This course is verified by Probitas Authentication as meeting the AS9104/3A requirements for continuing Professional Development. In the Aerospace Industry there is a focus on Defect Prevention to ensure that quality goals are met. Failure Mode and Effects Analysis (PFMEA) and Control Plan activities are recognized as being one of the most effective, on the journey to Zero Defects. This two-day course is designed to explain the core tools of Design Failure Mode and Effects Analysis (DFMEA), Process Flow Diagrams, Process Failure Mode and Effects Analysis (PFMEA) and Control Plans as described in AS13100 and RM13004.
Bio-composites have gained significant attention within the aerospace industry due to their potential as a sustainable solution that addresses the demand for lightweight materials with reduced environmental impact. These materials blend natural fibers sourced from renewable origins, such as plant-based fibers, with polymer matrices to fabricate composite materials that exhibit desirable mechanical properties and environmental friendliness. The aerospace sector's growing interest in bio-composites originates from those composites’ capacity to mitigate the industry's carbon footprint and decrease dependence on finite resources. This study aims to investigate the suitability of utilizing plant derived flax fabric/PLA (polylactic acid) matrix-based bio-composites in aerospace applications, as well as the recyclability potential of these composites in the circular manufacturing economy.
Selective Laser Melting (SLM) has gained widespread usage in aviation, aerospace, and die manufacturing due to its exceptional capacity for producing intricate metal components of highly complex geometries. Nevertheless, the instability inherent in the SLM process frequently results in irregularities in the quality of the fabricated components. As a result, this hinders the continuous progress and wider acceptance of SLM technology. Addressing these challenges, in-process quality control strategies during SLM operations have emerged as effective remedies for mitigating the quality inconsistencies found in the final components. This study focuses on utilizing optical emission spectroscopy and IR thermography to continuously monitor and analyze the SLM process within the powder bed, with the aim of strengthening process control and minimizing defects.
In applications demanding high performance under extreme conditions of pressure and temperature, a range of Mechanically Attached Fittings (MAFs) is offered by various Multinational Corporations (MNCs). These engineered fittings have been innovatively designed to meet the rigorous requirements of the aerospace industry, offering a cost-effective and lightweight alternative to traditional methods such as brazing, welding, or other mechanically attached tube joints. One prominent method employed for attaching these fittings to tubing is through Internal Swaging, a mechanical technique. This process involves the outward formation of rigid tubing into grooves within the fitting. One of the methods with which this intricate operation is achieved is by using a drawbolt - expander assembly within an elastomeric swaging machine.
This course is verified by Probitas as meeting the AS9104/3A requirements for Continuing Professional Development. This course 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.
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 course, you will not only learn the Boothroyd Dewhurst Method, you will actually apply it to your own product design!
Often, when assessing the distraction or ease of use of an in-vehicle task (such as entering a destination using the street address method), the first question is “How long does the task take, on average.” Mean static (while parked) task times can be estimated by summing times for the included task elements (e.g., press a button) from SAE J2365 or similar datasets. Times for the occlusion conditions in J2365 and the NHTSA Distraction Guidelines can be determined using Pettit’s Method or Purucker’s Method. These first approximations of mean task times are reasonable and can be determined quickly. The next question usually is “How likely is it that the task will exceed some limit.” Discrete event simulations such as IMPRINT can provide the answer. Unfortunately, those simulations require the distribution types and parameters (mean, standard deviation, etc.) for each task element, which generally are not available in the published literature for in-vehicle tasks (e.g., SAE J2365).
Multiple experimental studies were performed on galling intiation for variety of tooling materials, coatings and surface treatments, sheet materials with various surface textures and lubrication. Majority of studies were performed for small number of samples in laboratory conditions. In this paper, the methodology of screening experiment using different combinations of tooling configurations and sheet material in the lab followed by the high volume small scale U-bend performed in the progressive die on the mechanical press is discussed. The experimental study was performed to understand the effect of the interface between the sheet metal and the die surface on sheet metal flow during stamping operations. Aluminum sheet AA5754 2.5mm thick was used in this experimentation. The sheet was tested in laboratory conditions by pulling between two flat insert with controllable clamping force and through the drawbead system with variable radii of the female bead.
Characterization of Embedded Debris Particles on Failed Crankshaft Bearings Jianghuai Yang, Qigui Wang, Zhe Li Materials Engineering & Additive Design & Manufacturing, General Motors Co., LLC Crankshaft bearings serve the function of maintaining the lubrication oil films needed to support the crankshaft journals in hydrodynamic regime of rotation. Discontinuous oil films will cause the journal-bearing couple to be in a mixed or boundary friction condition, or even a bearing seizure or a spun bearing. This condition may further force the crankshaft to break and an engine shutdown. Spun bearings have been identified to be the top reason in engine warranty replacement. Excessive investigations have found large, embedded hard debris particles on the bearings are inevitably the culprit of destroying continuity of the oil films.
Since the popularization of the Electric Vehicle (EV) there has been a large movement of consumers, governments, and the automotive industry due to its environmentally friendly characteristics. Unlike an IC engine, the batteries use multitudes of rare earth minerals and complex manufacturing processes which in some cases have been shown to produce as many emissions as an ICE vehicle over its entire lifespan. Another unnoticed important environmental concern has been the final recycling and disposal of the power train after its use. Unlike an ICE engine, which can be melted down or re-used, recycling batteries are much more difficult. In most cases the recycling process and the byproducts produced can be very harmful to the environment. This paper aims to be a complete cradle-to-grave analysis of all emissions produced in the life of an EV battery.
A fundamental study on ductility of high strength steels in crash deformation is carried out to investigate the effect of local ductility of various materials on crash performance considering pre-strain produced by the press forming process. In this study, newly developed 980 MPa-grade QP (quenching and partitioning) steels are investigated to clarify the advantage of crash performance compared to conventional DP (Dual Phase) and TRIP steels. The features of QP steel are higher yield strength and higher local ductility due to the optimized microstructure. Axial crash tests are performed to evaluate the crashworthiness of different types of steel Based on the experimental results, the effect of the local duality of the preceding high-strength steel on the risk of material fracture is discussed. In this paper, a newly bending testing method (orthogonally reverse bending, ORB) is proposed to simulate the fracture during crash deformation considering press forming strain.
With the advent of this new era of electric-driven automobiles, the simulation and virtual digital twin modeling world is now embarking on new sets of challenges. Getting key insights into electric motor behavior has a significant impact on the net output and range of electric vehicles. In this paper, a complete 3D CFD model of an Electric Motor is developed to understand its churning losses at different operating speeds. The simulation study details how the flow field develops inside this electric motor at different operating speeds and oil temperatures. The contributions of the crown and weld endrings, crown and weld end-windings, and airgap to the net churning loss are also analyzed. The oil distribution patterns on the end-windings show the effect of the centrifugal effect in scrapping oil from the inner structures at higher speeds. Also, the effect of the sump height with higher operating speeds are also analyzed.
Heavy vehicles such as construction machinery generally require a large traction force. For this reason, axle components are equipped with a final reduction gear to provide a structure that can generate a large traction force. Basic analysis of vertical load, horizontal load (traction force), centrifugal force, and torsional torque applied to the wheels of heavy vehicles such as construction machinery and industrial vehicles, as well as actual working load analysis during actual operations, were conducted and compiled into a load analysis diagram. The loosening tendency of wheel bolts and nuts that fasten the wheel under actual working load was measured, and the loosening analysis method was presented. The causes of wheel fall-off accidents in heavy trucks, which have recently become a problem, were examined. Wheel bolts are generally tightened by the calibrated wrench method using a torque wrench.
In electric vehicle applications, the majority of the traction motors can be categorized as Permanent Magnet (PM) motors due to their outstanding performance. As indicated in the name, there are strong permanent magnets used inside the rotor of the motor, which interacts with the stator and causes strong magnetic pulling force during the assembly process. How to estimate this magnetic pulling force can be critical for manufacturing safety and efficiency. In this paper, a full 3D magnetostatic model has been proposed to calculate the baseline force using a dummy non-slotted cylinder stator and a simplified rotor for less meshing elements. Then, the full 360 deg model is simplified to a 90deg quarter model based on motor symmetry to save the simulation time from 2 days to 4 hours. A rotor position sweep was conducted using the quarter model to find the max pulling force position. The result shows that the max pulling force happens when the rotor is 1mm overlapping with the stator core.
A crucial component utilized in the trunk space is the luggage board. Positioned at the bottom of the trunk, the luggage board separates the vehicle body from the interior and provides support for luggage.The luggage board serves multiple functions, including load-bearing stiffness for luggage, partition structure functionality, noise insulation, and thermal insulation. To meet the increasing demand for luggage boards in response to the changing market environment, there is a need for a competitive new luggage board manufacturing method. To address this, the "integrated sandwich molding method" is required. The integrated sandwich molding method utilizes three key methodologies: grouping processes to integrate similar functions, analyzing materials to replace them with suitable alternatives, and overcoming any lacking functionality through integrated design structures.
Side doors are pivotal components of any vehicle, not only for their aesthetic and safety aspects but also due to their direct interaction with customers. Therefore, ensuring good structural performance of side doors is crucial, especially under various loading conditions during vehicle use. Among the vital performance criteria for door design, torsional stiffness plays an important role in ensuring an adequate life cycle. This paper focuses on investigating the impact of several door structural parameters on the torsional stiffness of side doors. These parameters include the positioning of the latch, the number of hinge mounting points on doors (single or double bolt), and the design of inner panel with or without Tailor Welded Blank (TWB) construction.
A lot of parts about 20,000 to 40,000 are composed of a car. When developing new car, design, manufacturing, cost, quality control and etc. are reviewed for these parts. In order to develop parts with low price and high quality, various factors such as design, manufacturing and cost need to optimize specifications for each part in development stage. In particular, this optimization is most effective when it is done at the design stage. A comprehensive review should be made based on various information such as design, manufacturing and cost for each component to optimize these specifications. However, the information is managed separately by each development department, so access to the information is limited. In addition, there are many inefficiencies in generating, searching, analyzing and processing the information.
The wear of the piston ring-cylinder liner system in gasoline engines is inevitable and significantly impacts fuel economy. Utilizing a custom-built linear reciprocating tribometer, this study assesses the wear resistance of newly developed engine cylinder coatings. The custom device offers a cost-effective means for tribological evaluation, optimizing coating process parameters with precise control over critical operational factors such as normal load and sliding frequency. Unlike conventional commercial tribometers, it ensures a more accurate simulation of the engine cylinder system. However, existing research lacks a comprehensive comparative analysis and procedure to establish precision limits for such modified devices. This study evaluates the custom tribometer's repeatability compared to a commercial wear-testing instrument, confirming its potential as a valuable tool for advanced wear testing on engine cylinder samples.