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During the development of the Geely Hybrid System (GHS), which combines a 15T Miller engine with an Electric Motor (EM) integrated into a 7-speed Dual-Clutch Transmission (P2.5), several hybrid-specific Noise, Vibration, and Harshness (NVH) issues have been encountered. The technology used, the system features, and the hybrid operating modes are analyzed. Changes within driving modes and their transitions are among the new challenges faced by NVH and system engineers [1, 2, 3]. The lack of engine combustion noise masking during electric drive and hybrid mode brings new requirements for gear design and structural integrity. These requirements ensure the system is robust and insensitive to the excitation. Attachment points and its dynamic stiffness are important to prevent structure-borne frequency content of gear whine and EM magnetic noise being transmitted to the vehicle cabin via powertrain mounts.

The coefficient of friction between surfaces is an important criterion for predicting metal behavior during sheet metal stamping processes. This research introduces an innovative technique to find the coefficient of friction on a lubricated aluminum sheet metal surface by simulating the industrial manufacturing stamping process while using 3D digital image correlation (3D-DIC) to track the deformation. During testing, a 5000 series aluminum specimen is placed inside a Stretch-Bend-Draw Simulator (SBDS), which operates with a tensile machine to create a stretch and bend effect. The friction coefficient at the contact point between an alloy sheet metal and a punch tool is calculated using an empirical equation previously developed. In order to solve for the unknown friction coefficient, the load force and the drawback force are both required. The tensile machine software only provides the load force applied on the specimen by the load cell.

Vehicle weight reduction is a significant challenge for the modern automotive industry. In recent years, the amount of vehicular components constructed from aluminum alloy has increased due to its light weighting capabilities. Automotive manufacturing processes, predominantly those utilizing various stamping applications, require a thorough understanding of aluminum fracture predictions methods, in order to accurately simulate the process using Finite Element Method (FEM) software or use it in automotive engineering manufacture. This paper presents the strain distribution of A5182 aluminum samples after punch impact under various conditions by Digital Image Correlation (DIC) system, its software also measured the complete strain history, in addition to sample curvature after it was impacted; therefore obtaining the data required to determine the amount of side-wall-curl (Aluminum sheet springback) present after formation.