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This paper documents a joint development process between General Motors and Dow Automotive to improve primary body structure frequencies on the GM family of midsize vans by utilizing cavity-filling structural foam. Optimum foam locations, foam quantity, and foam density within the body structure were determined by employing both math-based modeling and vehicle hardware testing techniques. Finite element analysis (FEA) simulations of the Body-In-White (BIW) and “trimmed body” were used to predict the global body structure modes and associated resonant frequencies with and without structural foam. The objective of the FEA activity was to quantify frequency improvements to the primary body structure modes of matchboxing, bending, and torsion when using structural foam. Comprehensive hardware testing on the vehicle was also executed to validate the frequency improvements observed in the FEA results.

Fundamental differences exist between sheet metal forming and hydroforming processes. Sheet metal forming is basically a one step metal fabrication process. Almost all plastic deformation of an originally flat blank is introduced when the punch is moved normal to a clamped sheet metal. Hydroforming, however, consists of multiple steps of tube making, pre-bending, crushing, pressurization, etc. Each of the above mentioned steps can introduce permanent plastic deformations. The forming limit diagram obtained for sheet metal forming may or may not be used in hydroforming evaluations. A failure criterion is proposed for predicting bursting failures in tube hydroforming. The tube material's stress-strain curve, obtainable from uniaxial tensile test and subjected to some postulations under large stress/strain states, is used in judging the failure.

This paper introduces for the first time a fully connectorized passive optical star for use with plastic optical fiber that addresses all automotive application requirements. A unique mixing element is presented that offers linear expandability, uniformity of insertion loss, and packaging flexibility. The star is constructed of all plastic molded components to make it low cost and produceable in high volume and is single-ended to facilitate vehicle integration. The star is connectorized to facilitate assembly into the vehicle power and signal distribution system.

The overall vision of this project was to develop a new technology that will be an enabler to reduce design and development time of HVAC systems by an order of magnitude. The objective initially was to develop a parametric model of an automotive HVAC Windshield Defrost Duct coupled to a passenger compartment. It can be used early on in the design cycle for conducting coarse packaging studies by quickly exploring “what-if” design alternatives. In addition to the packaging studies, performance of these design scenarios can be quickly studied by undertaking CFD simulation and analyzing flow distribution and windshield melting patterns. The validated geometry and CFD models can also be used as knowledge building tools to create knowledge data warehouses or repositories for precious lessons learned.

Using a combination of engineering test experience, explicit finite-element analysis, and advanced materials characterization, a predictive engineering method has been developed that can assist in the development of active top pads. An active top pad is the component of the instrument panel that covers the passenger airbag module and articulates during a crash event, allowing the airbag to deploy. This paper highlights the predictive analysis method, analytical results interpretation, and suggestions for future development.

This paper discusses an analytical technique for computing the failure rate of steel springs used in automotive part applications. Preliminary computations may be performed and used to predict spring failure rates quickly at a very early stage of a product development cycle and to establish program reliability impact before commitment. The analytical method is essentially a combination of various existing procedures that are logically sequenced to compute a spring probability of failure under various operational conditions. Fatigue life of a mechanical component can be computed from its S-N curve. For steels, the S-N curve can be approximated by formulae which describe the fatigue life as a function of its endurance limit and its alternating stress. Most springs in service are preloaded and the actual stress fluctuates about a mean level. In order to compute an equivalent alternating stress with zero mean, an analytical method based on the Goodman Diagram is used.

Brake squeal has been analyzed by finite elements for some time. Among several methods, complex eigenvalue analysis is proving useful in the design process. It requires hardware verification and it falls into a simulation process. However, it is fast and it can provide guidance for resolving engineering problems. There are successes as well as frustrations in implementing this analysis tool. Its capability, robustness and reliability are closely examined in many companies. Generally, the low frequency squealing mechanism is a rotor axial direction mode that couples the pads, rotor, and other components; while higher frequency squeal mainly exhibits a rotor tangential mode. Design modifications such as selection of rotor design, insulator, chamfer, and lining materials are aimed specifically to cure these noise-generating mechanisms. In GM, complex eigenvalue analysis is used for brake noise analysis and noise reduction. Finite element models are validated with component modal testing.

Contamination protection of brake rotors has been a challenge for the auto industry for a long time. As contamination of a rotor causes corrosion, and that in turn causes many issues like pulsation and excessive wear of rotors and linings, a rotor splash protection shield became a common part for most vehicles. While the rotor splash shield provides contamination protection for the brake rotor, it makes brake cooling performance worse because it blocks air reaching the brake rotor. Therefore, balancing between contamination protection and enabling brake cooling has become a key critical factor when the splash shield is designed. Although the analysis capability of brake cooling performance has become quite reliable, due to lack of technology to predict contamination patterns, the design of the splash protection shield has relied on engineering judgment and/or vehicle tests. Optimization opportunities were restricted by cost and time associated with vehicle tests.

This paper describes a test of 2500 General Motors passenger cars equipped with anti-lacerative windshields and driven in rental fleets. It also de840391 scribes the laboratory tests conducted prior to the fleet installation of the test windshields. Evaluation of haze development caused by abrasion of the anti-lacerative surface will take several more years of exposure. Other test results have been encouraging, except for the difficulties encountered in the removal of stickers and decals from the inner surface.

In a typical hydroforming operation, a round tube of constant wall thickness is bent into the overall shape desired for the final part, then placed between a pair of dies. Despite some small percentage of stretch that may occur as the tube expands, the wall thickness in the original tube is therefore substantially constant at all points. In some circumstances, a part is locally thickened or reinforced for extra strength. Normally, this is achieved by using a separate piece of reinforcement at selected location. In this paper, it is intended to present a unique method to achieve an optimal structural design allowing thin or thick gages where required along its cross-section. This is done via hydroforming an aluminum extrusion tube to an optimal frame structure having varied wall thickness to satisfy various loading requirements at a minimum weight. The engine cradle is used as an example to demonstrate this methodology.

Build variation has long been recognized as one of the most important factors in vehicle performance. In this study an elastic assembly simulation program is used to guide a wheelhouse assembly process design to reduce build variation. Five (5) different clamping schemes are evaluated through the simulation program. From the five proposed process design choices, the best assembly process was identified, which results in reduced assembly variation and less tooling and manufacturing costs. Two different variation simulation approaches, one based on perturbation and the other based on Design of Experiments, were used to predict the assembly variation. Good agreement between the two approaches provided a validity check for the simulation tool.

Constrained Layer Damping (CLD) treatments have long provided a means to effectively impart damping to a structure [1, 2 and 3]. Traditionally, CLD treatments are constructed of a very thin polymer layer constrained by a thicker metal layer. Because the adhesion of a thin polymer layer is very sensitive to surface finish, surfaces that a CLD treatment can be effectively applied to have historically been limited to those that are very flat and smooth. New developments in material technology have provided thicker materials that are very effective and less expensive to apply when used as the damping layer in a CLD treatment. This paper documents the effectiveness of such a treatment on a cast aluminum front cover for a V6 engine. Physical construction of the treatment, material properties and design criteria will be discussed. Candidate applications, the assembly process, methods for secondary mechanical fastening will be presented.

This paper describes the recent efforts on developing an automotive climate control system throughout integrating an electrically-controlled variable capacity scroll compressor with a fuzzy logic control-based refrigerant flow management. Applying electrically-controlled variable capacity compressor technology to climate control systems has a significant impact on improving vehicle fuel economy, achieving higher passenger comfort level, and extending air and refrigerant temperature controllability as well. In this regard, it is very important for automotive climate control engineers to layout a system-level temperature control strategy so that the operation of variable capacity compressor can be optimized through integrating the component control schemes into the system-level temperature control. Electronically controlled expansion devices have become widely available in automotive air conditioning (A/C) systems for the future vehicle applications(1, 2, 3 and 4).

An approximate analysis method for brake squeal is presented. Using MSC/NASTRAN a geometric nonlinear solution is run using a friction stiffness matrix to model the contact between the pad and rotor. The friction coefficient can be pressure dependent. Next, linearized complex modes are found where the interface is set in a slip condition. Since the entire interface is set sliding, it produces the maximum friction work possible during the vibration. It is a conservative measure for stability evaluation. An averaged friction coefficient is measured and used during squeal. Dynamically unstable modes are found during squeal. They are due to friction coupling of neighboring modes. When these modes are decoupled, they are stabilized and squeal is eliminated. Good correlation with experimental results is shown. It will be shown that the complex modes baseline solution is insensitive to the type of variations in pressure and velocity that occur in a test schedule.

The purpose of the Cadillac DeVille Night Vision System is to provide drivers with visual information beyond with the range of their headlamps. It can also help drivers see beyond the glare of oncoming vehicle’s headlamps. With increased visual range the driver may have more time to react to potentially dangerous situations. The system consists of a thermal imaging camera, a head-up display, and image controls. The camera senses temperature differences of objects in the road scene ahead and creates a thermal image of the scene. The head-up display projects this image onto the windshield creating a virtual image that appears at the front edge of the vehicle’s hood just below the driver’s line of sight. This paper will describe the system requirements and parameters of the 2000 Cadillac DeVille Night Vision system.

A methodology involving Design for Six Sigma (DFSS) and Multi-body dynamic simulation is employed to tune a body-on-frame vehicle, for improved ride (shake) performance. The design space is limited to four sets of symmetric body mounts for a vehicle. The stiffness and damping characteristics of the mounts are the control factors in the virtual experiment. Variation of these design parameters from the nominal settings, as well as axle size, tire and wheel combinations, tire pressure, shock damping, and vehicle speed constitute the noise factors. This approach proves to be an excellent predictor of the vehicle behavior, by which much insight as to influence of each parameter on vehicle performance is gained. Ultimately, specific recommendations for the control factor settings are provided. Subsequent hardware builds show excellent agreement with the analytical model and suggested tuning.

This paper will focus on the process, as used at AC Rochester, of performing reliability analyses early in the design phase of automotive component development and the integration of specific techniques and methods. This methodology forms an effective tool that achieves the identification of component failure modes and mechanisms with greater confidence than any single technique and provides for the simple and direct communication of the results. In addition, our experience shows that this process provides the maximum preventive impact on the product during the design phase, thus yielding demonstrably improved reliability characteristics on the production part. Specifically, a four-step up-front analysis process can facilitate the usefulness of various analytical techniques to the identification of product reliability problems.

Casting technology developmentshave led to a manufacturing process that allows the casting of thin wall (2-3mm) heat resistant ferritic stainless steel exhaust manifolds which can replace stamped and tubular weldments as well as iron castings where temperature requirements are increased. This casting process combines the thin wall and clean metal benefits of the counter gravity, vacuum-assist casting process using thin, light-weight bonded sand molds supported by vacuum-ridgidized sand. This combination is called the LSVAC (Loose Sand Vacuum Assisted Casting) process, a patented process. This process will significantly contribute to the growth of near-net shape steellstainless steel castings for automotive and allied industries. For exhaust manifolds, a modified grade of ferritic stainless steel with good oxidation resistance to 950°C in high dew point synthetic exhaust gas atmospheres was developed.

The rear cross-car stiffener subsystem is generally located at the underside of the rear compartment pan of a car body and connects the two rear longitudinal rails or rear rockers. The primary purpose of this subsystem is to maintain structural integrity as well as fuel system integrity in a rear angle impact or dynamic side impact collision. To evaluate the effect of this subsystem on lateral crashworthiness in a high speed angle impact, a finite element model consisting of the cross-car bar, a portion of rear compartment pan and both rear rails was developed and analyzed with the DYNA3D crashworthiness simulation software. Thus, the cross-car stiffener subsystem design including the welding pattern was finalized and the acceptable design was successfully implemented in the vehicle. Subsequently drop silo tests were carried out to further verify the design and to improve the manufacturing process.

Many traffic collisions are the result of the driver's failure to notice the other vehicle. It is often cited in police reports that the driver "looked but did not see.'' The purpose of Daytime Running Lights (DRLs) is to increase the visual contrast of DRL-equipped vehicles. Visual contrast, which is the difference in brightness between two areas, is an important characteristic enabling a driver to detect objects. This paper begins with a brief regulatory history of DRLs in the U.S. and how General Motors Corporation (GM) introduced DRL-equipped vehicles. It also describes a DRL effectiveness study conducted by Exponent Failure Analysis Associates of San Francisco for General Motors Corporation. The study compared the collision rates of specific General Motors Corporation, Saab, Volvo and Volkswagen vehicles before and immediately after the introduction of DRLs. Since DRLs are not visible from behind a vehicle, rear-end collisions were not included in the study.