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This course covers metal forming and related manufacturing processes, emphasizing practical applications. From forged or P/M connecting rods to tailor-welded blank forming, metal parts are integral to the automotive industry. As a high value adding category of manufacturing, metal forming is increasingly important to the core competency of automobile manufacturers and suppliers. A thorough survey of metal forming processes and metal forming mechanics will be performed, including bulk deformation, sheet-metal, and powder metallurgy operations. Design considerations are fully integrated into the course and are presented with every process.

Design for Manufacturing and Assembly (DFM+A), pioneered by Boothroyd and Dewhurst, has been used by many companies around the world to develop creative product designs that use optimal manufacturing and assembly processes.  Correctly applied, DFM+A analysis leads to significant reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes.  This course will include information on how DFM+A fits in with QFD, Concurrent Engineering, Robust Engineering, and other disciplines.

Fastener experts believe that upwards of 95% of all fastener failures are the result of either the wrong fastener for the job or improper installation. Improper installation or incorrect fastener selection can result in catastrophic loss or damage. Learn how to avoid issues by getting the answers in this course.

Fatigue is a structural failure mode that must be recognized and understood to develop products that meet life cycle durability requirements. In the age of lightweighting, fatigue strength is an important vehicle design requirement as engineers struggle to meet stringent weight constraints without adversely impacting durability. This technical concept course introduces the fatigue failure mode and analysis methods. It explains the physics of material fatigue, including damage accumulation that may progress to product failure over time, and it provides the needed foundation to develop effective fatigue prediction capabilities.

This course is offered in China only and presented in Mandarin Chinese. HMI design is an Interdisciplinary, which is based on human cognitive psychology and combines humanities, sociology, aesthetics, information science and other disciplines. While automotive technologies can be applied regardless of regions, HMI must be localized, as it is closely related to regional culture, people's living habits and characteristics. At the same time, HMI design has its own complete theoretical system, research and design methods and testing methods, instead of relying on experience.

The importance of weight reduction in vehicle design is well known. In recent years, OEMs have been working on vehicle lightweight research and application, particularly for new energy vehicles. Currently, many Chinese OEMs establish a lightweight target and expect that weight savings will be distributed among the vehicle’s various systems.  This tends to keep the weight reduction effort at the level of parts or partial weight loss design development and application.

This course is offered in China only and presented in Mandarin Chinese. Static perceptual quality is the term applied to the customer’s first impression of a car at the beginning of the buying process including how it looks, feels, and smells. This “first feeling” largely determines whether the customer continues through the purchase process. At present, OEMs have no systematic method for static perceptual quality in the whole vehicle design and development process, especially for the static perceptual quality review in the early stage of design and development before data freezing.

Design for Manufacturing and Assembly (DFM+A), pioneered by Boothroyd and Dewhurst, has been used by many companies around the world to develop creative product designs that use optimal manufacturing and assembly processes. Correctly applied, DFM+A analysis leads to significant reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes. In this two-day course, you will not only learn the Boothroyd Dewhurst Method, you will actually apply it to your own product design!

AMS-STD-595A Color Chips Precise Color Matching, Individual Color Chips: A 3 x 5 inch color chip supplied in a 3 x 5 inch protective envelope for each AMS-STD-595 color, suitable for matching quality control inspection purposes. SAE Product Code: EA-10032 AMS-STD-595 – Colors Used in Government Procurement. This standard presents the colors used by Government Activities in a format suitable for color selection matching and for quality control inspection for paints and coatings. Standard is used with DoD and other Federal Agencies as a primary source of color reference.

User's Manual for the BIOSID Side Impact Test Dummy (Sept. 2007) SAE Product Code: EA-24 This 42 page user's manual covers the Biosid 50th Percentile Male side impact crash test dummy. It is intended for use by technicians who work with this device. It covers the construction, assembly and disassembly, available instrumentation, external dimensions and segment masses, as well as calibration test procedures.

Eyellipse and Head Contour Locator Line - Adjustable Seat SAE Product Code: EA-5 The EA-5 is a drafting tool that describes the position of the eyellipse and the occupant head contour for horizontally adjustable seats with back angles between 5 and 40 degrees. Note! This product will be discontinued when current stock is depleted.

SAE J1052 Mar87 Motor Vehicle Driver and Passenger Head Position SAE Product Code: EA-6 The templates are two-dimensional shapes that describe the seated vehicle occupant head positions in side and rear view. The driver head position contours with seat travel apply to drivers in horizontally adjustable seats. The head position contours without seat travel apply to both drivers and passengers in fixed seats. Note! This product will be discontinued when current stock is depleted. The templates are two-dimensional shapes that describe the seated vehicle occupant head positions in side and rear view. The driver head position contours with seat travel apply to drivers in horizontally adjustable seats. The head position contours without seat travel apply to both drivers and passengers in fixed seats.

technology breakthroughs. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. In the episode "Composite Materials: Advanced Materials and Lightweighting" (30:20), Molded Fiber Glass Companies, known for its deep involvement in the creative development of the molded fiberglass process for the Corvette, demonstrates the manufacturing of sheet molded composite for fiberglass parts. Tanom Motors introduces the Tanom Invader , a blend between an automobile and a motorcycle made exclusively with composite materials. Finally, Euro-Composites demonstrates the manufacturing of honeycomb core material made out of aramid paper and phenolic resin used in aircraft structures.

User's Guide for the Six Month Old Infant Dummy (CRABI) (June 1995) SAE Product Code: EA-28 This 31 page user's manual covers the 6-month-old Child Restrain Air Bag Interaction (CRABI) infant dummy. It is intended for use by technicians who work with this device. It covers the construction and clothing, assembly and disassembly, available instrumentation, external dimensions and segment masses, as well as calibration test procedures. It includes instructions for joint adjustment and skin repair.

This technical paper collection contains 11 papers that focus on occupant protection biomechanics.

The energy crisis and rising gas price in the 2000s led to a growing popularity of hybrid vehicles. Hyundai-Kia Motors has been challenging to develop the new efficient eco-technology since introducing the mild type compact hybrid electric vehicle for domestic fleet in 2004 to meet the needs of the increasing automotive-related environmental issues. Now Hyundai has recently debuted a full HEV for global market, Sonata Hybrid. This system is cost effective solution and developed with the main purpose of improving fuel consumption and providing fun to drive. Presenter Seok Joon Kim, Hyundai Motor Company

This session focuses on particle emissions from combustion engines, including measurement methods and fuel effects. Presenter Leonidas D. Ntziachristos, Aristotle University Thessaloniki

When vehicles share certain information wirelessly via Dedicated Short Range Communications (DSRC), they enable a new layer of electronic vehicle safety that, when needed, can generate warnings to drivers and even initiate automatic preventive actions. Vehicle location and velocity provided by Global Navigation Systems (GNSS), including GPS, are key in allowing vehicle path estimation. GNSS is effective in accurately determining a vehicle's location coordinates in most driving environments, but its performance suffers from obstructions in dense urban environments. To combat this, augmentations to GNSS are being contemplated and tested. This testing has been typically done using a reference GNSS system complimented by expensive military-grade inertial sensors, which can still fail to provide adequate reference performance in certain environments.

Polypropylene is typically reinforced with commodities that are non renewable and require a great deal of energy to produce. The marketplace needs a reinforcement that can offer beneficial physical properties, such as impact, while being attained from a renewable green source. Compounding flax fiber, which is traditionally an agricultural waste product burned by farmers, with polypropylene yields physical properties similar to traditional glass filled polypropylene. This combination should lead to cost saving opportunities while not sacrificing part performance. Presenter James Preston, Rhetech Inc.