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2015-11-02 ...
  • November 2-6, 2015 (3 Sessions) - Live Online
Training / Education Online Web Seminars
Today's transportation industries are facing multi-disciplinary challenges. The product design and development process challenges often contradict each other, for example cost, weight, quality and performance. A central challenge is the need for cost and mass reduction to compete in the global market, while continuing to meet all new and existing requirements for quality and performance. Accelerated Concept to Product (ACP) Process is a performance-driven, holistic, product design development method intended to create a balance between structure and strength, synchronizing the individual facets of the product development process.
2015-09-29 ...
  • September 29-October 1, 2015 (2 Sessions) - Live Online
Training / Education Online Web Seminars
Today's transportation industries are facing multi-disciplinary challenges. The product design and development process challenges often contradict each other, for example cost, weight, quality and performance. A central challenge is the need for cost and mass reduction to compete in the global market, while continuing to meet all new and existing requirements for quality and performance. Accelerated Concept to Product (ACP) Process is a performance-driven, holistic, product design development method intended to create a balance between structure and strength, synchronizing the individual facets of the product development process.
2015-09-14 ...
  • September 14-15, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
Advanced High Strength Steels (AHSS) are now commonly used in automotive body structural applications. The high strength of this grade classification is attractive to help reduce mass in the automotive body through reduction in thickness. Strength also supports improvements in safety requirements so that mass increases are minimized. In some specific grades of AHSS, energy absorption is possible in addition to the high strength. This course will review the definition and properties of AHSS and cover several common applications in automotive body structures.
2015-08-10 ...
  • August 10-11, 2015 (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.
2015-05-25 ...
  • May 25-26, 2015 (8:30 a.m. - 4:30 p.m.) - Shanghai, China
  • July 27-28, 2015 (8:30 a.m. - 4:31 p.m.) - Warrendale, Pennsylvania
  • September 24-25, 2015 (8:30 a.m. - 4:30 p.m.) - Seattle, Washington
Training / Education Classroom Seminars
The September offering of this seminar will be conducted at the Sheraton Seattle Hotel and held in conjunction with the SAE 2015 AeroTech Congress & Exhibition. Register for this offering and you can register to attend the SAE 2015 AeroTech Congress & Exhibition for 25% off the classic member event rate.
2015-05-18 ...
  • May 18-19, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
  • November 9-10, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
Welding is one of the most important and widely used of the joining processes, providing distinct advantages in mechanical performance, ease of implementation, cost and adaptability. This seminar will provide engineers with applicable knowledge related to metallurgy, stress analysis and welding processes which will enable them to consider design, analysis, implementation and inspection of welds for their respective products.
2015-04-23
Event
This session deals with the manufacture of detail parts through laser sintering, stereo lithography, fused deposition modeling, and other emerging technologies. The session will explore technologies and methods for producing net or near net parts in various resins, plastics and metals directly from a CAD model that could employ design architectures that couldn't be achieved by other manufacturing methods.
2015-04-22
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.
2015-04-20 ...
  • April 20-21, 2015 (8:30 a.m. - 4:30 p.m.) - Detroit, Michigan
  • October 29-30, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
Attendees to the seminars held in conjunction with the SAE 2015 World Congress will receive COMPLETE access to Congress activities for only $55 per day. If interested, please contact our Customer Service department at +1.877.606.7323 (U.S. and Canada only) or +1.724.776.4970 (outside U.S. and Canada) to register for this special Congress daily rate. Preventing future problems and troubleshooting existing problems in today's stamping plants requires greater stamping process knowledge. The link between inputs and outputs isn't as clear as many think, increasing the need for detailed understanding of the variables involved.
2015-04-20 ...
  • April 20-21, 2015 (8:30 a.m. - 4:30 p.m.) - Detroit, Michigan
  • August 3-4, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
  • December 14-15, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
Attendees to the seminars held in conjunction with the SAE 2015 World Congress will receive COMPLETE access to Congress activities for only $55 per day. If interested, please contact our Customer Service department at +1.877.606.7323 (U.S. and Canada only) or +1.724.776.4970 (outside U.S. and Canada) to register for this special Congress daily rate. This seminar introduces participants to all aspects of threaded fasteners including nomenclature, geometric considerations, metallurgy, material properties, applied stresses, and considerations for fatigue, corrosion, brittle fracture and temperature.
2015-04-14
Technical Paper
2015-01-0531
Hiroyuki Yamashita, Hiroaki Ueno, Hiroyuki Nakai, Takahiro Higaki
Abstract When the strain is temporarily stopped during tensile testing of a metal, a stress relaxation phenomenon is known to occur whereby the stress diminishes with the passage of time. This phenomenon has been explained as the change of elastic strain into plastic strain. A technique was devised for deliberately causing strain dispersion to occur by applying the stress relaxation phenomenon during stamping. A new step motion that pause the die during forming was devised; it succeeded in modifying the deep-draw forming limit by a maximum of 40%. This new technique was verified through tensile and actual stamping tests. It was confirmed that the use of step motion causes the strain to disperse, thereby modifying the deep draw forming limit. The degree to which the forming limit is modified is dependent on the stop time and the temperature.
2015-04-14
Technical Paper
2015-01-0715
Terry Lynn Chapin, Van Thomas Walworth
Abstract Balancing the fill sequence of multiple cavities in a rubber injection mold is desirable for efficient cure rates, optimized cure times, and consistent quality of all molded parts. The reality is that most rubber injection molds do not provide a consistent uniform balanced fill sequence for all the cavities in the mold - even if the runner and cavity layout is geometrically balanced. A new runner design technique, named “The Vanturi Effect”, is disclosed to help address the inherent deficiencies of traditional runner and cavity layouts in order to achieve a more balanced fill sequence. Comparative analysis of molded runner samples reveals a significant and positive improvement in runner and cavity fill balancing when the Vanturi Effect is integrated into the runner design.
2015-04-14
Technical Paper
2015-01-0737
Sadegh Poozesh, Nelson Akafuah, Kozo Saito
Abstract Lack of a precise control over paint droplets released from current coating sprayers has motivated this study to develop an atomizer capable of generating a uniform flow of mono-dispersed droplets. In the current study, a numerical investigation based on CFD incorporating volume of fluid (VOF) multiphase model has been developed to capture the interface between air and paint phases for a typical atomizer equipped with piezoelectric actuator. Effects of inlet flow rate and actuator frequency on ejected droplets' characteristics, droplet diameter and their successive spacing are studied in detail. It will be shown that for a determined flow rate of paint, there is an optimum actuator frequency in which droplet size is minimum. Besides, there exists a direct relationship between the inlet paint velocity and obtained optimal actuator frequency.
2015-04-14
Technical Paper
2015-01-1612
Wei Liu, Gangfeng Tan, Jiafan Li, Xin Li, Fuzhao Mou, Yongqiang Ge
Abstract The hydraulic retarder is a significant auxiliary braking device [1] for the heavy duty vehicle. Traditionally, cooling circulatory system of the hydraulic retarder was coupled with the engine cooling system [2], and the thermal energy of the transmission medium would be cooled by the engine radiator ultimately. For this scheme, radiator's spare heat removal capacity could be fully utilized whereas the cooling system is very complicated and is hard to maintain. Furthermore, the corresponding of thermal management system lags behind the power change of the retarder. In this research, integrated cooling evaporation system is developed for the hydraulic retarder, which makes the cooling water contact with the transmission medium through the stator wall, so that it can rapidly response to the thermal variation of the retarder, keep the stability of the oil temperature and meanwhile reduce the risk of cooling medium leakage.
2015-04-14
Technical Paper
2015-01-0506
Toshiyuki Kondo, Shinichiro Watanabe, Nobuhiro Nanba
Abstract Today, conventional requests for automation and modern requests for flexibility in handling product diversity and changes in production volume regarding assembly operation are increasing. In order to satisfy those, the “Innovative Automation Cell” (Refer to Figure 1) has been proposed as an innovative assembly production system in lieu of an assembly line operation, which has been continuing with the use of automatic conveyance. Furthermore, technical developments were implemented, such as “Real-time Position Attitude Correction Technology” and “High-speed Emergency Recovery System”, as well as “Assembly Operation Support System”, to make an easy system for an operator, so as to minimize reduction of run rate in mass production practices. This article addresses the concept of the “Innovative Automation Cell”, the details of the developed technology, the effects of introduction to mass production, and future issues.
2015-04-14
Technical Paper
2015-01-0733
Nichole Verwys, Jesse Fritcher, Thomas DeMass
Abstract Dark, high gloss decorative finishes (i.e. piano black) are gaining increased application and demand in vehicle interiors; due to interior stylists' desire for this look. One significant concern with this trend is that scratches, and other appearance related defects such as orange peel (waviness), are more apparent to the customer. To address this issue, a highly scratch-resistant 2K clearcoat formulation was developed to minimize visible surface scratches, while also yielding minimal orange peel and exceptional DOI (distinctness of image); all while being applied using typical application techniques in the part finishing market. This output was accomplished by first benchmarking the consumer electronics market for appearance and scratch resistance, and then setting targets through that research.
2015-04-14
Technical Paper
2015-01-0505
Miguel Angel Reyes Belmonte, Colin D. Copeland, Drummond Hislop, George Hopkins, Adrian Schmieder, Scott Bredda, Sam Akehurst
Abstract Pressure and temperature levels within a modern internal combustion engine cylinder have been pushing to the limits of traditional materials and design. These operative conditions are due to the stringent emission and fuel economy standards that are forcing automotive engineers to develop engines with much higher power densities. Thus, downsized, turbocharged engines are an important technology to meet the future demands on transport efficiency. It is well known that within downsized turbocharged gasoline engines, thermal management becomes a vital issue for durability and combustion stability. In order to contribute to the understanding of engine thermal management, a conjugate heat transfer analysis of a downsized gasoline piston engine has been performed. The intent was to study the design possibilities afforded by the use of the Selective Laser Melting (SLM) additive manufacturing process.
2015-04-14
Technical Paper
2015-01-0551
Qiuren Chen, Haiding Guo, John V. Lasecki, John Hill, Xuming Su, John J. Bonnen
Abstract The fatigue strength and failure behavior of A5754-O adhesively bonded single lap joints by a hot-curing epoxy adhesive were investigated in this paper. The single lap joints tested include balanced substrate joints (meaning same thickness) and unbalanced substrate joints, involving combinations of different substrate thicknesses. Cyclic fatigue test results show that the fatigue strength of bonded joints increase with the increasing substrate thickness. SEM and Energy Dispersive X-ray (EDX) were employed to investigate the failure mode of the joints. Two fatigue failure modes, substrate failure and failure within the adhesive were found in the testing. The failure mode of the joint changes from cohesive failure to substrate failure as the axial load is decreased, which reveals a fatigue resistance competition between the adhesive layer and the aluminum substrate.
2015-04-14
Technical Paper
2015-01-1723
Dieter Gabriel, Thomas Hettich
Abstract Fuel economy legislation is requiring further improvements to piston friction reduction as well as additional gains in thermal efficiency. A piston material change from aluminum to steel is enabling advancements in both demands. Furthermore, steel material properties lead to increased piston strength, robustness and durability. All this can be achieved at a lower compression height compared to an aluminum reference piston. Therefore, piston mass can be reduced despite the increase in material density. Since steel pistons require cooling of the combustion bowl region and the ring belt just like the aluminum counterpart, MAHLE implemented a new innovative metal joining technology by using laser welding to generate a cooling gallery. The TopWeld® concept offers design flexibility which cannot be matched by any other welding process.
2015-04-14
Technical Paper
2015-01-0598
Xiaona Li, Changqing Du, Yongjun Zhou, Xin Xie, Xu Chen, Yaqian Zheng, Thomas Ankofski, Rodrigue Narainen, Cedric Xia, Thomas Stoughton, Lianxiang Yang
Abstract Accurate determination of the forming limit strain of aluminum sheet metal is an important topic which has not been fully solved by industry. Also, the effects of draw beads (enhanced forming limit behaviors), normally reported on steel sheet metals, on aluminum sheet metal is not fully understood. This paper introduces an experimental study on draw bead effects on aluminum sheet metals by measuring the forming limit strain zero (FLD0) of the sheet metal. Two kinds of aluminum, AL 6016-T4 and AL 5754-0, are used. Virgin material, 40% draw bead material and 60% draw bead material conditions are tested for each kind of aluminum. Marciniak punch tests were performed to create a plane strain condition. A dual camera Digital Image Correlation (DIC) system was used to record and measure the deformation distribution history during the punch test. The on-set necking timing is determined directly from surface shape change. The FLD0 of each test situation is reported in this article.
2015-04-14
Technical Paper
2015-01-0705
Koichi Taniguchi, Hiroshi Matsuda, Rinsei Ikeda, Kenji Oi
High joint strength of resistance spot welds is necessary for high rigidity and reliability of car body using ultra high strength steel (UHSS) sheets with tensile strength over 980MPa. We developed “pulsed current pattern” consisting the combination of short cool time and short-time high-current post-heating. This new process can achieve high cross tension strength (CTS) with sufficient tensile shear strength (TSS) in shorter welding time than conventional temper pattern. This paper presents the heating pattern and the effect on the joint strength by pulsed current pattern. Finite element analysis (FEA) for post-heating patterns was conducted using SORPAS. Temperature dependent material properties of 1180MPa grade steel were taken into account. FEA shows that the short-time high-current post-heating leads to rapid heating in nugget and heat affected zone (HAZ) compared to conventional temper pattern consisting long-time low-current post-heating.
2015-04-14
Technical Paper
2015-01-0701
Anupam Vivek, Bert Liu, Daniel Sakkinen, Mark Harris, Glenn Daehn
Vaporizing Foil Actuators (VFA) are based on the phenomenon of rapid vaporization of thin metallic foils and wires caused by passage of a capacitor bank-driven current, on the order of 100 kAmps. The burst of the conductor is accompanied with a high-pressure pulse which, as in the case of VFA, can be used for working metal at high strain rates. VFA have been applied toward a variety of impulse-based metal working operations such as collision welding, embossing, shearing, dynamic powder consolidation, shape calibration, and closed-die forming. While other applications are discussed briefly, this paper focuses on the use of VFA for collision welding of dissimilar metals, in particular, aluminum and steel. Aluminum alloy 6061 sheets of 1mm thickness were launched to velocities in excess of 800 m/s with input electrical energy of 8 kJ into 0.0762mm thick, dog-bone shaped aluminum foil actuators.
2015-04-14
Journal Article
2015-01-0744
Terrence Alger, Raphael Gukelberger, Jess Gingrich, Barrett Mangold
Abstract The use of cooled EGR as a knock suppression tool is gaining more acceptance worldwide. As cooled EGR become more prevalent, some challenges are presented for engine designers. In this study, the impact of cooled EGR on peak cylinder pressure was evaluated. A 1.6 L, 4-cylinder engine was operated with and without cooled EGR at several operating conditions. The impact of adding cooled EGR to the engine on peak cylinder pressure was then evaluated with an attempt to separate the effect due to advanced combustion phasing from the effect of increased manifold pressure. The results show that cooled EGR's impact on peak cylinder pressure is primarily due to the knock suppression effect, with the result that an EGR rate of 25% leads to an almost 50% increase in peak cylinder pressure at a mid-load condition if the combustion phasing is advanced to Knock Limited Spark Advance (KLSA). When combustion phasing was held constant, increasing the EGR rate had almost no effect on PCP.
2015-04-14
Technical Paper
2015-01-1371
Samuel T. Bartlett
Abstract With the many model variations produced on the same production line because of increasing power train options, fuel efficiency targets, performance and customer demands we saw limitations with our existing suspension mount equipment. Layout options were limited due to guided shifts and transfers. Large supporting frame work took up valuable floor space. Model wheelbase sizes and suspension pallets were limited to the model requirements of the original equipment. We needed an adaptable system to install the engine/front suspension assemblies and the rear suspension assemblies. We found a solution by utilizing the capabilities of 6-axis industrial robots to make the core components of the equipment simpler; many of the functions of a traditional machine can now be accomplished by the robot. We were able to vary install position to optimize handling characteristics and accommodate the model-to-model varieties on the same production line.
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