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This paper describes the application of a life prediction method for stainless steel exhaust manifolds. Examination of the exhaust manifold cracks indicated that many of the failures could be attributed to out-of-phase thermal fatigue due to compressive strains that occur at high temperatures. Therefore, the plastic strain range was used as the crack initiation criteria. In addition, the comparison of the calculated thermal fatigue stress-strain hysteresis to the experimental hysteresis made it clear that it was essential to use the stress-strain data that was obtained through tensile and compression testing by keeping the test specimens at the maximum temperature of the thermal fatigue test mode. A finite element crack prediction method was developed using the aforementioned material data and good results were obtained.

This paper builds on previous research on the development of a head displacement model for restrained occupants in frontal collisions. Physical and mathematical simulations were performed utilizing the 5th percentile female and 50th percentile male Hybrid III dummies to measure the effect of occupant size, seat belt system design and crash severity on resultant head displacement of occupants in frontal collisions. Sled and simulation accelerations ranged from 10 g to 20 g with delta-V's from 6.6 m/s to 10.0 m/s. Results indicate a difference between the 5th percentile female and 50th percentile male dummies. Preliminary assessment of head displacement as a function of occupant kinetic energy demonstrated good correlation.

Little has been reported in the literature on the compressive properties of muscle. These data are needed for the development of finite element models that address impact of the muscles, especially in the study of pedestrian impact. Tests were conducted to characterize the compressive response of muscle. Volunteers, cadaveric specimens and a Hybrid III dummy were impacted in the posterior and lateral aspect of the lower leg using a free flying pendulum. Volunteer muscles were tested while tensed and relaxed. The effects of muscle tension were found to influence results, especially in posterior leg impacts. Cadaveric response was found to be similar to that of the relaxed volunteer. The resulting data can be used to identify a material law using an inverse method.

At the 2002 MSEC, we presented a paper on the sled test evaluation of racecar head/neck restraint performance (Melvin, et al. 2002). Some individuals objected to the 3 msec clip filtering procedures used to eliminate artifactual spikes in the neck tension data for the HANS® device. As a result, we are presenting the same test data with the spikes left in the neck force data to reassure those individuals that these spikes did not significantly affect the results and conclusions of our original paper. In addition we will add new insights into understanding head/neck restraint performance gained during two more years of testing such systems. This paper re-evaluates the performance of three commercially available head/neck restraint systems using a stock car seating configuration and a realistic stock car crash pulse. The tests were conducted at an impact angle of 30 degrees to the right, with a midsize male Hybrid III anthropomorphic test device (ATD) modified for racecar crash testing.

Recent action by some racecar sanctioning bodies making head/neck restraint use mandatory for competitors has resulted in a number of methods attempting to provide head/neck restraint. This paper evaluates the performance of a number of commercially available head/neck restraint systems using a stock car seating configuration and a realistic stock car crash pulse. The tests were conducted at an impact angle of 30 degrees to the right, with a midsize male Hybrid III anthropomorphic test device (ATD) modified for racecar crash testing. A six-point latch and link racing harness restrained the ATD. The goal of the tests was to examine the performance of the head/neck restraint without the influence of the seat or steering wheel. Three head/neck restraint systems were tested using a sled pulse with a 35 mph (56 km/h) velocity change and 50G peak deceleration. Three tests with three samples of each system were performed to assess repeatability.

Although biomechanical studies on the knee-thigh-hip (KTH) complex have been extensive, interactions between the KTH and various vehicular interior design parameters in frontal automotive crashes for newer models have not been reported in the open literature to the best of our knowledge. A 3D finite element (FE) model of a 50th percentile male KTH complex, which includes explicit representations of the iliac wing, acetabulum, pubic rami, sacrum, articular cartilage, femoral head, femoral neck, femoral condyles, patella, and patella tendon, has been developed to simulate injuries such as fracture of the patella, femoral neck, acetabulum, and pubic rami of the KTH complex. Model results compared favorably against regional component test data including a three-point bending test of the femur, axial loading of the isolated knee-patella, axial loading of the KTH complex, axial loading of the femoral head, and lateral loading of the isolated pelvis.

Cervical facet joints are implicated as a major source of pain after whiplash injury. The purpose of this study was to investigate the proposed capsule strain injury mechanism of whiplash pain using neurophysiologic methods. Strain thresholds, threshold distribution, saturation strains and afterdischarge responses of capsule neural receptors were characterized in vivo. Goat C5-C6 facet joint capsules were used to identify and characterize capsule receptors in response to controlled uniaxial stretch by recording C6 dorsal rootlet nerve discharge. The joints were stretched at 0.5 mm/sec in a series of tests with 2 mm increments until the capsule ruptured. Ninety-two identified units were responsive to physiologic or noxious stretch while 28 were silent receptors. Among the 50 characterized responsive units, 42 showed low strain thresholds at 10.2±4.6% while 8 had high strain thresholds at 47.2±9.6%.

There has been much debate over “whiplash”-induced temporomandibular joint (TMJ) dysfunction following low-speed, rear-end automobile collisions. While several authors have reported TMJ injury based on case studies post collision, there has been little biomechanical evidence showing that rear-end impact was the primary cause of such injury. The purpose of this study was to measure the relative translation between the upper and lower incisors in cadavers subjected to low-speed, rear-end impacts. High-speed x-ray images used for this analysis were reported previously for the analysis of cadaveric cervical spine kinematics during low-speed, rear-end impacts. The cadavers were positioned at various seatback angles and body postures, producing an overall picture of various seating scenarios.

Typical automotive related abdominal injuries occur due to contact with the rim of the steering wheel, seatbelt and armrest, however, the rate is less than in other body regions. When solid abdominal organs, such as the liver, kidneys and spleen are involved, the injury severity tends to be higher. Although sled and pendulum impact tests have been conducted using cadavers and animals, the mechanical properties and the tissue level injury tolerance of abdominal solid organs are not well characterized. These data are needed in the development of computer models, the improvement of current anthropometric test devices and the enhancement of our understanding of abdominal injury mechanisms. In this study, a series of experimental tests on solid abdominal organs was conducted using porcine liver, kidney and spleen specimens. Additionally, the injury tolerance of the solid organs was deduced from the experimental data.

A MADYMO model of a racing car and driver was driven by 3-D accelerations recorded in actual crashes. Helmet, belt restraint, and padding characteristics were obtained from dynamics tests. Model results of HIC, head accelerations and neck forces and moments were studied along with driver injuries to provide insight into the efficacy of current injury assessment parameters used with the head and neck of crash test dummies. The results are also used to discuss the kinematics performance of the crash test dummy neck as modeled by the MADYMO version of the Hybrid III midsize male crash test dummy.

A total of eight low-speed, rear-end impact tests using two Post Mortem Human Subjects (PMHS) in a seated posture are reported. These tests were conducted using a HYGE-style mini-sled. Two test conditions were employed: 8 kph without a headrestraint or 16 kph with a headrestraint. Upper-body kinematics were captured for each test using a combination of transducers and high-speed video. A 3-2-2-2-accelerometer package was used to measure the generalized 3D kinematics of both the head and pelvis. An angular rate sensor and two single-axis linear accelerometers were used to measure angular speed, angular acceleration, and linear acceleration of T1 in the sagittal plane. Two high-speed video cameras were used to track targets rigidly attached to the head, T1, and pelvis. The cervical spine kinematics were captured with a high-speed, biplane x-ray system by tracking radiopaque markers implanted into each cervical vertebra.

The primary purpose of this research was to generate a “linked set” of data between collision severity, occupant weight and collision-induced seat belt markings to assist in reconstruction of motor vehicle accidents. The secondary purpose was to establish a preliminary threshold of belt load to produce known collision-induced seat belt markings. Sled tests were performed utilizing Hybrid III 5th and 50th percentile crash test dummies. Sled accelerations ranged from 10.0 g to 23.6 g and Delta-V’s from 6.4 m/s to 11.3 m/s. Post-test inspections and photographs taken of the seat belts documented collision-induced markings on components such as the D-Ring, latch plate, webbing and stitching. Belt loads were analyzed to establish preliminary thresholds for the production of observable markings.

In recent years, requests for automotive comfort are increasing, and the development of seats that cause little fatigue, even for long distance driving, has been required. Until now, seat riding comfort has been studied mainly using dynamic vibration analysis; and there are few studies that give importance to the sensory characteristics of the driver and passengers. In order to apply to the design of comfortable seating, we developed a new seat evaluation method that emphasizes the interaction between the human body and seat. For static seating comfort, we determined seat compliance as a new evaluation index by using a human body pressure distribution that is calculated by dividing the seat into 16 segments, and is related to seat flexion. For dynamic riding comfort, speed of the human body pressure distribution, and the acceleration of each human body part were made into an index.

The purpose of this study was to determine the effect of head-neck position on cervical facet stretch during low speed rear end impact. Twelve tests were conducted on four Post Mortem Human Subjects (PMHS) in a generic bucket seat environment. Three head positions, namely Normal (neutral), Zero Clearance between the head and head restraint, and Body Forward positions were tested. A high-speed x-ray system was used to record the motion of cervical vertebrae during these tests. Results demonstrate that: a) The maximum mean facet stretch at head restraint contact occurs at MS4 and MS5 for the Body Forward condition, b) The lower neck flexion moment, prior to head contact, shows a non-linear relationship with facet stretch, and c) “Differential rebound” during rear end impact increases facet stretch.

Currently, three-dimensional finite element models of the human body have been developed for frequently injured anatomical regions such as the brain, chest, extremities and pelvis. While a few models of the human body include the abdomen, these models have tended to oversimplify the complexity of the abdominal region. As the first step in understanding abdominal injuries via numerical methods, a 3D finite element model of a 50th percentile male human abdomen (WSUHAM) has been developed and validated against experimental data obtained from two sets of side impact tests and a series of frontal impact tests. The model includes a detailed representation of the liver, spleen, kidneys, spine, skin and major blood vessels.

Application of SiC power devices is regarded as a promising means of reducing the power loss of power modules mounted in power control units. Due to those high thermostable characteristics, the power module with SiC power devices are required to have higher operating temperature than the conventional power module with Si power devices. However, the limitations of current packaging technology prevent the utilization of the full potential of SiC power devices. To resolve these issues, the development of device bonding technology is very important. Although transient liquid phase (TLP) bonding is a promising technology for enabling high temperature operation because its bonding layer has a high melting point, the characteristics of the TLP bonding layer tend to damage the power devices. This paper describes the development of a bonding technology to achieve high temperature operation using a stress reduction effect.

In order to improve the fuel efficiency of Hybrid Electric Vehicles (HEVs), it is necessary to reduce the size and power loss of the HEV Power Control Units (PCUs). The loss of power devices (IGBTs and FWDs) used in a PCU accounts for approximately 20% of electric power loss of an HEV. Therefore, it is important to reduce the power loss while size reduction of the power devices. In order to achieve the newly developed PCU target for compact-size vehicles, the development targets for the power device were to achieve low power loss equivalent to its previous generation while size reduction by 25%. The size reduction was achieved by developing a new RC-IGBT (Reverse Conducting IGBT) with an IGBT and a FWD integration. As for the power loss aggravation, which was a major issue due to this integration, we optimized some important parameters like the IGBT and FWD surface layout and backside FWD pattern.

In October 1998, a new mass-produced car with titanium engine-valves was released from TOYOTA Motor Corporation. Both intake and exhaust valves were manufactured via a newly developed cost-effective P/M forging process. Furthermore, the material which was specially designed for the exhaust one is a unique titanium metal matrix composite (MMC). This paper discusses the materials and manufacturing methods used. The tensile, fatigue strength and creep resistance of the MMC are always superior to those for the typical heat-resistant steel of 21-4N. Both valves have achieved sufficient durability and reliability with a manufacturing cost acceptable for mass-produced automobile parts.

Numerical analyses frequently accompany experimental investigations that study injury biomechanics and improvements in automotive safety. Limited by computational speed, earlier mathematical models tended to simplify the system under study so that a set of differential equations could be written and solved. Advances in computing technology and analysis software have enabled the development of many sophisticated models that have the potential to provide a more comprehensive understanding of human impact response, injury mechanisms, and tolerance. In this article, 50 years of publications on numerical modeling published in the Stapp Car Crash Conference Proceedings and Journal were reviewed. These models were based on: (a) author-developed equations and software, (b) public and commercially available programs to solve rigid body dynamic models (such as MVMA2D, CAL3D or ATB, and MADYMO), and (c) finite element models.

The objective of this work was to evaluate a new tool for assessing brain injury. Many race car drivers have suffered concussion and other brain injuries and are in need of ways of evaluating better head protective systems and equipment. Current assessment guidelines such as HIC may not be adequate for assessing all scenarios. Finite element models of the brain have the potential to provide much better injury prediction for any scenario. At a previous Motorsports conference, results of a MADYMO model of a racing car and driver driven by 3-D accelerations recorded in actual crashes were presented. Model results from nine cases, some with concussion and some not, yielded head accelerations that were used to drive the Wayne State University Head Injury Model (WSUHIM). This model consists of over 310,000 elements and is capable of simulating direct and indirect impacts. It has been extensively validated using published cadaveric test data.