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Shaped elastomeric joints such as engine mounts or suspension bushings undergo broadband, multi-axis loading; however, in practice, the elastomeric joint properties are often measured at stepped single frequencies (non-resonant test method). This article helps provide insight into multi-axis properties with new benchmark experiments that are designed to permit direct comparison between system resonant and non-resonant identification methods of the dynamic stiffness matrices of elastomeric joints, including multi-axis (non-diagonal) terms. The joints are constructed with combinations of inclined elastomeric cylinders to control non-diagonal terms in the stiffness matrix. The resonant experiment consists of an elastic metal beam end-supported by elastomeric joints coupling the in-plane transverse and longitudinal beam motion.

The practical and proven use of computers in forming technology include: CAD/CAM for die making; transfer of geometric data from the customer's CAD/CAM system to that of the supplier and vice versa; application of artificial intelligence and expert systems for part and process design; simulation of metal flow to eliminate forging defects; prediction and optimization of process variables; and analysis of stresses in dies as well as prevention of premature die failure. Intelligent use of this information can lead to significant gains in product quality and productivity. This paper presents three examples of application of process simulation to forming : rolling, ring rolling and forging.

Previously we had found significant errors in the interfacial force results for a source-path-receiver system where only translational motions were measured. This paper examines the sources of those errors by using computational finite and boundary element models. The example case consists of a source structure (with few modes), a receiver (with many modes) and three steel rod paths. We first formulate indirect, yet exact, methods for estimating interfacial forces, by assuming that six-dimensional motions at any location are available though we focus on only the driving points. One- and three-dimensional sub-sets of the proposed formulation are compared with the six-dimensional theory in terms of interfacial force and partial sound pressure spectra.

The Buckeye Bullet set domestic as well as international speed records for electric vehicles in 2004. The next generation of land speed vehicle from Ohio State called the Buckeye Bullet 2 (henceforth the BB2) will again challenge and hopefully achieve several new speed records. The Buckeye Bullet suspension worked relatively well but was found to not be quite optimal for the vehicle. The purpose of the work outlined here was to develop a new front and rear suspension for the BB2 that would be an improvement over the suspension of the original Bullet. Previous to the start of this work part of the suspension had already been designed in the form of an upright/control arm setup. This paper works on taking the suspension to completion from this point of design. Work done includes developing the final design, determining suspension parameters, building an ADAMS model, and testing the ADAMS model.

Deformation Resistance Welding (DRW) is a process that employs resistance heating to raise the temperature of the materials being welded to the appropriate forging range, followed by shear deformation which increases the contacting surface area of the materials being welded. Because DRW is a new process, it became desirable to establish variable selection strategies which can be integrated into a production procedure. A factorial design of experiment was used to examine the influence of force, number of pulses, and weld cycles (heating/cooling time ratio) on the DRW process. Welded samples were tensile tested to determine their strength. Once tensile testing was complete, the resulting strengths were observed and compared to corresponding percent heat and percent reduction in thickness. Tensile strengths ranged from 107 kN to 22.2 kN. A relationship between the maximum current and the weld variables was established.

As we continue to create ever-lighter road vehicles, the challenge of balancing weight reduction and structural performance also continues. One of the key parts this occurs on is the hood, where lighter materials (e.g. aluminum) have been used. However, the aerodynamic loads, such as hood lift, are essentially unchanged and are driven by the front fascia and front grille size and styling shape. This paper outlines a combination CFD/FEA prediction method for hood deflection performance at high speeds, by using the surface pressures as boundary conditions for a FEA linear static deflection analysis. Additionally, custom post-processing methods were developed to enhance flow analysis and understanding. This enabled the modification of existing test methods to further improve accuracy to real world conditions. The application of these analytical methods and their correlation with experimental results are discussed in this paper.

Amongst various sources of noise and vibrations in gear meshing, transmission error and sliding friction between the teeth are two major constituents. As the operating conditions are altered, the magnitude of these two excitations is affected differently and either of them can become the dominant factor. In this article, an experimental investigation is presented for identifying the friction excitation and to study the influence of tribological parameters on the radiated sound. Since both friction and transmission error excitations occur at the same fundamental period of one meshing cycle, they result in similar spectral contents in the dynamic response. Hence specific methods like the variation of parameters are designed in order to distinguish between the individual vibration and noise sources. The two main tribological parameters that are varied are the lubricant and the surface finish characteristics of gear teeth.

In many vibration isolation problems, translational motion has been regarded as a major contributor to the energy transmitted from a source to a receiver. However, the rotational components of isolation paths must be incorporated as the frequency range of interest increases. This article focuses on the flexural motion of an elastomeric isolator but the longitudinal motion is also considered. In this study, the isolator is modeled using the Timoshenko beam theory (flexural motion) and the wave equation (longitudinal motion), and linear, time-invariant system assumption is made throughout this study. Two different frequency response characteristics of an elastomeric isolator are predicted by the Timoshenko beam theory and are compared with its subsets. A rigid body is employed for the source and the receiver is modeled using two alternate formulations: an infinite beam and then a finite beam. Power transmission efficiency concept is employed to quantify the isolation achieved.

The knowledge of frequency-dependent dynamic stiffnesses of mounts, in axial and flexural motions, is needed to determine the behavior of many automotive sub-systems. Consequently, characterization and modeling of vibration isolators is increasingly becoming more important in mid and high frequency regimes where very few methods are known to exist. This paper critically examines some of the approximate identification methods that have been proposed in the literature. Then we present a new experimental identification method that yields frequency-dependent multi-dimensional dynamic stiffnesses of an isolator. The scope is however limited to a linear time-invariant system and our analysis is restricted to the frequency domain. The new characterization method uses two inertial elements at both ends of an isolator and free boundary conditions are maintained during testing.

The acoustic attenuation performance of a single-pass, perforated concentric silencer filled with continuous strand fibers is investigated theoretically and experimentally. One-dimensional analytical and three-dimensional boundary element methods are employed to predict the acoustic attenuation in the absence of mean flow. Measured complex characteristic impedance and wave number are used to account for the wave propagation through absorbing fiber. The perforation impedance facing the fiber is also presented in terms of the complex characteristic impedance and wave number. The effects of perforate duct porosity and the fiber density are examined. Comparisons of predictions with the experiments illustrate the need for multidimensional analysis at higher frequencies, while the one-dimensional treatment provides a reasonable accuracy at lower frequencies, as expected. The study also shows a significant improvement in the acoustic attenuation of the silencer due to fiber absorption.

Fiber reinforced structural composites will play a key role in the development of the next generation of transportation vehicles (passenger cars, vans, light trucks and heavy trucks) due to their high strength-to-weight and stiffness-to-weight ratio compared to metals. An integrated assessment of the durability, reliability, and affordability of these materials is critical to facilitate the inclusion of these materials into new designs. The result of this assessment should provide information to find the balance between the three performance measures. This paper describes a method to develop this assessment in the fabrication of sheet molding compound (SMC) parts, and discusses the concept of Preform Insert Assembly (PIA) for improved affordability in the manufacturing of composite parts.

Modal sound radiation of a brake rotor is expressed in terms of analytical solutions of a generic thick annular disk having similar geometric dimensions. Finite element method is used to determine structural modes and response. Vibro-acoustic responses such as surface velocities and radiated sound pressures due to a multi-modal excitation are calculated from synthesized structural modes and modal acoustic radiation of the rotor using the modal expansion technique. In addition, acoustic power and radiation efficiency spectra corresponding to a specific force excitation are obtained from the sound pressure data. Accuracy of the new semi-analytical method has been confirmed by purely numerical analyses based on finite element and boundary element models. Our method should lead to an improved understanding of the sound radiation from a brake rotor and strategies to minimize squeal noise radiation could be formulated.

The single-parameter, in-process monitor and automatic control systems for the resistance spot welding process have been studied by many investigators. Some of these have already been commercialized and used by sheet metal fabricators. These control systems operate primarily on one of the three process parameters: maximum voltage or voltage drop, dynamic resistance, or thermal expansion between electrodes during nugget formation. Control systems based on voltage or dynamic resistance have been successfully implemented for industrial applications. A great amount of experience on these two control methods has been accumulated through trial-and-error approaches. The expansion-based control system is not commonly utilized due to lack of experience and understanding of the process. Since the expansion displacement between electrodes during welding responds directly to the weld nugget formation, this control parameter provides a better means to produce more precise spot welds.

The EcoCAR 2: Plugging into the Future team at the Ohio State University is designing a Parallel-Series Plug-in Hybrid Electric Vehicle capable of 50 miles of all-electric range. The vehicle features a 18.9-kWh lithium-ion battery pack with range extending operation in both series and parallel modes. This is made possible by a 1.8-L ethanol (E85) engine and 6-speed automated manual transmission. This vehicle is designed to drastically reduce fuel consumption, with a utility factor weighted fuel economy of 51 miles per gallon gasoline equivalent (mpgge), while meeting Tier II Bin 5 emissions standards. This report details the fabrication and control implementation process followed by the Ohio State team during Year 2 of the competition. The fabrication process includes finalizing designs based on identified requirements, building and assembling components, and performing extensive validation testing on the mechanical, electrical and control systems.

There exists a fairly extensive set of tire force measurements performed on dry pavement. But in order to develop a low-coefficient of friction tire model, a set of tire force measurements made on wet pavement is required. Using formulations and parameters obtained on dry roads, and then reducing friction level to that of a wet road is not sufficient to model tire forces in a high fidelity simulation. This paper describes the process of more accurately modeling low coefficient tire forces on the National Advanced Driving Simulator (NADS). It is believed that the tire model improvements will be useful in many types of NADS simulations, including ESC and other advanced vehicle technology studies. In order to produce results that would come from a road surface that would be sufficiently slippery, a set of tires were shaved to 4/32 inches and sent to a tire-testing lab for measurement.

Springback affects the dimensional accuracy and final shape of stamped parts. Accurate prediction of springback is necessary to design dies that produce the desired part geometry and tolerances. Springback occurs after stamping and ejection of the part because the state of the stresses and strains in the deformed material has changed. To accurately predict springback through finite element analysis, the material model should be well defined for accurate simulation and prediction of stresses and strains after unloading. Despite the development of several advanced material models that comprehensively describe the Bauschinger effect, transient behavior, permanent softening of the blank material, and unloading elastic modulus degradation, the prediction of springback is still not satisfactory for production parts. Dies are often recut several times, after the first tryouts, to compensate for springback and achieve the required part geometry.

The influence of die corner geometry on the attainable draw depth of rectangular parts was investigated using 3-D FEM and optimum rectangular blanks. Axisymmetric cup analysis was not adequate because a corner assist effect promotes corner draw. Guidelines for selecting corner radius were developed and the sensitivities of the maximum part depth to other process variables, such as drawbead restraint force; die clearance gap; friction coefficient; strain rate sensitivity; material anisotropy; and strain hardening exponent, were simulated. The results are much more conservative than handbook rules, which to not to take into account the details of blank size, drawbead restraint, die geometry, material properties, and friction.

Recent studies in sheet metal forming, conducted at universities world wide, emphasize the development of computer aided techniques for process simulation. To be practical and acceptable in a production environment, these codes must be easy to use and allow relatively quick solutions. Often, it is not necessary to make exact predictions but rather to establish the influence of process variables upon part quality, tool stresses, material flow, and material thickness variation. In cooperation with its industrial partners, the ERC for Net Shape Manufacturing of the Ohio State University has applied a number of computer codes for analysis and design of sheet metal forming operations. This paper gives a few selected examples taken from automotive applications and illustrates practical uses of computer simulations to improve productivity and reduce tool development and manufacturing costs.

Waterborne coatings are being used more widely in the automotive industry due to their environmentally benign properties. As the rheological properties of the waterborne coatings are significantly different from most solvent borne coatings, paint circulation systems that are designed for solvent borne coatings are not necessarily well suited for waterborne coatings. It is possible to fully characterize the rheology of the waterborne coatings and make an optimized design of the paint circulation system, resulting in improved finish quality and reduced operating cost.

Flight tests of a new 13% General Aviation Airfoil - the GA(W)-2 - gloved full span onto the existing wing of a Beech Sundowner have generated chordwise pressure distributions and wake surveys. Section lift, drag and moment coefficients derived from these measurements verify wind tunnel data and theory predicting the performance of this airfoil. The effect of steps, rivets and surface coatings upon the drag of the GA(W)-2 was also evaluated.