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A methodology for an efficient failure prediction of automotive steel wheels during fatigue experimental tests is proposed. The strategy joins the CDTire simulative package effectiveness to a specific wheel finite element model in order to deeply monitor the stress distribution among the component to predict damage. The numerical model acts as a Software-in-the-loop and it is calibrated with experimental data. The developed tool, called VirtualWheel, can be applied for the optimisation of design reducing prototyping and experimental test costs in the development phase. In the first section, the failure criterion is selected. In the second one, the conversion of hardware test-rig into virtual model is described in detail by focusing on critical aspects of finite element modelling. In conclusion, failure prediction is compared with experimental test results.

This paper deals with implementing process simulation in the developing of the manufacturing process for automobile panels and body parts. Starting from FEM analysis of material behaviour, suggestions about punch and die design can be obtained bringing direct and indirect benefits to other routing steps, thus saving time and resources. In order to point out these relationship and enhance these benefits, some real cases are presented and analysed for which a comparison among simulated and experimental results is given, using both circle grid and thickness analysis of the deformed blank sheet. Suggestions for part design modifications have been obtained that lead to a net improvement in formability and quality.

In the automotive field the application of electric propulsion systems based on fuel cells requires a constant and continuing research of several optimized solutions, especially in terms of weight and size reduction. These key-factors tend to influence significantly the performance of the vehicle where the system is installed on. The main objective of the paper is to obtain breakthroughs in designing, manufacturing and assembling a fuel cell stack through the development of innovative metallic bipolar plates, that allows to set up high power density stacks, by lowering sensibly weight and size. The research activity carried out by the aforementioned authors is focused on the choice of suitable materials and the development of optimized tools, processes and techniques, in order to be able to move rapidly towards thinner bipolar plates, with new compact geometries that ensure the required stack output power.

The aim of this paper is to study in deep the peculiar test-rigs and experimental procedures adopted to the fulfilment of the principal requirements of automotive steel wheels, in particular regarding fatigue damaging. In the discussion, the standard requirements, the OEM specifications and the dimensional and geometric tolerances are approached. As result of an increasingly necessity to improve the performance of the components, innovative virtual test benches are presented. Differently from their traditional precursors, virtual test-rigs give an extended view of the physical behaviour of the component as the possibility to monitor stress-strain distribution in deep. In the first section, the state of the art and the specifications are listed. Secondly, the adopted hardware test-rigs as the experimental tests are described in detail. In the third one, proposed virtual test-rig is discussed.

Aim of this work is the development of a lumped parameters simulation model of single-vane vacuum pumps for pneumatically actuated brake boosters. Kinematic and fluid-dynamic models are integrated in a simulation environment to create a tool aimed at evaluating the vacuum pump performance and at guiding the designer during the prototype development. The paper describes extensively the mathematical model, the time domain simulation and experimental analyses performed on a camshaft mounted unit. Great emphasis is placed on the evaluation of the geometric quantities of the control volumes into which the vacuum pump has been divided. For each control volume the mass and energy conservation equations lead to the determination of the instantaneous pressure. The volume of each variable chamber and the respective angular derivative are calculated as function of the shaft position starting from the stator track profile supplied as a generic closed polyline.

The Atmospheric Revitalization System (ARS) provides carbon dioxide removal, trace contaminant control, and gas constituent analysis. In this field, the interest of RecycLAB [5], the TAS-I Advanced Live Support Research & Development laboratory is directed to trace gas contaminants removal and monitoring. During manned space mission, the decontamination of cabin or rack air after contingency events such as fire or pyrolysis is a priority for the crew safety. In this paper, basic zeolites, obtained by impregnation of common zeolites with a basic oxide, are used to remove acid gas contaminants from air stream. A multi-functional system, able to accommodate reactors of different shape, characteristics and set-up, is used at this purpose. This breadboard, called ZEUS (Zeolites for an Environmental-control Unit in Space), is made of AISI 316L stainless steel and consists of a closed loop, in which the inner volume is completely isolated from the external environment.