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A low profile high directivity antenna is designed to operate at 5.9 GHz for Vehicle-to-Vehicle (V2V) and Vehicle-to-Infrastructure (V2I) communications to ensure connectivity in different propagation channels. Patch antennas are still an ongoing topic of interest due to their advantages: low profile, low cost, and ease of fabrication. One disadvantage of the patch antenna is low directivity which results in low range performance. In this paper, we introduce an efficient and novel way to improve the directivity of patch antenna using topology optimization and design of experiments (DoE). Numerical simulations are done using Method of Moments (MoM) technique in the commercially available tool, FEKO. We use global response surface method (GRSM) for double objectives topology optimization. Numerical results show a promising use of topology optimization and DoE techniques for the systematic design of high directivity of low profile single element patch antennas.

Laser transmission welding is a relatively new technique for joining thermoplastic components in the automotive industry. Laser energy is passed through a laser-transparent part and dissipated as heat in a laser-absorbent component. There is currently no standardized test to assess the strength of laser transmission welds made using thermoplastic materials. A properly-designed test allows the weld strength of the joint to be measured accurately and rapidly. This paper reports on a technique for measuring overlap shear strength. This study compares two weld orientations (weld line parallel and perpendicular to assembly loading) using polycarbonate, polypropylene, polyamide 6, polyamide 6 reinforced with 30% glass fibres and polyamide mXD6 reinforced with 50% glass fibres. Assemblies were made using a range of laser powers. In order to simulate industrial conditions, artificial gaps were also introduced between the transparent and absorbent parts.

The effect of hydroforming on the mechanical properties and dynamic crush behaviors of tapered aluminum 6063-T4 tubes with octagonal cross section are investigated by experiments. First, the thickness profile of the hydroformed tube is measured by non-destructive examination technique using ultrasonic thickness gauge. The effect of hydroforming on the mechanical properties of the tube is investigated by quasi-static tensile tests of specimens prepared from different regions of the tube based on the thickness profile. The effect of hydroforming on the dynamic crush behaviors of the tube is investigated by axial crush tests under dynamic loads. Specimens and tubes are tested in two different heat treatment conditions: hydroformed-T4 (as-received) and T6. The results of the quasi-static tensile tests for the specimens in hydroformed-T4 condition show different amounts of work hardening depending on the regions, which the specimens are prepared from.

This paper presents the results of CFD study on sunroof buffeting suppression using a dividing bar. The role of a dividing bar in side window buffeting case was illustrated in a previous study [8]. For the baseline model of the selected vehicle in this study, a very high level of sunroof buffeting, 133dB, has been found. The CFD simulation shows that the buffeting noise can be significantly reduced if a dividing bar is installed at the sunroof. A further optimization study on the dividing bar demonstrates that the peak buffeting level can be reduced to 123dB for the selected vehicle if the dividing bar is installed at its optimal location, 65% of the total length from the front edge of the sunroof. The peak buffeting level can be further reduced to 100dB if the dividing bar takes its optimal width 80mm, 15% of the total length of the sunroof for this vehicle, while staying at its optimal location.

More than 200 tensile-shear resistance spot welded specimens were produced and tested to analyze the effect of spot weld spacing, weld size, sheet thickness, and adhesive on the ultimate strength of joints made from a mild hot dip galvannealed steel and an unexposed quality hot dip galvannealed 590 MPa minimum tensile strength dual phase steel (DP590). The geometric layout parameters were analyzed by a design of experiment (DOE) approach. The analysis showed that weld size is a primary factor affecting the strength of the joints for a given material. It was also determined that structural adhesive created a large relative strengthening for joints made from the mild steel. Interactions of the geometrical factors are also presented.

Specific energy absorption (SEA) is a quantitative measure of the efficiency of a structural member in absorbing impact energy. For an extruded aluminum crash can, SEA generally depends upon the topology of its cross-section. An investigation is carried out to determine the optimal cross-sectional topologies for maximizing SEA while considering manufacturing constrains such as, permissible die radii, gauges, etc. A comprehensive DOE type matrix of cross-sectional topologies has been developed by considering a wide variety of practical shapes and configurations. Since it is critical to include all feasible topologies, much thought and care has been given in developing this matrix. Detailed finite element crash analyses are carried out to simulate axial crushing of the selected crash cans topologies and the resulting specific energy absorption (SEA) is estimated for each case.

Single-plane balancing is a very well-understood process, whereby an imbalance vector is determined and then opposed by a similar vector of equal magnitude but 180° out of phase. This is used in many situations to improve machine performance, vibration, noise etc. However, there is inherent in this process a sensitivity to errors of measurement and correction, since a large imbalance vector and the equally large correction vector must be of exactly equal magnitude and exactly 180° apart for perfect balance. This paper examines the effect of errors in measurement of the initial imbalance and correction of it on the residual balance of automotive drivelines. In particular, it examines the effects of the errors present in a system whereby a system balance correction is made, on a driveline assembly, at discrete points around a given plane (at bolt locations). Errors occur in measurement of vibration, in calculating correction masses and in applying those correction masses.

The vibration-generating mechanisms inside an engine are highly non-linear (combustion, valve operation, hydraulic bearing behavior, etc.). However, the engine structure, under the influence of these vibration-generating mechanisms, responds in a highly linear way. For the development and optimization of the engine structure for noise and vibration it is beneficial to use fast and ‘simple’ linear models, like linear FE-models, measured modal models or measured FRF-models. All these models allow a qualitative assessment of variants without excitation information. But, for true optimization, internal excitation spectra are needed in order to avoid that effort is spent to optimize non-critical system properties. Unfortunately, these internal excitation spectra are difficult to measure. Direct measurement of combustion pressure is still feasible, but crank-bearing forces, piston guidance forces etc. can only be identified indirectly.

Modern vehicles contain a multitude of networked electronics. This feature causes distributed functions in distributed electronics. Malfunctions occurring during EMC testing cannot be allocated precisely without detailed knowledge of the data streams. The electromagnetic environment during EMC-testing limits the possibilities of using standard solutions to detect these malfunctions. The paper will present a new tool, which is able to track the data streams in a CAN-Bus system during EMC-testing. By integrating EMC related parameters in the existing data stream of the vehicle's data bus, it is possible to keep a record of malfunctions as they occur.

Traditional methods used to produce a die set (from developing initial machining cutter paths through finalized die tryout to produce a part that meets design intent) begin with draw simulation and development. It is here, traditionally, that scientific evaluation of actual metal stretch and theoretical ideals end. In past programs, a designed part would be simulated for stretch and a development model created to include various die compensations (i.e. springback, overcrown, etc.) based on past experience for area and amount. At this point, the die is cut and undergoes a metamorphosis through die tryout to finally produce a quality part. This is currently an open loop system. This paper will focus on the differences in the predicted way the die should look and the actual outcome (after part buyoff).

Springback study on a Dodge Ram fender outer panel is detailed in this paper. A simple measurement fixture is designed for the panel, wherein non-contact laser scan technology is applied The measurement data are compared with the original CAD design surface and deviation contour maps are obtained. Consistency of measurement is studied at different sections among three samples. Details of FEA simulations are outlined. The comparison between measurement and simulation prediction is summarized. A method to describe the consistency of measurement and the accuracy of simulation prediction is proposed. The targets for measurement consistency and simulation accuracy are verified. A sensitivity analysis is also performed to investigate various simulation input parameters.

In most aspects of mechanical design related to a motor vehicle there are two ways to treat dynamic fatigue problems. These are the time domain and the frequency domain approaches. Time domain approaches are the most common and most widely used especially in the automotive industries and accordingly it is the method of choice for the fatigue calculation of welded structures. In previous papers the frequency approach has been successful applied showing a good correlation with the life and damage estimated using a time based approach; in this paper the same comparative process has been applied but now extended specifically to welded structures. Both the frequency domain approach and time domain approach are used for numerically predicting the fatigue life of the seam welds of a thin sheet powertrain installation bracketry of a commercial truck submitted to variable amplitude loading. Predicted results are then compared with bench tests results, and their accuracy are rated.

This paper presents the results of optimization study for sunroof buffeting reduction using CFD technology. For an early prototype vehicle as a baseline model in this study a high level of sunroof buffeting 133dB has been found. The CFD simulation shows that the buffeting noise can be reduced by installing a wind deflector at its optimal angle 40 degrees from the upward vertical line. Further optimization study demonstrates that the buffeting peak SPL can be reduced to 97dB if the sunroof glass moves to its optimal position, 50% of the total length of the sunroof from the front edge. For any other vehicles, the optimization procedure is the same to get the optimal parameters. On the other hand, however, this optimization study is only based on fluid dynamics principle without considering manufacturability, styling, cost, etc. Further work is needed to utilize the results in the production design.

A new family of automotive three-way conversion (TWC) catalyst technologies has been developed using a Precision Metal Addition (PMA) process. Precious metal (PGM) fixation onto the support occurs during the PMA step when the PGM is added to the slurry immediately prior to application to the monolith substrate. PMA slurries can be prepared with high precision and the slurry manufacturing process is greatly simplified. Further, it has been found that with the use of new generation washcoat (WC) materials, the same WC composition can be used for all three PGMs - Pt, Pd & Rh. Negative interactions between Pd and Rh in the same WC layer do not occur, providing advantages over older technologies. Thus, new WC compositions coupled with the PMA process offers precious metal flexibility. This FlexMetal family of catalyst technologies includes single layer Pd-only, Pd/Rh and Pt/Rh and dual layer bi-metal Pd/Rh and Pt/Rh and tri-metal Pt/Pd/Rh.

In an effort to ensure that the characteristics of prototype friction materials do not differ from those of the “same” material when introduced into volume production and that, in production, these characteristics do not vary over time, DaimlerChrysler has instigated the processes of Shoe and Lining Fingerprinting and Production Variation Reduction. For the launch of the 1999 Jeep Grand Cherokee the concept of Production Variation Reduction was extended by the Jeep Platform and BBA Friction, Inc., to 25 pre-production batches of material to eliminate prototype to production variability.

An early development vehicle experienced an unusually high rate of windshield breakage. Most breaks were identified as due to impact, but the severity of impact was low. It was reasoned that the windshield should possess a greater level of robustness to impact. Many theories were put forth to explain the breakage data. It was universally agreed that the unusual breakage rate could be due to only one condition, but its source was indefinite. The condition present must be tensile stress. One of three situations were considered regarding its source: 1) the tensile stress was present in the glass after manufacture due to improper annealing; 2) the installation of the windshield into the vehicle body put the glass into stress; 3) some combination of the other two sources. A gray-field polariscope was used to measure the stresses of the windshield from both the manufacturing process as well as the installation in the vehicle.

The automobile industry is seeing an increased need for the application of plastics and their derivatives in various forms such as fiber reinforced plastics, in the design and manufacture of various automotive structural components, to reduce weight, cost and improve fuel efficiency. A lot of effort is being directed at the development of structural plastics, to meet specific automotive requirements such as stiffness, safety, strength, durability and environmental standards and recyclability. This paper presents the concept of reinforcing large injection molded fiber reinforced body panels with structural uni-directional fibers (carbon, graphite, kevlar or fiber glass) wound in tension around the body panels by filament winding technique. Structural uni-directional fibers in tension wound around the fiber reinforced plastic inner body panels would place these body panels under compression.

Today, vehicle architectures are changing continuously due to the need for increasing vehicle electrification. Electric motors have helped sustain this requirement. Traditional internal combustion engines are being replaced or coupled with traction motors or in-wheel motor systems in full-electric or hybrid-electric vehicles. With the use of electric motor in a vehicle, the number of parts can be reduced. This leads to reduced packaging size and complexity. Also, CO2 emissions are reduced, and overall efficiency is increased. But the task of designing an electric motor which is assembled in a vehicle could be quite complex. The design of an electric motor can affect the durability, and noise and vibration characteristic of the vehicle structure to which it is connected. The design of the vehicle structure to which the motor attaches should be able to sustain the magnetic torque generated by the motor.

To evaluate the performance of Body-in-white design different attributes needs to be evaluated at various design levels. The current paper focus on evaluation and improvement of Body in white structure in detailed design stage of product development by identifying common performance contributors with multiple model inputs and design validation plans to achieve global performance of the structure. This paper explains the methodology to evaluate the results of Initial Analysis and design iterations for multiple Design verification plans individually and also combined. Sensitivity study is carried out by Multi model DOE (Design of experiments) optimization method to identify the global performance effecting contributors for each design validation plan. The methodology could generate a design which improve stiffness on local joinery sections and also global structural stiffness parameters in both static and dynamic condition by keeping the overall mass in acceptable range.