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This specification covers quality assurance sampling and testing procedures used to determine conformance to applicable material specifications of corrosion- and heat-resistant steel and alloy forgings.

This document describes the 2-D computer-aided design (CAD) template for the HPM-1 H-point machine or HPD available from SAE. The elements of the HPD include the curve shapes, datum points and lines, and calibration references. The intended purpose for this information is to provide a master CAD reference for design and benchmarking. The content and format of the data files that are available are also described.

This document describes the 2-D computer-aided design (CAD) template for the HPM-1 H-point machine or HPD available from SAE. The elements of the HPD include the curve shapes, datum points and lines, and calibration references. The intended purpose for this information is to provide a master CAD reference for design and benchmarking. The content and format of the data files that are available are also described.

A theoretical model is presented for predicting springback of wide sheet metal subjected to 2D-stretch-bending operation. The material is assumed to be normal anisotropic with n-th power hardening law, σ = Fεn. Two types of stretch-bending experiment, bending with simultaneous stretching and stretch-bending followed by consecutive re-stretching, is conducted using AK sheet steel and sheet aluminum alloy A5182-O. The measured values of springback are in good agreement with analytical ones for a wide range of bending radii, stretching forces, and loading conditions. Furthermore, a calculation method for predicting springback configurations of 2D sheet metal parts with arbitrary cross-sections which include both stretch-bending and stretch-bending-unbending deformation is proposed.

THE development of the two-stage torque converter with automatic double clutch is presented here. The author covers particularly the substitution of casting for fabrication for several of the units in the transmission.

This paper describes the engineering, manufacturing and integration necessary to produce the Corvette's first ever all-aluminum spaceframe (see Figure 1). The engineering and manufacturing of the spaceframe was a joint venture between General Motors and suppliers ALCOA (Aluminum Company of America) and Dana Corporation. ALCOA led the initial design of the spaceframe; Dana Corp led the manufacturing; General Motors' Engineering and Manufacturing groups led the integration of the assembly. The aluminum spaceframe design is modeled after the baseline steel structure of the Corvette coupe. The aluminum spaceframe reduces 140 lbs from the steel baseline and enters the plant at 285 lbs. This frame allows the 2006 Corvette Z06 to enter the market at a 3100 lbs curb weight. Aluminum casting, extruding, stamping, hydroforming, laser welding, Metal Inert Gas (MIG) welding, Self Pierce Riveting (SPR), and full spaceframe machining make up the main technologies used to produce this spaceframe.

The General Motors (GM) Corvette design team was challenged with providing a C6 Z06 vehicle spaceframe that maintained the structural performance of its C5 predecessor while reducing mass by at least 56 kg. An additional requirement inherent to the project was that the design must be integrated into the C6 assembly processes with minimal disruption, i.e. seamless integration. In response to this challenge, a collaborative team was formed, consisting of design engineers from General Motors, Alcoa and Dana Corporation. The result of this collaborative effort is an aluminum Z06 spaceframe that satisfies the high performance expectations of the vehicle while reducing the mass by approximately 62 kg. The frame consists of aluminum extrusions, castings and sheets joined by MIG welding, laser welding and self-piercing rivets. The extrusions are 6XXX series alloys, the castings are permanent mold A356 while the sheet panels are formed from the 5XXX series of alloys.

Weight reduction of automobiles is key technology in order to improve fuel economy and driving performance. Concerning of the motorcycle engine, weight reduction is also the fundamental and important technologies. Cylinder is one of the main parts of engine and the wear characteristics of the cylinder liner are largely related to the engine performance. Gray iron liners squeezed in aluminum cylinder block have been widely used. This is due to the excellent resistance to abrasion of gray iron. In order to realize light all aluminum cylinder, the good abrasion resistant method is necessary to develop to be applied with inner surface of liners. We have developed the new Rapid Composite Plating System for the motorcycle engine cylinders. This system made it possible to adopt all aluminum cylinders without cast iron liners to new type of engine.

The 42-Volt electrical system is being introduced in automobiles to provide the extra power needed for various electromagnetic devices. These paper discuses the opportunity offered by the 42Volt for powder metal parts and the challenges. Major opportunities are in motors. A brief discussion of motors and the performance requirements for the magnetic core material used is included. Brushless motor design can benefit the most from insulated iron powder compacts because of the design simplicity of powder metal parts and three dimensional flux capability which is most beneficial in rotating devices.(P/M stands for powder metallurgy and not permanent magnets)

This paper presents a discussion of the component evaluation and design development work performed in developing a 4300 F reentry vehicle nose cap temperature sensor. Material compatabilities, insulation resistance, and atmospheric pressure effects on bare wire calibration data are discussed in some detail. The final design is outlined and the application problems discussed. The probe utilizes: a sintered iridium high temperature sheath (4300 F) and platinum 20% rhodium as the low temperature sheath (3000 F); beryllia as insulation -- hard fired at 4300 F and compacted powder at 3000 F; tungsten versus tungsten 26% rhenium as the thermocouple pair.

Crankshafts of motorcycles require high strength, high reliability and low manufacturing cost. Recently, a reduction of Pb content in the free-cutting steel, which is harmful substance, is required. In order to satisfy such requirements, we started the development of Pb-free free-cutting steel which simultaneously enabled the omission of the normalizing process. For the omission of normalizing process, we adjusted the content of Carbon, Manganese and Nitrogen of the steel. This developed steel can obtain adequate hardness and fine microstructure by air-cooling after forging. Pb-free free-cutting steel was developed based on Calcium-sulfur free-cutting steel. Pb free-cutting steel is excellent in cutting chips frangibility in lathe process. We thought that it was necessary that cutting chips frangibility of developed steel was equal to Pb free-cutting steel. It was found that cutting chips frangibility depend on a non-metallic inclusion's composition, shape and dispersion.

Hayes Lemmerz has pursued fin configurations in straight and curved fin rotors to achieve high airflow velocity. The largest increase in airflow velocity of 37.2% is achieved by curving fins to a specific entry and exit angle and increasing surface area by increasing fin number. There is a need for funneling air into the narrow entry in the hub area. The new “Hayes Air Director” successfully channels air into the curved fins. Hayes Lemmerz is in the process of casting rotors with curved fins and the air director idea. Dynamometer and vehicle tests will follow. The current renwood model of the rotor design shows 34.8 to 37.2% increase in airflow velocity when tested on the Hayes Airflow machine.

To date the market for P/M stainless steel has not developed appreciably, and has centered largely on the development of austenitic 300 series stainless steels. Although these stainless steels are noted for their resistance to corrosion in many media, it has been difficult for P/M parts fabricators to produce parts that will sustain 1,000 hours of protection in a 5% salt solution. The problem starts with the water atomized powders and continues with the sintering practice exercised to produce the parts. Reasons for lack of corrosion resistance, based upon these considerations, will be discussed. In addition, the ferritic stainless steels are being considered seriously for fuel injectors. These emerging applications derive from the corrosive environment that may become a problem if and when alternative fuels are introduced. P/M ferritic stainless steels may also assume a position as a corrosion resistant magnetic material required in ABS systems which are currently emerging.

The existing market conditions place heavy demands on the steel foundries to increase their capacity and output. Expansion hinges on the ability of the foundry to “earn the dollar” to permit the modernization of existing facilities and construction of new plants. It also requires that the foundry industry modernize its production methods and techniques; update its equipment; and that the consumer engineer assist in developing casting design features that will be more readily adaptable to the capabilities of the foundry operation. “A Bigger Payload from Steel Foundries” requires more than physical expansion-it demands cooperative and intelligent endeavor on the part of foundry management and consumer engineering.

A process for simultaneously optimizing the mechanical performance and minimizing the weight of an automotive body-in-white will be developed herein. The process begins with appropriate load path definition though calculation of an optimized topology. Load paths are then converted to sheet metal, and initial critical cross sections are sized and shaped based on packaging, engineering judgment, and stress and stiffness approximations. As a general direction of design, section requirements are based on an overall vehicle “design for stiffness first” philosophy. Design for impact and durability requirements, which generally call for strength rather than stiffness, are then addressed by judicious application of the most recently developed automotive grade advanced high strength steels. Sheet metal gages, including tailored blanks design, are selected via experience and topometry optimization studies.

During the last several years the use of magnesium die-castings for automotive applications has been on the rise. Magnesium's use in die-cast form has been expanding at an average growth rate of more than 15% a year. Reasons for the increase are both practical and economic. Magnesium die-castings offer components having the lowest mass when compared to almost any other structural material. Magnesium die-alloys exhibit properties that bridge the gap between engineered plastics and metals. The mechanical performance ratios (strength-to-weight and stiffness-to-weight) of magnesium also compete favorably with metals and plastics. Economically, magnesium alloys prices have fallen during the last several years making them extremely competitive with other materials.

The prime function of crown wheel pinion is to receive the power from transmission & distribute to two-wheel ends. Doing so these members will experience the tremendous bending fatigue. Shot peen is the one of the latest technology used to improve the bending fatigue of the CWP [1]. In this particular case- six CWP are taken for the study to understand the effect of the operations after shot peen process. Three Samples are named as batch A, another 3 samples are named as batch B. Both the batch CWP are shot peened. Then as a regular production practice the batch A CWP are process through hard turning ➔ Abrasive lapping ➔ Hot lubriting (manganese phosphate) ➔ Fully finish ready for assembly. Then both the batch A & batch B samples are taken for residual stress analysis using X-Ray diffraction technique. The measurement location is 50 microns below the surface. The results tabulated, found that batch A samples shows decrease in Residual stress relatively to batch B.

Abstract This article discusses a multi-item planning and scheduling problem in a job-shop system with consideration of energy consumption. Planning is considered by a set of periods, each one is characterized by a demand, energy, and length. Scheduling is determined by the sequences of jobs on available resources. A Mixed-Integer Linear Programming (MILP) problem is formulated to integrate planning and scheduling, it is considered as an NP-difficult problem. A Genetic Algorithm (GA) is then developed to solve the MILP, and then a hybridized approach of simulated annealing with genetic algorithm (HGASA) is presented to optimize the results. Finally, numerical results are presented and analyzed to evaluate the effectiveness of the proposed algorithms.

Precipitation Hardened Stainless Steel (PHSS) is one of the martensitic steels that possess exceptional strength and corrosion resistance. Because of its characteristics, this PHSS is exclusively adopted in numerous engineering uses such as nuclear, chemical and marine industries. Welding is one of the important methods of joining that helps to make weldments with better performance characteristics. Corrosion behaviour is one of the important characteristics that contribute hugely to marine and other corrosion-related environments and also this is the most common problem for most of the manufacturing industries. The goal of this study was to analyze the PHSS weldments’ corrosive behavior and compare it with that of the two commonly used welding processes, namely MIG and TIG. The corrosive properties of the weldments were evaluated using various mediums, such as nitric acid, ferric chloride, and Oxalic acid.