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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

Introduction to Car Hacking with CANbus

2019-12-19
Vehicle cybersecurity vulnerabilities could impact a vehicle's safe operation. Therefore, engineers should ensure that systems are designed free of unreasonable risks to motor vehicle safety, including those that may result due to existence of potential cybersecurity vulnerabilities. The automotive industry is making vehicle cybersecurity an organizational priority.
Training / Education

Fundamentals of Threaded Fasteners

2019-12-18
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

Introduction to Airframe Engineering Design for Manufacturing, Assembly and Automation

2019-12-16
Why is a design for manufacturing, assembly and automation so important?  This introductory course on airframe engineering will cover the importance of design for manufacturing, assembly and automation in aerospace.  It will review what the key drivers are for a “good” design and some of the key points for manufacturing and assembly of aircraft components.    It will look at how an engineer can combine traditional technologies with new, cutting-edge technologies, to determine the best scenario for success.  
Technical Paper

To establish the correlation in between Computer Aided Engineering & physical testing of automotive parts returnable case (Stacktainer).

2019-11-21
2019-28-2569
Automotive returnable cases (Stacktainers) are being used to transport the automotive parts through surface & seaways. No automotive manufacturer wants to spend money on woods, paper & cardboard again and again, it`s better to pay once for robust & reusable cases. these provide better protection to parts from its manufacturing to assembly line of vehicle. While transporting, any kind of crack or failure of returnable cases may lead to loss of money, human & time. To ensure the safety, these pallets have to be validated for vibrations coming from surface irregularities, sea waves & load due to stacking of cases one above other. The objective of this study is to establish a correlation in between the physical testing & simulation in Computer added Engineering (CAE) of automotive returnable case (Stacktainers). There are different types of tests considered to validate the returnable case, rough road evaluation, Multi-axial Vibration & strength evaluation.
Technical Paper

FABRICATION AND WEAR CHARACTERISTICS BASALT FIBER REINFORCED POLYPROPYLENE MATRIX COMPOSITES

2019-11-21
2019-28-2570
Generally brake pads are manufacturing by use of asbestos materials, these materials are chemically harmful and toxic, affects human health. The present investigation fabricates polypropylene composites with mixing constant volume [5 Vol.%] of alumina nano particles and different volume percentages [0%, 5%, 10% & 15%] of basalt fibre by hand layup compression technique. The wear characteristics of polypropylene matrix composites were tested by dry sliding condition using pin on disc apparatus configuration with hardened steel counter-face at elevated temperature. The load was applied 30N to 70N with the interval of 20N and varying of sliding speed 300 rpm to 900rpm with the interval of 300rpm for the time period of 0-180 sec. The wear rate was decreases with addition of alumina nano particle and also increases the frictional force for the effect of basalt fibre content present in the composites. The co-efficient of friction was increases from 0.1 to 0.66 under normal loading condition.
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

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

MOLD IN COLOR DIAMOND WHITE ASA MATERIAL FOR AUTOMOTIVE EXTERIOR APPLICATION

2019-11-21
2019-28-2562
In this paper, mold in color diamond white ASA material has been explored for front bumper grill, fender arch extension and hinge cover applications. Other than aesthetic requirements, these parts have precise fitment requirement under sun load condition in real world usage profile. Structural durability of the design was validated by virtual engineering. Part design and material combinations with better tooling design iterations were analysed by using mold flow analysis. Complete product performances were validated for predefined key test metrics such as structural durability, thermal aging, cold impact, scratch resistance, and weathering criteria. This part met required specification. This mold in color ASA material-based parts has various benefits such as environmentally friendly manufacturing by eliminating environmental issues of coating, easily recycled, and faster part production because intended color achieved in one step during molding.
Technical Paper

Load Distribution Optimization of seatbelts using validated finite element approach.

2019-11-21
2019-28-2575
The seat belt system is one of most imperative component of the safety instrument family in a vehicle. The main purpose of seat belt is to minimize the injuries by preventing the occupant from impacting hard interior parts of the vehicle and also the passenger from being thrown-out from the vehicle in case of rollover accidents. The standard three-point belts, mounted to the vehicle in three places, namely anchor, D ring and buckle. The position of D ring is very important to distribute the impact load evenly to the occupants. Very high load in any of these locations could cause breakage of the mountings and also concentrated loading on the occupant chest of pelvis. This study mainly focuses on the seatbelt assembly performance improvement against ECE-R16 sled test. The sled test was carried out first using 28g peak acceleration pulse and measurement of forces at shoulder and anchor position was measured using the load cell.
Technical Paper

Development of low cost closed crankcase ventilation with oil mist separation system on light duty diesel engine.

2019-11-21
2019-28-2578
Currently automotive industry is facing bi-fold challenge of reduction in Greenhouse gases emissions as well as low operating cost. On one hand Emission regulations are getting more and more stringent on other hand there is major focus no customer value proposition. Engine blow by gases are one of the source of Greenhouse gases emission from engine. Blow by gases not only consist of unburn hydrocarbons but also carry large amount of oil. If oil is not separated from these gases, it will led to major oil consumption and hence increase total operating cost of Vehicle. In this paper, effort has been taken to develop a low cost closed crank case ventilation with oil mist separation system on diesel engine.
Technical Paper

ENHANCE STRENGTH, ACCURACY AND PRECISION OF THE 3D PRINTED ASSEMBLY AID GAUGES

2019-11-21
2019-28-2568
ENHANCE STRENGTH, ACCURACY AND PRECISION OF THE 3D PRINTED ASSEMBLY AID GAUGES Ramesh Kavalur1, Raghavendra Rao 1 1 Body in White, Manufacturing Engineering, General Motors Technical Centre India Pvt. Ltd, India, Keywords - Additive manufacturing, assembly aid gauges, 3D printer. Research Objective - Automotive manufacturing impressively implementing 3D printed jigs and fixtures. Traditional manufacturing of metal assembly aid gauges have limitations such as lead time and causes dent and rough marks on the outer panel of the body. On the other hand, 3D printed jigs and fixtures, demands more time (depends on complexity), have low level of precision and they offer lower strength. It is observed that this occurs because of the inefficient design and manufacturing without understanding the functionality and capability of the 3D printer.
Technical Paper

FOUR WAY ADJUSTABLE HEAD RESTRAINT SYSTEM

2019-11-21
2019-28-2528
To reduce the incidence of whiplash-associated disorders caused by rear impacts, head restraints should be closer to the head which decreases the amount of relative motion and it is believed to reduce the risk of soft tissue neck injury. Drivers are raising complaints that the head restraint causes discomfort by interfering with their preferred head position, forcing them to select a more reclined seat back angle [1]. This paper is about the importance of head restraint system and how it can be improved by adjusting the angle between the head restraint and passenger`s head. It is essential to carry out research on head restraint that can be adjusted in forward and backward direction letting the cost of seats remain in budget.
Technical Paper

THE NEED OF PERSONALIZATION AND OPPORTUNITIES IN AUTONOMOUS VEHICELS AND SHARED MOBILITY

2019-11-21
2019-28-2520
Shared mobility and Autonomous shared mobility take major share in Mobility 4.0. Personalization in a shared mobility will play a significant role in customer engagement in Autonomous world. In case of personal vehicle each customer will have their own personal settings in their own vehicle; in case of Autonomous shared mobility or shared mobility, we can satisfy individual customer need only by personalizing the vehicle for each individual user needs. This will give a cognitive feel of personal vehicle in a shared environment. We need technologies in improving vehicle interior and exterior systems and design to address personalization. We will be discussing on feasible opportunities of personalization and with illustrations in Vehicle Interior Cabin Space, Seat comfort, Compartments, Vehicle interior & Exterior Access / Controls.
Technical Paper

Potential for Emission Reduction and Fuel Economy with Micro & Mild HEV

2019-11-21
2019-28-2504
The development of modern combustion engines (spark ignition as well as compression ignition) for vehicles compliant with future oriented emission legislation (BS6, Euro VI, China 6) has introduced several technologies for improvement of both fuel efficiency as well as low emissions combustion strategies. Some of these technologies as there are high pressure multiple injection systems or sophisticated exhaust gas aftertreatment system imply substantial increase in test and calibration time as well as equipment cost. With the introduction of 48V systems for hybridization a cost-efficient enhancement and, partially, an even attractive alternative is now available. An overview will be given on current technologies as well as on implemented or simulated vehicle concepts for light duty gasoline and diesel powertrains.
Technical Paper

SIMULATION OF SOFTENING AND RUPTURE IN MULTILAYERED FUEL TANK MATERIAL

2019-11-21
2019-28-2557
Research and/or Engineering Questions/Objective Plastic automotive fuel tanks made up of blow molded, multi-layered, high-density polyethylene (HDPE) material can take complex shapes with varying thickness. Accidental drop of fuel tank from a height during handling can lead to development of cracks. Damage can also occur due to an impact during a crash. This can be catastrophic due to flammability of the fuel. The objective of this work is to characterize and develop a failure model for the fuel tank material to simulate damage and enhance predictive capability of CAE for chassis and safety load cases. Methodology Different aspects were considered to develop a characterization and modelling strategy for the HDPE fuel tank. Material properties can be influenced by factors such as, service temperature, rate of deformation, state of stress etc.
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

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

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.
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