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Technical Paper

SPOT WELD FATIGUE DURABILITY PERFORMANCE EVALUATION THROUGH THE USE OF FEA

2009-10-06
2009-36-0189
The sheet metal joining through spot welding is the most widely used process for automotive body building, where an average vehicle has around 5,000 spot welding points in its structure. In this sense, the spot welding project is critical to the final product performance and it must be done in a way that can assure both quality and durability of the vehicle, already taking into consideration the fact that the spot weld mechanical properties related to fatigue and rupture resistance are much lower when compared to other available welding techniques like MIG welding for example. These properties have a direct impact in the fatigue durability and crashworthiness properties of the vehicle, as a significant part of the structural resistance goes through these spot welds. With this scenario, the correct application of FEA techniques is very important to assure that the projected joints and spot weld disposition meet the product targets in terms of safety and durability.
Technical Paper

Optimization of a Clutch Disc Torsional Damping System Design

2002-11-19
2002-01-3389
1 During the development of a new clutch disc damping system and after three months of hard work the engineering team got stuck with unsatisfactory system performance (rattle noise), despite the help of a computer simulation software. The only alternative seemed to be using a more expensive damping concept but, besides the fact that there wasn't much development time left, that option would increase part cost by unacceptable US$ 200, plus development cost. The team then decided to try Taguchi's Robust Engineering optimization approach for the first time. In just two weeks the authors got a 4.6 dB gain on the signal-to-noise ratio. That allowed us to keep the initially proposed system, thus avoiding the cost increase. Besides, the authors were able to keep the development schedule on track.
Technical Paper

Damper Analysis using Energy Method

2002-11-19
2002-01-3536
The force x velocity graph is the most used tool for suspension damper analysis. This approach hides important information regarding the bleeds / spring / orifice combination. This paper describes the energy analysis, comparing two different damper suppliers, with comfort measurements using B&K Human Response Vibration Meter and MTS single channel Four Post system.
Technical Paper

Reference of Legal Requirements Applied for Wheels on Passenger or Light Truck Vehicles in 2016

2016-10-25
2016-36-0140
This work aims to summarize in a single form all legal requirements that dictates the minimum safety compliance required by government edicts to any wheel manufacture to have their products available for passenger or light truck vehicle in any country around the world in the year of 2016. It is not intention of this paper compare or discuss the different requirement among the countries but indicate to the manufactures of wheels what legal edicts they need to meet in case they are willing to go overseas to explore the wheel market of other country. Before start designing wheels for passenger or light truck application, any manufacture should be sure about what the government of the new market demands for wheels when installed on vehicle axis or just available as temporary spare. Another objective of this paper is to be a short reference for new automakers to know what to demand from their suppliers of wheels before starting business with them or shipping vehicles to any new market.
Technical Paper

Decor Mold with PP Film

2011-10-04
2011-36-0007
The challenge of this project is to make a development of a low cost material and has a high resolution digital film to be applied through a process of injection molding plastic material the surface has an alternative finish in decorative pieces. In the current process is too large is not feasible because of the cost is the cost of being a material of high performance and is on top of plastics engineering. Now the consumer has seen the cars (Popular) with very plastic material inside, leaving the car or with a dark look much lower. This project has to change the main idea that consumer sentiment Popular car, in your pocket without adding the automaker will have a freedom in design for rapid change in appearance or individual customization (geometric patterns, images, etc …) to enhance the accuracy of the finished piece. Expected outcomes (products specific to the program): Research and defines the IMD, the printing process, forming, injection and raw materials.
Technical Paper

Vehicle Integration, Gear Material and Heat Treatment Effects on Rear Axle Whining Noise

2017-11-07
2017-36-0129
This paper will focus whining noise on rear axles applied in mid-size trucks. Vehicle integration changes during development affect directly the gear noise perception, in which it may be intensified. Also, gear material and heat treatment choices for the rear axle need to be done carefully, taking into consideration the integration changes and also the driver usage. A lessons learned collection over the diverse aspects of a rear axle whining noise will be the basis of this paper.
Technical Paper

Knowledge Management in R&D Departments of Automotive Companies

2011-10-04
2011-36-0048
For many years the knowledge in an organization has been very well treated and protected, by a discipline widely known as Knowledge Management (KM). Despite it can be consider one of the main pillars of any automotive research and development (R&D) department, several companies do not pay attention to it as they should. Who does manage and apply it appropriately certainly has been granted with innumerous business opportunities, maximizing the usage of its resources, reducing development and validation time consumption and minimizing the inherent risks of new projects. This paper covers pure KM concepts and presents several tools and practices that have been proven very good and effective for knowledge identification, storage and usage by R&D departments.
Technical Paper

Reliable Measurement of Fuel Level

1992-11-01
921450
The fuel indicator float inside the fuel tank, also called just float or erroneously, fuel indicator, is in reality a fuel level sender. It is apparently a really simple part, but it consists of a small system constituted of the float itself; the float arm articulated to an axle carrying a moving contact over a resistor; and the resistor inside a housing/flange. Its function is to convert the fuel level measurements inside the tank in suitable information to the instruments in the vehicle instrument panel. Since a few years ago, it has suffered successive changes toward the objective of improving quality, durability, reliability and performance, or even motivated by innovations in the installation environment and correlated systems, such as, emission controls, affecting the tank internal space, and highly corrosive type fuels.
Technical Paper

Study of a Relationship between Upper Body Mass and its Stiffness, in Order to Support the Platform Selection for Future Programs

2012-10-02
2012-36-0166
Body in White (BIW) torsional stiffness is an important parameter for passenger vehicles, influencing its behavior regarding Noise, Vibration & Harshness (NVH), durability and handling. A BIW with high stiffness may impact mass and cost since it would be necessary to add reinforcements and/or increase thickness of the panels with more contribution for this parameter. An OEM (Original Equipment Manufacturer) may have to choose an existing platform to continue a particular vehicle family and this decision will be based on mass and costs. This work aims to study a relationship between mass and stiffness of some platforms, trying to give an auxiliary parameter to help in the OEM's decision, differentiating the stiffness of the lower (platform) and upper body.
Technical Paper

Design for Six Sigma (DFSS): a technical and economical analysis of its application in the Vehicle Development Process

2004-11-16
2004-01-3308
The existent competitiveness in the automobile industry has been taking their manufacturers to an incessant search for methods and processes that seek the production of vehicles with quality and accessible costs to their costumers. The Vehicle Development Process (VDP) became an essential element for the success of a vehicle in the market, because the companies found out that, when concentrating their efforts during the development phase, the opportunities for product improvement will be much less onerous when compared with the costs spent when the vehicle are already in production. On the other hand, those improvement opportunities are evidently more difficult of be pointed during VDP than when the vehicle is already in production. This article aims to evaluate how the Design for Six Sigma (DFSS) methodology can be applied to the vehicle development process in order to provide significant results in terms of quality improvement, cost optimization and reduction of development timing.
Technical Paper

Studies on a Usage of a Limited Slip Differential Without Full Locking Features Compared to Open Type Differential and Traction Control in Mid-Size Truck - Drivers for Strategic Decision Balancing Technical Performance and Customer Perception

2015-09-22
2015-36-0164
Basic driveline configurations offered in mid-size trucks have a standard “open” differential. Open differentials allow smooth cornering, as the outside tire must spin faster on corners as it travels a larger arc, when compared to the inner tire. This system has a main problem when traction is lost, due to slippery roads, different friction coefficients between pavements or even when the axle is submitted to a twist ditch. All of the power goes to the wheel with the least traction and the pickup is stuck. In order to improve traction on these situations, limited slip differentials were developed. A limited-slip differential will prevent excessive power from being allocated just to one wheel, and thereby keeping both wheels in powered rotation. There are several solutions offered in the market, each one presenting different torque transfer capabilities.
Technical Paper

Challenges on Drivetrain System Integration on Pick-up Trucks

2014-09-30
2014-36-0292
Changes in the macro economic scenario of Brazil during the latest 10 years resulted on several changes in the auto industry market. One, which affected important requirements of the light duty trucks, regards the migration of customers from passenger car segments to light duty pickups. A considerable portion of these new pick-up customers expects an overall level of comfort, handling, noise and vibration similar to the levels found in passenger cars. One possible conclusion of this trend is that an optimized vehicle system integration is vital to prevent potential issues and to assure the achievement of customer satisfaction. Among several vehicle systems, the Drivetrain integration deserves the major attention. This paper shares lessons learned on the integration of the manual Transmission, external shifter, mountings, propeller shaft, rear axle and suspension with the rest of the vehicle.
Journal Article

The Influence of Wheel Rotations to the Lateral Runout of a Hybrid Material or Dimensionally Reduced Wheel Bearing Flange

2021-10-11
2021-01-1298
The automotive industry is continuously striving to reduce vehicle mass by reducing the mass of components including wheel bearings. A typical wheel bearing assembly is mostly steel, including both the wheel and knuckle mounting flanges. Mass optimization of the wheel hub has traditionally been accomplished by reducing the cross-sectional thickness of these components. Recently bearing suppliers have also investigated the use of alternative materials. While bearing component performance is verified through analysis and testing by the supplier, additional effects from system integration and performance over time also need to be comprehended. In a recent new vehicle architecture, the wheel bearing hub flange was reduced to optimize it for low mass. In addition, holes were added for further mass reduction. The design met all the supplier and OEM component level specifications.
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