Search Results

Since their introduction in automobiles, polymeric materials have enabled designers and engineers to differentiate products based on performance attributes, mechanical response, aesthetics, and manufacturing techniques. A large segment of these applications utilizes polypropylene (PP) resins. One of the attractive features of PP polymers is the ability to tailor their mechanical, thermal and processing performance envelope via modification of their composition and the addition of fillers. Key to the successful application of PP resins in structural systems is the ability of designers and engineers to understand the material response and to properly model the behavior of PP structures upon different mechanical and thermal loading conditions.

European car manufacturers and suppliers are currently stepping up the effort to develop solutions to meet pedestrian safety requirements, which will come into effect, starting in 2005. Numerous concepts, both active and passive, are being investigated to fulfil the pedestrian safety specifications, in addition to the many other limitations imposed on the front end of the car. All of them deal with the topic of energy absorption. Here, an approach to achieving a passive solution will be presented, describing the development of the ‘Virtual Stiffness Profile’ (VSP) to help identify the optimum balance of engineering and styling to meet the requirements. In this paper, specific emphasis is placed on the lower leg impact.

Modular front-end carriers to pre-assemble front-end components such as cooling systems, lights, and bumper beam have been in production in different vehicles for several years. Compression molded or overmolded steel/plastic carriers have traditionally been used. The present paper explains the design, material options, and engineering optimization of a composite front-end carrier, which utilizes long glass fiber injection moldable resins and adhesively bonded steel reinforcements. Experimental evaluation of prototypes shows the system met the functional performance requirements at minimum weight.

Automotive manufacturers are driving for improvement, creativity and innovation in vehicle systems in order to differentiate products in the global market. Progress in fuel efficiency, occupant safety, comfort, recyclable friendly pre-assembled modular systems, and novel manufacturing methods is difficult to achieve if no major departure from the traditional design, engineering, material mix, and assembly approaches is considered. More importantly, these benefits will not materialize unless the relationship between automotive manufacturers and suppliers changes, allowing suppliers to take a more active role in the vehicle development process. The present paper explores achievements made towards the development of new, innovative technologies to address simplification and overall performance improvements using non-traditional materials.

An approach to a solution to conflicts of interest posed by new pedestrian safety requirements is presented here. The effects of various design parameters on pedestrian safety, and the resulting influence on other requirements are examined. Limitations and possible solution envelopes are determined with regard to styling, packaging and functionality. Material choice and the stiffness of the structure are used as variables to fine-tune the system. The paper explores the effects of using current front-end materials and new material options versus what can be achieved by modifying or developing designs and structures to fulfil the set of conflicting requirements. Computer Aided Engineering (CAE) techniques are used extensively for this work, in order to determine the sensitivity of the behaviour of front-end systems to design and material characteristics.