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2017-05-11 ...
  • May 11-12, 2017 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
Today's necessity for quickly delivering products to market limits product development time and leaves less room for error and 're-dos.' With so many plastic materials available, it is crucial that those involved in product design understand resin properties and how they affect part design and manufacturability. To help you make the best plastic choices the first time, this seminar provides an overview of polymer chemistry, explains the methods for testing properties of plastics and presents a method of systematic selection that will optimize your plastics material selection process.
2017-04-06
Event
Presentations of this session will address application and research on coatings for exterior body and plastics (including polycarbonate) as well as vehicle interiors and underbody/underhood. Focus will be on the 3-10 year timeframe.
2017-04-06
Event
Presentations related to welding and joining of similar or dissimilar materials of plastics, composites, aluminum, magnesium, titanium, and conventional and advanced high strength steels will be given. Papers related to friction stir (spot) welding, ultrasonic welding, resistance welding, arc welding, laser welding, brazing or soldering, riveting and bolting, and adhesive are planned as well. Papers related to strength, fracture and fatigue of welds, joints and fasteners have been invited.
2017-04-06
Event
Presentations related to welding and joining of similar or dissimilar materials of plastics, composites, aluminum, magnesium, titanium, and conventional and advanced high strength steels will be given. Papers related to friction stir (spot) welding, ultrasonic welding, resistance welding, arc welding, laser welding, brazing or soldering, riveting and bolting, and adhesive are planned as well. Papers related to strength, fracture and fatigue of welds, joints and fasteners have been invited.
2017-04-06
Event
Presentations of this session will address application and research on coatings for exterior body and plastics (including polycarbonate) as well as vehicle interiors and underbody/underhood. Focus will be on the 3-10 year timeframe.
2017-04-05
Event
Presentations related to welding and joining of similar or dissimilar materials of plastics, composites, aluminum, magnesium, titanium, and conventional and advanced high strength steels will be given. Papers related to friction stir (spot) welding, ultrasonic welding, resistance welding, arc welding, laser welding, brazing or soldering, riveting and bolting, and adhesive are planned as well. Papers related to strength, fracture and fatigue of welds, joints and fasteners have been invited.
2017-04-05
Event
Presentations of this session will address the development of Polymeric Multi Material & Composite materials for automotive interiors and exteriors, powertrain components, as well as structural and non-structural applications. Focus is on design, processes, bonding and manufacturing technologies, as well as lightweighting strategies.
2017-04-04
Event
Presentations of this session will address the development of Polymeric Multi Material & Composite materials for automotive interiors and exteriors, powertrain components, as well as structural and non-structural applications. Focus is on design, processes, bonding and manufacturing technologies, as well as lightweighting strategies.
2017-04-04
Event
Presentations of this session will address the development of Polymeric Multi Material & Composite materials for automotive interiors and exteriors, powertrain components, as well as structural and non-structural applications. Focus is on design, processes, bonding and manufacturing technologies, as well as lightweighting strategies.
2017-03-28
Technical Paper
2017-01-0371
Raju Gandikota, Amit Nair, Kurt Miller
Testing elastomeric materials that undergo large strains pose challenges especially when establishing failure criteria. The failure criterion for composites and polymers based on finite elasticity published byFeng (1) requires testing under uni-axial and bi-axial stretching modes. The classic inflation of a circular disk for bi-axial stretch mode poses stability and safety challenges. The test can also be sensitive to end constraints resulting in failure of materials at the constraints. Bi-axial stretching with a hemispherical punch is explored in this work. The bi-axial stretching allows controlled and repeatabletesting. It establishes clear and reliable failure mechanism of the material at the poles. Through a combination of testing and numerical methods, the stretch ratios and its relation to failure has been established.
2017-03-28
Technical Paper
2017-01-0363
Karthik Ramaswamy, Vinay L. Virupaksha, Jeanne Polan, Biswajit Tripathy
EPP foams are most commonly used in automotive applications for pedestrian protection and to meet low speed bumper regulatory requirements. In today’s automotive world the design of vehicles are predominantly driven by CAE. This makes it necessary to have validated material model for EPP foams in order to simulate and predict performance under various loading conditions. Since most of the automotive OEMs depend on local material suppliers for their global vehicle applications it is necessary to understand the variation in mechanical properties of the EPP foams and their effect on performance predictions. In this paper, EPP foams from three suppliers across global regions are characterized to study the inter-supplier variation in mechanical properties. In order to understand the effect of inter-supplier variation on vehicle performance, LSDYNA rate dependent material model is developed and validated for low speed and pedestrian protection load cases.
2017-03-28
Technical Paper
2017-01-0480
Mingde Ding
For structural application, composite parts structure is much more affected by load cases than steel part structure. Engine room bracket of EV, which is structural part and is used to bear Motor Controller, Charger and so on, has different load cases for different EV. Three commonest load cases that are Case 1: bearing 65kg (without suspension part), Case 2: bearing 68kg(including 3.5kg suspension part) and Case 3: bearing 70.1kg (including 5.6kg suspension part). According to topology optimization, structurel 1 was obtained, and then CAE analysis including (strength, stiffness and model) was carried out for abovement three load cases. For Case 1 and Case 2, the analysis result can meet the requirement. However, for Case 3, the stiffness and model analysis result can not satisfy the requirement. To meet the analysis result of Case 3, Structure 1 was optimized and structure 2 was obtained. The CAE analysis was conducted and the results can satisfy the requirements.
2017-03-28
Technical Paper
2017-01-0508
Gabor Kiss, Yuya Ando, Martin Schifko
After the e-coating the paint on the surface is like a sponge and carry liquid which slowly drains off. The retain water carries about 5-10 liter for 100mm² BIW surface area. When the retain water drains off, residual liquids may areas at areas nobody is expecting. These liquids are potential causers in the oven either to destroy the corrosion protection mainly caused by boiling or may lead to bake drips. The density of the residual liquid is changing during the heating process in the oven. Depending on the evaporation of residual puddles and density change the total volume may increase although the weight is getting less. This is the critical situation which may lead to bake drips. In this talk we would outline our technology which allows to predict retain water behavior and the arising of bake drips successfully
2017-03-28
Technical Paper
2017-01-1270
Xiaoming Chen
As future vehicles need to improve fuel economy, the use of magnesium for lightweight component is increasing to enable fuel consumption reductions. The finite element modeling of magnesium, especially at limit states can be improved by incorporating shear behavior. Three shear strain coupon test samples were developed for magnesium alloys. The samples generated shear failures in the specimens while using a uniaxial servo-hydraulic load frame. Three dimensional digital image correlation was used to optically measure the full-field strain on the surface of the test specimens. Finite element simulations were conducted on selected shear samples for steel and aluminum using magnesium material input to locate shear zones. Initiators were created to force material damage to initiate in the shear zones. The samples were tested using cast magnesium AM60 and extruded magnesium EZ20. The results showed that damage and material separation in all samples started at the initiators.
2017-03-28
Technical Paper
2017-01-1268
Xiaoming Chen
In recent years, lightweight structure designs become one of the major trends in automotive industry. There are four major aspects that are considered to develop lightweight automotive structures, including using advanced materials, manufacturing methods, design optimization, and additional cost of weight saved assessment. This paper presents the development work of a lightweight subframe for a compact car using Magnesium Casting design. The subframe design needs to meet NVH, strength, and durability, corrosion, and joint strength as well. CAE tools are heavily used to generate and validate the structural performance of the design, including topology and shape optimization, static stiffness, modal, strength and durability analyses. A prototype is also built for component and field tests to validate the feasibility of this design, including component modal test, strength test, and durability test, and vehicle proving ground durability test.
2017-03-28
Technical Paper
2017-01-0486
Daniel Frantz
In light of growing global awareness of environmental concerns, automotive manufacturers have received pressure from governmental regulations and consumer demand to incorporate more recycled materials into vehicle production. Polyamide 6 (nylon 6, PA6), a polymer used in many automotive components, is a prime target for the incorporation of recycled materials. PA6 is used and recovered by the carpet industry, and can be processed into a usable recycled polymer (RPA6). To evaluate the potential use of RPA6, injection molded samples comprised of RPA6, glass fiber, and one of three recycled fillers (rice husk ash, micronized rubber powder, and torrefied biomass) will be prepared and subjected to mechanical, thermal, morphological, and rheological testing. It is predicted that these materials will meet the requirements for automotive door handles, engine fan shrouds, and turn signal arms, which are typically made from glass-reinforced nylons.
2017-03-28
Technical Paper
2017-01-0505
Aditi Chavannavar
Polyurethane dispersions (PUDs) have seen rapid growth in recent years as alternatives to their solvent based analogs. They offer the advantages of enabling low VOC formulations while providing superior appearance and mechanical properties. Polyurethane-acrylic hybrids combine the advantages of a polyurethane dispersion with the benefits of an acrylic emulsion. This synergistic combination offers properties such as good hardness development and chemical resistance in addition to enhanced mechanical properties. In this paper, we discuss new PUD-acrylic hybrids that are NMP and solvent free, have a pendulum hardness of 100 oscillations compared to a standard acrylic emulsion that has 80; and offer excellent scratch and abrasion resistance equivalent to that of an acrylic system. In addition to these, the new polyurethane dispersions provide good haptic qualities and have excellent adhesion to plastic substrates such as ABS, PC, PMMA and PVC.
2017-03-28
Technical Paper
2017-01-0477
Harish M. Rao, Jidong Kang, Garret Huff, Katherine Avery, Xuming Su
The use of carbon fiber reinforced polymer (CFRP) composites presents an attractive solution for automotive lightweighting due to the extensive weight savings. One of the key challenges to using CFRP for structural applications is developing and characterizing a robust joining technique for CFRP to metal sheets. Self-piercing rivet (SPR) has emerged as an economical and viable joining technique and is successfully used by the automotive industry in joining aluminum sheets. In this paper, the tensile and fatigue properties of continuous braided fiber CFRP to AA6011-T82 lap-shear SPRs are presented for joints produced with rivet head heights at two values within the nominal range. Even within the narrow range of head heights considered “nominal”, the rivet head piercing was found to have a dominant effect on both the tensile and fatigue properties of the lap-shear SPR joints.
2017-03-28
Technical Paper
2017-01-0489
Hyunkwon Jo, Jaemin Park, Heeseung Yang, Hyunchul Lee, Hyunmin Park
Automotive industry faced the intense competition have been tried to lower product prices as well as satisfy performance in order to secure demands. Various ways to reduce manufacturing cost in this market environment have been approached, especially shortening manufacturing time has been mainly proposed. Because traditionally shortening manufacturing time activities took place in production sites, so they were not systematical and limited so the effect was less than expected. To overcome this, these activities should extend to development stage of product. Recently many plastic products have been widely used in automobile parts for light weight to improve fuel efficiency. The manufacturing process of such as plastic parts consists of injection molding and assembling parts. The process of injection molding process takes longer than other assembling if the product is big or complicated.
2017-03-28
Technical Paper
2017-01-0488
Raju Gandikota
Testing elastomeric materials that undergo large strains pose challenges especially when establishing failure criteria. The failure criterion for composites and polymers based on finite elasticity published byFeng (1) requires testing under uni-axial and bi-axial stretching modes. The classic inflation of a circular disk for bi-axial stretch mode poses stability and safety challenges. The test can also be sensitive to end constraints resulting in failure of materials at the constraints. Bi-axial stretching with a hemispherical punch is explored in this work. The bi-axial stretching allows controlled and repeatabletesting. It establishes clear and reliable failure mechanism of the material at the poles. Through a combination of testing and numerical methods, the stretch ratios and its relation to failure has been established.
2017-03-28
Technical Paper
2017-01-0482
Cristiano Grings Herbert, 1Lt Luiz Rogério De Andrade Lima PhD, 1Lt Cristiane gonçalves PhD
Phthalates have been extensively used in rubbers formulation as plasticizer additive for PVC and NBR promoting processing parameters or reducing cost. The most commonly used plasticizer in PVC compounds was di-2-ethylhexyl phthalate (DEHP) currently not recommend due toxicity. In many studies it is described that DEHP is liable of producing toxic and adverse effects and able to act as potential carcinogenic agent. Therefore it is listed as prohibited to the Global Automotive Declarable Substance List (GADSL). Phthalates alternatives are already available but the compatibility in automotive fuel system with biodiesel was not extensively understood. This aspect is important since plasticizer may migrate and change rubber properties. Tri-2-ethylhexyl trimellitate (TOTM) and di-2-ethylhexyl terephthalate (DEHT) plasticizers have been studied the carcinogenicity and chronic toxicity potential and the migration to blood in medical devices.
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