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To get a better understanding of the characteristics of the high pressure gasoline sprays impinging on a wall, a fundamental study was conducted in a high-temperature high-pressure constant volume vessel under the simulated engine conditions of in-cylinder pressures, temperatures, and wall temperatures. The injection pressure was varied from 20 to 120 MPa. The spray tip penetration, vapor mass distribution, and vaporization rate were quantitatively measured with the laser absorption-scattering (LAS) technique. The velocity fields of the wall-impinging sprays under vaporizing conditions were measured with the particle image velocimetry (PIV) technique using silicone oil droplets as tracers. The effects of injection pressure and spray/wall interactions on spray characteristics were investigated. The results showed that the increased injection pressure improved penetration, vaporization, and turbulence of the sprays.

A road vehicle’s cornering motion is known to be a compound motion composed mainly of forward, sideslip and yaw motions. But little is known about the aerodynamics of cornering because little study has been conducted in this field. By clarifying and understanding a vehicle’s aerodynamic characteristics during cornering, a vehicle’s maneuvering stability during high-speed driving can be aerodynamically improved. Therefore, in this study, the aerodynamic characteristics of a vehicle’s cornering motion, i.e. the compound motion of forward, sideslip and yaw motions, were investigated. We also considered proposing an aerodynamics evaluation method for vehicles in dynamic maneuvering. Firstly, we decomposed cornering motion into yaw and sideslip motions. Then, we assumed that the aerodynamic side force and yaw moment of a cornering motion could be expressed by superposing linear expressions of yaw motion parameters and those of sideslip motion parameters, respectively.

The present study investigated the aerodynamic pitching stability of sedan-type vehicles under the influence of A- and C-pillar geometrical configurations. The numerical method used for the investigation is based on the Large Eddy Simulation (LES) method. Whilst, the Arbitrary Lagrangian-Eulerian (ALE) method was employed to realize the prescribed pitching oscillation of vehicles during dynamic pitching and fluid flow coupled simulations. The trailing vortices that shed from the A-pillar and C-pillar edges produced the opposite tendencies on how they affect the aerodynamic pitching stability of vehicles. In particular, the vortex shed from the A-pillar edge tended to enhance the pitching oscillation of vehicle, while the vortex shed from the C-pillar edge tended to suppress it. Hence, the vehicle with rounded A-pillar and angular C-pillar exhibited a higher aerodynamic damping than the vehicle with the opposite A- and C-pillars configurations.

The purpose of this study is to define requirements for technological and business success in the world's first implementation of Reverse-Supply-Chain, in which bumper materials of end-of-life vehicles (ELV) are recycled for use as ingredients in new bumper materials. In Japan, ELVs are recovered following to the government regulation. About 20% (700,000 ton) of such collected ELVs are automotive shredder residues (ASR), most of which are burnt as fuel or used as landfill trash. ASRs are mainly plastics, which are largely used as materials of bumpers. The reverse-supply-chain was started as a small business by a collaboration between the car manufacture (Mazda), dismantler, and resource-recycling business operator, and enhanced by the development of easy-to-recycle bumpers, technologies of paint removal from crushed bumpers and sorting-out, a material quality control method, and improvement in transportation efficiency.

In the present study, two kinds of simplified vehicle models, which can reproduce flow structures around the two sedan-type vehicles in the previous study, are constructed for the object and the unsteady flow structures are extracted using Large-Eddy Simulation technique. The numerical results are validated in a stationary condition by comparing the results with a wind-tunnel experiment and details of steady and unsteady flow characteristics around the models, especially above the trunk deck, are investigated. In quasi- and non- stationary manner with regard to vehicle pitch motion, unsteady flow characteristics are also investigated and their relations to an aerodynamic stability are discussed.

This study shows an example in which the conventional aerodynamic evaluation method that focuses on “steady” aerodynamic lift coefficient is not necessarily sufficient to evaluate vehicle's straight-ahead stability at high speed, and proposes a new aerodynamic evaluation method for vehicle stability. In vehicle development, it is generally said that vehicle with lower aerodynamic lift coefficient has better straight-ahead stability at high speed. However, in some cases, straight-ahead stability differs between two vehicles with similar low aerodynamic lift coefficient. It is natural to think that this variation is caused by the difference of suspension characteristics or vehicle body rigidity. But from our experiences, different straight-ahead stability was observed between two vehicles having same suspension characteristics, same vehicle body rigidity and almost similar aerodynamic lift coefficient, but different vehicle configurations.

In this report, we proposed an objective evaluation method of the seat lateral support according to the mechanisms to create the performance differences that we reported previously [1]. First, we showed an effect of scrutinizing Seat Pressure Distribution's change during vehicle turn to gain a quantitative index for explaining subjective evaluation results. Second, we showed the examples of the differences of the results according to the subjects and selected the best-correlated subject among them with a market survey result. Then, we contrived a loading condition to SAE manikin to reproduce the subject's Seat Pressure Distribution. Final, by a specific calculation of the Seat Pressure Distribution, the method to indicate the performance rating that had strong correlation with market survey was clarified.

Seat lumbar support is thought to be essential for seating comfort as it plays important role in the driver's fatigue during long term driving. We tried to evaluate the lumbar support performance objectively with Seat Pressure Distribution. First, the tolerance in the measurement was eliminated by application of ASPECT manikin that reproduced a human seating torso posture [1, 2]. Second, an analysis method to visualize the seat support balance on the human back was developed. Third, a hypothesis for the optimal support balance to minimize the fatigue was proposed according to the fatigue growing mechanisms. Examining the deviation of each seat result from the optimal support, the performances were quantitatively evaluated. In addition to that, the effect of the lumbar support adjuster was taken into consideration to predict the market evaluation more precisely.

We have developed injection molding technologies consist of a new high-strength long-glass fiber reinforced polypropylene (PPLGF). They are key technologies of new modular design for substantial reductions of weight and cost, offering integrated functionality. The strength of injection molded parts are three times stronger than that of the conventional material. This technology makes it possible to replace parts from steel stamping and press molded glass-mat reinforced polypropylene. The front end and door modules of Atenza / Mazda6, Demio / Mazda2, RX-8 employs the module carriers using this material, resulting in dramatic weight and cost savings. (Fig. 1)

New press forming method was developed for ensuring shape-accuracy of draw parts with high strength steel sheet(HSS) of very high tensile strength such as 780MPa. In the new method, step drawing method was combined with crash forming method by applying cam flange die structure to drawing dies. Furthermore, the die structure in the method is simple. At the trial press-forming by the model die even with 780MPa high strength steel sheets, the side wall warps in particular were restrained within a specified tolerance, that is ±0.00067[1/mm] of the variation of curvature(Δ 1/ ρ). Now the method is applied to press-forming some automotive body parts, such as front side member, etc.

Mixture formation processes play a vital role on the performance of a D.I. Gasoline engine. Quantitative measurement of liquid and vapor phase concentration distribution in a D.I. gasoline spray is very important in understanding the mixture formation processes. In this paper, an unique laser absorption scattering (LAS) technique was employed to investigate the mixture formation processes of a fuel spray injected by a D.I. gasoline injector into a high pressure and temperature constant volume vessel. P-xylene, which is quite suitable for the application of the LAS technique, was selected as the test fuel. The temporal variations of the concentration distribution of both the liquid and vapor phases in the spray were quantitatively clarified. Then the effects of injection pressure and quantity on the concentration distributions of both the liquid and vapor phases in the spray were analyzed.

We have developed injection molding technologies consist of a new high-strength long-glass fiber reinforced polypropylene (PPLGF). They are key technologies of new modular design for substantial reductions of weight and cost, offering integrated functionality. The strength of injection molded parts are three times stronger than that of the conventional material. This technology makes it possible to replace parts from steel stamping and press molded glass-mat reinforced polypropylene. The front end and door modules of Mazda 6 employ the module carriers using this material, resulting in dramatic weight and cost savings.

Aerodynamic noise generated in production vehicle has been evaluated using experiment and numerical simulation. Finite difference method (FDM) and finite element method (FEM) are applied to analyze the flow field, and Lighthill's analogy is employed to conduct acoustic analysis. The flow fields around front-pillar obtained by numerical simulations agree with those by experiment for two cases with different front-pillar shape. Moreover, the distribution of acoustic source predicted by FEM is consistent with that obtained by experiment. Present study ascertained the feasibility and applicability of FEM with SGS model towards prediction of aerodynamic noise generated in production vehicle.

Thixomolding® produces net-shape parts from Magnesium alloys in a single step process involving high speed injection molding of semi-solid thixotropic alloys. A description of the process and status of commercial developments will be presented.. The mechanical properties and microstructures of Thixomolded® AZ-91D magnesium materials will be presented. Tensile strengths of semi-solid AZ-91D at both room temperature and elevated temperatures ( 373K, 423K) are compared with die cast AZ-91D. Data on enhanced creep properties of Thixomolded® AZ91-D alloy relative to die cast AZ-91D will be examined with respect to relative changes in microstructural features. Controlling the percent solids in the semi-solid state prior to injection molding can lead to improved creep performance for use in net-shape automotive components.

To investigate NO formation in a combustion flame, PLIF (Planar Laser-Induced-Fluorescence) technique was applied to measure the NO fluorescence distribution in a constant-volume combustion chamber and in a sparkignition engine. The NO fluorescence distribution was taken by an image intensified CCD camera. In the constant-volume combustion chamber, the high NO fluorescence intensity was concentrically observed in the thin flame zone along the flame front. In postflame gas behind the flame zone, the NO fluorescence was widely distributed with weak intensity. In the case of the engine, the fluorescence was distributed in the broad flame zone. The fluorescence intensity had high value near the flame front, and decreased from the flame front to the postflame gas. As the equivalence ratio was changed, the fluorescence intensity reached maximum value at slightly lean condition.