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Training / Education

Vehicle Crash Reconstruction Principles and Technology

2020-02-17
Crash reconstruction is a scientific process that utilizes principles of physics and empirical data to analyze the physical, electronic, video, audio, and testimonial evidence from a crash to determine how and why the crash occurred. This course will introduce this reconstruction process as it gets applied to various crash types - in-line and intersection collisions, pedestrian collisions, motorcycle crashes, rollover crashes, and heavy truck crashes. Methods of evidence documentation will be covered. Analysis methods will also be presented for electronic data from event data recorders and for video.
Training / Education

Side Impact Occupant Safety and CAE

2019-11-25
Side impact crashes account for approximately twenty-six percent of all motor vehicle fatal crashes, second only to frontal crashes, according to a report by the National Highway Transportation and Safety Administration (NHTSA). While car companies and suppliers continue to develop new technologies that make vehicles safer, NHTSA rolled out updated safety regulations (FMVSS 214) based on new research studies, making vehicle safety design more and more complex. This seminar is designed to familiarize participants with the engineering principles behind vehicle and restraint designs for occupant safety.
Technical Paper

A new appraisal of the thermomechanical behaviour of a hybrid composite brake disc in a formula vehicle

2019-11-21
2019-28-2572
A new appraisal of the thermomechanical behaviour of a hybrid composite brake disc in a formula vehicle Research Objective This paper presents a hybrid composite brake disc with reduced Un Sprung Weight clearing thermal and structural analysis in a formula vehicle.Main purpose of this study is to analyse thermomechanical behaviour of composite brake disc for a formula vehicle under severe braking conditions. Methodology In the disk brake system, the disc is a major part of a device used for slowing or stopping the rotation of a wheel. Repetitive braking of the vehicle leads to heat generation during each braking condition. Based on the practical understanding the brake disc was remodelled with unique slotting patterns and grooves, using the selected aluminium alloy of (AA8081) with reinforcement particle of Silicon carbide (SiC) and Graphite (Gr) as a hybrid composite material for this proposed work.
Technical Paper

High rigidity and light weight bumper material development in India

2019-11-21
2019-28-2553
Vehicle weight reduction becomes important at the view point of fuel efficiency improvement and CO2 reduction in India also as well as developed countries. With this background, High tensile and Super high tensile steel application has become increasing. Similary, weight reduction of big plastic parts like bumper face is one of the most important items, so Honda has developed Thin-wall and light weight bumper face. In the development of light weight bumper, rigidity, impact strength and flowability which are main requirement are cotradictory property. It is necessary to develop new material to achieve this technical concern. Moreover, we verified part shape and thickness optimization to achieve part requirement. Established high property material and part manufacturing technology were applied for current CITY firstly, and it has been expanded to other models sequentially to contribute weight reduction for Honda vehicles.
Technical Paper

Autonomous Car in India

2019-11-21
2019-28-2522
Automation is expanding in every possible direction and it was only time before it reached the Automobile sector. There has been tremendous traction towards autonomous cars since last 2-3 yrs as a probable solution to reduce accidents and promote safe and comfortable commute. Many companies have expressed their interest in developing some part(s) of it and when would all of this culminate resulting in a fully autonomous car. But as every coin has two aspects so same does automation. This paper covers the future of autonomous cars from Indian perspective, covering possible challenges, complex use cases, advantages, technology enablers, economy outlook etc. India has the dubious honor of ranking first in road deaths in the world at present & accounts for 10 percent of global road accidents with more than 1.46 lakh fatalities annually.
Technical Paper

Self-Sensing, Lightweight and High Modulus Carbon Nanotube Composites for Improved Efficiency and Safety of Electric Vehicles

2019-11-21
2019-28-2532
Carbon Composites (CFRP) have been touted to be an essential component of future automobiles due to their mechanical properties and lightweight. CFRP has been adopted successfully for secondary and primary structures in Aerospace industry. In Automobiles, they are incorporated in models like the BMW i-series. CFRP suffers from 2 major problems. Delamination of Composites leads to catastrophic and rapid failure which could be dangerous in passenger vehicles. Delamination occurs whenever there is a shock on the composite. Secondly, Composites need regular expensive maintenance to ensure that the material is intact and will not compromise passenger safety. Carbon Nanotubes in composites have shown a substantial increase in delamination resistance. A 0.1wt% addition of HiPCO® Single-walled Carbon Nanotube provides both self-sensing and improved fracture resistance.
Technical Paper

C123 Methodology for concept design of the Chassis Frame

2019-11-21
2019-28-2534
Objective This paper explores the usage of Altair simulation driven concept process, C123 for developing the chassis frame of the SUV along with Multidisciplinary optimisation tool. C123 process is useful for strategic & systematic usage of optimisation to generate design alternatives, trade-off information, best balanced designs, design sensitivities, to actively support the concept development process on daily basis. Methodology C123 is used for developing initial concept design of the chassis frame of the SUV. C123 process is independent of vehicle architectures, manufacture process (e.g. extrusions, sheet metal) & material selection (e.g. metals, composites, mixed etc.) and platform sharing strategy. C1 process is used for identification of optimum Structural Layout, C2 is for rapid optimum Sizing of idealized Sections, C3 is used for detailed optimum Sizing of Manufacturable Sections. Automatic process is used for handling pre and post processing process very efficiently.
Technical Paper

High Durable PU Metallic Monocoat system for tractor sheet metal application.

2019-11-21
2019-28-2541
In sheet metal painting for various applications like Tractor, Automobile, most attractive coating is metallic paints and it is widely applied using 3 coats 2 bake or 3 coat 1 bake technology. Both options, results in high energy consumption, higher production throughput time & lower productivity in manufacturing process. During various brainstorming & sustainable initiatives, paint application process was identified for alternative thinking to reduce burden on environment & save energy. Various other industry benchmarking & field performance requirement studies helped us identify the critical to quality parameters. We worked jointly with supplier to develop mono-coat system without compromising the performance & aesthetical properties. This results in achieving better productivity, elimination of two paint layers, substantial reduction in volatile organic content, elimination of one baking cycle and energy saving.
Technical Paper

Design of Additive Manufactured Thermoplastic Component as FMVSS 201U Countermeasure

2019-11-21
2019-28-2547
Research and/or Engineering Questing/Objectives: Safety of the occupant in passenger cars is one of the regulatory requirements in many developed countries. This includes upper interior head impact load case of the unbelted occupant during crash (FMVSS 201U) as one of them. During a crash event the occupant head can collide with the interior parts of the vehicle, such as a headliner, pillar trim and other subsequent components in the loading direction. Injury on the head is quantified in terms of the Head Injury Criterion of a crash test dummy (HIC(d)) value which should be less than 1000 per standard. Several ways can be adopted to reduce the HIC(d) value. These include a change in the design of ribs in the safety plastic components, headliner profile change, use of countermeasure foam between headliner and the exterior sheet metal parts, or a combination of any of these to absorb the energy of impact.
Technical Paper

Injury Reduction in Vehicle to Pedestrian Collision using Deployable Pedestrian Protection System in Vehicles

2019-11-21
2019-28-2551
Head injuries are the main source of road fatalities in when a pedestrian is involved in an accident with the vehicle. The frontal part of vehicle such as engine hood, lower-windshield area and A-pillars are the possible location of head impact in such accidents. The head impact with hard points located in these areas result in the fatal head injuries. The effect of impact can be reduced by using the deployable pedestrian protection systems (DPPS) such as hood-lifters and windshield airbag in the vehicle. The study shows how these systems are effective in reducing the fatalities in pedestrian accidents and how to evaluate the performance of these deployable systems.
Technical Paper

MITIGATION FOR EDGE CORROSION PROTECTION FOR AUTOMOTIVE BODIES

2019-11-21
2019-28-2561
TITLE: MITIGATION FOR EDGE CORROSION PROTECTION FOR AUTOMOTIVE BODIES. Keyword: Edge corrosion, Edge protection, Rust on edges, Corrosion mitigation. Objective: A major challenge to automotive industry is to protect the vehicle from corrosion in varying environment with respect to different service conditions. One of the main types of corrosion that affects aesthetic look is edge corrosion on sheet metal. Mostly edge is acting as starting point of corrosion due to unprotected metal exposed to environment. A special attention to be given to exposed edges to protect from rust formation. Methodology: To mitigate corrosion in visible area, various solution proposed in manufacturing process, material usage, sealer application, BIW design. Samples were prepared as per design of experiments with respect to manufacturing process condition and subjected for testing. Results: Proposed solutions were validated in manufacturing process line and reports are discussed.
Technical Paper

A Mathematical Approach to Determine Die Wear during Forging Process and Validation by Experimental Technique

2019-11-21
2019-28-2563
The automotive industry is constantly trying to develop cost effective, high strength and lightweight components to meet the emission and safety norms while remaining competitive in the market. Forging process plays an important role to produce most of the structural components in a vehicle. Precision forging technology is used to produce components with little or no flash leading to elimination of machining process after forging. The load acting on the dies during net or near net forging is very high and leads to wear in the die. In order to have a good die it is important that die wear which is an inevitable phenomenon in a bulk metal forming processes is predicted mathematically. In this study a review on the vast number of studies done in the area of wear and various predictive models is carried out.
Technical Paper

STATISTICAL ANALYSIS OF LOW CYCLE FATIGUE PROPERTIES IN METALS FOR ROBUST DESIGN

2019-11-21
2019-28-2576
Objective: In ground vehicle industry, strain life approach is commonly used for predicting fatigue life. This approach requires use of fatigue material properties such as fatigue strength coefficient (σf'), fatigue strength exponent (b), fatigue ductility coefficient (εf'), fatigue ductility exponent (c), cyclic strength coefficient (K′) and cyclic strain hardening exponent (n′). These properties are obtained from stable hysteresis loop of constant amplitude strain-controlled uniaxial fatigue tests. Usually fatigue material properties represent 50th percentile experimental data and doesn't account possible material variation in the fatigue life calculation. However, for robust design of vehicle components, variation in material properties need to be taken into account. In this paper, methodology to develop 5th percentile (B5), 10th percentile (B10) and 20th percentile (B20) fatigue material properties are discussed.
Technical Paper

Determine Thermal Fatigue Requirements for PEPS Antenna Copper Wire over Vehicle Lifetime with defined Reliability Requirements.

2019-11-21
2019-28-2582
Reliability states the degree to which the result of a measurement, calculation, or specification can be depended on to be accurate. And, tests according to GMW specifications represents a minimum of 15 years of vehicle life time with defined Reliability and Confidence level. In this work, actual number of thermal cycles for Thermal Fatigue tests (Thermal Shock and Power Temperature Cycle) are calculated for Copper Wire whose Coffin Manson exponent is 5. Overstressing the PEPS Antenna under thermal fatigue requirement (defined number of thermal cycles based on Reliability and Confidence requirements) will lead to broken Copper wire which will result in component’s functional failure and thus impossible to continue reliability testing. The objective of this paper is to determine thermal fatigue requirements for Antenna’s Copper wire whose Coffin Manson exponent is 5.
Technical Paper

Optimization of the critical parameters affecting the fuel lid performance

2019-11-21
2019-28-2413
Fuel lid is one of the parts which are mostly operated mechanically by the end user while filling the fuel. Therefore part design should be done in such a manner that it can be operated smoothly without any hassles. The conventional steel fuel filler doors are of two types: Three-piece type fuel filler doors also known as the dog-leg type and two-piece type fuel filler doors also known as the butterfly type. Both types of fuel filler doors have a pin that acts as a rotational hinge axis about which the fuel filler door opens and closes. Depending on the styling and shape of the side body outer, fuel lid type is decided. In the current study, dog-leg type fuel lid is considered. The factors that primarily affect the opening-closing performance are the weight of fuel lid, hinge axis, and the friction at the hinge area. The orientation of the hinge axis is derived from the profile of the side body outer panel. The fuel lid weight and hinge axis are decided in the initial design stage.
Technical Paper

A Machine Learning based Multi-objective Multidisciplinary Design Optimization (MMDO) for Lightweighting the Automotive Structures

2019-11-21
2019-28-2424
The present work involves Machine Learning (ML) based Multi-objective Multidisciplinary Design Optimization (MMDO) for lightweighting the automotive structures. The challenge in deployment of MMDO algorithms in solving real-world automotive structural design problems is the enormous time involved in solving full vehicle finite element models that involve large number of design variables and multiple performance constraints pertaining to vehicle dynamics, durability, crash and NVH domains. With the availability of powerful workstations and using the advanced Computer Aided Engineering (CAE) tools, it has become possible to generate huge sets of simulation data pertaining to multiple domains.
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