fatigue life prediction. Additionally this paper also examines the development a design Master S-N curve for self-piercing rivets. The design Master S-N curve accounts for factors such as various combinations of similar and dissimilar metal sheets, various sheet thicknesses, stacking sequence, and load ratios. A large amount of published data was collapsed into a single Master S-N curve with reasonable data scattering.
2016-04-05
Technical Paper
2016-01-0499
Xu Zhang, Jennifer Johrendt
Successful manufacture of Carbon Fibre Reinforced Polymers (CFRP) by Long-Fibre Reinforced Thermoplastic (LFT) processes requires knowledge of the effect of numerous processing parameters such as temperature set-points, rotational machinery speeds, and matrix melt flow rates on the resulting material properties after the final compression moulding of the charge is complete. The degree to which the mechanical properties of the resulting material depend on these processing parameters is integral to the design of materials by any process, but the case study presented here highlights the manufacture of CFRP by LFT as a specific example. The material processing trials are part of the research performed by the International Composites Research Centre (ICRC) at the Fraunhofer Project Centre (FPC) located at the University of Western Ontario in London, Ontario, Canada.
2016-04-05
Technical Paper
2016-01-1130
Mike Johns, Heinz Kamping, Kristian Krueger, James Mynderse, Chris Riedel
Tapered roller bearings used to support pinion and differential gears in automotive drive axles perform best, with accurate assembled preload. If the preload is too high, durability goes down and drag losses go up. If the preload is too low, the result can be poor roller load distribution and edge loading inside the bearing also resulting is lower life. Low preload also results in low system stiffness and noise and vibration issues. The most common assembly methods rely on bearing friction or dimensional measurements to adjust preload. These methods are difficult to automate or result in a wide preload range. Tapered roller bearings require the rotation as the preload is applied, to seat the rollers and avoid uneven load distribution and localized brinelling. To apply preload and measure torque at the same time, requires a specialized machine. In addition friction torque is sensitive to lubricant and rust preventative properties.
2016-04-05
Technical Paper
2016-01-1198
Pascal Schmalen, Peter Plapper, Wayne Cai
Laser welding of dissimilar metals such as Aluminum and Copper, which is required for Li-ion battery joining, is challenging due to the inevitable formation of the brittle and high electrical-resistant intermetallic compounds. Recent research has shown that by using a novel technology, called laser braze-welding, the Al-Cu intermetallics can be minimized to achieve superior mechanical and electrical joint performance. This paper investigates the robustness of the laser braze-welding process. Three product and process categories, i.e. choice of materials, joint configurations, and process conditions, are studied. It is found that in-process impacts such as sample cleanness and shielding gas fluctuations have a minor influence on the process robustness. Furthermore, many pre-process impacts, e.g. design changes such as multiple layers or anodized base material can be successfully welded by process adaption.
2016-04-05
Journal Article
2016-01-0504
Shin-Jang Sung, Jwo Pan
New analytical stress intensity factor solutions for spot welds in lap-shear specimens under clamped loading conditions are developed based on the beam bending theory to account for the bending moment on the clamped grips and the closed form solutions for rigid inclusions in thin plates under various loading conditions. The analytical solutions for selected ratios of the specimen width to the nugget diameter are compared with the computational solutions based on three-dimensional finite element analyses. Analytical stress intensity factor solutions as functions of the ratio of the specimen width to the nugget diameter for both the pinned connected and clamped loading conditions are compared and presented for future engineering applications. The analytical solutions can include the effects of the weld gap, weld bend, and load offset due to the spacer arrangement at the specimen edges.
2016-04-05
Journal Article
2016-01-1258
Tatsuya Iida, Hiroya Mitani, Mamoru Sato
Inside a paint booth in which automobile bodies or bumpers (called works) are painted, air whose temperature and humidity are adjusted by air-conditioning equipment is sent by supply fan through filter to remove dust and to become laminar flow, and it is supplied from top to the bottom of the pain booth. Traditionally, paint which did not attach to the works during spraying (called paint mist) flows at high speed through a slit opening called Venturi scrubber with a mixture of air and water, and thus the paint mist is collected. This paint mist collecting Venturi scrubber system has two main issues which are requiring large space and large amount of energy from pressure loss. We have adopted a new principle for paint mist collection to develop a new system which has target size of 1/2 and energy consumption of 40% reduction compared to the conventional equipment.
2016-04-05
Journal Article
2016-01-1560
Bo Lin, Chinedum E. Okwudire
Ball nut assemblies (BNAs) are used in a variety of applications, e.g., automotive, aerospace and manufacturing, for converting rotary motion to linear motion (or vice versa). In these application areas, accurate characterization of the dynamics of BNAs using low-order models is very useful for performance simulation and analyses. Existing low-order contact load models of BNAs are inadequate, partly because they only consider the axial deformations of the screw and nut. This paper presents a low-order load distribution model for BNAs which considers the axial, torsional and lateral deformations of the screw and nut. The screw and nut are modeled as finite element beams, while Hertzian Contact Theory is used to model the contact condition between the balls and raceways of the screw and nut. The interactions between the forces and displacements of the screw and nut and those at the ball-raceway contact points are established using transformation matrices.
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