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Training / Education

Introduction to Advanced High Strength Steel Applications and Manufacturing

2019-10-08
Advanced High Strength Steels (AHSS) are now commonly used in automotive body structural applications. The high strength of this grade classification is attractive to help reduce mass in the automotive body through reduction in thickness. Strength also supports improvements in safety requirements so that mass increases are minimized. In some specific grades of AHSS, energy absorption is possible in addition to the high strength. This course will review the definition and properties of AHSS and cover several common applications in automotive body structures.
Training / Education

Introduction to Rubber Science and Technology

2019-10-08
Rubber – a loosely cross-linked network of polymer chains that when strained to high levels will forcibly return to at or near it original dimensions. This course is designed to provide the participant with a thorough understanding of rubber’s engineering characteristics. This class will introduce the various sources of rubber, both natural and synthetic. The class will contrast the differences between rubber and plastics; including thermoplastic rubber. Detailed discussions on how to select the correct rubber polymer for the application, highlighting the pros and cons of each major rubber type.
Training / Education

Basics of Silicone Rubber Science and Technology

2019-10-07
Silicone rubber is comprised of inorganic-organic polymers. These materials consist of an inorganic backbone with organic side groups attached to silicon atoms. This family of polymers possesses unmatched versatility giving the formulator and user multiple forms and methods to cross link the polymers into rubber materials having the widest service temperature range of any rubber material. This course is designed to provide the participant with a thorough understanding of silicone’s engineering characteristics.
Training / Education

Design for Manufacturing & Assembly (DFM/DFA)

2019-06-26
Design for Manufacturing and Assembly (DFM+A), pioneered by Boothroyd and Dewhurst, has been used by many companies around the world to develop creative product designs that use optimal manufacturing and assembly processes. Correctly applied, DFM+A analysis leads to significant reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes. In this two-day seminar, you will not only learn the Boothroyd Dewhurst Method, you will actually apply it to your own product design!
Training / Education

Automotive Plastics Principles of Materials & Process Selection

2019-06-10
Plastic - any class of synthetically-produced organic compounds capable of being molded and hardened into a specific shape or form. This course is designed to offer a basic understanding of plastics and plastic processing. Using plastics can be simple, but there is much more behind producing high performance plastic parts. This seminar will walk you through the molding process, provide a comprehensive look at the variables in the manufacturing mix, and review characteristics of typical automotive plastics such as PP, PVC, ABS, and more.
Technical Paper

Multiphysics Multi-Objective Optimization for Electric Motor NVH

2019-06-05
2019-01-1461
Prediction of noise/vibration at the design stage is important for motor design. However, due to the multiphysics nature of the noise, vibration, harshness (NVH) simulation, an integrated workflow is required for wide adoption across industries [1-5]. ANSYS Workbench provides a platform where electromagnetic, structural and acoustic solvers can communicate with each other without user interventions. Based on the platform, multiple design points can be created with statistical sampling on given design spaces and solved by distributed high performance computers. Response surfaces can then be created with the solution from the design points and used for multi-objective optimization. To demonstrate the optimization workflow, multiple parameters for a motor design similar to the Prius motor are created.
Technical Paper

Noise and Vibration End-of-Line Production Testing and Analysis Challenges

2019-06-05
2019-01-1464
Theoretical modeling continues to play a larger role in noise and vibration engineering; however, until products are perfectly made, there will be a need to evaluate their end of line (EOL) performance. Manufacturing production of a wide range of items has classically involved some amount of subjective and/or evolved objective quality testing along the line or at the end of the line. This testing can have goals of determining product safety, durability, functionality, or the vibration/sound quality. A vibration-based measurement approach is often used for many of those goals. Often, many modern products utilize some combination of electric motors, internal combustion engines, and power transmission rotational components. The EOL testing for many of these rotational components is after many years now heavily refined in the measurement and analysis methods, and the separation of good, bad and marginally bad samples may not always be challenging.
Technical Paper

A Computational Process to Effectively Design Seals for Better Wind Noise Performance

2019-06-05
2019-01-1472
Ability to assess noise transmitted through seals to cabin interiors early in the design process is very important for automotive manufacturers. When seal design is inadequate, noise transmitted can dominate the interior noise, making the wind noise performance of the vehicle unacceptable. This may cause launch delays costing a great deal of money and loss of sales. Designing seals using conventional experimental processes is challenging, since the location and strength of flow noise sources are not known when the seal design is planned. Making changes to the seal system after the tooling stage is expensive for OEMs, as the supplier must cover tool and redesign costs. Deliberate overdesign by adding multiple layers of seals everywhere reduces profit by raising part and manufacturing costs.
Technical Paper

Structure-borne prediction on a tire-suspension assembly using experimental invariant spindle forces.

2019-06-05
2019-01-1541
Road induced noise is getting more and more significant in context of the electrification of the powertrain. The automotive industry is seeking for technologies to predict the contribution of vehicle components upfront, early in the development process. Classical Transfer Path Analysis (TPA) is a well-established technique that successfully identifies the transmission paths of noise and vibration from different excitation sources to the target responses, but has some drawbacks, such as that it requires the physical availability of the vehicle. To achieve shorter development cycles, avoid costly and time-consuming design iterations, and due to the limited availability of prototypes, engineers derived a method that addresses these requirements.
Technical Paper

Fatigue Life of Electronic Power Steering Control Unit (EPCU) under Mechanical Vibration loads.

2019-06-05
2019-01-1536
In current scenario, we have challenges in vibration testing on the electronics product considering the cost of testing, time taken for each prototype, pre-conditions and environment effects. Having said this, we have made technical advancement with the use of technology through finite element analysis (FEA) and computer methods. We had a challenging problem for Electronic Power Steering Control Unit (EPCU) to finalize the designs for harmonic, transient and random vibration loads at operating temperature’s (-30C; 120C) in ±X, ±Y and ±Z directions with respect to car co-ordinate systems as per the test requirements. To solve this complex problem, we proposed finite element analysis and computer methods to finalize the EPCU design where more than 40parts to be validated on the PCB during functional conditions. To start with, we understood the product qualification through test requirement document for the EPCU under mechanical vibrations loads.
Technical Paper

Evaluation of uncertainties in classical and component (blocked force) transfer path analysis (TPA)

2019-06-05
2019-01-1544
In situ component TPA (originally named in situ source path contribution analysis [Elliott et al. J. Sound Vib., 332 (24) (2013)] has been attracting considerable attention recently. The measurements required with the in situ method are almost identical to conventional TPA but there are two major advantages. First, there is no need to dismantle the vehicle or assembly since all measurements are conducted in situ. Secondly, the forces obtained by matrix inversion are the blocked forces which are an independent property of the source component and are therefore transferrable to different assemblies. The current paper extends this idea of mathematically decoupling components from in situ measurements. The in situ measurement of blocked forces is first considered. A substructure decoupling approach is then described from which independent properties (accelerances) of coupling elements and other components can be extracted from in situ measurements.
Technical Paper

Numerical Prediction and Verification of Noise Radiation Characteristics of Diesel Engine Block

2019-06-05
2019-01-1591
To assess contribution of structure-borne noise from the engine, it is critical to characterize dynamic and vibro-acoustic properties of the engine components and assembly. In this paper, a component level study of a three-cylinder diesel engine block is presented. Virtual analysis was done to predict natural frequencies and mode shapes of the engine block at the first step. Then, these results were used to decide the optimum test location and an experimental modal test was conducted on the engine block. The initial virtual model was correlated with test using natural frequencies and mode shapes. Then, the virtual model was updated with damping derived from experimental modal test to match vibration frequency response functions. Further, the virtual model was used for prediction of vibro-acoustic transfer functions. The vibro-acoustic transfer functions were also obtained from test. The results of transfer function were correlated with test.
Technical Paper

New acoustic material for vehicle applications and measurement techniques to determine absorption coefficient for small size test samples

2019-06-05
2019-01-1585
A new sound absorbing material for vehicle applications is presented and acoustic properties are investigated in this paper. The material is made of natural leather collagen and inhibits unique characteristics of genuine leather. Production technology uses the residues of leather industry, is ecofriendly and allows fabrication of the parts of any shape. The price is competitive to synthetic polymers. Absorption coefficient is one of the most commonly used parameters to characterize acoustic properties of materials. There are two main techniques to experimentally determine the absorption coefficient: the impedance tube transfer function method and reverberant room method. In the second case the absorption coefficient is determined at random incident sound field while in the impedance tube only direct incident field is considered. The main advantage of the first method however is the small size of samples.
Technical Paper

Fast accurate non-destructive measurement of absorber impedance and absorption

2019-06-05
2019-01-1584
Cabin acoustic comfort is a major contributor to the potential sales success of new aircraft, cars, trucks, and trains. Recent design challenges have included the increased use of composites, and the switch to electrically powered vehicles, each of which change the interior noise spectral content and level. The role of acoustic absorption in cabins is key to the optimisation of cabin acoustic comfort for modern vehicles, with acoustic impedance data needed in order to assess and optimise the impact of each component of a given lay-up. Measurements of absorbing interior trim are traditionally performed using either sample holder tests in a static impedance tube (impedance and absorption), or through tests in reverberation rooms (absorption only). Both of these procedures present challenges. In-tube absorption and impedance measurements are destructive, requiring highly accurate sample cutting and sealing.
Training / Education

Fundamentals of Threaded Fasteners

2019-04-15
Fastener experts believe that upwards of 95% of all fastener failures are the result of either the wrong fastener for the job or improper installation. Whether this shocking figure is accurate or not, it is irrefutable that threaded fasteners are poorly misunderstood by many in both the fastener and user communities. In October 1990 the USS Iwo Jima suffered a catastrophic steam valve accident minutes after leaving port following repairs to its steam plant. In one of the single most deadly events of Operation Desert Storm, ten of the eleven crewmen present in the engine compartment would lose their lives.
Training / Education

Design for Manufacture and Assembly (DFM/DFA)

2019-04-10
This seminar provides a functional understanding of the principles involved in conducting a Design for Manufacture/Design for Assembly study. DFM/DFA can support both manual and automated processes resulting in significant cost savings through simpler designs with fewer components. Related topics include workstation layouts, ergonomic considerations and errorproofing. Actual examples from the automotive industry are used to support the lecture and participants complete actual design efficiency using the DFM/DFA worksheet.
Technical Paper

Developing high dielectric strength alumina for spark plugs

2019-04-02
2019-01-1192
Engine downsizing and widely adopted Gasoline Turbo Direct injection (GTDi) technology has led to harsher application conditions for spark plugs, which demand insulators with higher dielectric strength to meet the new challenges in modern engine platforms. To improve conventional alumina insulators, the influences of material properties, such as porosity, grain size, glass chemistry and surface finish, on dielectric strength performance are studied. It is also found that, the manufacturing process can greatly impact the final performance. Hence, the effort in optimizing process variables will be discussed and the performance of resultant Autolite HD95 ceramic will be reviewed against those of several leading manufacturers.
Technical Paper

Assessment of a Three-Semester Mechanical Engineering Capstone Design Sequence Based on the SAE Collegiate Design Series

2019-04-02
2019-01-1126
Mechanical engineering seniors at Lawrence Technological University complete a capstone design project: either an SAE collegiate design series (CDS) vehicle or an industry-sponsored project (ISP). Starting in 2015, the Lawrence Tech CDS advisors worked together to redesign the five-credit three-semester sequence. The overall goals of the modifications were to improve student design, project management and communication skills; integrate SAE CDS projects into the curriculum; and increase faculty advisor involvement in the classroom. Initial results from the 2015-2016 academic year showed improvement in the first offering of the new sequence (Mynderse et. al. 2016). Ongoing assessment of course modifications includes faculty advisor observation, student surveys, and direct assessment of student technical output. This work expands on previous results with finalized learning outcomes, resulting session-by-session schedules, and new assessment data.
Technical Paper

Development and Research of Laser Ranging Vehicle Driving Deviation Test System

2019-04-02
2019-01-0926
Before the new car goes offline, due to assembly errors, inaccurate four-wheel positioning, etc., the vehicle will run off on a flat road, which will affect the driving comfort and safety. At present, most automobile manufacturers choose to perform the deviation test in the process of vehicle offline detection. Compared with other detection methods, the online deviation test system is developed with high precision of laser ranging, fast response and good reliability, which can realize fast and high-precision detection of vehicle deviation. In this paper, test system software is based on the LabVIEW platform to develop, a variety of communication methods to build the communication system, using information check and queue task processing to control, to meet the test needs. Firstly, the calculation model of the deviation of the test system is established.
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