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Training / Education

Design for Manufacturing & Assembly (DFM/DFA)

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

Design for Manufacture and Assembly (DFM/DFA)

This seminar provides both a functional understanding of the principles involved in conducting a Design for Manufacture/Design for Assembly (DFM/DFA) study and the process for implementing a DFM/DFA culture into the organization. DFM/DFA principles can apply to both manual and automated processes resulting in significant cost savings through not only simpler designs with fewer components but also analyses workstation setup and workflow, part orientations during build, and design considerations such as component placement, tolerancing and servicing considerations.
Technical Paper

Data-based Process-Integrated 3D-Measurements of Magnesium Parts for Lightweight Car Body Construction

The aim of a research project was to develop a system for the analysis, processing and addressing of data flows of process-integrated 3D-measurements of magnesium workpieces for car body construction and its prototypical application. By applying optical measuring methods for quality control and using object-specific measurement for process control, considerable savings of energy and other resources can be achieved in automotive engineering. The QM standards for measuring systems for forming processes in the automotive sector place high demands on accuracy and measuring speed. By using multi-camera systems, clock rates of less than 10 seconds and accuracies of 30-40 μm over the entire measuring range can be guaranteed. The modular design of a system facilitates process integration due to the relatively low effort required for different manufacturing tasks. The performance analysis of the measuring system and the process landscape design were carried out.

SAE Truck & Off-Highway Engineering: April 2021

Material selection for battery enclosures Mass reduction is the main reason BEV makers choose aluminum for battery enclosures, but cost and thermal requirements favor steel and polymer composites. Startup targets medium-duty EVs Atlis Motors purpose-engineers nearly all the vital components for an electric pickup and platform capable of spanning several market segments. High-voltage hybrids FEV engineers evaluate 48V and high-voltage parallel hybrid architectures for Class 6-7 commercial vehicles. Certain setups show more promise than others. Hemphill's mission: Support the innovation ecosystem Schaeffler America CTO Jeff Hemphill brings impressive technical chops and well-honed communication skills to his new role as 2021 SAE International president.
Technical Paper

Application of quality tools to reduce pneumatic leaks in the commercial vehicle brake system.

This article describes a case study applied in a commercial vehicle company, with a focus on analyzing and reducing process failures generated in the products' pneumatic brake system. The production method of the assembly line based on the concept of flexible sequencing, with alternation of models, which makes the assembly of the brake system complex, contributing to a potential scenario of failures such as leaks and loss of efficiency of the brake system. The methodology used based on the DMAIC method (Define, Measure, Analyze, Improve, Control) for failure analysis, together with Quality Tools, such as Brainstorming, Ishikawa, and Pareto Diagram.
Technical Paper

Design of a Mono-Leaf in Sandwich Structure for Application in Light-Load Vehicle Using Finite Element Method

This paper aims to present the design of a mono-leaf in steel/composite sandwich structure (epoxy/glass fiber). The automotive main challenges now-a-days are fuel economy and CO2 emission reduction. To achieve such goals, the usage of new materials and design optimization procedures are required. This research focuses on light-load commercial vehicles, in special, rear suspension. Leaf springs are the key components of such suspension. Therefore, the design optimization procedure developed is centered into leaf spring weight reduction. The design optimization procedure was bounded by industry regulatory standards and base on analytical and numerical experiments. Once the design phase is completed, a finite element analysis was performed using ANSYS Workbench®. The finite element analysis not only provided a detailed mapping of stress and displacement fields, but it also allowed to identify possible regions of failures.
Journal Article

Design and Optimization of Forced-Air Cooling System for Commercial Vehicle Brake System

Abstract To maintain the vehicle speed in a proper range, the commercial vehicle needs to brake frequently on a downhill path. The drum brake system of the medium- and heavy-duty commercial vehicles often faces the danger of brake fade, which reduces brake efficiency or even causes braking failure. They are critical potential risks on the road. The kinetic energy is transferred into thermal energy during the braking process. The temperature rises dramatically during the braking process due to the massive thermal energy caused by the huge mass of the commercial vehicle. The brake efficiency and the life of the brake drum will decrease with the rising temperature. A malfunction of the brake system may occur if the drum brake is overheated. To improve the cooling efficiency of the drum brake, a forced-air cooling system driven by the air compressor in the diesel is designed for the drum brake system after the analysis of its thermal model.
Journal Article

Effects of Ambient Oxygen and Density on Primary Soot Size under Diesel-Like Conditions Using a Lagrangian Soot Tracking Model

Abstract This article investigates the effect of ambient oxygen (O2) levels and ambient density on the primary soot size under diesel engine-like conditions via the Lagrangian soot tracking (LST) method. The numerical studies and soot analysis are carried out for an n-heptane spray flame in the Sandia constant volume combustion chamber. Numerical studies are carried out at two O2 levels of 15% and 12%, as well as two ambient densities of 14.8 kg/m3 and 30 kg/m3. The LST model involves treating the soot particles formed in the spray flame as Lagrangian particles, and their individual soot information is stored. Based on the primary soot size distribution for soot particles in the core of the spray jet, an increase in ambient density from 14.8 kg/m3 to 30 kg/m3 is shown to increase the peak and mean soot size by a factor of 1.5. Furthermore, the peak and mean primary soot size decreases with decreasing O2 levels from 15% to 12%.