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Impact resistance of plastic underbody parts was studied using simulated injection-molded specimen which can be tested according to different types of material used, injection molding variants like position and number of injection molding gates, and features of ribs. Material applied was glass fiber reinforced polyamide which can be used in underbody parts. Test was performed using several combinations of injection molding gates and rib types. From the test result, optimal design guide for plastic underbody parts was determined. Also, new high impact resistant plastic material made of glass fiber reinforced polyamide 66 (PA66) and polyamide 6 (PA6) alloy was developed and the material properties useful for CAE were determined. As a case study, oil pan and muffler housing were designed following the optimal design guide and CAE. And the reliability of the sample muffler housing designed was verified.

A method and equipment for the determination of material limits for polymeric thrust elements is presented along with initial data based on the system. Methods are presented to better simulate drive train thrust element operation on equipment that utilizes production ready mating components under actual load, speed, and lubrication conditions. Initial results for limited materials are presented. This study allows for a more complete understanding of the effects of the product of pressure and velocity (PV) on material wear and frictional behavior for drive train applications of thrust elements.