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New methods are required for implementing the proliferation and sophistication of electronic controls and features to meet the customer's quality expectations. Vehicle electronic integration provides a potential solution for reconciling the seemingly contradictory objectives of high quality at reasonable cost. No module can be considered independently with this global approach. OEM subsystem and component suppliers' devices will need to play in concert with the overall vehicle's electrical/electronic strategy. Some new, separately packaged electronic features may eventually be assimilated within the framework of other electronic controllers.

Seats play an important role in determining customer satisfaction and safety. They also represent three to five percent of the overall vehicle cost and weight. Therefore, automotive manufacturers are continuously seeking ways to improve the areas of comfort, safety, reliability, cost and weight within the seat system. The purpose of this paper is to review the development of an automotive front seat constructed of injection molded nylon frames and metal mechanisms. This development program was initiated for the purpose of reducing vehicle weight while increasing the reliability and safety of the front seats. This paper will review the material and process selection decision, a design overview, the performance criteria and the results of tests performed on the injection molded front seats.

Resin transfer molding (RTM) is the process of choice for the Body Panels of the Viper Sports car. The objective of this paper is to outline the reasons for the choice of RTM, and discuss development of technology for Class A surfaces and the paint system. Accomplishments to date and finally the work yet to be completed will also be defined. Conclusions from the work to date indicate that the RTM process enables a reduction in vehicle development time through faster prototypes and tool build times and that high quality, Class A surfaces can be successfully achieved even with epoxy tools. Additional work is ongoing to reduce cycle times and finishing costs, and to improve the in-process dimensional stability.

This paper describes the development of a rubber-like skin Finite Elements Model (FEM) for the Hybrid III headform and an experimental method to determine its material properties. The finite element modeling procedures, using material parameters derived from tests conducted on the headform skin (rubber) material, are described. Dynamic responses and computations of HIC using the developed headform model show that an Elastic-Plastic Hydrodynamic (EPH) material model of the rubber can be used for headform impact simulations. The results obtained from the headform simulation using an EPH rubber material model and drop tower tests of the headform on both a rigid and a deformable structure will be compared, in order to show the applicability of the EPH model.

Fastener failure due to hydrogen embrittlement is of significant concern in the automotive industry. These types of failures occur unexpectedly. They may be very costly to the automotive company and fastener supplier, not only monetarily, but also in terms of customer satisfaction and safety. This paper is an overview of a program which one automotive company initiated to minimize hydrogen embrittlement in fasteners. The objectives of the program were two-fold. One was to obtain a better understanding of the hydrogen embrittlement phenomena as it relates to automotive fastener materials and processes. The second and most important objective, was to eliminate hydrogen embrittlement failures in vehicles. Early program efforts concentrated on a review of fastener applications and corrosion protection systems to optimize coated fasteners for hydrogen embrittlement resistance.

Hand dismantling of certain automotive parts has been an accepted process to remove high value materials, but in large scale recycling this may not be economical. In plastics, a pure non contaminated material stream is critical for maintaining high material values and this means designing plastic parts that can be machine separated. One candidate for separating the plastics in vehicle subsystems such as instrument panels and door trim panels is density separation. In order to better understand what processes are required to develop design requirements for automated plastic separation methods Chrysler and the Vehicle Recycling Partnership have undertaken a major materials separation study with MBA Polymers. In this paper, we describe the material separation methods and the application of these methods to three automotive interior assemblies.

With the increasing demand to improve recyclability of automobiles worldwide the Vehicle Recycling Partnership (VRP) a cooperative effort among Chrysler, Ford and General Motors has been formed. The VRP has been developing preferred practices for improvement of recyclability for future vehicle subsystems. These preferred practices are intended to assist engineers and designers in improving recyclability without impairing the performance of the subsystem. This paper discusses the practices of specific design for recycling of plastic bumper fascia systems and what the designer should consider in developing a design to improve and maximize recyclability.

The commercial validation of a optimized RRIM polyurethane substrate with a novel barrier coat for fascia applications is reviewed which creates cost competitiveness to thermoplastic olefins (TPO), without sacrificing performance. Meeting fascia performance requirements with thinner and lighter RRIM materials containing recyclate and the subsequent application of a barrier coat eliminating the traditional primecoat cycle was investigated.

Environmental costs are a delayed financial burden that result from product decisions made early in the product life cycle--early material choices may create regulatory and waste management costs that were not factored into the acquisition cost. This paper outlines a step-wise approach to determine decision points; environmental, health, safety and recycling (EHS&R) cost drivers that affect decisions; and sources of information required to conduct a Life Cycle Management (LCM) review. Additionally, how LCM fits into the larger concurrent engineering framework is illustrated with an electrocoat primer example. Upstream and downstream supply chain processes are reviewed, as well as organizational challenges that affect the decision process.

The object of this paper is to present an overview of the procedure leading to the selection of suspension system pivot points, show how to resolve terrain and maneuver loads at the tire contact patch to the vehicles' structure, illustrate the modeling technique used for stress analysis of suspension system components, and illustrate a few examples of suspension system models used to aid in the solution of ride and handling problems.

A SIMPLE method of predicting truck performance in terms of grade ability at a given road speed, taking into consideration rolling resistance, air resistance, and chassis friction is presented here. A brief review of fundamental considerations is given first, then the method recommended for predicting vehicle ability at a selected speed, and finally a few words on the prediction of maximum possible road speed and selection of gear ratios. The basis of the solution is the determination and expression of vehicle resistances in terms of horsepower - that is, in terms of forces acting at a velocity. A convenient method of solving the grade problem at a given speed is by means of a tabular computation sheet, which is given, together with tables and charts. These assist in making the computation an easy one as well as giving the necessary data on vehicle resistances.

THIS year the Chrysler Corp. has introduced a new V-8 engine designed to meet market conditions requiring larger displacements. Versions of the basic engine are available in several models of the Corporation's cars. This engine provides increased vehicle performance with excellent economy, durability, and quietness. Emphasis on minimum weight and production economy led to many novel design features which should interest the automotive engineer. The paper will include a review of the overall design considerations, as well as a description and discussion of the engine and its component parts.

An automotive cockpit module is a complex assembly, which consists of components and sub-systems. The critical systems in the cockpit module are the instrument panel (IP), the floor console, and door trim assemblies, which consist of many plastic trims. Stiffness is one of the most important parameters for the plastic trims' design, and it should be optimum to meet all the three functional requirements of safety, vibration and durability. This paper presents how the CAE application and various other techniques are used efficiently to predict the stiffness, and the strength of automotive cockpit systems, which will reduce the product development cycle time and cost. The implicit solver is used for the most of the stiffness analysis, and the explicit techniques are used in highly non-linear situations. This paper also shows the correlations of the CAE results and the physical test results, which will give more confidence in product design and reduce the cost of prototype testing.