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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.

This paper presents the “Virtual Failure Mode and Effects Analysis (vFMEA)” system, which is a high-fidelity electrical-failure-simulation platform, and applies it to the software verification of an electric power steering (EPS) system. The vFMEA system enables engineers to dynamically inject a drift fault into a circuit model of the electronic control unit (ECU) of an EPS system, to analyze system-level failure effects, and to verify software-implemented safety mechanisms, which consequently reduces both cost and time of development. The vFMEA system can verify test cases that cannot be verified using an actual ECU and can improve test coverage as well. It consists of a cycle-accurate microcontroller model with mass-production software implemented in binary format, analog and digital circuit models, mechanical models, and a state-triggered fault-injection mechanism.

“Virtual Failure Mode and Effects Analysis” (vFMEA), a novel safety-verification method of control software for automotive electronic systems, was proposed to save prototyping cost at verification stage. The proposed vFMEA is system-level FMEA method, which uses virtualized electronic control units (ECUs) consisting of microcontroller models on a microcontroller simulator and a transistor-level circuit models on a circuit simulator. By using the structure, the control software in binary code formats can be verified when a circuit-level fault occurs in the ECU hardware. As an illustrative example, vFMEA was applied to an engine ECU. As a result of short-circuit fault into a driver IC, engine revolution and engine speed decreased. However, the engine continued to operate normally when an open-circuit fault occurred in a capacitor connected in parallel. Effects of the hardware faults in ECU on a vehicle are demonstrated; thereby software verification can be performed using vFMEA system.

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.

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.

This paper investigates the application of the Hybrid FE-SEA method to the prediction of the Transmission Loss (TL) of a front-of-dash component. SEA subsystems are used to represent the source and receiving chambers of a TL test suite and an FE structural subsystem is used to represent the dash component. The potential advantages of the Hybrid FE-SEA method for this application are that: (i) it can provide detailed narrowband predictions of the radiation efficiency and TL of a given component across a broad frequency range and (ii) the computational cost of the approach is typically several orders of magnitude less than that of traditional low frequency FE/BEM/IEM methods. The approach is also potentially well suited to existing analysis processes since information from detailed component level models can be used to update and refine targets obtained from system level SEA models (the use of a common environment for such models simplifies model management).

This paper presents an experimental comparative study between the OCTOGONAL-Gate Silicon-on-Insulator (SOI) nMOSFET (OSM) and the conventional SOI nMOSFET (CSM) considering the same bias conditions and the same gate area (AG), in order to verify the influence of this new MOSFET layout style to handle high current for automotive modules. Analog integrated circuits (ICs) design tends to be considered an art due to a large number of variables and objectives to achieve the product specifications. The designer has to find the right tradeoffs to achieve the desired automotive specification such as low power, low voltage, high speed and high current driver. SOI MOSFET's technology is required to provide the growth of embedded electronics. This growth is driving demand for power-handling devices that are smaller yet still provide high current driver capabilities.

Predicting the vibration of a motor gearbox assembly driven by a PWM inverter in the early stages of development is demanding because the assembly is one of the dominant noise sources of electric vehicles (EVs). In this paper, we propose a simulation model that can predict the transient vibration excited by gear meshing, reaction force from the mount, and electromagnetic forces including the carrier frequency component of the inverter up to 10 kHz. By utilizing the techniques of structural model reduction and state space modeling, the proposed model can predict the vibration of assembly in the operating condition with a system level EV simulator. A verification test was conducted to compare the simulation results with the running test results of the EV.

Future automobiles are required to support an increasing number of complex, distributed functions such as active safety and X-by-wire. Because of safety concerns and the need to deliver correct designs in a short time, system properties should be verified in advance on function models, by simulation or model checking. To ensure that the properties still hold for the final deployed system, the implementation of the models into tasks and communication messages should preserve properties of the model, or in general, its semantics. FlexRay offers the possibility of deterministic communication and can be used to define distributed implementations that are provably equivalent to synchronous reactive models like those created from Simulink. However, the low level communication layers and the FlexRay schedule must be carefully designed to ensure the preservation of communication flows and functional outputs.

During the early phase of vehicle development, one of the key design attributes to consider is visibility for the driver. Visibility is the ability to see the surrounding environment as one is driving. This need should drive the vehicle design enabling a move favorable view for the driver. Certain vehicle characteristics such as the size of windshield and the design of the pillar influence the perception of visibility for the driver. One specific characteristic influencing satisfaction is forward up vision, which is the subject of this paper. The objective of this project was to analyze the influence of forward up vision on driver satisfaction under real world driving conditions. Other influences such as the positon of the occupant in the seat was also studied. This study was supported by research, statistical data analysis and dynamic clinics.

During the early phase of vehicle development, one of the key design attributes to consider is visibility for the driver. Visibility is the ability to see one’s surrounding environment while they are driving. Therefore, it is one of the key requirements to be considered during the vehicle design. Certain vehicle characteristics such as the size of windshield and the design of the pillars influence the perception of visibility for the driver. One specific characteristic influencing satisfaction is A-pillar obscuration and location, which is the subject of this paper. The objective of this project is to analyze the relationship between the A-pillar obscuration/location with the driver satisfaction under real world driving conditions, based on research, statistical data analysis and dynamic clinics. Other influences, such as the position of the occupant in the seat was also studied and captured in this paper.

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.

It has the aim to discuss the evolution of electronics components, integrated circuits, new transistors concepts and associate its importance in the automotive modules. Today, the challenge is to have devices which consume less power, suitable for high-energy radiation environment, less parasitic capacitances, high speed, easier device isolation, high gain, easier scale-down of threshold voltage, no latch-up and higher integration density. The improvement of those characteristics mentioned and others in the electronic devices enable the automotive industry to have a more robust product and give the possibility to integrate new features in comfort, safety, infotainment and telematics modules. Finally, the intention is to discuss advanced structures, such as the silicon-on-insulator (SOI) and show how it affects the electronics modules applied for the automotive area.

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 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.

Among the most important finishing structures of a vehicle interior, the door trim panels reduce external noises, present ergonomic concepts generating comfort, improve appearance, and provide objects storage, knobs and buttons. The panels usually composed of several molded parts (trim, armrest, etc.) connected to each other also have structural function as support closing loads, protect occupants of door internal mechanisms, energy absorption in side impacts and resist misuse conditions. Therefore, these trims usually made of polymeric materials must to present good structural integrity, demanding appropriate connections between components to have good load distribution. The connections between parts can be made using bolts, interference fits (like self-locking), welding tubular plastic towers (heat stakes), or clips (such as snap fits) and last two are the most common due to be cheap and with good retention.

The main objective of this paper is to simulate the springback using combined kinematic/isotropic hardening model. Material parameters in the hardening model are identified by an inverse method. Three-point bending test is conducted on 6022-T4 aluminum sheet. Punch stroke, punch load, bending strain and bending angle are measured directly during the tests. Bending moments are then computed from these measured data. Bending moments are also calculated based on a constitutive model. Material parameters are identified by minimizing the normalized error between two bending moments. Micro genetic algorithm is used in the optimization procedure. Stress-strain curves is generated with the material parameters found in this way, which can be used with other plastic models. ABAQUS/Standard 5.8, which has the combined isotropic/kinematic hardening model, is used to simulate draw-bend of 6022-T4 series aluminum sheet. Absolute springback angles are predicted very accurately.

Sintered parts mechanical properties are very sensitive to final density, which inevitable cause an enormous density gradient in the green part coming from the compaction process strategy. The current experimental method to assess green density occurs mainly in set up by cutting the green parts in pieces and measuring its average density in a balance using Archimedes principle. Simulation is the more accurate method to verify gradient density and the main benefit would be the correlation with the critical region in terms of stresses obtained by FEA and try to pursue the optimization process. This paper shows a case study of a part that had your fatigue limit improved 1000% using compaction process simulation for better optimization.

Efficient methods for simulating operators performing part handling tasks in manufacturing plants are needed. The simulation of part handling motions is an important step towards the implementation of virtual manufacturing for the purpose of improving worker productivity and reducing injuries in the workplace. However, industrial assembly tasks are often complex and involve multiple interactions between workers and their environment. The purpose of this paper is to present a series of industrial simulations using the Human Motion Simulation Framework developed at the University of Michigan. Three automotive assembly operations spanning scenarios, such as small and large parts, tool use, walking, re-grasping, reaching inside a vehicle, etc. were selected.

This paper presents a simplified approach for formability simulation of automotive body structural sections in the early design stage of vehicle development process. Plane strain approach is investigated for its applicability and accuracy by comparing the analytical results with the measured results of automotive body side panel. The plane strain approach was tried based on the fact that for a certain section location of a stamped panel, the minor strains are relatively small and negligible compared to the major strains. The state of plane strain can be induced mainly through symmetry and applied boundary conditions. This approach is both cost effective and time saving for analyzing sheet metal formability in early vehicle development stage, since only few sections of the entire panel need be analyzed.