Search Results

One of the issues in stamping of advanced high strength steels (AHSS) is the stretch bending fracture on a sharp radius (commonly referred to as shear fracture). Shear fracture typically occurs at a strain level below the conventional forming limit curve (FLC). Therefore it is difficult to predict in computer simulations using the FLC as the failure criterion. A modified Mohr-Coulomb (M-C) fracture criterion has been developed to predict shear fracture. The model parameters for several AHSS have been calibrated using various tests including the butter-fly shaped shear test. In this paper, validation simulations are conducted using the modified (M-C) fracture criterion for a dual phase (DP) 780 steel to predict fracture in the stretch forming simulator (SFS) test and the bending under tension (BUT) test. Various deformation fracture modes are analyzed, and the range of usability of the criterion is identified.

The aim of this study was to explore if fingernail delamination injury following EMU glove use may be caused by compression-induced blood flow occlusion in the finger. During compression tests, finger blood flow decreased more than 60%, however this occurred more rapidly for finger pad compression (4 N) than for fingertips (10 N). A pressure bulb compression test resulted in 50% and 45% decreased blood flow at 100 mmHg and 200 mmHg, respectively. These results indicate that the finger pad pressure required to articulate stiff gloves is more likely to contribute to injury than the fingertip pressure associated with tight fitting gloves.

Battery packs for Hybrids, Plug-in Hybrids, and Electric Vehicles are assembled from a system of modules (sheets) with a tight sheet metal casing around them. Each module consists of an array of individual cells which vary in the composition of electrodes and separator from one manufacturer to another. In this paper a general procedure is outlined on the development of a constitutive and computational model of a cylindrical cell. Particular emphasis is placed on correct prediction of initiation and propagation of a tearing fracture of the steel can. The computational model correctly predicts rupture of the steel can which could release aggressive chemicals, fumes, or spread the ignited fire to the neighboring cells. The initiation site of skin fracture depends on many factors such as the ductility of the casing material, constitutive behavior of the system of electrodes, and type of loading.

Thin sandwich sheets hold a promise for widespread use in automotive industry due to their good crash and formability properties. In this paper, thin stainless steel sandwich sheets with low-density core materials are investigated with regard to their performance in crashworthiness applications. The total thickness of the sandwich materials is about 1.2mm: 0.2mm thick facings and a 0.8mm thick sandwich core. Throughout the crushing of prismatic sandwich profiles, the sandwich facings are bent and stretched while the sandwich core is crushed under shear loading. Thus, a high shear crushing strength of the sandwich core material is beneficial for the overall energy absorption of the sandwich profile. It is shown theoretically that the weight specific shear crushing strength of hexagonal metallic honeycombs is higher than the one of fiber cores - irrespective of their relative density or microstructural geometry.

Vehicle weight reduction, reduced costs and improved safety performance are the main driving forces behind material selection for automotive applications. These goals are conflicting in nature and solutions will be realized by innovative design, advanced material processing and advanced materials. Advanced high strength steels are engineered materials that provide a remarkable combination of formability, strength, ductility, durability, strain-rate sensitivity and strain hardening characteristics essential to meeting the goals of automotive design. These characteristics act as enablers to cost- and mass-effective solutions. The ULSAB-AVC program demonstrates a solution to these conflicting goals and the advantages that are possible with the utilization of the advance high strength steels and provides a prediction of the material content of future body structures.

The ability to make accurate decisions concerning early body-in-white architectures is critical to an automaker since these decisions often have long term cost and weight impacts. We address this need with a methodology which can be used to assist in body architecture decisions using process-based technical cost modeling (TCM) as a filter to evaluate alternate designs. Despite the data limitations of early design concepts, TCM can be used to identify key trends for cost-effectiveness between design variants. A compact body-in-white architecture will be used as a case study to illustrate this technique. The baseline steel structure will be compared to several alternate aluminum intensive structures in the context of production volume.

Currently, states that are out of compliance with the National Ambient Air Quality Standards must, according to the Clean Air Act Amendments of 1990 (CAAA), develop and implement control strategies that demonstrate specific degrees of reduction in emissions-with the degree of reduction depending upon the severity of the problem. One tool that has been developed to aid regulators in both deciding an appropriate course of action and to demonstrate the desired reductions in mobile emissions is EPA's Mobile 5a emission estimation model. In our study, Mobile 5a has been used to examine the effects of regulatory strategies, as applied to the Northeast United States, on vehicle emissions under worst-case ozone-forming conditions.

Low volume manufacturing has become increasingly important for the automotive industry. Globalization trends have led automakers and their suppliers to operate in developing regions where minimum efficient scales can not always be achieved. With proper maintenance, standard cast iron stamping tools can be used to produce millions of parts, but require large investments. Thus at high production volumes, the impact of the tooling investment on individual piece costs is minimized. However, at low volumes there is a substantial cost penalty. In light of the trends towards localized manufacturing and relatively low demands in some developing markets, low cost stamping tools are needed. Several alternate tooling technologies exist, each of which require significantly lower initial investments, but suffer from greatly reduced tool lives. However, the use of these technologies at intermediate to high volumes requires multiple tool sets thus eliminating their cost advantage.

With the increasing complexity of automotive systems and the related increasing use of software in them, new approaches are needed to ensure safety. In these new types of automotive systems, safety and reliability are different and require different engineering approaches. Accidents are increasingly due to design errors and to dysfunctional interactions among components rather than component failure. In addition, safety must be engineered and built into the design from the beginning; it is not possible to effectively and affordably add safety devices onto a finished design. This paper describes the need for new approaches to automotive safety and describes an alternative to the traditional reliability-based approaches to safety engineering. The new approach is based on systems theory and views accidents in terms of lack of control or enforcement of the behavioral constraints required to ensure safety.