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Viewing 1 to 30 of 5770
2016-04-14
Event
These sessions are seeking abstracts that specifically address the development of polymeric and 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. Abstracts on the analysis of functional performance of these materials are encouraged.
2016-04-14
Event
These sessions are seeking abstracts that specifically address the development of polymeric and 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. Abstracts on the analysis of functional performance of these materials are encouraged.
2016-04-05
Technical Paper
2016-01-0518
Choonsoo Han
Thermoplastic polyester elastomer (TPEE) has the properties of both rubber and engineering plastic. The most important characteristics of this material are its high elasticity and rigidity. So, those properties are enable to high durability against fatigue and large deformation cycles. In this study, the rebound bumper of suspension system in vehicle, using thermoplastic polyester elastomer was conducted. The plastic elastomer rebound bumper allows cost reduction and light weight on by integrating several components, such as coil spring, spring guides, blocker, stop rubber etc. In order to satisfy several component requirements such as specific compression set and Load-Displacement curve etc, we evaluated the performance change according to the design and material of the component. This study shows that how to modify the design of the rebound bumper to meet the requirments, and to choose the optimum material through the verification comparing several materials.
2016-04-05
Technical Paper
2016-01-0512
Chae-Hwan Hong
A unique crystallization behavior of poly(L-lactide) (PLLA)/poly(D-lactide) (PDLA) stereocomplex(SC) was observed when a PLLA/PDLA blend was subjected to the specific melting conditions. We tried to blend PLLA and PDLA at overall compositions to form PLA stereocomplexes. Moreover, impact modifier and reinforcement materials such as talc and glass fiber were added to enhance the mechanical and thermal properties such as impact strength and HDT. As a result, we got one representative result, one composite recipe with HDT 115oC. For more economic technology, we tried to blend PLLA and Polypropylene at overall compositions and we got another representative result which could be applied to current PP/talc composites and ABS materials. The core technology of this might be the well dispersion of glass fibers into the matrix resin such as PP, PLLA and impact strength modifier. HDT value of this PP/PLA/GF composite increased over 150oC and impact strength also increased to 70 J/m.
2016-04-05
Technical Paper
2016-01-0508
Hyung Seok KIM
This study provides a tire puncture sealant including NR latex and acrylic emenrseion, which has a reduced viscosity at -40℃, and is also exellent storage stability at -40℃ to 70℃, initial sealaing performance. Also, this study provides device for sealaing inflatable objects. 'One- Piece Tire Repair Kit' can reduced weight and operation steps.
2016-04-05
Technical Paper
2016-01-0422
Robert A. Smith, Christopher Rudzinskas
“Molecular Analysis of Automotive Electrical Components Contaminated with Engine and Powertrain Performance Fluids” Robert A. Smith and Christopher R. Rudzinskas, Advanced Materials Group, Delphi Electrical/Electronic Architecture, Warren, Ohio Increased government regulations for increased fuel efficiency to combat rising fuel costs and environmental concerns has led to marked reduction in the size of cars. Automobile downsizing has reduced engine compartment volumes - decreasing separation of polymeric electrical components from fluid accesses and reservoirs and increasing the risks of spillage onto the components. The spatial separation has been reduced even further with trends toward high performance turbo-charged engines with enhanced automotive performance. Once contaminated, the polymeric component is then exposed to heating, due to engine performance, which could exacerbate fluid contamination into the interior of the part through imbibition into amorphous regions.
2016-04-05
Technical Paper
2016-01-0496
Leonardo Farfan-Cabrera, Ezequiel A. Gallardo
Debris are progressively generated through wear occurred by the interaction of various mechanical elements into engines, steering gear boxes, transmissions, differentials, etc. Besides, they can interfere with the normal operation of such components even generating more damage in other parts due to three-body abrasion. Hence, dynamic seals are devices susceptible to interact with such very fine debris concentrated in the working lubes. Recently, owing to many testing advantages, the micro-scale abrasion test has been extensively used to study three-body abrasion of hard materials, coatings, polymers, etc., however, it has not been applied for elastomeric materials assessment. The paper presents a study of three-body abrasion of an elastomeric dynamic seal (samples extracted from an automotive commercial Acrylonitrile-butadiene NBR rotary seal) under lubricated conditions by using a TE66 Micro-Scale Abrasion Tester.
2016-04-05
Technical Paper
2016-01-1312
Tom Wood
Abstract Consumers demand a higher level of sound quality inside passenger vehicles. The interior acoustic behavior is perceived as a convenience element. There is a clear expectation of higher sound quality throughout all passenger vehicle segments including light commercial vehicles (LCV). NVH concepts and materials must deal with this increase in consumer expectations. At the same time, OEM requirements for NVH components like sound barriers, absorbers, and damping materials are expected to contribute to the reduction in both fuel consumption and CO2 emissions. Damping materials are designed to reduce structureborne noise of a vehicle body. Low frequency noise (<1000 Hz) is caused by vibration transmitted from the road, wheel/suspension, powertrain, and air stream excitation into the vehicle body. Today, damping products are one of the basic NVH measures employed to eliminate disturbing noise by converting vibrational energy into (imperceptible) thermal energy.
2016-04-05
Technical Paper
2016-01-0532
Masaya Miura, Koichiro Hayashi, Kenichiro Yoshimoto, Natsuhiko Katahira
Weight reduction for a fuel cell vehicle (FCV) is important to ensure the long driving distance. One approach to reduce the vehicle weight involves using a carbon fiber reinforced plastic (CFRP) which has higher specific strength and stiffness. However, a conventional thermoset CFRP needs a long chemical reaction time and is not easy to be introduced for mass production vehicles. In this work, we developed a new stampable thermoplastic CFRP material for a mass production body structural part, and applied the CFRP to the stack frame of "MIRAI". A continuous fiber reinforced composite can utilize fiber strength efficiently, but its shape formability at stamping is poor. To realize a shape formability target, a discontinuous fiber was selected. However, discontinuous fiber reinforced composites tend to have relatively poor mechanical properties, and are not easy to ensure reliability. A carbon fiber-sheet molding compound (C-SMC) is one of the discontinuous CFRP materials.
2016-04-05
Technical Paper
2016-01-0393
Kevin P. Barbash, William V. Mars
We demonstrate here an accounting of damage accrual under road loads for a filled natural rubber bushing. The accounting is useful to developers who wish to avoid the typical risks in development programs: either the risk of premature failure, or of costly overdesign. The accounting begins with characterization of the elastomer to quantify governing behaviors: stress-strain response, fatigue crack growth rate, crack precursor size, and strain crystallization. Finite Element Analysis is used to construct a nonlinear mapping between loads and strain components within each element. Multiaxial, variable amplitude strain histories are computed from road loads. Damage accrues in this reckoning via the growth of cracks. Crack growth is calculated via integration of a rate law from an initial size to a size marking end-of-life.
2016-04-05
Technical Paper
2016-01-0517
Kentaro Kimura, Ryoji Habuchi, Tetsuya Kono, Tadashi Mori, Kaname Arimizu
The automotive industry is constantly trying to improve in areas of passenger comfort, especially in areas of noise reduction. In addition to noise reduction, the weight reduction of automotive parts needs to be achieved in order to improve fuel efficiency. These items are all driven by the end customer's demands for more environmentally friendly vehicles that still meet their comfort expectations. General soundproofing methods for noisy vehicle systems consists of two components: 1. a resin molded rigid cover and 2. a sound absorption material. Sound proofing performance is generally enhanced in proportion with the added weight to a rigid cover in the form an outer-shell. This makes it difficult to improve on both the silencing characteristic and weight saving at the same time.
2016-04-05
Journal Article
2016-01-0493
Roger Gorges, David Latham, Ian Laing, Ronald Brock
Modern high-speed diesel engines place increasing demands on engine components and specifically for crankshaft bearings there is a requirement to endure increased peak cylinder pressures and resulting loads transmitted through the connecting rods and crankshaft. Seizure and wear resistance of the bearings play a crucial role in modern engine development as a result of these loads and their impact on the lubricant film. In order to attend to these demands, MAHLE has developed a novel high-performance polymer coating containing lubricant-filled microcapsules. The Microcapsules are designed to rupture during nascent scuff and high wear events and consequently release the contained lubricant “on demand”, i.e. just when it is needed to prevent seizure. A clear tendency for the novel polymer coating to provide better recovery after scuffing events was measured, allowing for continuing safe operation of the bearings and thus reducing the seizure risk.
2016-04-05
Technical Paper
2016-01-0286
Changsheng Wang, Haijiang Liu, Tao Zhang, Zhiyong Zhu, Liang Liu
With the increasing development in automotive industry, finite element (FE) analysis with model bias prediction has been used more and more widely in the fields of chassis design, body weight reduction optimization and some components development, which reduced the development cycles and enhanced analysis accuracy significantly. However, in the simulation process of plastic fuel tank system, there is few study of model validation or verification, which results that non-risky design decisions cannot be enhanced due to too much consuming time. In this study, to correct the discrepancy and uncertainty of the simulated finite element model, Bayesian inference-based method is employed, to quantify model uncertainty and evaluate the simulated results based on collected data from real mechanical tests of plastic fuel tanks and FE simulations under the same boundary conditions.
2016-04-05
Journal Article
2016-01-0373
Mohammadreza Eftekhari, Ali Fatemi, Abolhassan Khosrovaneh
An experimental study was conducted to evaluate the variable amplitude fatigue behavior of a neat polymer (polypropylene impact co-polymer) and a polymer composite made of polybutylene terephthalate (PBT) with 30 wt% short glass fiber. Fatigue tests were conducted on un-notched and notched specimens at room temperatures. Plate-type specimens were prepared in the transverse direction with respect to the injection mold flow direction and a central circular hole was drilled in the center of notched specimens. Two step loadings (high-low and low-high) tests at two damage ratio of 0.2 and 0.5 for R = 0.1 and -1 were conducted to investigate load sequence effects and predictions of the linear damage rule. Different behaviors were observed for unreinforced and short glass fiber reinforced polymers under two step loadings.
2016-04-05
Journal Article
2016-01-0506
Daisuke Tomomatsu
The change from metal to resin parts is an important technological development for reducing vehicle weight. Honda fuel piping uses metal pipes for the long under-floor section to both ends of which shorter resin piping is joined. Different resin materials have been used for the resin piping at the two ends. The piping at the front is made from a high-temperature-specification resin material for the 120°C environment of the engine compartment, while the piping at the rear is a low-temperature-specification resin material for the 80°C environment around the fuel tank. Although resin material has a lower specific gravity and is lighter than metal material, it has the drawback of higher cost. The long under-floor section was therefore left in metal material, sacrificing that aspect of weight reduction.
2016-04-05
Journal Article
2016-01-0514
Yan Meng, Yong Xia, Qing Zhou, Shaoting Lin
There has been a rising interest of car manufactures for using plastic materials in interior and exterior trims and safety parts since plastics have quite a few attractive properties: they are light-weight, inexpensive, easy to form, ductile and sustainable. Widely application of thermoplastics drives the demand for reliable and robust methods to modeling structural parts made from plastics. Different from metallic materials, yielding behavior of plastics are pressure dependent and influenced by temperature and strain rate as well. Plastic flow criteria of isotropic polymers has been intensively studied under uniaxial loading. While biaxial tension data is critical in the construction of yielding surface of plastics. However, reliable biaxial tension curve is lacked especially for thermoplastics. The main difficulties consist of two aspects.
2016-04-05
Journal Article
2016-01-0515
Jee Young Youn, Seok Hwan Kim, Yong Sun (Steven) Jin
The increased demand to reduce weight is forcing automotive industry to replace some metal under hood components with plastic materials. Parts such as engine cylinder head cover, air intake manifold was already replaced from metal to plastic. In recently Parts which is located in the underbody parts like engine and transmission oil pans is developing as a plastic material. In this case, impact resistance performance is very important to have reliability against splatting of rocks or impact of hump. In this research, Impact resistance of plastic underbody parts was studied using simulated plastic injection molding specimen which is able to test as type of material, foaming method (position and number of injection molding gate), and feature of ribs. Applied material was glass fiber reinforced polyamide which is able to apply for underbody part. Test was performed as several combination of injection molding gate and rib type.
2016-04-05
Journal Article
2016-01-0516
Saida Khan, Santosh Kumar Sarang, Ichiro Hiratsuka
Fiber reinforced composite-metal hybrids are of great interest in automotive industry because of their excellent mechanical properties and light-weighting potential. Adhesive bonding is a preferred joining technique for manufacturing fiber reinforced composite metal hybrids. The most important step in adhesive bonding of multi-material hybrid joining is surface treatment. In this paper, AA 7xxx-T5 extruded Aluminum surface was treated using different conventional surface treatment methods. The intent is to stiffen Aluminum with lightweight fiber reinforced epoxy tape/mat for energy absorbing part application. The treated surface was characterized using water contact angle measurement for surface energy, optical profilometry for surface roughness, SEM for surface features and Auger electron spectroscopy for chemical analysis of surface. The adhesion strength between Aluminum and continuous glass fiber reinforced epoxy mat was evaluated by lap shear test.
2016-04-05
Journal Article
2016-01-0519
Xiaoqing Xu, Bohan Liu, Yan Wang, Yibing Li
The mechanical behavior of polyvinyl butyral (PVB) film plays an important role in windshield crashworthiness and pedestrian protection and should be depth study. In this article, the uniaxial tension tests of PVB film at various strain rates (0.001 s-1, 0.01 s-1, 0.1 s-1, 1 s-1) and temperatures (-10oC, 0oC, 10oC, 23oC, 40oC, 55oC, 70oC) are conducted to investigate its mechanical behavior. Then, temperature and strain rate dependent viscoelastic characteristics of PVB are systematically studied. The results show that PVB is a kind of temperature and strain rate sensitive thermal viscoelastic material. Temperature increase and strain rate decrease have the same influence on mechanical properties of PVB. Besides, the mechanical characteristics of PVB change non-linearly with temperature and strain rate. Finally, two thermal viscoelastic constitutive model (ZWT model and DSGZ model) are suggested to describe the tension behavior of PVB film at various strain rates and temperatures.
2016-04-05
Journal Article
2016-01-1375
Masahiro Ueda, Satoshi Ito, Daichi Suzuki
Good ride comfort performance, which is represented by noise, vibration, harshness, has high solicitation power for customers. These phenomena are a result of vibration caused at the engine/powertrain or from road surfaces, transmitted to cabin. Therefore, for reduction of these vibrations, a large number of rubber parts are used at the attachment point of cabin, such as engine mounting and suspension bushing. In the vehicle development, demands to examine the vehicle performance including rubber parts using CAE, before prototype evaluation, is increasing. For that reason, a rubber material model which can represent dynamic characteristics (amplitude dependence, frequency dependence, etc.) of the rubber parts with high precision is necessary, but it is difficult to perform amplitude dependence and frequency dependence at the same time using the rubber material model implemented by commercial structure analysis solver.
2016-04-05
Technical Paper
2016-01-0513
Yohei Miki, Hisao Futamata, Masahiko Inoue, Masashi Takekoshi, Kohbun Yamada
Unexpected noise may occur at around air intake manifold when the air throttle is quickly opened. In order to solve this problem, mesh is often mounted into the air flow between the manifold and the throttle. In this study the effect of mesh design on the noise reduction was investigated. Several designs of the mesh were tested with actual air intake unit, and the mechanism of the noise generation and its attenuation was discussed with visualization studies. Based on those experiments, an optimized mesh design was conducted. Furthermore integration of mesh and rubber gasket was examined. Finally rubber mesh-gaskets which provide sealing and noise attenuation for air intake has been proposed in this study.
2016-04-05
Journal Article
2016-01-0497
Brian Falzon, Wei Tan
The development of the latest generation of wide-body carbon-fibre composite passenger aircraft has heralded a new era in the utilisation of these materials. The premise of superior specific strength and stiffness, corrosion and fatigue resistance, is tempered by high development costs, slow production rates and lengthy and expensive certification programmes. Substantial effort is currently being directed towards the development of new modelling and simulation tools, at all levels of the development cycle, to mitigate these shortcomings. One of the primary challenges is to reduce the extent of physical testing, in the certification process, by adopting a ‘certification by simulation’ approach. In essence, this aspirational objective requires the ability to reliably predict the evolution and progression of damage in composites. The aerospace industry has been at the forefront of developing advanced composites modelling tools.
2016-04-05
Technical Paper
2016-01-0507
Kazunori Miyake, Tomoya Nishida, Takanori Kurokawa, Hirokazu Arai
Sliding intermediate shaft of Electric Power Steering (EPS) system is used for torque transmission from steering wheel or motor and buffering reverse input from tire. Required performances of sliding intermediate shaft are lowering sliding loads and improvement of wear-resistance for prevention of rattle noise. Therefore, polyamide coating material with good sliding properties is treated in the sliding types of intermediate shaft. Conventionally, sliding types of intermediate shaft with polyamide coating have been used in vehicle interior. On the other hand, extension of applied area to engine room is needed. In that case use temperature rises from 80 ℃ to 120 ℃. However, in high temperature conditions, there is concerns about increase of friction coefficient and wear volume of polyamide by deterioration of sliding properties of polyamide. Therefore, improvement of sliding properties of polyamide in high temperature is necessary.
2016-04-05
Technical Paper
2016-01-0511
Na Qiu, Yunkai Gao, Jianguang Fang, Shanshan Wang
As a potential material for lightweighting, PMMA has proven to perform well in optical behavior and weather resistance. However, the application in automotive glazing, especially rear window considering its large size has seldom been studied. This paper aims to investigate the defrost performance of PMMA rear window using both numerical and experimental methods. The finite element analysis results were found to be in good agreement with the experimental data. Based on the validated finite element model, we further optimized the defrost efficiency by changing the arrangement of heating line. The results demonstrated the frost layer on the version-related region of PMMA rear window can melt within 30 minutes, which meet the requirement of defrost efficiency.
2016-04-05
Journal Article
2016-01-0527
Anthony Berejka, Dan Montoney, Dan Dispenza, Len Poveromo, Rick Galloway, Marshall Cleland, Mark Driscoll
The power demands in terms of kilowatt-hour electrical use were compared for autoclave curing commercial thermosetting carbon fiber pre-pregs with an innovative alternative of high energy X-ray curing. An automotive component, now made with carbon fiber composites, was selected as an illustrative example, an Aston-Martin hood. Temperature resistant polyester molds for these hoods were used. Ply lay-up was facilitated using an automated cutting device. Manufacturer recommended autoclave curing conditions were used to cure the matrices. X-rays, which can penetrate about 15 cm in unit density materials (as through mold walls), were used to cure pre-pregs made with a specialty matrix material using the same molds, but doing so without adding any heat for curing. High energy X-ray equipment, generated from a 7 MeV, 700 kW electron beam, is in commercial use for medical device sterilization, as are 10 MeV electron beams. This same equipment can also be used for composite curing.
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