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Viewing 1 to 30 of 18404
2015-05-11
Event
2015-04-22 ...
  • April 22-24, 2015 (8:30 a.m. - 4:30 p.m.) - Detroit, Michigan
  • August 5-7, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
  • December 16-18, 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. There is a potential for metal fatigue in any situation where a component is subjected to cyclic loads. Fatigue failures of various types are a key concern in increasing the reliability of products.
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.
2015-04-20 ...
  • 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.
2015-04-14
Technical Paper
2015-01-0519
Susumu Maeda, Atsushi Kobayashi, Yuichiro Shimizu, Masao Kanayama, Yuya Gyotoku, Masato Yuya, Hideki Imataka
We developed a technique where compound layers can be controlled freely by controlling the atmosphere during nitriding treatment. This technique enabled can be mass-produced. Developing a new material enabled maximal utilization of the developed nitriding technique. High-strength nitriding gear manufacturing technology was established through these techniques. Ring gears are thin and have a large diameter, and their use in a high-load environment demands precision and strength; however, carburizing causes distortions, and additional processing becomes necessary to ensure the precision of the teeth. Gas-nitrocarburizing treatment is applied, aimed at ensuring precision, but the resulting fatigue resistance is lower than that of carburized items. Therefore, thickness and tooth width must be increased through design changes to decrease pressure on the gear faces and stress at the root-of-teeth, and the resulting weight increase was a disadvantage.
2015-04-14
Technical Paper
2015-01-0518
Hirokuni Fuchigami
Suspension springs size and weight reduction necessitates high stress design. Increasing stress increases the strength of the spring material to ensure sag resistance and durability. Increasing the strength increases its susceptibility to hydrogen embrittlement, and the propagation of fatigue cracks. This makes the spring surface layer extremely important. We analyzed the prior austenite grain size and hardness distribution in the spring surface layer. Steel wire for a cold-formed spring was produced using surface layer heat treatment; hydrogen embrittlement and corrosion resistance of a spring from this wire were evaluated. Grain refinement is an effective method of increasing resistance to hydrogen embrittlement, and a method of grain refinement using induction heating and quenching is used for the wire material employed in cold-formed springs. We refined the grain by repeating induction heating and quenching to realize a reverse transformation from α’ to γ.
2015-04-14
Technical Paper
2015-01-0537
Hong Tae Kang, Abolhassan Khosrovaneh, Xuming Su, Yung-Li Lee, Mingchao Guo, Chonghua Jiang, Zhen Li
Magnesium alloys have low weldability, thus self-piercing rivet (SPR) joint is one of options for joining them. This research investigates the fatigue performance of SPR for magnesium alloys including AZ31, AM30, and AM60. Lap-shear and coach peel specimens for these alloys are fabricated and tested for understanding fatigue performance of the joint. Structural stress – life (S-N) curves are developed with the test results. This approach is validated with simple structural specimens that include three or two joints in each specimen. It is also intensively studied to identify the proper representation of the joint in finite element models.
2015-04-14
Technical Paper
2015-01-0554
Rafaa Esmaael, Vernon fernandez
An accurate prediction of elasto-plastic cyclic deformation becomes extremely important in design optimization. Which lead to a more accurate fatigue life prediction and weight savings. In this project a two-step notch root prediction method based on interpolation between linear and Neuber’s notch strain amplitude solutions is proposed. The accuracy of this method is assessed by comparing the results with the results obtained from elasto-plastic finite element analysis. Different types of steels with different yield strengths were used in this study. Notch deformation behavior under cyclic loading conditions was monitored for a double notched flat plate and a circumference notched round bar to cover plain stress and plain strain conditions. Elastic as well as elasto-plastic finite element analyses are performed.
2015-04-14
Technical Paper
2015-01-0524
Maniraj perumal, Baskar Anthonysamy, Ashokkumar Sundaramoorthy
This method and its special process are particularly suited for the production of Porous free combustion chamber proto type aluminium cylinder head casting. Current methods for producing porus free combustion chamber are graphite coating and CI/Cu metal chill which are moderately effective in achieving porus free combustion chamber. However, these current methods have serious drawbacks like high rejections due to blow holes/gas porosity generated from graphite coating and fine porosity due to prolonged cooling because of slow rate of cooling while peak temperature of metal chills. Using a typical aluminum alloy such as A356 or EN AC-AlSi7mg for prototype casting in regular sand casting practice, large SDAS (> 50 Чm) and medium amount of hydrogen content are possible in a prototype head.
2015-04-14
Technical Paper
2015-01-0516
Nan Wang
Current die design recommendations attempt to limit the production of burrs through accurate alignment of the upper and lower edges. For aluminum automotive exterior panels, this translates to a gap less than 0.1 mm. However, the tolerances required by such standards often exceed the capabilities of many trim dies. Experimental results on influence of trimming conditions on the shape of the sheared surface will be combined with the results of stretching strips after trimming. The objective of the research described in this paper is to study the mechanism of fracture generation and cracks propagation during half-a-dog bone tensile test representing stretch flanging condition. One side of the sample had sheared surface obtained by the trimming process while the other side of the sample had a smooth surface. The effect of texture of the sheared edge on stretchability of Al sheet was investigated. Significant attention was paid to understanding of fracture sources.
2015-04-14
Technical Paper
2015-01-0410
Kevin Smith
MMLV Corrosion Mitigation Kevin D Smith1, Ying Zhang1 1 Magna International ABSTRACT Magna International, the U.S Department of Energy and Ford Motor Company initiated the Multi Materials Light Vehicle (MMLV) program in 2012, in an effort to reduce vehicle mass. A full-vehicle mass reduction of 23.5% was successfully achieved, and with it comes a host of new challenges in the form of overall vehicle corrosion protection and prevention in the use of multi lightweight materials. This paper will present the test results relative to two (2) corrosion mitigation strategies associated with a common multimaterial body-in-white (BIW) structure. The “conventional” corrosion mitigation strategy included a pretreated and E-coated fully assembled BIW structure. The “alternative” corrosion mitigation strategy included integration/assembly of seven (7) corrosion protected BIW module subassemblies, prior to integration of the modules in a BIW Framing Station.
2015-04-14
Technical Paper
2015-01-0407
Timothy W. Skszek, Matthew Zaluzec
Title: Multi-Material Lightweight Vehicle (MMLV) Project Overview Authors: Magna International: Tim Skszek & Jeff Conklin Ford Motor Company: Matthew Zaluzec and David Wagner Abstract: The Multimaterial Lightweight Vehicle (MMLV) developed by Magna International and Ford Motor Company is a result of a US Department of Energy project DE-EE0005574. The project demonstrates the lightweighting potential of a five passenger sedan, while maintaining vehicle performance, occupant safety and utility of the baseline production vehicle. Prototype vehicles were manufactured and limited full vehicle testing was conducted. The Mach-1 vehicle design, comprised of commercially available materials and production processes, achieved a 364kg (23.5%) full vehicle mass reduction, enabling the application of a 1-liter 3 cylinder engine, resulting in a significant environmental benefit and fuel reduction.
2015-04-14
Technical Paper
2015-01-0511
Bradford Johnson, John Henshaw, Nia R. Harrison, S. George Luckey
Increasing fuel economy is a high priority of the automotive industry due to consumer demand and government regulations. High strength aluminum alloys such as AA7075-T6 can be used in strength-critical automotive applications to reduce vehicle weight and thus improve fuel economy. However, these aluminum alloys are known to be susceptible to stress corrosion cracking (SCC) for thick plate. The level of susceptibility to SCC must be determined before a material is implemented. ASTM standards exist that generate semi-quantitative data primarily for use in screening materials for SCC. For the purposes of this work ASTM G139 (breaking load method) has been used to evaluate sheet AA7075-T6 for use in automotive applications. A tensile fixture applying a constant strain was used to quantitatively measure residual strength of the material after exposure to a corrosive environment.
2015-04-14
Technical Paper
2015-01-1240
Timothy W. Skszek
Paper Title: MMLV - Lightweight Transmission Components Author: John Sabo, Magna International Abstract: The Multi-Material Lightweight Vehicle (“MMLV”) is a lightweight vehicle development project between Ford and Magna International, 50% co-funded by US Department of Energy (DOE) and Canadian Provincial grants. The goal of the project is to use lightweight material systems and manufacturing technologies to achieve significant overall weight reduction and demonstrate viability of such design by component-level testing. This paper presents a summary of the MMLV design development for lightweight transmission and driveline components, supported by extensive use of CAE analysis and component-level testing of prototype parts. A total mass reduction of 14kg (13.8%) relative to the 2012 Fusion baseline vehicle transmission and driveline components was achieved.
2015-04-14
Technical Paper
2015-01-0408
Randy Beals
Vehma / Cosma Engineering International, the U.S. Department of Energy and Ford Motor Company initiated the Multi Materials Lightweight Vehicle (MMLV) Project in 2012. The goal of producing a multi-material vehicle, approximately 25% mass reduction relative to the baseline has been achieved. This paper reviews the mass reduction and structural performance of aluminum high pressure vacuum die cast (hpvdc) applications for a lightweight, multi-material body in white (BIW) relative to a C/D segment production vehicle. Selected stiffness, durability and crash requirements are assessed. The structure incorporates aluminum castings, extrusions and sheet as well as steel sheet, assembled using structural adhesive bonding and a variety of joining technologies. No other body structure in high volume production incorporates this combination of materials and joining processes.
2015-04-14
Technical Paper
2015-01-0517
Masaaki Kawahara, Noriaki Katori
Reduction of fatigue and improvement of drivability have been required in commercial vehicles and automated manual transmissions are widely used. Further reduction of shifting time results in faster collision and slide between chamfers of sleeve and dog gear, and wear of chamfers increases. In this study, mechanism of the wear was clarified and a machine to evaluate the wear by test piece Base was developed. Using this machine, materials to improve the wear resistance were developed. It was found that addition of B and Ti-Nb had significant effect in the improvement of wear resistance. The developed material showed 45 % reduction in wear in transmission durability test.
2015-04-14
Technical Paper
2015-01-0522
Robert Cryderman, Danielle Rickert, Kelly Puzak, John Speer, David Matlock, Michael Burnett
Fracture split forged steel connecting rods are utilized in many new high performance automotive engines to increase durability. Higher strength levels are needed as the power density increases. Fracture splitting without plastic deformation is necessary for manufacturability. Metallurgical design is a key for achieving the required performance levels. Several medium carbon steels containing 0.07 wt pct P, 0.06 wt pct S and various amounts of Mn, Si, V, and N were produced by vacuum induction melting laboratory heats and hot working the cast ingots into plates. The plates were cooled at varying rates to simulate typical cooling methods after forging. Microstructures were generally ferrite and pearlite as evaluated by light optical and scanning electron microscopy.
2015-04-14
Technical Paper
2015-01-1613
Timothy W. Skszek
MMLV: Vehicle Durability Design, Simulation and Testing Nikhil Bolar1, Allen T. Li2, Jeff Wallace2 1Magna International 2Ford Motor Company Magna International, Ford Motor Company, and the U.S. Department of Energy initiated the Multi Materials Lightweight Vehicle (MMLV) Project in 2012. A mass reduction of 23.5% relative to a baseline 2013 Ford Fusion has been achieved. The three key attributes of structural performance evaluation for vehicle development are Safety, Noise, Vibration and Harshness (NVH) and Durability. This paper presents the full vehicle durability assessment of the MMLV Mach-I Concept Vehicle using CAE simulation of the body-in-white structure, subframe and closure designs, as well as the full vehicle field durability test at the Ford Motor Company Michigan Proving Ground.
2015-04-14
Technical Paper
2015-01-1722
Edmond Ilia, Giorgio Lanni, Kevin Tutton, Doug Sinclair
The advent of more efficient direct injection turbocharged engines has increased the need for higher performance components, able to withstand in particular higher compressive loads in operation. In this respect, new high strength materials for powder forged connecting rods were developed and introduced in production with excellent results. Among them, HS170M is currently used to manufacture connecting rods for several high performance engines, which not only have higher strength, but less variation in their mechanical properties. The results of numerous benchmark studies have shown that powder forged connecting rods manufactured with HS170M are stronger than their steel forged counterparts manufactured with microalloyed steels, are easier to machine and fracture split, and represent a cost effective way to manufacture this important high reliability automotive component.
2015-04-14
Technical Paper
2015-01-0514
Sugrib K. shaha, Frank Czerwinski, Wojciech Kasprzak, Jacob Friedman, Daolun Chen
The uniaxial compression test was used to assess an influence of strain amount on the behavior of precipitates and texture of the Al-7%Si-1%Cu-0.5%Mg alloy, modified with micro-additions of V, Zr and Ti in as-cast and T6 heat treated conditions. As revealed through metallographic examinations, fracturing and re-orientation of the second phase particles increased with increasing compression strain. For both conditions of the alloy, the intermetallic particles experienced substantially more frequent cracking than the eutectic silicon. At the same time, the precipitates in the T6 heat treated alloy were also more resistant to rotate within the alloy matrix as a result of nano-size Al3X (X=Zr, Ti, & V) secondary precipitates. The crystallographic texture was measured and correlated with deformation behavior of the alloy. The weak texture of {011}<211> and {111}<110} components, detected after casting, transformed to nearly randomized texture due to heat treatment.
2015-04-14
Technical Paper
2015-01-0528
Armin Abedini, Cliff Butcher, David Anderson, Michael Worswick, Timothy Skszek
The development of stress state dependent fracture surfaces and damage models to predict failure in automotive forming and crash simulations has created great interests in developing experimental tests to characterize failure in constant stress states. The stress state is defined by the three invariants of the stress tensor that are typically expressed in terms of the stress triaxiality and lode parameters. The shear loading condition is critical to the development of the fracture surfaces since it corresponds to the origin of the surface with a stress triaxiality and lode parameter of zero. Numerous types of in-plane shear tests have been proposed in the literature that are suitable to automotive sheet materials with the butterfly-like specimens becoming popular in recent years. The butterfly shear test involves through-thickness machining of the specimen to create a reduced section where fracture will initiate.
Viewing 1 to 30 of 18404

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