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This paper is based on, and in continuation of the work previously published in ASEE NCS Conference held in Grand Rapids, MI [1]. Automotive seating rail structures are one of the key components in the automotive industry because they carry the entire weight of passenger and they hold the structure for seating foams and other assembled key components such as side airbag and seatbelt systems. The entire seating is supported firmly and attached to the bottom bodywork of the vehicle through the linkage assembly called the seat rails. Seat rails are adjustable in their longitudinal motion which plays an important role in giving the passengers enough leg room to make them feel comfortable. Therefore, seat rails under the various operating conditions, should be able to withstand the weight of the passenger along with the other assembled parts as mentioned above. Also, functional requirements such as crash safety is very important to avoid or to minimize injuries to the occupants.

The objective of this work was to design an automated bed clearing mechanism for the Anet brand A8 3D printer, which uses Fused Deposition Modeling (FDM) process. This work has been carried out as a capstone course. Many OEMs are focusing on using functional 3D printed parts to replace metal parts that otherwise require complex assemblies or to reduce weight. The concept behind the work presented in this paper was to allow every user to be able to print multiple parts without human interaction. This saves time to load and unload one part at a time. The idea was to develop a universal bed clearing mechanism that can be used for most brands of 3D printers. Upon researching into the many different styles and designs of printers, it became clear that the designs are different and complex to create a universal product. It was decided to aim for the most common style of 3D printers for which easy modeling and testing should be possible.

The objective of this project is to analyze potential design changes that can improve the performance of helical spring in an independent suspension. The performance of the helical spring was based upon the result measure of maximum value of stress acting on it and the amount displacement caused when the spring undergoes loading. The design changes in the spring were limited to coil cross section, spring diameter (constant & variable), pitch and length of the spring. The project was divided into Stage I & Stage II. For Stage I, using all the possible combinations of these design parameters, linear stress analysis was performed on different spring designs and their Stress and displacement results were evaluated. Based on the results, the spring designs were classified as over designed or under designed springs.

Mechanical counter-pressure (MCP) spacesuit designs have been a promising, but elusive alternative to historical and current gas pressurized spacesuit technology since the Apollo program. One of the important potential advantages of the approach is enhanced mobility as a result of reduced bulk and joint torques, but the literature provides essentially no quantitative joint torque data or quantitative analytical support. Decisions on the value of investment in MCP technology and on the direction of technology development are hampered by this lack of information since the perceived mobility advantages are an important factor. An experimental study of a simple mechanical counter-pressure suit (elbow) hinge joint has been performed to provide some test data and analytical background on this issue to support future evaluation of the technology potential and future development efforts.

Impinging jets are an established technique for obtaining high local heat transfer coefficients between a fluid and a surface. Factors such as jet attachment, surface angle, jet angle, separation distance between jet orifice and surface of impingement, and trajectory influence heat transfer dramatically. In the current study, the specific application of interest is air issuing from the defroster's nozzles of a vehicle and impinging on a glass windshield. The current work is aimed at studying the flow patterns off a vehicle windshield as a result of air issuing from various nozzle configurations. The effects of openings' geometry (circular vs rectangular), number of openings, angle that the windshield makes with the horizontal plane and angle of impinging jet, on windshield heat transfer is examined. An optimal configuration will be recommended for better heat transfer.

The transmission mount in a powertrain mounting system is often a primary path for noise. This is especially the case when the transmission is mounted directly to the body without the benefit of a structural frame or isolation between the bracket and body. Since most transmissions generate frequencies above 150Hz, the transmission mount system becomes a likely noise path for this and higher frequencies. A combination of very stiff transmission bracket and very soft rubber mount between the transmission bracket and the transmission would help this problem. In this paper the development an optimally designed transmission mount for a longitudinally mounted powertrain is presented. The development procedure of such a design considers the transmission mount as part of the total system.

A coupler has been developed to prevent windshield wiper systems from being damaged by excessive loads that can occur when the normal wiping pattern is restricted. The coupler is composed of a pultruded composite rod with injection-molded plastic spherical joints (a.k.a. sockets) attached at either end. The sockets are used to attach the coupler to the crank and rocker of the windshield wiper linkage. Because the loads exerted on a coupler vary in magnitude and direction during a wiping cycle, the joint between the sockets and the pultruded composite rod must be robust. The paradigm for attaching sockets to steel couplers (i.e. over-molding the sockets around holes stamped into the ends of traditional steel couplers) was applied to the pultruded rods, tested, and found to produce inadequate joint strength. This paper details the methodology that was employed to produce and optimize an acceptable means to attach the injection-molded sockets to the pultruded rods.

Large hood mounted plastic trim components are subjected to complex and often extreme loading conditions. Typical loading conditions include solar and thermal cycling, as well as road and powertrain induced vibrations, aero lift and buffeting, and mechanical loads such as car wash. For the above components understanding and classifying the typical loading conditions is an essential and important step in achieving long term quality. This paper discusses different approaches to the design, analysis, development, and testing of plastic trim components. Samples of analysis and test results are presented to demonstrate how to identify and prevent the loss of the part function. Some useful guidelines and practices for addressing thermal expansion, dimensional variation, and redundancy in attachments are also discussed.

Doors inside an automotive HVAC module are essential components to ensure occupant comfort by controlling the cabin temperature and directing the air flow. For temperature control, the function of a door is not only to close/block the airflow path via the door seal that presses against HVAC wall, but also control the amount of hot and cold airflow to maintain cabin temperature. To meet the stringent OEM sealing requirement while maintaining a cost-effective product, a “V-Shape” soft rubber seal is commonly used. However, in certain conditions when the door is in the position other than closed which creates a small gap, this “V-Shape” seal is susceptible to the generation of objectionable whistle noise for the vehicle passengers. This nuisance can easily reduce end-customer satisfaction to the overall HVAC performance.

Sliding contact between friction surfaces occurs in numerous torque transfer elements: torque converter clutches, shifting clutches, launch or starting clutches, limited slip differential clutches, and in the meshing of gear teeth under load. The total temperature in a friction interface is the sum of the equilibrium temperature with no sliding and a transient temperature rise, the flash temperature, caused by the work done while sliding. In a wet shifting clutch the equilibrium temperature is typically the bulk oil temperature and the flash temperature is the temperature rise during clutch engagement. The flash temperature is an important factor in the performance and durability of a clutch since it affects such things as the reactivity of the sliding surfaces and lubricant constituents (e.g., oxidation) and thermal stress in the components. Knowing how high the flash temperature becomes is valuable for the formulation of ATF, gear oil, engine oil and other lubricants.

This paper describes experiments conducted to determine the effect of multiple spark discharge ignition systems and spark plug electrode design on cold start performance of a dedicated E85 fueled vehicle. Tests were conducted using three different ignition configurations: OEM ignition and spark plugs, multiple spark discharge ignition with OEM spark plugs, and multiple spark discharge ignition with large gap circular electrode spark plugs. The multiple spark discharge ignition with OEM spark plugs showed a significant improvement in cold start performance over the OEM ignition, but the addition of the circular electrode spark plugs caused a decrease in cold start performance. The circular ground spark plugs did produce a higher ending coolant temperature than either of the other configurations.

The objective of this paper is to determine the whirling bending critical speeds of pultruded composite shafts in simply supported boundary conditions. Theoretical studies have been carried using Patran to determine the natural frequencies and the mode shapes for the Jeffcot and Kikuchi rigid rotor models. A tabletop experimental apparatus has been fabricated and the bending critical speeds have been measured for various span lengths between the supports. The results of this study may be useful in identifying whether pultruded composite shafts can be employed as drive shafts in automotive or other industries.

Cylinder air/fuel ratio distribution is an important factor affecting the economy, power, vibration, and emissions of an internal combustion engine. Currently, production automobiles utilize an exhaust gas sensor located in the main exhaust stream in order to regulate air/fuel mixtures. By measuring the oxygen content of the exhaust gas for each cylinder independently, the degree of air/fuel variation between cylinders can be determined. This information can be used to determine the mixture quality of specific cylinders. Knowing these variances can lead to design changes in the intake and exhaust manifolds as well as better control of fuel metering which will improve the output of the engine. This study was carried out using a 1991 3.8L Buick V-6 engine with customized exhaust manifolds utilizing exhaust gas oxygen sensors for each cylinder in addition to the sensor located in the main combined exhaust gas stream. Production level, ZrO2 sensors were used for this experimental study.

In automotive assembly facilities worldwide, many critical vehicle systems such as brakes, power steering, radiator, and air conditioning require the appropriate fluid to function. In order to insure that these critical vehicle systems receive the correct amount of properly treated fluid, automotive manufacturers employ a method called Evacuation and Fill. Due to their closed-loop design, many critical vehicle systems must be first exposed to vacuum prior to being flooded with fluid. Only after the evacuation and fill process is complete will the critical vehicle system be able to perform as specified. It has long been thought, but never proven, that humidity and entrenched fluid were major hindrances to the Evacuation and Fill process. Consequently, Ford Motor Company Advanced Manufacturing Technology Development, Sandalwood Enterprises, Kettering University, and Dominion Tool & Die conducted a detailed project on this subject.

This paper describes the experiments conducted to determine the effect of high energy multiple spark discharge (MSD) ignition systems and spark plug electrode design, on the cold start performance of a vehicle which was converted for dedicated operation on E85 (a blend of 85% ethanol and 15% gasoline) fuel. Tests were conducted using three different ignition configurations; original equipment manufacturer (OEM) ignition and spark plugs, high energy multiple spark discharge (MSD) ignition with OEM, J-type spark plugs, and high energy MSD ignition with surface gap electrode spark plugs. The high energy MSD ignition with OEM spark plugs showed a significant improvement in cold start performance over the OEM ignition. The addition of the surface gap spark plugs caused a decrease in cold start performance. Despite this, the surface gap spark plugs produced higher ending coolant temperature than the other configurations.

A comprehensive finite element methodology is developed to predict the compressible flow performance of a non-symmetric 7-blade axial flow fan, and to quantify the source strength and sound pressure levels at any location in the system. The acoustic and flow performances of the fan are predicted simultaneously using a computational aero-acoustic technique combining transient flow analysis and noise propagation. The calculated sound power levels compare favorably with the measured sound power data per AMCA 300-96 code.

This paper aims to study the NVH and acoustic performance of a 3-phase AC induction motor in order to develop an approach to reduce the magnetic component of noise from an electric motor in an electric vehicle (EV). The final goal of this project is to reduce the magnetic component of sound from the motor by making modifications to the end bracket of the motor housing. EVs are being considered the future of mobility mainly due to the fact that they are environment-friendly. As many companies are already investing in this technology, electric drives are set to become extremely popular in the years to come. The heart of an EV is its motor. Modern electric vehicles are quiet, furthermore with the lack of an IC engine to mask most sounds from other components, the sound from the electric motor and other auxiliary parts become more prominent.

The first objective of this paper was to evaluate a public domain finite element (FE) model of a 1990 Ford Taurus from the perspective of crush energy absorption. The validity of the FE model was examined by first comparing simulation results to several published full-frontal crash tests. Secondly, the suitability of the model for underride simulation was evaluated against two series of full-scale crash tests into vertically offset rigid barriers. Next, the evaluated FE model was used to pursue the main objective of this work, namely to develop an approach for estimating underride crush energy. The linear-spring methodology was adopted whereby the underride crush stiffness was determined by relating the residual upper radiator support deformation to crush energy. An underride crush stiffness estimation method was proposed based on modifying the full-frontal stiffness coefficients.

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.