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Technical Paper

A Study on the Cyclic Plastic Zone Size Method, ω*, for Digital Fatigue Life Prediction of Arc-Welded Joints

Various prediction methods have been proposed for evaluating the fatigue life of welded joints by combining finite element analysis (FEA) with an experimental database. However, to obtain more universal and accurate fatigue life predictions, it is necessary to have criteria for making integrated evaluations of the fatigue strength of welded joints. This paper presents a study that focuses on the local cyclic plastic zone size (ω*) as the criterion of fatigue strength and investigates its validity. The definition of ω* was given by the relationship between the stress state at the notch tip and the elastic strain which was defined along the strain-life fatigue curve (ε - N diagram) of a base metal. As a result of using ω*, it was found that an integrated fatigue life prediction was possible to a certain extent for notch and arc-welded joint specimens.
Technical Paper

Collapse of Thin-Walled Curved Beam with Closed-Hat Section - Part 2: Simulation by Plane Plastic Hinge Model

This paper describes a calculating method to predict the quasi-static collapsing behaviors of spot-welded closed-hat section curved beams under axial compression. The overall deformat ions and the local buckling modes of beams were calculated using a geometrical model. Force-displacement relations were predicted by a elastic-plastic structural analysis method using the ‘plastic hinge’ concept. Collapsing tests were made on beams which are differenting section size, rotation angle, and metal sheet thickness. Comparisons between the calculated and experimental results of deformed shapes of beams, the local buckling modes and the force displacement relations are discussed.
Technical Paper

Application of FEM and Evaluation Method for Connecting Rod Design

A structural analysis for the connecting rod was performed in consideration of bearing crush, oil clearance and initial deformation of the big end bore caused by tightening force of the rod bolts. This analysis enabled to calculate not only the bearing pressure distribution but also the three-dimensional stress state with accuracy. A new fatigue criterion for multi-axial out-of-phase stress was proposed by using mean stress tensor and alternating stress tensor of complex number in this study. This criterion was developed to improve the classical multi-axial “yield criteria”. This criterion is simple, comprehensive and suitable for the evaluation of three-dimensional FEM results. The connecting rods exhibiting high reliability under severe conditions were investigated through the stress analysis and the new evaluation criterion.
Technical Paper

Development of Four-Cyele Engine for Motorcycle

To improve performance of motorcycle 4 cycle 250 cc engine, we examined the following. (1) We improved crank balance so that friction loss of crank shaft was reduced. (2) We reduced air intake resistance and improved exhaust system so that volumetric efficiency was increased. (3) We reduced weight of valve system parts so that maximum RPM was increased. As these improvement, we have achieved 33.1 kw/15000 RPM and torque increase in low and middle RPM range for motorcycle 250 cc engine on 1989 year model.
Technical Paper

U-Shaped Radiator for Motorcycle

Motorcycles arrange the radiator in front of the engine. So, the size of radiator is not wider than the width of engine or the width of frame. We design the motorcycle similar to road-racer. We hope that the width of radiator is as narrow as possible, because motorcycle can run as fast as possible. So, it is necessary that the width of engine and frame is narrow as much as we can, and the width of radiator is limited. But for the water-cooled engine, the temperature of coolant has better be low so as to product the effective combustion. So, it is necessary that the width of radiator has better be wide, but it contradict the above. “U-Shaped Radiator” solves the above problem. The structure is that radiator bends U-form in the front of motorcycle. Now we can improve the cooling performance (+30%) in comparison with the same width radiator.
Technical Paper

Development and Current Status of the New CAD System “SCADEM-2”

The CAD/CAM system, named “SCADEM-2”, in Suzuki Motor Co., Ltd. Motorcycle Engineering Division was developed, based on the old system “SCADEM”. 3D CAD/CAM system “SCADEM-2” is more accessible for operating, more speedy for processing and more complete for generating figures than the old system. Since this system opened in 1987, has been popularly used by most designers of Motorcycle Engineering Division. It's main functions are Design (3D), Drafting (2D), Electrical Schematic, and FEM Processing.
Technical Paper

Heat Resisting Plasma Spray Coating on a Cylinder Head of Aluminum Alloy

A new method was developed to help determine the conditions that would create adhesion strength of heat-resisting coatings formed in plasma spraying. This method is a combination of an experiment design that uses a Latin square and multiple regression analysis. Since it allows the direct analysis of experimental data, conditions can be determined in one third of the number of tests required by conventional experimental methods. The multiple regression equation gained through this study is also effective in comparing the heat resistance of the heat-resisting coating.
Technical Paper

An Analysis of 3 Pt. Belted Occupant Impact Dynamics in Frontal Collision and its Application

3-point belted occupant impact dynamics in frontal collision has been analyzed using finite element method (FEM) computer simulation models. The results from this simulation were compared with experimental results obtained from dummies on sleds or in small size car frontal crash tests. The correlation between the simulation and the experiments in terms of the head injury criterion (HIC), head acceleration, chest acceleration, and dummy motion and kinematics was relatively good. It was confirmed that dummy impact dynamics was influenced by the structure and the geometrical lay-out of the belt system, the seat belt webbing elongation rate, and the seat cushion hardness. The simulation method and dummy impact dynamics were also used, to a lesser extent, to analyze the performance of 2-point seat belt and air bag systems.
Technical Paper

Outline of Ultra Light Weight Vehicle and Its Body Design

This paper presents the evolution of the unique Japanese mini-car (K class vehicle), starting from the social needs and early legal requirements, and the features of the vehicle combined with prospective subjects to be an international commodity. This paper also describes the body design process of the Suzuki Alto/Fronte to illustrate the design of a modern K class vehicle.
Technical Paper

Suzuki Production Rotary Engine, Model RE-5 for Powering Motorcycles

This paper describes the technical data on the development of rotary engine, Model RE-5 which is designed to power motorcycle, and has a piston displacement of 497 cc in a single rotor. During the process of development, a number of problems such as combustion variation on low-load, cracking of the stationary gear, oil consumption and etc. were solved. Moreover, we made a success of discovering most suited structure of plug located on the trailing side to prevent fouling and preignition.