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A systematic life cycle management (LCM) approach has been used by Chrysler Corporation to compare existing and alternate hydraulic fluids and lubricating oils in thirteen classifications at a manufacturing facility. The presence of restricted or regulated chemicals, recyclability, and recycled content of the various products were also compared. For ten of the thirteen types of product, an alternate product was identified as more beneficial. This LCM study provided Chrysler personnel with a practical purchasing tool to identify the most cost effective hydraulic fluid or lubricant oil product available for a chosen application on an LCM basis.

The reliability of an electronic sensor in the automotive applications is assessed using data from Fleet Test and proving ground Vehicle Endurance test. These nonfailure data are multiply censored at different mileage. Reliability analysis of data with no failure is rarely discussed in most reliability literature. This paper applies the Weibull maximum likelihood analysis based on known values of the Weibull shape parameter to extract useful reliability information. The well-known Weibayes and Weibest methods are subsets of the discussed approach. The sensitivity of the change of reliability levels over a range of Weibull shape parameter values is also examined in our case. The Huang-Porter (1991) approach of obtaining a reliability lower bound regardless of the Weibull shape parameter values is also applied and its potential of practical application is discussed. Practical limitations of all methods are discussed.

Higher horsepower per liter engines have put more demand on the crankshaft, often requiring the use of forged steel. This paper examines cost reduction opportunities to offset the penalties associated with forged steel, with raw material and machinability being the primary factors evaluated. A cost model for crankshaft processing is utilized in this paper as a design tool to select the lowest cost material grade. This model is supported by fatigue and machinability data for various steel grades. Materials considered are medium carbon, low alloy, and microalloy steels; the effects of sulfur as a machining enhancer is also studied.

A unique opportunity arose to make a direct comparison of aluminum, sheet molding compound (SMC) and steel using a common hood design. In considering all possible material combinations of inner and outer panels, it was discovered that some of the combinations were incompatible due to material properties. Only the compatible material combinations were considered. Three different joining techniques - welding, bonding and bonded hem flanging - were evaluated. The cost, weight and structural performance of the chosen hood material combinations were established. Areas of further development were identified, including design optimization for specific material combinations.

A computer-controlled body panel testing machine has been used to quantify stiffness and dent resistance of body panels at Chrysler. The influence of yield strength and local reinforcement on the mechanical behavior of automotive door panels has been investigated. Medium strength steels in the range of 210 -240 MPa yield strength have produced significant improvements in dent resistance over a 160 MPa yield strength steel. Considerable improvements in dent resistance can also be attributed to the use of local, adhesively attached, glass fiber reinforcement patches. The effects of boundary conditions and panel shape on stiffness and dent resistance are illustrated in this application.

A running loss test procedure has been developed which integrates a point-source collection method to measure fuel evaporative running loss from vehicles during their operation on the chassis dynamometer. The point-source method is part of a complete running loss test procedure which employs the combination of site-specific collection devices on the vehicle, and a sampling pump with sampling lines. Fugitive fuel vapor is drawn into these collectors which have been matched to characteristics of the vehicle and the test cell. The composite vapor sample is routed to a collection bag through an adaptation of the ordinary constant volume dilution system typically used for vehicle exhaust gas sampling. Analysis of the contents of such bags provides an accurate measure of the mass and species of running loss collected during each of three LA-4* driving cycles. Other running loss sampling methods were considered by the Auto-Oil Air Quality Improvement Research Program (AQIRP or Program).

This study analyzes the vibration characteristics of the valve train of a 2.0L SOHC Chrysler Corp. Neon engine over a range of operating speeds to investigate and demonstrate the advantages and limitations of various dynamic measurements such as displacement, velocity, and acceleration in this application. The valve train was tested in a motoring fixture at speeds of 500 to 3500 camshaft rpm. The advantages of analyzing both time and frequency domain measurements are described. Both frequency and order analysis were done on the data. The theoretical order spectra of cam displacement and acceleration were computed and compared to the experimental data. Deconvolution was used to uncover characteristic frequencies of vibration in the system. The theoretical cam acceleration spectrum was deconvolved from measured acceleration spectra to reveal the frequency response function of the follower system.

This paper presents the development of a test procedure for evaluation of inadvertent deployment of air bags. The methodology and early development of the procedure is discussed along with additional criteria thought to be required for trucks and sport utility vehicles. Tests conducted address severe off-road use in relation to air bag sensing systems. Data is collected from accelerometers. After worst case test conditions are identified (examples include rough road, snow plowing and jerk towing events), the data is analyzed and comparisons for design decisions can be made.

Five heats of vanadium-microalloyed steel with carbon contents from 0.29% to 0.40% and sulfur contents from 0.031% to 0.110% were forged into automotive spindles and air cooled. Three of the steels were continuously cast whereas the other two were ingot cast. The forged spindles were subjected to microstructural analysis, mechanical property testing, full component testing and machinability testing. The microstructures of the five steels consisted of pearlite and ferrite which nucleated on prior austenite grain boundaries and predominantly on intragranularly dispersed sulfide inclusions of the resulfurized grades. Ultimate tensile strengths and room temperature Charpy V-notch impact toughness values were relatively insensitive to processing and compositional variations. The room temperature tensile and room-temperature impact properties ranged from 820 MPa to 1000 MPa (120 to 145 ksi) and from 13 Joules to 19 Joules (10 to 14 ft-lbs), respectively, for the various steels.

The J1850 bus requirements promote an unique and well characterized physical layer behavior developed through the learning curve of previous multiplex solutions. Design requirements such as: 1) Reliably interconnecting all of the vehicle's most complex modules, 2) Consistently withstanding the vehicle's harsh environment, and 3) Meeting SAE's functionality requirements, were all a formidable task to achieve. This paper will highlight the path taken to achieve a J1850 Bus interface which successfully met all of the design and functional goals. Chrysler's C2D insights will be discussed and related to goals for J1850. Other design considerations will also be discussed such as EMC issues, custom test equipment, and vehicle and component testability. In turn, silicon processes with special structures and topologies will be discussed relating the specific design with the needed electrical behavior. The HIP7020 J1850 BUS TRANSCEIVER I/O for MULTIPLEX WIRING accomplishes these requirements.

MIL 3's OPNET simulator was used to model Chrysler's J1850 bus. Modeled were both J1850 bus characteristics and those portions of control modules (e.g., the engine controller) which communicate on the bus. Current Chrysler control module algorithms and proposed Chrysler J1850 message formats were used to design the control module models. The control module models include all messages which are transmitted at fixed intervals over the J1850 bus. The effects of function-based messages (e.g., messages to be transmitted on a particular sensor or push-button reading) on system load were investigated by transmitting an additional message with a fixed, relatively high priority at 50 millisecond intervals.

Vacuum insulation and phase-change thermal storage have been used to enhance the heat retention of a prototype catalytic converter. Storing heat in the converter between trips allows exhaust gases to be converted more quickly, significantly reducing cold-start emissions. Using a small metal hydride, the thermal conductance of the vacuum insulation can be varied continuously between 0.49 and 27 W/m2K (R-12 to R-0.2 insulation) to prevent overheating of the catalyst. A prototype was installed in a Dodge Neon with a 2.0-liter engine. Following a standard preconditioning and a 23-hour cold soak, an FTP (Federal Test Procedure) emissions test was performed. Although exhaust temperatures during the preconditioning were not hot enough to melt the phase-change material, the vacuum insulation performed well, resulting in a converter temperature of 146°C after the 23-hour cold soak at 27°C.

This paper describes the development of a rubber-like skin Finite Elements Model (FEM) for the Hybrid III headform and an experimental method to determine its material properties. The finite element modeling procedures, using material parameters derived from tests conducted on the headform skin (rubber) material, are described. Dynamic responses and computations of HIC using the developed headform model show that an Elastic-Plastic Hydrodynamic (EPH) material model of the rubber can be used for headform impact simulations. The results obtained from the headform simulation using an EPH rubber material model and drop tower tests of the headform on both a rigid and a deformable structure will be compared, in order to show the applicability of the EPH model.

The changes in reliability of the Electrical/Electronic Systems of a vehicle-line during its early design and development engineering processes have been studied. A computerized vehicle failure tracking system was used to provide results from several stages of early development vehicle testing at the proving grounds. The data were analyzed using a software program that assumes that failures in a repairable system, such as a car, occur as a nonhomogeneous Poisson process. Results suggest that, under normal circumstances, a significant and quantitative improvement in reliability is achievable as the system or component design progresses through the early design and development processes. This also provides a means of predicting future system(s) reliability when the system(s) is in production.

Resistance to dents and dings, caused by plant handling and in-service use, is generally recognized as an important performance requirement for automotive outer body panels. This paper examines the dent resistance improvements that can be achieved by maximizing surface stretch, through adjustments to the press settings, and substitution of a higher strength steel grade. Initially, the stamping process was optimized using the steel supplied for production: a Ti/Nb-stabilized, ultra low carbon (ULC) grade. The stamping process was subsequently optimized with a Nb-stabilized, rephosphorized ULC steel, at various thicknesses. The formed panels were evaluated for percent surface stretch, percent thinning, in-panel yield strength after forming, and dent performance. The results showed that dent resistance can be significantly improved, even at a reduced steel thickness, thus demonstrating a potential for weight savings.

Fastener failure due to hydrogen embrittlement is of significant concern in the automotive industry. These types of failures occur unexpectedly. They may be very costly to the automotive company and fastener supplier, not only monetarily, but also in terms of customer satisfaction and safety. This paper is an overview of a program which one automotive company initiated to minimize hydrogen embrittlement in fasteners. The objectives of the program were two-fold. One was to obtain a better understanding of the hydrogen embrittlement phenomena as it relates to automotive fastener materials and processes. The second and most important objective, was to eliminate hydrogen embrittlement failures in vehicles. Early program efforts concentrated on a review of fastener applications and corrosion protection systems to optimize coated fasteners for hydrogen embrittlement resistance.

Environmental costs are a delayed financial burden that result from product decisions made early in the product life cycle--early material choices may create regulatory and waste management costs that were not factored into the acquisition cost. This paper outlines a step-wise approach to determine decision points; environmental, health, safety and recycling (EHS&R) cost drivers that affect decisions; and sources of information required to conduct a Life Cycle Management (LCM) review. Additionally, how LCM fits into the larger concurrent engineering framework is illustrated with an electrocoat primer example. Upstream and downstream supply chain processes are reviewed, as well as organizational challenges that affect the decision process.

The Finite Element predictions of the physical response of foams during impact by a rigid body (such as, the Hybrid III head form) is determined by material law equations generally approximated based on the theory of elastoplasticity. However, the structural aspect of foam, its discontinuous nature, makes it difficult to apply the laws of continuum mechanics and construct constitutive equations for foam-like material. One part of the problem relates to the state of stress. In materials such as steel, the state of hydrostatic stress does not affect the stress strain behavior under uniaxial compression or tension in plastic regime. In other words, when steel is subject to hydrostatic pressures the stress strain characteristic can be predicted from a uniaxial test. However, if the stresses acting on a section of foam are triaxial, the response of a head-form may be different than predicted from uniaxial test data.

In recent years, strict weight reduction targets have pushed auto manufacturers to use lighter gauge sheet steels in all areas of the vehicle including exterior body panels. As sheet metal thicknesses are reduced, dentability of body panels becomes of increasing concern. Thus, the goal becomes one of reducing sheet metal thickness while maintaining acceptable dent resistance. Most prior work in this area has focused on quasi-static loading conditions. In this study, both quasi-static and dynamic dent tests are evaluated. Fully assembled doors made from mild, medium strength bake hardenable and non-bake hardenable steels are examined. The quasi-static dent test is run at a test speed of 0.1 m/minute while the dynamic dent test is run at a test speed of 26.8 m/minute. Dynamic dent testing is of interest because it more closely approximates real life denting conditions such as in-plant handling and transit damage, and parking lot damage from car door and shopping cart impact.

Chrysler is a company run by automotive enthusiasts, and its motorsports programs are an integral part of the company's corporate, brand, and product development process. Chrysler's motorsports programs are executed from within its Platform Team system by the same engineers, using the same processes and facilities as production vehicle programs. This results in teaching and inspiring engineers, designers, and technicians, as well as providing genuine technical benefits to the company. This paper tells the “how” story of the design, build, and test of the Dodge Stratus Super Touring Car. Detailed results have been purposely omitted from the paper due to the competitive nature of motor racing.