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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.

This paper reports on the experimental study of carbide and polycrystalline diamond (PCD) drills used for drilling composite/titanium stacks. Materials systems used in this study were multi-directional carbon fiber in an epoxy matrix and titanium 6Al-4V. The drill materials included tungsten carbide (WC; 9%Co ultra fine grain) and polycrystalline diamond (PCD; bimodal grade). Torque and thrust force were measured during the drilling experiments. Tool wear of both drills was periodically examined during the drilling tests using various microscopic techniques such as optical and Scanning Electron Microscope (SEM). Effect of tool materials and process condition on hole quality parameters such as hole diameter, surface roughness, and titanium burrs, were examined. Dissimilar mechanical and thermal properties of the stacks affected the tool life and resulted in the decreased hole quality for both cutting tool materials, although to a differing degree.

A need to develop methodologies to obtain objective measurements of the effects of different seat contours on people is evident. In an effort to monitor muscle activity during static seated postures, electromyography (EMG) was employed. In an experimental setting, fatigue was induced in back extensor muscles for different seated postures. The resultant EMG signals were then sampled bilaterally for three different vertebral levels and the effects of the different seating systems on posture were evaluated. In preliminary tests involving 4 subjects of similar size and build, utilizing three differently contoured seats, findings support the use of EMG to quantify muscular fatigue as a viable means of objectively measuring the effects of different seat contours.

Flame spread over a melting thermally thick composite polymer is investigated in a channel flow above a condensed fuel. The condensed fuel consists of an isotropic (melted layer of) liquid near the heated surface and an anisotropic (not-yet-melted) solid surrounding it. The influence of the solid anisotropy is evaluated by changing the solid conductivity (ksx or ksy) in one particular direction (x in horizontal flame spread direction or y in vertical direction, see schematics in Figure 1) while keeping the other properties fixed. Note that the liquid conductivity kl has no isotropic behavior. Numerically, it is found that the flame spread rate decreases with either increasing ksx or ksy. The decrease with respect to ksy is less than for a comparable case described by the de Ris formula for an isotropic pure solid. The flame spread rate is more accurately determined by an analytical formula derived for spread across a melting solid fuel.

This study showed that subfracture impact loading to a joint creates stresses in cartilage and bone which can initiate a chronic osteoarthrosis. The magnitude and location of the impact induced stresses are dependent on the orientation and the intensity of loading. Impact loading produced lesions on retro-patellar cartilage and their depths increased as the thickness of subchondral bone increased with time post-impact. Mechanical tests of cartilage indicated significant softening twelve months post-impact. These alterations are similar to those documented clinically as early OA. In vitro impacts of isolated limbs, together with mathematical models, showed that high mean stress generated during impact may help protect joint tissues from acute injury. This study and others are being used to develop stress-based tissue failure criteria for predicting an osteoarthrosis following subfracture impact loading.

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.

Lower extremity injuries due to automobile accidents are often overlooked, but can have a profound societal cost. Knee injuries, for example, account for approximately 10% of the total injuries. Fracture of the knee is not only an acute issue but may also have chronic, or long term, consequences. The criterion currently used for evaluation of knee injuries in new automobiles, however, is based on experimental impact data from the 70''s using seated human cadavers. These studies involved various padded and rigid impact interfaces that slightly alter the duration of contact. Based on these data and a simple mathematical model of the femur, it appears fracture tolerance increases as contact duration shortens. In contrast, more recent studies have shown mitigation of gross fractures of the knee itself using padded interfaces. The use of padded interfaces, however, result in coincidental changes in contact duration and knee contact area.

While the number of deaths from vehicle accidents is declining, probably because of mandatory seat belt laws and air bags, a high frequency of lower extremity injuries from frontal crashes still occurs. For the years 1979-1995 the National Accident Sampling System (NASS) indicates that knee injuries (AIS 1-4) occur in approximately 10% of cases. Patella and femur fractures are the most frequent knee injuries. Current literature suggests that knee fractures occur in seated cadavers for knee impact forces of 7.3 to 21.0 kN. Experimental data shown in a study by Melvin et al. (1975) further suggests that fracture tolerance of the knee may be reduced for an impact directed obliquely to the axis of the femur. The current study hypothesized that the patella is more vulnerable to fracture from an oblique versus an axial impact (directed along the femoral axis), and that the fracture pattern would vary with impact direction.

Resonant frequencies of a resonant bending system with notched crankshaft sections are obtained experimentally and numerically in order to investigate the effect of notch depth on the drop of the resonant frequency of the system. Notches with the depths ranging from 1 to 5 mm, machined by an EDM (Electrical-Discharging Machining) system, were introduced in crankshaft sections at the fillet between the main crank pin and crank cheek. The resonant frequencies of the resonant bending system with the crankshaft sections with various notch depths were first obtained from the experiments. Three-dimensional finite element models of the resonant bending system with the crankshafts sections with various notch depths are then generated. The resonant frequencies based on the finite element computations are in good agreement with those based on the experimental results.

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.

This paper describes additional and more recent results from the DaimlerChrysler study of HANS that includes a sensitivity analysis of HANS performance to variations in crash dummy neck length and other impact test conditions. The objective of the tests was to determine the robustness of the HANS concept in a variety of conditions that might occur in actual use. The results show that the variations in test parameters do effect injury measures from the crash dummy, but HANS provides substantial reductions in injury potential in all cases compared to not using HANS. Also, no injuries were indicated with HANS.

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).

The relationship of the airbag fire-distribution as a function of impact velocity to the airbag fire-time is studied through the use of an optimization procedure. The study is conducted by abstracting the sensor algorithm and its associated constraints into a simple mathematical formulation. An airbag fire objective function is constructed that integrates the fire-rate and fire-time requirements. The function requires the input of a single acceleration time history; it produces an output depending on the airbag fire condition. Numerical search of the optimal fire threshold curve is achieved through parameterizing this curve and applying a modified simplex search optimization algorithm that determines the optimal threshold function parameters without computing the complete objective function in the parameter space. Numerical results are given to show the effectiveness and potential difficulties with the automatic search scheme.

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.

The responses of the THOR and the Hybrid-III ATDs to head and neck loading due to a deploying air bag were investigated. Matched pair tests were conducted to compare the responses of the two ATDs under similar loading conditions. The two 50th percentile male ATDs, in the driver as well as the passenger positions, were placed close to the air bag systems, in order to enhance the interaction between the deploying air bag and the chin-neck-jaw regions of the ATDs. Although both ATDs nominally meet the same calibration corridors, they differ significantly in their kinematic and dynamic responses to interaction with a deploying air bag. The difference between the structural designs of the Hybrid-III's and the THOR's neck appears to result in significant differences in the manner in which the loads applied on the head are resisted.

A finite element model for hybrid III dummy's lower torso is presented. All details of the dummy's knee structure are carefully considered. In order to justify the finite element model, numerical results are made to compare with the experimental results from both knee impact test and knee slider impact test. It is found that the finite element results agree very well with their experimental counterparts.

The mechanical behavior of a commercially available single layer polypropylene (PP) separator was investigated using a dynamic mechanical analyzer (DMA). Samples were tested along the machine direction (MD) and transverse direction (TD). The tensile stress-strain, tensile creep and viscoelastic behaviors were studied. Experiments were performed in two conditions: (1) dry and (2) wet, i.e., samples submersed in dimethyl carbonate (DMC). The experimental results revealed that the mechanical properties of the separator were much lower while being submersed in DMC. This finding suggests that the mechanical properties measured at a dry condition may not be sufficient to represent the in-situ material behavior. Therefore, it is important to conduct material characterization in an environment close to the service condition.

Lower extremity (knee) trauma is currently based on a bone fracture criterion derived from impacts of aged specimens. Recent clinical studies, however, indicate that a chronic disease (post-traumatic osteoarthritis), may be precipitated after mechanical insult without obvious bone fracture(1). It is hypothesized this is due to microcracking of subchondral bone under cartilage. This hard tissue layer is known to change with age and pathology. Ten ‘aged’ (71 years) and ten ‘young’ (47 years) cadaver knee joints were impacted to study the influence of age and pathology on the fracture load, and incidents of occult injury. Our results indicate that fracture load, per se, was independent of specimen age. On the other hand, severely pathological specimens required significantly higher loads to fracture bone. Occult microcraking was also observed in subfracture experiments, however, fewer incidents were recorded for the ‘aged’ specimens.

Ring wear may not be a problem in most current automotive engines. However, a small alteration in the ring face geometry can significantly affect the hydrodynamic lubrication characteristics of the ring. This in turn can cause excessive frictional losses and blowby in an engine. As engines become more compact and highly loaded, ring wear is likely to be more severe than in current engines. In order to assess the effect of ring loading, a piston ring wear model has been developed through the use of ring dynamics analysis with the assumption of a linear relationship between ring wear and the friction work applied on the surface of the ring. This ring wear analysis clearly shows that the higher the engine speed, the lower the wear rates at the same power output. This finding is consistent with the limited experimental data available.

The purpose of this work was to develop a fiber optic imaging system for use in flow visualization studies at the Michigan State University Engine Research Laboratory. A flexible fiber optic image carrier was coupled with a high speed rotating prism camera to create a unique imaging system which can easily reach remote location test sites. The flow visualization study was conducted on a motored 3.5 L four-valve engine test rig. A 40 watt pulsed copper vapor laser was synchronized with the camera to produce motion picture film at 5000 frames per second (fps). The image carrier which is attached to the camera contained an 80 degree field of view (FOV) tip adapter for viewing the entire cross-sectional area of the cylinder. The area imaged was a radial plane located 3 cm from the intake valves. The engine rig was motored at 850 rpm with a flow rate of 18 kg/hr. Entrained microballoon seeding particles were filmed as they traveled through the cylinder.