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Hole expansion of a dual phase steel, DP600, was numerically investigated using a damage-based constitutive law to predict failure. The parameters governing void nucleation and coalescence were identified from an extensive review of the x-ray micro-tomography data available in the literature to ensure physically-sound predictions of damage evolution. A recently proposed technique to experimentally quantify work-hardening and damage in the shear-affected zone is incorporated into the damage model to enable fracture predictions of holes with sheared edges. Finite-element simulations of a hole expansion test with a conical punch were performed for both a punched and milled hole edge condition and the predicted hole expansion ratios are in very good agreement with the experiment values reported by several researchers.

Honda has developed a new next-generation 3.5 L V6 gasoline engine using our latest Earth Dreams Technology. The overall design objective for the engine was to reduce CO₂ emissions and provide driving exhilaration. The Earth Dreams Technology concept is to increase fuel economy while reducing emissions. To achieve this and provide an exhilarating driving experience, 3-stage Variable Valve Timing and Lift Electronic Control (VTEC) was combined with the Variable Cylinder Management (VCM) system. This valve train technology in conjunction with Direct Injection (DI), resulted in dramatic improvements in output (a 3.3% increase) and combined mode fuel economy (20% reduction). Helping to achieve Midsize Luxury Sedan level NV, a new mount system was developed to reduce engine vibrations during three-cylinder-mode operation. In this paper, we will explain the 3-stage VTEC with VCM + DI system, friction reducing technology, and the structure and benefit of the new engine mount system.

Small crack growth from notches under variable amplitude loading requires that crack opening stress be followed on a cycle by cycle basis and taken into account in making fatigue life predictions. The use of constant amplitude fatigue life data that ignores changes in crack opening stress due to high stress overloads in variable amplitude fatigue leads to non-conservative fatigue life predictions. Similarly fatigue life predictions based on small crack growth calculations for cracks growing from flaws in notches are non-conservative when constant amplitude crack growth data are used. These non-conservative predictions have, in both cases, been shown to be due to severe reductions in fatigue crack closure arising from large (overload or underload) cycles in a typical service load history.

A control algorithm is developed for active/semi-active suspensions which can provide more comfort and better handling simultaneously. A weighting parameter is tuned online which is derived from two components - slow and fast adaptation to assign weights to comfort and handling. After establishing through simulations that the proposed adaptive control algorithm can demonstrate a performance better than some controllers in prior-art, it is implemented on an actual vehicle (Cadillac STS) which is equipped with MR dampers and several sensors. The vehicle is tested on smooth and rough roads and over speed bumps.

Energy management strategies greatly influence the power performance and fuel economy of series hybrid electric tracked bulldozers. In this paper, we present a procedure for the design of a power management strategy by defining a cost function, in this case, the minimization of the vehicle’s fuel consumption over a driving cycle. To explore the fuel-saving potential of a series hybrid electric tracked bulldozer, a dynamic programming (DP) algorithm is utilized to determine the optimal control actions for a series hybrid powertrain, and this can be the benchmark for the assessment of other control strategies. The results from comparing the DP strategy and the rule-based control strategy indicate that this procedure results in approximately a 7% improvement in fuel economy.

The interactions between automatic controls, physics, and driver is an important step towards highly automated driving. This study investigates the dynamical interactions between human-selected driving modes, vehicle controller and physical plant parameters, to determine how to optimally adapt powertrain control to different human-like driving requirements. A cyber-physical system (CPS) based framework is proposed for co-design optimization of the physical plant parameters and controller variables for an electric powertrain, in view of vehicle’s dynamic performance, ride comfort, and energy efficiency under different driving modes. System structure, performance requirements and constraints, optimization goals and methodology are investigated. Intelligent powertrain control algorithms are synthesized for three driving modes, namely sport, eco, and normal modes, with appropriate protocol selections. The performance exploration methodology is presented.

The development and calibration of stress state-dependent failure criteria for advanced high-strength steel (AHSS) and aluminum alloys requires characterization under proportional loading conditions. Traditional tests to construct a forming limit diagram (FLD), such as Marciniak or Nakazima tests, are based upon identifying the onset of strain localization or a tensile instability (neck). However, the onset of localization is strongly dependent on the through-thickness strain gradient that can delay or suppress the formation of a tensile instability so that cracking may occur before localization. As a result, the material fracture limit becomes the effective forming limit in deformation modes with severe through-thickness strain gradients, and this is not considered in the traditional FLD. In this study, a novel bending test apparatus was developed based upon the VDA 238-100 specification to characterize fracture in plane strain bending using digital image correlation (DIC).

A simulation tool has been developed for predicting steering effort of a vehicle during steering power-assist system failure. The vehicle system is modeled with the inclusion of a system-level vehicle model and a steering system model that are linked together through the steering moment at the kingpin and front road wheel angle. A driver model has also been designed to provide closed-loop steering angular input to make the car follow a certain target path. The simulation model is correlated well with actual vehicle tests under various steering input and lateral acceleration conditions. Also illustrated are some examples of comparison between measured and simulated sensitivity study for selected factors.

The performance of a commercial Cu-zeolite SCR catalyst after differing degrees of hydrothermal aging (aged for 72 hours at 500, 700 and 800°C with 10% moisture balanced with air) was studied by spatially resolving different key reactions using gas-phase FTIR measurements. Gases were sampled along a channel at different positions and analyzed using FTIR, which overcomes the interference of water and nitrogen on ammonia concentration detection encountered in standard mass spectrometer-based spatial resolution measurements. The NO:NO₂ concentration ratio was changed so that the standard (NO:NO₂ = 1:0), fast (NO:NO₂ = 1:1) and NO₂ (NO:NO₂ = 0:1) SCR reactions could be investigated as a function of the catalyst's hydrothermal aging extent. In addition, the effects of hydrothermal aging on the activity of NH₃ and NO oxidation were also investigated. Hydrothermal aging had little effect on NO oxidation activity.

Significant improvement in fuel consumption, torque delivery and emission could be achieved through flexible control of the valve timings, duration and lift. In most existing electro-hydraulic variable valve actuation systems, the desired valve lift within every engine cycle is achieved by accurately controlling of the solenoid-valve opening interval; however, due to slow response time, precision control of these valves is difficult particularly during higher engine speeds. In this paper a new lift control strategy is proposed based on the hydraulic supply pressure and flow control. In this method, in order to control the peak valve lift, the hydraulic pump speed is precisely controlled using a two-input gearbox mechanism. This eliminates the need for precision control of the solenoid valves opening interval within every cycle.

Vehicle-to-Vehicle (V2V) safety application research based on short range real-time communication has been researched for over a decade. Examples of V2V applications include Electronic Emergency Brake Light, Do Not Pass Warning, Lane Departure Warning, and Intersection Movement Assist. It is hoped that these applications, whether present as warning or intervention, will help reduce the incidence of traffic collisions, fatalities, injuries, and property damage. The safety benefits of these applications will likely depend on many factors, such as usability, market penetration, driver acceptance, and reliability. Some applications, such as DNPW and IMA, require a longer communication range to be effective. In addition, Dedicated Short Range Communications (DSRC) may be required to communicate without direct line of sight. The signal needs to overcome shadowing effects of other vehicles and buildings that are in the way.

The effects of bead surface roughness on friction, die pickup, and sheet surface damage in the drawbead test were investigated. Beads of HRC 58 hardness were prepared from centerless-ground rod by circumferential honing to 0.05 μm roughness, followed by finishing with 100, 400, or 600 grit SiC paper in the axial direction. Paraffinic base oils with viscosities of 4.5, 30, and 285 mm2/s were used neat and in conjunction with stearic acid. The effects of bead roughness depended on the nature of metal transfer, especially its distribution and firmness of attachment. The presence of a boundary additive increased, decreased, or had no effect on friction depending on the particular coating and bead finish.

Residual stress prediction arising from manufacturing processes provides paramount information for the fatigue performance assessment of components subjected to cyclic loading. The determination of the material model to be applied in the numerical model should be taken carefully. This study focuses on the estimation of residual stresses generated after deep rolling of cast iron crankshafts. The researched literature on the field employs the available commercial material codes without closer consideration on their reverse loading capacities. To mitigate this gap, a single element model was used to compare potential material models with tensile-compression experiments. The best fit model was then applied to a previously developed crankshaft deep rolling numerical model. In order to confront the simulation outcomes, residual stresses were measured in two directions on real crankshaft specimens that passed through the same modeled deep rolling process.

A predictive model of a specific vehicle was modeled in the system-level physical modeling tool, MapleSim, for performance and fuel consumption prediction of a full vehicle powertrain, driving a multi-body chassis model with tire models. The project also includes investigation into overall fuel efficiency and effect on vehicle handling for different drive cycles. The goals of this project were to investigate: 1) the relationships between the forces at tire/road interfaces during various drive cycles and the fuel efficiency of a vehicle, and 2) the interaction between the powertrain and the chassis of the vehicle. To accomplish these goals, a complete vehicle model was created in the lumped-parameter physical modeling tool, MapleSim. A great deal of effort has gone into using real parameters and to assure that some mathematical rigour has been employed in its development.

A series of eight sled tests was conducted using Hybrid III dummies and cadavers in order to examine the influence of foot placement on the brake pedal in frontal collisions. The brake pedal in the sled runs was fixed in a fully depressed position and the occupants' muscles were not tensed. The cadaver limbs and the Hybrid III lower extremities with 45° ankle and soft joint-stop were extensively instrumented to determine response during the crash event. Brake pedal reaction forces were measured using a six-axis load cell and high speed film was used for kinematic analysis of the crashes. Four right foot positions were identified from previous simulation studies as those orientations most likely to induce injury. In each test, the left foot was positioned on a simulated footrest, acting as a control variable that produced repeatable results in all dummy tests. Each of the different right foot orientations resulted in different loads and motions of the right leg and foot.

An Articulated Total Body frontal crash simulation was created with the dummy's right foot placed on the brake pedal. This study examined how interaction of the driver's foot with the brake pedal influenced the behavior of the lower extremities in frontal collisions. Braking parameters considered in the study included foot position on the pedal, whether or not the occupant's muscles were tensed and if the brake pedal was rigid or was allowed to depress. Two basic foot positions were identified as most likely to induce injury of the lower limb. One represented a foot that was pivoted about the heel from the gas pedal to the brake pedal. The other position replicated a foot that was lifted from the gas pedal to the brake pedal, resulting in an initial gap between the heel and floor. Both positions resulted in different loads and behavior of the foot, indicating that driver pre-impact position is a contributing factor to one's injury risk.

A serpentine flow channel is one of the most common and practical channel layouts for a PEM fuel cell since it ensures the removal of water produced in a cell. While the reactant flows along the flow channel, it can also leak or cross to neighboring channels via the porous gas diffusion layer due to a high pressure gradient. Such a cross flow leads to effective water removal in a gas diffusion layer thus enlarging the active area for reaction although this cross flow has largely been ignored in previous studies. In this study, neutron radiography is applied to investigate the liquid water accumulation and its effect on the performance of a PEM fuel cell. Liquid water tends to accumulate in the gas diffusion layer adjacent to the flow channel area while the liquid water formed in the gas diffusion layer next to the channel land area seems to be effectively removed by the cross leakage flow between the adjacent flow channels.

In this study, a finite element software application (SORPAS®) is used to simulate the effect of pulsing on the expected weld thermal cycle during resistance spot welding (RSW). The predicted local cooling rates are used in combination with experimental observation to study the effect pulsing has on the microstructure and mechanical properties of Zn-coated DP600 AHSS (1.2mm thick) spot welds. Experimental observation of the weld microstructure was obtained by metallographic procedures and mechanical properties were determined by tensile shear testing. Microstructural changes in the weld metal and heat affect zone (HAZ) were characterized with respect to process parameters.

A resin fuel lid capable of being electrostatically painted on-line with the vehicle body-in-white was developed to achieve a light weight fuel adapter assembly with improved color match to surrounding body panels when compared with outsourced painting. The fuel lid was molded out of a conductive, high heat capable PA/PPO resin, and painted with automotive body paint systems. Key development items for this part included validation of part conductivity, on-line capability of the resin material, development of an attachment scheme to achieve proper grounding of the part, determination of paint jig location for proper paint coverage and color match to the body, and evaluation of the final fit & finish. These studies were conducted in combination of both lab and on-line trials. Additionally, the final painted part assembly was extensively tested to achieve the appropriate quality of the surface treatment and strength and durability of the design construction.

A serpentine flow channel can be considered as neighboring channels connected in series, and is one of the most common and practical channel layouts for PEM fuel cells since it ensures the removal of liquid water produced in a cell with excellent performance and acceptable parasitic load. During the reactant flows along the flow channel, it can also leak or cross directly to the neighboring channel via the porous gas diffusion layer due to the high pressure gradient caused by the short distance. Such a cross flow leads to a larger effective flow area resulting in a substantially lower amount of pressure drop in an actual PEM fuel cell compared to the case without cross flow. In this work, an analytical solution is obtained for the cross flow in a PEM fuel cell with a serpentine flow channel based on the assumption that the velocity of cross flow is linearly distributed in the gas diffusion layer between two successive U-turns.