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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.

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.

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.

The Isodamp damping material (also known as Navy Damp) used in the ribs of current crash test dummies provides human-like damping to the thorax under impact. However, the range of temperature over which it can be used is very small. A new rib design using laminates of steel, fiberglass, and commercially available viscoelastic material has been constructed. Load-deflection response and hysteresis of the laminated ribs were compared with corresponding conventional ribs fabricated from steel and Isodamp. Impact tests were conducted on laminated and conventional ribs at 18.5° C, 22.2° C and 26.6° C. Results indicate that the response of the laminated ribs is essentially the same as that of the ribs with Isodamp at 22.2° C, which is the operating temperature of the conventional ribs. The variation in the impact response of the newly developed laminated ribs in the temperature range of 18.5° C to 26.6° C was less than 10%.

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.

A review was conducted of injuries associated with ejection through motor vehicle glazing, using the 1988 through 1991 National Accident Sampling System data maintained by the National Highway Traffic Safety Administration. The review indicated that one percent of the occupants in towaway crashes were ejected and that 22 percent of fatalities in towaway crashes were ejected. Fifty-three percent of complete ejections were through the glazing openings in motor vehicles. Current motor vehicle glazing does not contribute significantly to occupant injuries, but the effects of glazing changes on serious injuries will need to be considered.

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.

This paper presents an approach for evaluating the effects of brake system component degradation on vehicle braking performance. The approach involves the use of an inertial brake dynamometer, vehicle computer simulation, and vehicle test. The approach, procedures, and results of the study of the effects of worn friction materials, worn discs and drums, and contaminated brakes are presented.

The paper presents a comparison of kinematic responses between the MVMA-2D and the MAC-DAN pedestrian models and pedestrian cadaver kinematics observed in staged car/pedestrian impact tests. The paper also discusses the injuries experienced in the cadaver tests. Seven cadaver specimens in the standing posture were impacted at 25 mph by two different cars: one having a steel bumper and the other having a plastic bumper. The MVMA-2D and MAC-DAN mathematical pedestrian models were employed to simulate pedestrian impacts at 25 mph by a vehicle with a stylized geometry that is similar to the vehicles used in cadaver tests. Comparison of the simulations and the cadaver tests show that both models require further refinement to be able to more accurately simulate the kinematics of the lower legs during impacts with the vehicle bumper.

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.

The Bellanca Skyrocket II, possessor of five world speed records, is a single engine aircraft with high performance that has been attributed to a laminar flow airfoil and an all composite structure. Utilization of composite materials in the Skyrocket II is unique since this selection was made to increase the aerodynamic efficiency of the aircraft. Flight tests are in progress to measure the overall aircraft drag and the wing section drag for comparison with the predicted performance of the Skyrocket. Initial results show the zero lift drag is indeed low, with CDO = 0.016.

Previously-reported draw-bend tests showed large discrepancies in springback angles from those predicted by two-dimensional finite element modeling (FEM). In some cases, the predicted angle was several times the measured angle. With more careful 3-D simulation taking into account anticlastic curvature, a significant discrepancy persisted. In order to evaluate the role of the Bauschinger Effect in springback, a transient hardening model was constructed based on novel tension-compression tests for for three sheet materials: drawing-quality steel (baseline material), high-strength low-alloy steel, and 6022-T4 aluminum alloy. This model reproduces the main features of hardening following a strain reversal: low yield stress, rapid strain hardening, and, optionally, permanent softening or hardening relative to the monotonic hardening law. The hardening law was implemented and 3-D FEM was carried out for comparison with the draw-bend springback results.