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This paper presents the results of a strength analysis of a newly developed steel structure featuring a special cross section achieved with the hydroforming process that minimizes the influence of springback. This structure has been developed in pursuit of further weight reductions for the steel body in white. A steel tube with tensile strength of 590 MPa was fabricated in a low-pressure hydroforming operation, resulting in thicker side walls. The results of a three-point bending test showed that the bending strength of the new steel structure with thicker side walls was substantially increased. A finite element crush analysis based on the results of a forming analysis was shown to be effective in predicting the strength of the structure, including the effect of work hardening.

A flag is a global boolean variable used to achieve synchronization between various tasks of an embedded system. An application implementing flags performs actions or events based on the value of the flags. If flag variables are not implemented properly, certain synchronization related issues can arise which can lead to unexpected behavior or failure of the underlying system. In this paper, we present an automated verification technique to identify and verify flag usage patterns at an early stage of code development. We propose a two-step approach which consists of: a. identification of all potential flag variables and b. verification of flag usage patterns against predefined set of rules. The results of our experiment demonstrate that the proposed approach reduces the cost and complexity of the flag review process by almost 70%.

To reduce quenching distortion, step gas quenching has been proposed in recent years, which refers to rapid gas cooling of steel from austenitizing temperature to a point above or below Ms temperature, where it is held for a specific period of time, followed by gas cooling. In this study, by using infrared thermography combined with conventional thermocouple, a new temperature monitoring and control system was developed to realize the step gas quenching process of a hypoid ring gear after low pressure carburizing. The test production results indicate that by using the new monitoring and control system, we can control the gas quenching process and the distortion of carburized gear treated by step gas quenching can be reduced significantly compared with standard gas quenching.

Technologies applied to the Nissan Tino Hybrid, marketed in March 2000, in Japan, are expected to evolve into the core powertrain technologies of the future, for the following technical advantages inherent to hybrid EVs: 1 Regeneration of deceleration energy 2 Motor driven propulsion at low speed, combined with power-assisted operation in the mid- and high-load ranges. It is expected that a number of models will be introduced to the market in the future, which pursue these advantages in various forms, resulting in HEV technologies to accelerate the use of electric power for the vehicle. Fuel cell vehicles will be included in this future scenario. In this paper, our view on the future HEV technologies will be described. In addition, the latest technologies applied to the Nissan Tino Hybrid will be introduced.

Cold forging has been applied to form a component of the constant velocity joint. This part, slide joint housing, is made of JIS S48C (SAE 1048) high carbon steel. As it has been very difficult to form this part by cold forging, it has been formed by hot forging up until now. Success was obtained in forming this part by cold forging through improving the chemical composition of S48C high carbon steel and tool design, determining the optimum condition for heat treating the slug, and using a TiC coated punch. Since this slide joint housing, which is nearly net shape, was able to be formed through this cold forging technique, material saving was improved about 40% and machining time was reduced much in comparison with hot forging. Manufacturing cost can be greatly reduced through this cold forging which has been developed.

The demands on valve seat insert materials, in terms of providing greater wear-resistance at higher temperatures, enhanced machinability and using non-environmentally hazardous materials at a reasonably low cost have intensified in recent years. Due therefore to these strong demands in the market, research was made into the possibility of producing a new valve seat insert material. As a result a high speed steel based new improved material was developed, which satisfies the necessary required demands and the evaluation trials, using actual gasoline engine endurance tests, were found to be very successful.

Generally, cobalt-contained sintered materials have mainly been applied for exhaust valve seat inserts (VSI). However, there is a trend to restrict the use of cobalt as well as lead environmental law, and cobalt is expensive. To solve these problems, a new exhaust VSI on the assumption of being cobalt and lead free, applicable for conventional engines, having good machinability, and with a reduced cost was developed. The new exhaust VSI is a material dispersed with two types of hard particles, Fe-Cr-C and Fe-Mo-Si, in the matrix of an Fe-3.5mass%Mo at the ratio of 15 mass % and 10 mass % respectively.

Nissan has developed a second generation ceramic turbocharger rotor which provides greater reliability and higher performance than a conventional ceramic rotor. The new rotor is made of silicon nitride, which has demonstrated sufficient strength in vehicle applications. The bonding technique for joining the ceramic rotor to the metal shaft has been confirmed through experimentation to have sufficient reliability. The second generation rotor is featured by the low stress design and higher dynamic strength, and two factors contribute to its higher reliability. The rotor shape was optimized on the basis of results obtained in two analyses of particle impact resistance and applied combined stress. Test results show that the reliability of the second generation rotor have been substantially improved over those of the conventional rotor now being used on production vehicles.

The energy crisis and rising gas price in the 2000s led to a growing popularity of hybrid vehicles. Hyundai-Kia Motors has been challenging to develop the new efficient eco-technology since introducing the mild type compact hybrid electric vehicle for domestic fleet in 2004 to meet the needs of the increasing automotive-related environmental issues. Now Hyundai has recently debuted a full HEV for global market, Sonata Hybrid. This system is cost effective solution and developed with the main purpose of improving fuel consumption and providing fun to drive. Presenter Seok Joon Kim, Hyundai Motor Company

Nissan’s variable compression turbo (VC-Turbo) engine has a multilink mechanism that continuously adjusts the top and bottom dead centers of the piston to change the compression ratio and achieve both fuel economy and high power performance. Increasing the exhaust gas recirculation (EGR) rate is an effective way to further reduce the fuel consumption, although this increases the exhaust gas condensation in the cylinder bores, causing a more corrosive environment. When the EGR rate is increased in a VC-Turbo engine, the combined effect of piston sliding and exhaust gas condensation at the top dead center accelerates the corrosive wear of the thermal spray coating. Stainless steel coating is used to improve the corrosion resistance, but the adhesion strength between the coating and the cylinder bores is reduced.

Three Japanese automobile manufacturers-Mitsubishi Motors Corp., Nissan Motor Co., Ltd., and Toyo Kogyo Co., Ltd.-have been making efforts over the past three years to design and develop effective thermal reactor-exhaust gas recirculation and catalytic converter systems suitable for small engines. The work is being done by members participating in the IIEC (Inter-Industry Emission Control) Program, and the exhaust emission levels of the concept vehicles developed by these companies have met the goal established by the IIEC Program at low mileage. Each system, however, has a characteristic relationship between exhaust emission level and loss of fuel economy. Much investigation is required, particularly with respect to durability, before any system that will fully satisfy all service requirements can be completed. This paper reports the progress of research and development of the individual concept vehicles.

The key-points in the diffusion bonding technique of green compacts during sintering, are the material compositions, which should be chosen according to their dimensional change during sintering, and the fitting clearance, which should be maintained in the range of press fit. Applying this technique, we have developed sinter-diffusion bonded idler sprockets for automotive engines by comfirming the bonding strength and torsional fatigue strength. And we also have developed a nondestructive analysis method for assuring the joint strength of idler sprockets in the mass production.

This paper presents the technologies incorporated in an electric vehicle (EV)/hybrid electric vehicle (HEV) inverter built with power semiconductors of silicon carbide (SiC) metal-oxide-semiconductor field-effect transistors (MOSFETs) instead of conventional silicon (Si) insulated gate bipolar transistors (IGBTs). A SiC inverter prototype of 2.9 L in size for driving an 80-kW motor was fabricated and evaluated on a motor test bench. The SiC inverter prototype attained average efficiency of 98.5% in the Worldwide harmonized Light-duty Test Cycle (WLTC) driving mode. The two main technologies achieved with this SiC inverter prototype are described. The first one is a new direct-cooled power module with a thick copper (Cu) heat spreader located under the semiconductors that improves thermal resistance by 34% compared with a conventional direct-cooled power module.

The durability test with road-load input is necessary for evaluating durability of body and chassis structure in automotive applications. This paper shows the method to analyze road-load input to a suspension system for development of a simple component level bench test. This method enables the extraction of the essential inputs to evaluate the durability of suspension parts using the transfer function (frequency response function) measured by Multi-axial Road Simulator and wheel force transducers. These extracted inputs contribute to development of a new realistic component bench test.

The effects of lubricant oil and fuel properties on low speed pre-ignition (LSPI) occurrence in boosted S.I. engines were experimentally evaluated with multi-cylinder engine and de-correlated oil and fuel matrices. Further, the auto-ignitability of fuel spray droplets and evaporated homogeneous fuel/oil mixtures were evaluated in a combustion bomb and pressure differential scanning calorimetry (PDSC) tests to analyze the fundamental ignition process. The work investigated the effect of engine conditions, fuel volatility and various lubricant additives on LSPI occurrence. The results support the validity of aspects of the LSPI mechanism hypothesis based on the phenomenon of droplets of lubricant oil/fuel mixture (caused by adhesion of fuel spray on the liner wall) flying into the chamber and autoigniting before spark ignition.

This paper describes a newly developed steel composition and surface modification methods for improving the rolling contact fatigue strength of parts used in transmission systems, especially continuously variable transmissions (CVTs) to increase their torque capacity. The mechanisms of two types of typical rolling contact fatigue phenomenon in case hardening steel were examined with the aim of improving rolling contact fatigue strength. One concerned white etching constituents (WEC) and the other one concerned peculiar microstructural changes caused by hydrogen originating from decomposition of the lubrication oil as a result of repeated rolling contact stress cycles. The rolling contact fatigue strength limit due to WEC has been improved markedly by dispersing fine M23C6 alloy carbides in the martensite matrix at the subsurface layer of parts.

Methods to evaluate the light degradation environment of automotive interior materials in the market have been studied. The aim for this study was calculating the light degradation environment quantitatively on the basis of meteorologically observed value. For the quantitative light degradation factor, Equivalent Total Sunshing Energy (ESE) was used. ESE was a value presented by the authors in 1982. Although ESE correlates closely with the degradation, it takes more than one year to determine at a given resion. With this new method, a monthly average daily ESE at the gien resion was estimated numetically based on the meteorologically observed monthly average solar radiation and monthly maximum air temperature at the resion. The calculated value in relation to actual measured value were accurate to within 10%.

The International Lubricant Standardization and Approval Committee (ILSAC) ATF subcommittee members have compared the two oxidation bench test methods, Aluminum Beaker Oxidation Test (ABOT) and Indiana Stirring Oxidation Stability Test (ISOT), using a number of factory-fill and service-fill ATFs obtained in Japan and in the US. In many cases, the ATFs were more severely oxidized after the ABOT procedure than after the same duration of the ISOT procedure. The relative severity of these two tests was influenced by the composition of the ATFs. The bench test oxidation data were compared with the transmission and the vehicle oxidation test data.

This paper describes the plastic body panels developed for the Nissan Be-1 which was released and put on sale in Japan in January 1987. The panels include four body parts: left and right front fenders, front apron and rear apron. They are made of a thermoplastic resin and are produced by injection molding. The top paint coat can be sprayed on all four panels simultaneously with other steel body panels. The panels provide a high-quality appearance that is in no way inferior to the paint quality of steel panels. This is true during initial use as well as over long periods of time. Besides providing weight reductions, they also deliver improved resistance to impacts. CAE process was applied to develop these panels and proved to be quite effective.

Internal combustion engines experience severe valve train wear and the reduction of valve seat and seat insert wear has been a long-standing issue. In this work, worn valve seats and inserts were examined to obtain a fundamental understanding of the wear mechanisms and the results were applied in developing new valve seat insert materials. The new exhaust valve insert material for gasoline engines is a sintered alloy steel containing Co-base hard particles, with lead infiltrated only for inserts used in unleaded gasoline engines. The new intake valve insert material for gasoline engines is a high-Mo sintered steel, obtained through transient liquid phase sintering and with copper precipitated uniformly. This material can be used for both leaded and unleaded gasoline engines. Valve and valve seat insert wear has long been an issue of concern to engine designers and manufacturers.