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Technical Paper

Technical Assessment of an Automotive System through the Methodology of Engineering Value / Analysis Value

In the current automotive industry, in an increasingly challenging environment due to strong competition, to develop a product that performs its functions objectively, with quality and mainly with the lowest possible cost, these are the keys to conquer competitive advantage. This paper is intended to explore cost reduction of an automotive system by using the techniques of the methodology EV / AV (Engineering Value / Analysis Value). The analysis are framed as exploratory, in the form of study, with ratings of the components and their functions, followed by the generation of ideas with the completion of an indication of a great potential for a product development with optimized cost.
Technical Paper

Acoustic Development Differences Between Theoretical And Experimental Process for Automotive Exhaust System

Acoustics, in a broad sense, is an essential product attribute in the automotive industry, therefore, it is relevant to study and compare theoretical and numerical predictions to experimental acoustic measurements, key elements of many acoustic development processes. The numerical methods used in the industry for acoustic predictions are widely used for exhaust system optimization. However, the numerical and theoretical predictions very often differ from experimental results, due to modeling simplifications, temperature variations (which have high influence on speed of sound), manufacturing variations in prototype parts among others. This article aims to demonstrate the relevant steps for acoustics development applied in automotive exhaust systems and present a comparative study between experimental tests and computer simulations results for each process. The exhaust system chosen for this development was intended for a popular car 4-cylinder 1.0-liter engine.
Technical Paper

Vehicle Interior Noise Reduction Using Innovative Roof Trim Structure

It is known acoustic comfort is a key feature to meet customer expectations for many products. In the current automotive industry, vehicle interior quietness is seen as one of the most important product attributes regarding perceived quality. A quiet interior can be achieved through an appropriate balance of noise sources levels and acoustic materials. However, the choice of the most efficient acoustic content may be challenging under severe cost and mass restraints commonly found in emerging market vehicles. Therefore, it is fundamental to develop efficient materials which will provide high acoustic performance with lower weight and cost. In this paper the fine tuning of the headliner structure is presented as an efficient way to increase acoustic performance. Structures currently employed for this vehicle subsystem are described. Airflow resistance and sound absorption measurements are used to guide development and make precise manufacturing process changes.
Technical Paper

Daytime Running Light (DRL) Application on Brazilian Vehicles

Brazil, that presents one of the highest accidents indexes of the world, does not have any specific regulation related to the use of an external light during the day time which provides a better visibility of the vehicle in movement and according to studies gives more reaction time for the other road users. Many countries in Europe and North America shows good results since they adopted the lights on during the day with collision reduction of vehicle to vehicle, vehicle to pedestrian and vehicle to cyclists. The aim of this study is to show the benefits of the Daytime Running Lights (DRL) and its relation to the reduction of the traffic accidents, as well as a brief analysis on the use of a dedicated system, which can be more efficient since it can be designed to provide a light distribution allowing a better visibility as possible.
Technical Paper

Blanks Physical Parameters Optimization for Automotive Panels Deep Drawing

This work conducted an optimization in sheet metal blank's sizes for cold pressing automotive parts, comparing dimensional characteristics of automotive hood outer panels deep drawn with commonly used blank sizes for this process. As a result, it was possible to suggest modifications to smaller blank sizes, accordingly to the improvement accomplished in this work. The experimental study was conducted from observations in part's superficial aspects after its deep drawing process, which was realized in a commonly used tooling for automotive industry, with a blank's width reduction for the suggested case. The results showed a cost reduction opportunity based in this optimization.
Technical Paper

Treatment of End of Life Vehicles in Brazil: Challenges and Opportunities

Style changes and technological advances have led to reduced service life of current products as automobiles. These are among the goods that are constantly re-designed to meet our growing needs for improved products. However, these demands for new products and more modern has meant a great cost to our natural resources, such as excessive use of raw materials, water and energy during production, use and end of life cycle of these assets. The increasing scarcity of land available for the proper disposal of waste in landfills, in addition to the high cost of implementing these areas and the increasing distances to urban centers imply the need to reduce solid waste generation, including here the automotive. The growth of the automotive market has created a serious problem due to the disposal of urban waste volumes generated, the great diversity of materials involved and their toxicity.
Technical Paper

Control of Airborne Road Noise Using Sealers

Noise generated during tire/road interaction has significant impact on the acoustic comfort of a vehicle. One of the most common approaches to attenuate road noise levels consists on the addition of mass treatments to the vehicle panels. However, the acoustic performance of sealing elements is also relevant and has an important contribution to the noise transmission into the vehicle interior. In this paper the correct balance between the mass added to treat vehicle panels and sealing content is investigated. The procedure to quantify the critical road noise transmission paths consists of recording interior noise levels as applied treatment is removed from potential weak areas, such as wheelhouses, floor, doors and body pillars. It is observed that the noise propagation through body pillars has a direct influence on road noise levels.
Technical Paper

Computational method to assess the SUV drivers' dynamics due to rollover crashes

Even though the rollover is not the most frequent type of accident, it is of the greatest significance with respect to injury and trauma caused to the vehicle occupants. The need to reduce death incidence and serious injuries has increased the importance of computational simulations and prototype testing. This study presents finite element model to simulate rollover events and to predict possible injuries caused in the head, neck, thorax and cervical spine. Numerical models of a sport utility vehicle (SUV) are simulated including anthropomorphic dummy to represent the driver. The injury risks and traumas are verified to the driver considering belted and unbelted dummies. The computational methodology developed proved to be efficient for the evaluation of the vehicle's roof structure in rollover events.
Technical Paper

ISO Headform Pedestrian Protection test results comparison at critical bonnet regions

Test Protocols for pedestrian head protection in a car pedestrian accident have been discussed for several Technical Communities in order to identify ideal boundary test conditions to evaluate injury limits. With the purpose to harmonize with final Global Technical Regulation 9 for Pedestrian Protection published by ECE in January 2009, European New Car Assessment Program (ENCAP) has changed their Child and Adult headform weight and geometry boundary test conditions. However 5 Kph remains as difference between both protocols. This work presents a comparative head impact test analysis for both headform at ENCAP and GTR#9 boundary test conditions when performed at critical bonnet regions.
Technical Paper

Computational Methodologies for Vehicles Roof Strength Assessment to Prevent Occupants Injury in Rollover Crashes

Among all types of vehicle crashes, rollover is the most complex and yet least understood. During the last decades, a constant increase in the studies involving rollover crashes and injuries associated with it can be observed. Although the rollover is not the most frequent type of accident, it is of the greatest significance with respect to injury and trauma caused to the vehicle occupants. The existing standards and procedures to test rollover crashworthiness are still not suitable to computer simulation because of the huge computational effort required, and the need of faithful/overly complex representation of the aspects involved in real crashes. The objective of the present work is the development of computational models particularly adapted to simulate different standards and procedures used to evaluate the vehicles' roof strength. The models are compared with other approaches, and their advantages/disadvantages are discussed.
Technical Paper

A case-study about side door closing effort

Door Closing Effort is one of the first impressions a potential customer has about a vehicle. The energy someone needs to give out to push and lock a side door vehicle is easily felt and can enhance the impression of a robust and high quality design vehicle. In other words, Door Closing Effort is one of the issues manufacturers shall look over in order to achieve perfect levels of Human Vehicle Integration (HVI). The aim of this paper is to present a case study of Side Door Closing Effort of a specific Hummer vehicle. It will be shown how door closing effort varies according to several parameters, and how to improve the design and/or production process in view of achieving better effort levels, considering the Hummer case as a background. Several variables that influence on the overall energy of this process have been evaluated, and the physical differences were weighted to demonstrate what really counts for reaching a comfortable level of Door Closing Effort.
Technical Paper

A Case Study About Side Door Closing Sound Quality

Side Door Closing Sound Quality is one of the first impressions a potential customer has about a vehicle. It can enhance an impression of robust and high quality vehicle. This paper is a study of Side Door Closing Sound of a specific vehicle model. The main objective is to understand how Door Closing Sound Quality varies over several vehicles samples and how to improve the design and/or production process in order to achieve better Sound Quality. Two vehicles (same model) with distinct performance have been chosen among several samples. Both have been evaluated and the physical differences are weighted to realize what really matter for Door Closing Sound Quality.
Technical Paper


The present work gives an overview of the current situation of failures that may occur in automotive components, showing their distribution in the vehicle and the causes that make them occur, trying to emphasize the different materials which are used in the manufacturing of these components. This work is a technical approach strictly supported by an engineering concept which aims to discuss the different factors which contribute to cause premature failures of automotive components, prior to their utilization in the field or when they are exposed to the most variable conditions of use. One of the most important objectives of this study is to call the attention of design engineers, research engineers and manufacturing people to the importance of the components integrity which shall be taken into primary consideration in the design phase as well as in the specification of the material and process of manufacturing.