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Currently, advancements in Rapid Prototyping (RP) technologies have led to considerable amount of research activities and has been playing a major role in the area of tooling development for which Rapid Tooling (RT) term was coined. While rapid prototyping techniques are employed to make prototype tools, the basic idea of the rapid tooling is to produce prototype and zero series parts by using prototype tools so the parts truly represent the future production. This paper will present an evaluation of a RP and RT technique in developing tools (punch and dies) for sheet metal forming, which had been manufactured and tested. Both punch and die have been manufactured by combining Stereolithography (SL), RP technique, with nickel electroforming process. The stereolithography technique that had been utilized in developing models for the tools had been built with modeling pattern called Accurate Clear Epoxy Solid (ACES).

Currently, advancements in Rapid Prototyping (RP) technologies have led to considerable amount of research activities and has been playing a major role in the area of tooling development for which Rapid Tooling (RT) term was coined. Rapid prototyping techniques are employed to make prototype tools. While, the basic idea of the rapid tooling is to produce prototype and zero series parts by using prototype tools so the parts truly represent the future production. This paper will present an evaluation of a RP & RT technique in developing tools (punch and dies) for sheet metal forming, which had been manufactured and tested. Both punch and die have been manufactured directly from Stereolithography (SL). The stereolithography technique that had been utilized in developing models for the tools had been built with modeling pattern called QuickCast infiltrated with Aluminum-Filled Epoxy, designated as Quick Tool.

Sensitivity analysis is a usual method to evaluate how “sensitive” is a product performance to changes in its design variables. This type of analysis identifies the critical variables related to product performance and other aspects that may have less demanding manufacturing controls. This paper presents a case study in the automotive market, applying the 1-D dynamic modeling as an auxiliary tool to the sensitivity analysis. The objective of this procedure is to reduce physical prototypes tests. This evaluation, if taken during preliminary design of the system, could give competitive advantages, with a reduction in product development cycle time and cost.

It is well known that backpressure is one of the important parameters to be minimised during the exhaust system development. Unfortunately, during the first phases of an engineering process of a new engine, engine prototypes are not available yet. Due to this the exhaust system backpressure is generally evaluated using simulation software, and/or measuring the backpressure by a flow rig test at room temperature. Goal of this paper is to compare exhaust backpressure results obtained respectively: i) at the room temperature flow rig; ii) at the engine dyno bench; iii) by simulation with one of the most common 1D fluidodynamics simulation tool (Gt-Power). A correlation of the three different techniques is presented.

Inverters are solid state devices which change DC to 120VAC electricity. They are sufficiently rugged and reliable to make them practical for use on utility vehicles for operating thumpers, tools, lights and induction motor loads. The SCR type rather than the transistor type inverter is generally required for inductive and reactive loads. Static inverters operate from battery input. They provide power without running an engine, but are limited by battery capacity so work best in intermittent load applications. Dynamic inverters operate from alternator input and will handle continuous loads to 7200 watts with truck engine running.

This paper describes the concept, design, and options of a new power shift transmission family for industrial equipment in the 50-100 hp range. The converter, clutch, and gearing arrangements provide the basis for various transmission configurations with both a drop and straight through output. The designs allow multiple usage of components within a transmission and between different sizes of transmissions. The various gearing, bearing, and clutch designs are based on proved experience factors, and as such will provide a new reliable family of transmissions.

A review of the Pure Oil Performance Trials conducted at Daytona International Speedway are presented. Background information pertaining to conducting of tests, design of the equipment, and instrumentation required for the various events are discussed. The performance trials have evolved into three basic tests -- Economy, Acceleration, and Braking. The objective of the Performance Trials is to provide data that motorists can utilize in evaluating new cars and selecting new models.

The size of the 1978 automotive service market is the total dollars spent on car and truck repair and maintenance in 1978. The 1978 personal-use automotive service market is the retail dollars spent in 1978 on repair and maintenance for cars and trucks used primarily for personal transportation. Service market estimates in this report do not include body repair parts and body repairs. Bureau of Economic Analysis data indicate a personal-use service market, excluding do-it-yourself (DIY) service, of $36 billion. A similar estimate made by General Motors Research Laboratories, based on a large national survey of actual consumer expenditures, is $ 37 billion. The personal-use automotive service market, excluding DIY, is roughly 3/4's the size of the total automotive service market, based on data from the Motor and Equipment Manufacturers Association and Frost & Sullivan, Inc.

This paper presents 1D engine simulation used for engine control strategy optimization for a twin-scroll turbocharged gasoline direct injection 2.0 L engine with twin camphaser. The results show good agreement of the engine model behavior with testbed acquisitions for a large amount of steady state set points and under transient operating conditions. The presented method demonstrates that a 1D engine code represents a useful and efficient tool during all steps of the engine control development process from design to real-time for such an advanced engine technology.

The potential contributions of acoustical technology to manufacturing companies pervade nearly all of its functions from marketing and product planning to design engineering and quality control. Despite this, however, companies generally feel uneasy when they embark on programs to use acoustics in their operations because the technology seems complicated and somehow harder to “get a handle on” than it is in other cases. But the issues of product sound, and the benefits of acoustics on a diagnostic tool are too important to ignore, so in this paper we discuss these issues in a “20 questions” format to help planners, engineers and managers as they proceed to implement acoustical technology in their organizations.

This is a report of a workshop held in mid-August of 2002 at Northwestern University, Evanston, Illinois, to explore what it takes to make a decision regarding environmental systems in the US. The participants in the workshop represented federal government, industry, non-governmental organizations and academia. During the two and a half day workshop, discussions were held on the policy drivers, the strategies and tactics (through a SWOT analysis), the decisions the automotive industry is facing today and the tools available to support decision making.

This paper describes a series of 200–300 hp gas turbine engines being developed by the AiResearch-Phoenix Division of the Garrett Corp. for the U.S. Army Engineer Research and Development Laboratories. These engines, which include both simple cycle and regenerative types, are intended for ground power applications, primarily for direct driving high speed equipment such as high frequency alternators. Descriptions are given of the basic approach taken to meet the Army’s requirements, the resulting engine configurations, the development progress to date, and future program plans and timing.

Each year car manufacturers release new production models that are unique and innovative. The production model is the result of a lengthy process of testing aerodynamics, safety, engine components, and vehicle styling. The new technologies introduced in these vehicles reflect changing standards as well as trends of the market. From Acura to Volvo, this book provides a snapshot of the key engineering concepts and trends of the passenger vehicle industry over the course of a year. For each of the 43 new production models, articles from Automotive Engineering International (AEI) magazine detail technology developments as well as a comprehensive look at the 2013 passenger car models. This book provides those with an interest in new vehicles with all the information on the key automotive engineering and technology advancements of the year.

Each year car manufacturers release new production models that are unique and innovative. These cars begin as concepts then go through the process of prototyping. The process of creating a new model can take years, involving extensive testing and refining of aerodynamics, safety, engine components, and vehicle styling. The production model is the result of this lengthy process, and its new technologies reflect the latest engineering standards as well as market trends. The 2014 Passenger Car Yearbook details the key engineering developments in the passenger vehicle industry of the year. Each new car model is profiled in its own chapter with one or more articles that were previously published and written by the award-winning editors of Automotive Engineering International. The novel engineering aspects of each new model are explored in depth.

Every year global automakers introduce new or significantly re-engineered passenger vehicles with increasingly advanced technology intended to exceed consumer expectations and satisfy increasingly stringent government regulations. Some of these technologies are firsts-of-their-kind and start trends that other automakers soon follow—with the innovations becoming adopted across the board. The supply community is also increasingly playing a more significant role in helping the original equipment manufacturers research, develop, and introduce the latest engineering innovations that help bring competitive advantage for their automaker partners. Each year, the editors of SAE’s Automotive Engineering magazine publish many articles focused on the technology and engineering innovations of new passenger and concept vehicles, and these articles have been collected into this volume.

On January 14, 2004 President George W Bush outlined a new vision for NASA that has humans venturing back to the moon by 2020. With this ambitious goal, new tools and models have been developed to help define and predict the amount of space radiation astronauts will be exposed to during transit and habitation on the moon. A representative scenario is used that includes a trajectory from LEO to a Lunar Base, and simplified CAD models for the transit and habitat structures. For this study galactic cosmic rays, solar proton events, and trapped electron and proton environments are simulated using new dynamic environment models to generate energetic electron, and light and heavy ion fluences. Detailed calculations are presented to assess the human exposure for transit segments and surface stays.

In the design and development of modern cars with respect to comfort, silence and safety, state of the art experimental modal analysis is one of the essential development tools. Due to the large amount of degrees of freedom of such a large and complex system like a car with all its components, a complete simulation by FEM can not be realised easily and requires an enormous expenditure of work and calculations. In addition the simulations are based on assumed system parameters and thus the vibration behaviour of the resulting prototypes often is not completely identical to the simulated model. In contrast to conventional measurements with accelerometers, the 3-D Scanning Vibrometer enables fast and efficient non-contact measurements of the in-plane and out-of-plane vibration behaviour at all optical accessible surfaces. The method easily allows to increase the number of measured points to obtain a high measurement point density.

During sheet metal forming processes, the friction conditions have a decisive influence on forming limits, the robustness of the production process and the quality of the parts produced, with significant forces required to overcome friction between the sheet and the tools. If lot-to-lot reproducibility is to be guaranteed, an appropriate method of characterizing the sheet surface topography is needed to monitor the sheet metal fabrication process. Newly developed optical measurement techniques and computer workstation technology are presented which enable the topography of sheet surfaces to be described in three dimensions.