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The Auto/Steel Partnership established the Light Truck Frame Project Group in 1996 with two objectives: (a) to develop materials, design and fabrication knowledge that would enable the frames on North American OEM (original equipment manufacturer) light trucks to be reduced in weight, and (b) to improve corrosion resistance of frames on these vehicles, thereby allowing a reduction in the thickness of the components and a reduction in frame weight. To address the issues relating to corrosion, a subgroup of the Light Truck Frame Project Group was formed. The group comprised representatives from the North American automotive companies, test laboratories, frame manufacturers, and steel producers. As part of a comprehensive test program, the Corrosion Subgroup has completed tests on frame coatings. Using coated panels of a low carbon hot rolled and pickled steel sheet and two types of accelerated cyclic corrosion tests, seven frame coatings were tested for corrosion performance.

This paper describes the recent efforts on developing an automotive climate control system throughout integrating an electrically-controlled variable capacity scroll compressor with a fuzzy logic control-based refrigerant flow management. Applying electrically-controlled variable capacity compressor technology to climate control systems has a significant impact on improving vehicle fuel economy, achieving higher passenger comfort level, and extending air and refrigerant temperature controllability as well. In this regard, it is very important for automotive climate control engineers to layout a system-level temperature control strategy so that the operation of variable capacity compressor can be optimized through integrating the component control schemes into the system-level temperature control. Electronically controlled expansion devices have become widely available in automotive air conditioning (A/C) systems for the future vehicle applications(1, 2, 3 and 4).

The overall vision of this project was to develop a new technology that will be an enabler to reduce design and development time of HVAC systems by an order of magnitude. The objective initially was to develop a parametric model of an automotive HVAC Windshield Defrost Duct coupled to a passenger compartment. It can be used early on in the design cycle for conducting coarse packaging studies by quickly exploring “what-if” design alternatives. In addition to the packaging studies, performance of these design scenarios can be quickly studied by undertaking CFD simulation and analyzing flow distribution and windshield melting patterns. The validated geometry and CFD models can also be used as knowledge building tools to create knowledge data warehouses or repositories for precious lessons learned.

The air bag safety issues became evident in 1995 and other factors have conjoined to change the climate regarding motor vehicle safety. Traditionally, motor vehicle safety issues have been evaluated based upon the effects upon average adult males. The new climate requires consideration of the effects on persons of differing size and gender. By including consideration of children and women, rulemaking and the applied technologies are able to better optimize safety than is the case when rules are focused only on the average adult male. Automotive electronics serves a key role in the migration from a one-size-fits- all protection to a more customized protection for a variety of occupants. The enhancements have been the most prominent in the area of sensing, be it the sensing and characterization of the crash itself, or the sensing and characterization of occupants in the vehicle.

The complexity of designing and implementing a vehicle electrical control system for ultra fuel-efficient hybrid vehicles is significantly greater than that of a conventional vehicle. To quickly demonstrate and iterate capabilities of these vehicles, an efficient and rapid means for developing requirements, mapping these into an electrical control and communications architecture, and developing prototype systems is needed. The General Motors Precept concept vehicle is an example of an energy- efficient vehicular control system developed using a "requirements to software'' development process and electronic controller infrastructure that demonstrates these attributes. The Precept is General Motors Corporation's technology demonstration concept vehicle developed to address General Motors Corporation's commitment to the Partnership for a New Generation (PNGV) program.

This paper documents the development process of the 2001 Pontiac Aztek body structure for improved noise & vibration performance. Successful vehicle development under an accelerated timing schedule demands clearly defined body structure vibration performance targets and critical dependence on the math based modeling process. Specifications for global body structure vibration performance were generated through a two step process. First, a benchmarking activity was undertaken to comprehend competitive vehicle performance. Secondly, a frequency domain “mode map” was constructed to minimize vehicle subsystem interaction. Computer simulation models were developed to predict the body structure performance. A coarse full body structure model was used to define body structure section size and joint requirements. Detailed analysis models of body joint areas were used to synthesize the joint design.

A vehicle perceived to be solid and vibration free is said to have good “structural feel”. Specification for vehicle design to achieve a good stuctural feel depends heavily on the management of resonant modes existing in the low frequency domain. These resonances include vehicle rigid body, chassis subsystem, body flexure and large component modes. A process to specify the placement of resonant modes in the low frequency domain is discussed. This process allocates blocks within the frequency domain for classes of resonant modes stated above. Segregation of these blocks of resonant modes in the frequency domain limits modal interaction, thereby minimizing sympathetic vibration. Additionally, known areas of human body sensitivity within this low frequency domain are stated. Lastly, known vibration inputs are identified. This process is cognizant of these inputs and avoids overlapping with the vehicle resonant modes to provide further insurance of minimal modal interaction.

In a typical hydroforming operation, a round tube of constant wall thickness is bent into the overall shape desired for the final part, then placed between a pair of dies. Despite some small percentage of stretch that may occur as the tube expands, the wall thickness in the original tube is therefore substantially constant at all points. In some circumstances, a part is locally thickened or reinforced for extra strength. Normally, this is achieved by using a separate piece of reinforcement at selected location. In this paper, it is intended to present a unique method to achieve an optimal structural design allowing thin or thick gages where required along its cross-section. This is done via hydroforming an aluminum extrusion tube to an optimal frame structure having varied wall thickness to satisfy various loading requirements at a minimum weight. The engine cradle is used as an example to demonstrate this methodology.

An approximate analysis method for brake squeal is presented. Using MSC/NASTRAN a geometric nonlinear solution is run using a friction stiffness matrix to model the contact between the pad and rotor. The friction coefficient can be pressure dependent. Next, linearized complex modes are found where the interface is set in a slip condition. Since the entire interface is set sliding, it produces the maximum friction work possible during the vibration. It is a conservative measure for stability evaluation. An averaged friction coefficient is measured and used during squeal. Dynamically unstable modes are found during squeal. They are due to friction coupling of neighboring modes. When these modes are decoupled, they are stabilized and squeal is eliminated. Good correlation with experimental results is shown. It will be shown that the complex modes baseline solution is insensitive to the type of variations in pressure and velocity that occur in a test schedule.

Using a combination of engineering test experience, explicit finite-element analysis, and advanced materials characterization, a predictive engineering method has been developed that can assist in the development of active top pads. An active top pad is the component of the instrument panel that covers the passenger airbag module and articulates during a crash event, allowing the airbag to deploy. This paper highlights the predictive analysis method, analytical results interpretation, and suggestions for future development.

This study was initiated to evaluate the thermal characteristics of a vehicle underbody using math-based computational fluid dynamics (CFD) simulation based on 3-D configuration. Simulations without heat shields were carried out for different vehicle operating conditions which placed several areas at risk of exceeding their thermal design limits. Subsequently, simulations with several heat shield designs were performed. Results show that areas at risk without shields are well within thermal design limits when shielded. Part of the CFD simulation results were compared with experimental data, with reasonable correlation. The CFD approach can provide useful design information in a very short time frame.

Aspirating airbag modules are unique from other designs in that the gas entering the airbag is a mixture of inflator-delivered gas and ambient-temperature air entrained from the atmosphere surrounding the module. Today's sophisticated computer simulations of an airbag deployment typically require as input the mass-flow rate, chemical composition and thermal history of the gas exiting the canister and entering the airbag. While the mass-flow rate and temperature of the inflator-delivered gas can be obtained from a standard tank test, information on air entrainment into an aspirated canister is limited. The purpose of this study is to provide quantitative information about the aspirated mass-flow rate during airbag deployment. Pressure and velocity measurements are combined with high-speed photography in order to gain further insight into the relationship between the canister pressure, the rate of cabin-air entrainment and the airbag deployment.

This paper presents an optimization technique for clamping forces determination in fixture design. First, the finite element analysis (FEA) is applied to determine the coefficients of compliant matrix of a fixture-workpiece system subjected to machining and clamping forces. Then, a nonlinear optimization model is constructed in terms of the FEA results and mechanical and geometrical constraints. The optimization model is derived to determine the feasible clamps under the corresponding force effects. The optimal magnitude and direction of clamping forces minimize the workpiece deformation at particular key points. Finally, a scaled engine block with the 3-2-1 fixturing principle is given as an example.

The use of regrind acrylonitrile-butadiene-styrene (ABS) for automotive parts and components results in two types of financial savings. The first is the shared monetary savings between General Motors and the molder for the difference in the virgin resin price versus price of the ABS regrind. The second is a societal energy savings seen in the life cycle of virgin ABS versus reground ABS. An added benefit is the preservation of natural resources used to produce virgin ABS.

A family of adult and child size dummies was developed under the direction of two task groups of the SAE Mechanical Human Simulation Subcommittee of the Human Biomechanics and Simulation Standards Committee. These new child size dummies represent fiftieth percentile children who are 6 months, 12 months, 18 months, 3 years, and 6 years old. The sizes and total body weights of the dummies were based on detailed anthropometry studies of children of these ages. The techniques used to establish the segment masses and the resulting design goals are detailed. Appropriate impact response requirements were scaled from the biofidelity response requirements of the Hybrid III, taking into account the differences in size, mass and elastic modulus of bone between adults and children. The techniques used to establish the biomechanical impact response requirements for the child dummies are discussed and the resulting biomechanical impact response requirements are given.

This paper describes the application of Statistical Energy Analysis (SEA) and Experimental SEA (ESEA) to calculating the transmission of air-borne and structure-borne noise in a mid-sized sedan. SEA can be applied rapidly in the early stages of vehicle design where the degree of geometric detail is relatively low. It is well suited to the analysis of multiple paths of vibrational energy flow from multiple sources into the passenger compartment at mid to high frequencies. However, the application of SEA is made difficult by the geometry of the vehicle's subsystems and joints. Experience with current unibody vehicles leads to distinct modeling strategies for the various frequency ranges in which airborne or structure-borne noise predominates. The theory and application of ESEA to structure-borne noise is discussed. ESEA yields loss factors and input powers which are combined with an analytical SEA model to yield a single hybrid model.

The development of systems and components for control of exterior noise has traditionally been done through an iterative process of on road testing. Frequently, road testing of vehicle modifications are delayed due to ambient environmental changes that prevent testing. Vehicle dynamometers used for powertrain development often had limited space preventing far field measurements. Recently, several European vehicle manufacturers constructed facilities that provided adequate space for simulation of the road test. This paper describes the first implementation of that technology in the U.S.. The facility is typical of those used world wide, but it is important to recognize some of the challenges to effective utilization of the technique to correlate this measurement to on road certification.

This paper summarizes the design, development, fabrication, validation, and application of a new device called the Skin Thermal Transducer (STT). The development of this instrument was driven by the demand for reliable information on human skin temperatures during contact with a warm surface on the interior of an automobile. The primary technology that enabled the development of the STT was the thermo-electric cooler (TEC) in combination with a heat sink that is used to simulate the core temperature of the human body. The STT was validated with human skin data and the agreement was within an acceptable range. The STT provides the automotive engineer with a measuring device to optimize and validate the underbody regions of the vehicle with respect to occupant thermal comfort. The STT can also be applied to optimize other automotive and non-automotive products in which the human skin touches a warm surface.

A global thermal model of a vehicle powertrain is used to quantify how different engine design and powertrain calibration strategies influence the performance of a vehicle heating system. Each strategy is evaluated on its ability to improve the warm-up and heat rejection characteristics of a small-displacement, spark-ignition engine while minimizing any adverse effect on fuel consumption or emissions. An energy audit analysis shows that the two strategies having the greatest impact on heating system performance are advancing the spark and forcing the transmission to operate in a lower gear. Changes in head mass, exhaust port diameter, and coolant flow rate influence the coolant warm-up rate but have relatively little effect on steady state heat transfer at the heater core.

The air passages in tailpipe end geometries are investigated with Computational Fluid Dynamics (CFD) simulations. The overall objective of the simulations is to select an optimum design which has a mimimum capacity for noise generation. This is accomplished by comparing pressure drops between inlet and outlet and by examining the turbulent kinetic energy levels in the flow domain. Two designs for the tailpipe end geometries were evaluated. It was found that turbulent kinetic energy levels and pressure drops were lowest in a single pipe design which had relatively smooth internal contours. We conclude that the present CFD approach can provide useful design information in a short time frame (a few weeks) for exhaust pipe tip geometries for reduced pressure drop and noise generation.