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Ten mold-in-color black polymers were evaluated for exterior weathering in an attempt to improve the specifications for exterior mold-in-color plastics to meet five year durability for a 95th percentile sunbelt customer. Four different weathering methods were utilized including Arizona exposure, Florida exposure, and Xenon arc exposures per the GMNA and the GM Europe methods. Colorfastness, gloss retention and other material property changes due to weathering were measured and analyzed against two GM durability standards. For the appearance attributes, correlations between actual exposure and accelerated exposure were attempted. Test results before and after polishing were also analyzed. Finally, in addition to comparing the performance of the ten polymers, the four weathering methods are compared and discussed with recommendations for the preferred testing regimen.

Current trends in vehicle development, including both automotive and commercial vehicles, are characterized by short model life cycles, reduced development time, concurrent design and manufacturing development, reduced design changes, and reduced total cost. All of these are driven by customer demand of higher load capacity, reduced weight, extended durability and warranty requirement, better NVH performance and reduced cost. These trends have resulted in increased usage of computational simulation tools in design, manufacturing, and testing, i.e. virtual testing or virtual prototyping. This paper summarizes our work in virtual testing, i.e. fatigue life simulations using computational fracture mechanics for commercial vehicle axle gearing development. First, fatigue life simulation results by using computational fracture mechanics CRACKS software were verified by comparing with gear teeth bending fatigue test data and three point bending fatigue test data.

This paper discusses the virtual development process used to support design of a high-tonnage hydroform press. It also discusses the optimized design for structural integrity while achieving low target cost. Other considerations included optimization of setup issues such as press fabrication and assembly. Due to tightly constrained development time, a diverse range of CAE methodologies were used to refine and validate the design. Detailed linear and nonlinear finite element models were developed to provide the required accuracy in the critical regions of the press structure. From these detailed models simplified analytical tools were developed to calculate the key press parameters such as alternating stress and predicted fatigue life. Finite element models were validated with physical strain gage measurements from an array of strain gages installed on the production presses.

In recent truck applications, single-piece large-diameter propshafts, in lieu of two-piece propshafts, have become more prevalent to reduce cost and mass. These large-diameter props, however, amplify driveline radiated noise. The challenge presented is to optimize prop shaft modal tuning to achieve acceptable radiated noise levels. Historically, CAE methods and capabilities have not been able to accurately predict propshaft airborne noise making it impossible to cascade subsystem noise requirements needed to achieve desired vehicle level performance. As a result, late and costly changes can be needed to make a given vehicle commercially acceptable for N&V performance prior to launch. This paper will cover the development of a two-step CAE method to predict modal characteristics and airborne noise sensitivities of large-diameter single piece aluminum propshafts fitted with different liner treatments.

Friction Launch transmissions use a wet multi-plate clutch to replace the torque converter in an automatic transmission. By using one of the range clutches inside the transmission, the benefits of this integrated friction launch technology (IFL), such as reduction in mass, packaging, and cost, can be enhanced. The availability of new automatic transmissions with higher number of speeds and wider ratio spreads makes IFL technology more viable than ever before. The new GM Rear-Wheel-Drive (RWD) six-speed transmission has paved the way for a full implementation of integrated friction launch technology in a GM full size Sport-Utility Vehicle (SUV). This project focuses on both hardware and control issues with the friction launch clutch. The hardware issues include designing the clutch for launch energy, cooling, and durability.

This paper describes the validation of RAMSIS, a 3-D CAD human model for ergonomic vehicle evaluation. At GM NAO, the model’s capability to correctly predict position and posture in vehicle CAD environments was tested. H- and Eye point locations between RAMSIS manikins and their human counterparts were compared. At GM/SAAB the model’s postural discomfort predictability was evaluated. Changes in postural discomfort predictions of the RAMSIS manikins were compared to that of the human subjects when they evaluated two different driving buck conditions. We concluded that RAMSIS has good position, posture and postural discomfort prediction capabilities and is a useful CAD ergonomic evaluation and design tool for vehicle interiors.

Sound absorbing materials are commonly compressed when installed in passenger compartments or underhood applications altering the sound absorption performance of the material. However, most prior work has focused on uncompressed materials and only a few models based on poroelastic properties are available for compressed materials. Empirical models based on flow resistivity are commonly used to characterize the complex wavenumber and characteristic impedance of uncompressed sound absorbing materials from which the sound absorption can be determined. In this work, the sound absorption is measured for both uncompressed and compressed samples of fiber and foam, and the flow resistivity is curve fit using an appropriate empirical model. Following this, the flow resistivity of the material is determined as a function of the compression ratio.

Numerical acoustics has traditionally been relegated to a prediction only role. However, recent work has shown that numerical acoustics techniques can be used to diagnose noise problems. The starting point for these techniques is the acoustic transfer vector (ATV). First of all, ATV's can be used to conduct contribution analyses which can assess which parts of a machine are the predominant noise sources. As an example, the sound power contribution and radiation efficiency from parts of a running diesel engine are presented in this paper. Additionally, ATV's can be used to reliably reconstruct the vibration on a machine surface. This procedure, commonly called inverse numerical acoustics (INA), utilizes measured sound pressures along with ATV's to reconstruct the surface velocity. The procedure is demonstrated on an engine cover for which the reconstructed vibration had excellent agreement with experimental results.

Carbon nanomaterials such as vertically aligned carbon nanotubes arrays are emerging new materials that have demonstrated superior mechanical, thermal, and electrical properties. The carbon nanomaterials have the huge potential for a wide range of vehicular applications, including lightweight and multifunctional composites, high-efficiency batteries and ultracapacitors, durable thermal coatings, etc. In order to design the carbon nanomaterials for various applications, it is very important to develop effective computational methods to model such materials and structures. The present work presents a structural mechanics approach to effectively model the mechanical behavior of vertically aligned carbon nanotube arrays. The carbon nanotube may be viewed as a geometrical space frame structure with primary bonds between any two neighboring atoms and thus can be modeled using three-dimensional beam elements.

This paper presents the criteria in selecting the size of the tuning capacitor, and the cost tradeoff between magnet volume and tuning capacitor in a free piston Stirling engine power generation system. The permissible range of capacitor size corresponding to different magnet volume, in order to prevent magnet demagnetization and stabilize the operation of the system, is determined. Within the permissible range suitable capacitor size may be selected to compensate the inductive load of the system to improve the overall power factor. If the capacitor size is not in the permissible range, there would exists a danger of losing magnet strength, or unstable operation of the engine that would destroy the engine due to unbounded amplitude of piston oscillations. The theory developed is then applied to a practical system, and the cost tradeoff between magnet volume and capacitor is studied.

The so-called Modified Martempering discussed in this work differs from the standard martempering by that the temperature of the quenching bath is below the Ms point. In spite of the fact the lower temperature increases the severity of quenching, this also usually avoids the bainite formation, and by this reason, it is possible to make a fair comparison between different processes, which result in different microstructures. The present study shows the results in terms of mechanical properties, impact resistance in special of a cold work tool steel class, after being heat treated by the isothermal modified martempering process, as well as a comparison with the conventional quenching and tempering process and the austempering as well.

Fatigue testing of components is used to validate new product designs as well as changes made to existing designs. On new designs it is common to initially test parts at the design stage (design verification or DV) and then again at the production stage (production verification or PV) to make sure the performance has not changed. On changes to existing designs typically the life of the new part (B) is compared to that of the old part (A). When comparing the fatigue life Weibull analysis is normally used to evaluate the data. The expectation is that the B10 or B50 life of the new part or PV parts should be equal to or better than that of the old parts or the DV parts. However, fatigue testing has a great deal of inherent variability in the resulting life. In this paper the variability of numerous carburized and induction hardened components is examined.

The scope of this paper is to determine the affects that non-petroleum based fuels such as: rapeseed methyl ester (RME) and soy methyl ester (SME) have on thermoset elastomers. The thermoset elastomers that have been evaluated are NBR (Nitrile Butadiene Rubber), NBR/PVC (Nitrile Butadiene Rubber & Polyvinyl Chloride), Epichlorohydrin homo- (Homopolymer of Epichlorohydrin), co- (Copolymer of Epichlorohydrin), ter- (Terpolymer of Ecpichlorohydrin), and Di-, and ter FKM (Fluorinated Rubber). The different elastomers have been subjected to aging in neat fatty acid methyl esters, RME and SME, at a variety of durations and temperatures. The effects of this exposure on the properties of thermoset elastomers are described in this paper.

It is well understood that conditions encountered during racetrack driving are amongst the most severe to which vehicle braking systems can be subjected. High braking pressure is combined with enormous energy input and high temperatures for multiple braking events. Brake fade, degradation of brake pedal feel, and brake lining taper/overall wear are common results of racetrack usage. This paper focuses on how racetrack and high energy driving-type conditioning affects the performance of the brake caliper - in particular, its ability to maintain an even pressure distribution at all of its interfaces (pad to rotor, piston to pad backing plate, and housing to pad backing plate).

A new Diesel engine, called the Duramax 6600 (Fig.1), has been designed by Isuzu Motors (Isuzu) for an upcoming full-size General Motors (GM) pickup truck. It incorporates the latest Diesel technology in order to improve on the inherent strengths of a Diesel engine, such as fuel economy, torque and reliability, while also producing higher output, smoother driveability, and lower noise. The Duramax 6600 is an entirely new 90° V8 direct injection (DI) intercooled engine with a water-cooled turbocharger. Its fuel injection system employs a fully electronically controlled common rail system that has high-pressure injection capabilities. Isuzu had the design responsibility of the base engine, while GM Truck Group was responsible for designing the installation and packaging within the vehicle. Engine validation relied on Isuzu's proven validation process, in addition to GM Powertrain's expertise in engine validation.

It has been shown that the addition of a small amount of nanoparticles into a fluid results in anomalous increase in the thermal conductivity of the mixture, and the resulting nanofluid may provide better overall thermal management and better lubrication in many applications, such as heat transfer fluids, engine oils, transmission fluids, gear oils, coolants and other similar fluids and lubricants. The potential benefits of this technology to the automotive and related industries would be more efficient engines, reduced size and weight of the cooling and propulsion systems, lowered operating temperature of the mechanical systems, and increased life of the engine and other mechanical systems. The new mechanisms for this phenomenon of anomalous thermal conductivity increase have been proposed. The heat transfer properties of a series of graphite nanofluids were presented, and the experimental results were compared with the conventional heat transfer theory for pure liquids.

Hydroformed components are replacing stamped parts in automotive frames and front end and roof structures to improve the crash performance of vehicles. Due to the increasing application of hydroformed components, a better understanding of the crash behavior of these parts is necessary to improve the correlation between full-vehicle crash tests and FEM analysis. Accurately predicting the performance of hydroformed components will reduce the amount of physical crash testing necessary to develop the new components and new vehicles as well as reduce cycle time. Virgin material properties are commonly used in FEM analysis of hydroformed components, which leads to erroneous prediction of the full-vehicle crash response. Changes in gauge and material properties during the hydroforming process are intuitive and can be reasonably predicted by using forming simulations. The effects of the forming process have been investigated in the FEA models that are created for crash analyses.

Quasi-static tensile properties of TRIP590 steels from three different manufacturers were investigated using digital image correlation (DIC). The focus was on the post-uniform elongation behavior which can be very different for steels of the same grade owing to different manufacturing processes. Miniature tensile specimens, cut at 0°, 45°, and 90° relative to the rolling direction, were strained to failure in an instrumented tensile stage. True stress-true strain curves were computed from digital strain gages superimposed on digital images captured from one gage section surface during tensile deformation. Microstructural phases in undeformed and fracture specimens were identified with optical microscopy using the color tint etching process. Fracture surface analyses conducted with scanning electron microscopy and energy dispersive spectroscopy were used to investigate microvoids and inclusions in all materials.

Over the last two decades, engine research was mainly focused on reducing fuel consumption in view of compliance with more stringent homologation cycles and customer expectations. As it is well known, the objective of overall engine efficiency optimization can be achieved only through the improvement of each element of the efficiency chain, of which mechanical constitutes one of the two key pillars (together with thermodynamics). In this framework, the friction reduction for each mechanical subsystem has been one of the most important topics of modern Diesel engine development. The present paper analyzes the crankshaft potential as contributor to the mechanical efficiency improvement, by investigating the synergistic impact of crankshaft design itself and oil viscosity characteristics (including new ultra-low-viscosity formulations already discussed by the author in [1]).

Over the last two decades, engine research has been mainly focused on reducing fuel consumption in view of compliance with stringent homologation targets and customer expectations. As it is well known, the objective of overall engine efficiency optimization can be achieved only through the improvement of each element of the efficiency chain, of which mechanical constitutes one of the two key pillars (together with thermodynamics). In this framework, the friction reduction for each mechanical subsystems has been one of the most important topics of modern Diesel engine development. In particular, the present paper analyzes the lubrication circuit potential as contributor to the mechanical efficiency improvement, by investigating the synergistic impact of oil circuit design, oil viscosity characteristics (including new ultra-low formulations) and thermal management. For this purpose, a combination of theoretical and experimental tools were used.