Search results for: automotive wire harness

Authors: Francesco Nespoli

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After having posed a theoretical framework combining framing theory and new rhetoric, the paper analyze the shift in communication both adopted by UAW and FCA during the negotiations in fall 2015. The paper argues that mistakes and adjustments played a determinant role respectively in the rejection of the first tentative agreement and in the ratification of the contract. The purpose of the paper is to set a new theoretical framework for the analysis of communication in industrial relations, by describing a narrative construction of reality from the perspective of the new rhetoric. The paper thus analyze all public text, speeches, tweets and Facebook posts by the union reading them as part of the narrative set by the organization condensed by the slogan 'it’s our time'. That narrative tried to gain consensus from the members matching the expectations due to the industry recovery after more than five years of workers' sacrifices. In doing so, the analysis points out a shift in the communication strategy of the union after the first rejection of a tentative agreement in 15 years. The findings suggest that, from the communication point of view, consultation in industrial relations can be conceived as a particular kind of political communication where identification with the audience through deliberate narrative may not be effective if it is not preceded by a listening campaign.

Keywords: communication, consultation, automotive, FCA

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Authors: Roman Knizek, Denisa Knizkova

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This paper describes the development of a nanofiber membrane for sport and outdoor use at the Technical University of Liberec (TUL) and the following cooperation with a private Czech company which launched this product onto the market. For making this membrane, Polyurethan was electrospun on the Nanospider spinning machine, and a wire string electrode was used. The created nanofiber membrane with a nanofiber diameter of 150 nm was subsequently hydrophobisied using a low vacuum plasma and Fluorocarbon monomer C6 type. After this hydrophobic treatment, the nanofiber membrane contact angle was higher than 125o, and its oleophobicity was 6. The last step was a lamination of this nanofiber membrane with a woven or knitted fabric to create a 3-layer laminate. Gravure printing technology and polyurethane hot-melt adhesive were used. The gravure roller has a mesh of 17. The resulting 3-layer laminate has a water vapor permeability Ret of 1.6 [Pa.m2.W-1] (– measured in compliance with ISO 11092), it is 100% windproof (– measured in compliance with ISO 9237), and the water column is above 10 000 mm (– measured in compliance with ISO 20811). This nanofiber membrane which was developed in the laboratories of the Technical University of Liberec was then produced industrially by a private company. A low vacuum plasma line and a lamination line were needed for industrial production, and the process had to be fine-tuned to achieve the same parameters as those achieved in the TUL laboratories. The result of this work is a newly developed nanofiber membrane which offers much better properties, especially water vapor permeability, than other competitive membranes. It is an example of product development and the consequent fine-tuning for industrial production; it is also an example of the cooperation between a Czech state university and a private company.

Keywords: nanofiber membrane, start-up, state university, private company, product

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Authors: Radwa Mabrook

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Virtual Reality (VR) content creation is a complex and an expensive process, which requires multi-disciplinary teams of content creators. Grant schemes from technology companies help media organisations to explore the VR potential in journalism and factual storytelling. Media organisations try to do as much as they can in-house, but they may outsource due to time constraints and skill availability. Journalists, game developers, sound designers and creative artists work together and bring in new cultures of work. This study explores the collaborative experimental nature of VR content creation, through tracing every actor involved in the process and examining their perceptions of the VR work. The study builds on Actor Network Theory (ANT), which decomposes phenomena into their basic elements and traces the interrelations among them. Therefore, the researcher conducted 22 semi-structured interviews with VR content creators between November 2017 and April 2018. Purposive and snowball sampling techniques allowed the researcher to recruit fact-based VR content creators from production studios and media organisations, as well as freelancers. Interviews lasted up to three hours, and they were a mix of Skype calls and in-person interviews. Participants consented for their interviews to be recorded, and for their names to be revealed in the study. The researcher coded interviews’ transcripts in Nvivo software, looking for key themes that correspond with the research questions. The study revealed that VR content creators must be adaptive to change, open to learn and comfortable with mistakes. The VR content creation process is very iterative because VR has no established work flow or visual grammar. Multi-disciplinary VR team members often speak different languages making it hard to communicate. However, adaptive content creators perceive VR work as a fun experience and an opportunity to learn. The traditional sense of competition and the strive for information exclusivity are now replaced by a strong drive for knowledge sharing. VR content creators are open to share their methods of work and their experiences. They target to build a collaborative network that aims to harness VR technology for journalism and factual storytelling. Indeed, VR is instilling collaborative and experimental cultures in journalism.

Keywords: collaborative culture, content creation, experimental culture, virtual reality

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Authors: Miroslav Gutten, Jozef Jurcik, Daniel Korenciak, Milan Sebok, Matej Kuceraa

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This paper deals with the phenomenon of the undesirable detonation combustion in internal combustion engines. A control unit of the engine monitors these detonations using piezoelectric knock sensors. With the control of these sensors the detonations can be objectively measured just outside the car. If this component provides small amplitude of the output voltage it could happen that there would have been in the areas of the engine ignition combustion. The paper deals with the design of a simple device for the detection of this disorder. A construction of the testing device for the knock sensor suitable for diagnostics of knock combustion in internal combustion engines will be presented. The output signal of presented sensor will be described by Bessel functions. Using the first voltage extremes on the characteristics it is possible to create a reference for the evaluation of the polynomial residue. It should be taken into account that the velocity of sound in air is 330 m/s. This sound impinges on the walls of the combustion chamber and is detected by the sensor. The resonant frequency of the clicking of the motor is usually in the range from 5 kHz to 15 kHz. The sensor worked in the field to 37 kHz, which shall be taken into account on an own sensor resonance.

Keywords: diagnostics, knock sensor, measurement, testing device

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Authors: Essam Shalaby, Alexander Churyumov, Malak Abou El-Khair, Atef Daoud

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A comparative study of the thermal and mechanical behavior of squeezed A359 composites containing 5, 10 and 15 wt.% SiC, (SiC+ Si3N4) and AlN particulates was investigated. Stir followed by squeeze casting techniques are used to produce A359 composites. It was noticed that, A359/AlN composites have high thermal conductivity as compared to A359 alloy and even to A359/SiC or A359/(SiC+Si3N4) composites. Microstructures of the composites have shown homogeneous and even distribution of reinforcements within the matrix. Interfacial reactions between particles and matrix were investigated using X-ray diffraction and energy dispersive X-ray analysis. The presence of particles led not only to increase peak hardness of the composites but also to accelerate the aging kinetics. As compared with A359 matrix alloy, compression test of the composites has exhibited a significant increase in the yield and the ultimate compressive strengths with a relative reduction in the failure strain. Those light weight composites have a high potential to be used for automotive and aerospace applications.

Keywords: metal-matrix composite, squeeze, microstructure, thermal conductivity, compressive properties

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Authors: Philipp Burger, Jonas Sommer, Haneen Daoud, Franz Hilmer, Uwe Glatzel

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Press-hardened structural components made of coated high-strength steel are an essential part of the automotive industry when it comes to weight reduction, safety, and durability. Alternative heat treatment processes, such as contact heating, have been developed to improve the efficiency of this process. However, contact heating of the steel sheets often results in cracking within the Al-Si-coated layer. Therefore, this paper will address the development of alternative coating compositions based on Al-Si-X, suitable for contact heating. For this purpose, robot-assisted thermal arc spray was applied to coat the high-strength steel sheets. This ensured high reproducibility as well as effectiveness. The influence of the coating parameters and the variation of the nozzle geometry on the microstructure of the developed coatings will be discussed. Finally, the surface and mechanical properties after contact heating and press hardening will be presented.

Keywords: press hardening, hot stamping, thermal spraying, arc spraying, coating compositions

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Authors: Olurankinse Felix

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Local governments in Ondo State Nigeria are the third tier of government saddled with the responsibility of providing governance and economic services at the grassroots. To be able to do this, the Constitution of the Federal Republic of Nigeria provided that a proportion of Federation Account be allocated to them in addition to their internally generated revenue. From the allocation and other incidental sources of revenue, the local governments are expected to provide basic infrastructures and other social amenities to better the lots of the rural dwellers. Nevertheless, local governments’ performances in terms of provision of social amenities are without questioning and quite not encouraging. Assessing the performance of local governments in this period of dearth and scarcity of resources is highly indispensable more so that the activities of local governments’ staff are bedeviled and characterized with fraud, corruption and mismanagement. Considering the direct impact of the consequences of their action on the living standard of the rural dwellers therefore calls for the need to evaluate their level of performances using capital budgeting approach. The paper being a time series study adopts the survey design. Data were obtained through secondary source mainly from the Annual financial statements and publication of approved budgets estimates covering the period of study (2008-2012). The use of ratio analysis was employed in analyzing the comparative level of performances of the local governments under study. The result of the study shows that less than 30% of the local governments were able to harness the budgetary allocation to provide amenities to the beneficiaries while majority of the local governments were involved in unethical conduct ranging from theft of fund, corruption, diversion of funds and extra-budgetary activities. Also, there is poor internally generated revenue to complement the statutory allocation and besides, the monthly withholding of larger portions of local government share by the state in the name of joint account were also seen as contributory factors. The study recommends the need for transparency and accountability in public fund management through the oversight function of the state house of assembly. Also local government should be made to be autonomous and independent of the state by jettisoning the idea of joint account.

Keywords: performance, transparency and accountability, capital budgeting, joint account, local government autonomy

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Authors: S. Thomet, S. De-Paoli, F. Ghaffari, J. M. Daveau, P. Roche, O. Romain

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In this paper, we present a hardware module dedicated to understanding the fail reason of a System on Chip (SoC) exposed to a particle beam. Impact of Single-Event Effects (SEE) on processor-based SoCs is a concern that has increased in the past decade, particularly for terrestrial applications with automotive safety increasing requirements, as well as consumer and industrial domains. The SEE created by the impact of a particle on an SoC may have consequences that can end to instability or crashes. Specific hardening techniques for hardware and software have been developed to make such systems more reliable. SoC is then qualified using cosmic ray Accelerated Soft-Error Rate (ASER) to ensure the Soft-Error Rate (SER) remains in mission profiles. Understanding where errors are occurring is another challenge because of the complexity of operations performed in an SoC. Common techniques to monitor an SoC running under a beam are based on non-intrusive debug, consisting of recording the program counter and doing some consistency checking on the fly. To detect and understand SEE, we have developed a module embedded within the SoC that provide support for recording probes, hardware watchpoints, and a memory mapped register bank dedicated to software usage. To identify CPU failure modes and the most important resources to probe, we have carried out a fault injection campaign on the RTL model of the SoC. Probes are placed on generic CPU registers and bus accesses. They highlight the propagation of errors and allow identifying the failure modes. Typical resulting errors are bit-flips in resources creating bad addresses, illegal instructions, longer than expected loops, or incorrect bus accesses. Although our module is processor agnostic, it has been interfaced to a RISC-V by probing some of the processor registers. Probes are then recorded in a ring buffer. Associated hardware watchpoints are allowing to do some control, such as start or stop event recording or halt the processor. Finally, the module is also providing a bank of registers where the firmware running on the SoC can log information. Typical usage is for operating system context switch recording. The module is connected to a dedicated debug bus and is interfaced to a remote controller via a debugger link. Thus, a remote controller can interact with the monitoring module without any intrusiveness on the SoC. Moreover, in case of CPU unresponsiveness, or system-bus stall, the recorded information can still be recovered, providing the fail reason. A preliminary version of the module has been integrated into a test chip currently being manufactured at ST in 28-nm FDSOI technology. The module has been triplicated to provide reliable information on the SoC behavior. As the primary application domain is automotive and safety, the efficiency of the module will be evaluated by exposing the test chip under a fast-neutron beam by the end of the year. In the meantime, it will be tested with alpha particles and electromagnetic fault injection (EMFI). We will report in the paper on fault-injection results as well as irradiation results.

Keywords: fault injection, SoC fail reason, SoC soft error rate, terrestrial application

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Authors: Liu Ying-jie, Lu Wen-bo, Peng Cheng-jian

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With the development of the automotive technology and electric vehicle, the contribution of the wind noise on the interior noise becomes the main source of noise. The main transfer path which the exterior excitation is transmitted through is the greenhouse panels and side windows. Simulating the wind noise transmitted into the vehicle accurately in the early development stage can be very challenging. The basic methodologies of this study were based on the Lighthill analogy; the exterior flow field around a passenger car was computed using unsteady Computational Fluid Dynamics (CFD) firstly and then a Finite Element Method (FEM) was used to compute the interior acoustic response. The major findings of this study include: 1) The Sound Pressure Level (SPL) response at driver’s ear locations is mainly induced by the turbulence pressure fluctuation; 2) Peaks were found over the full frequency range. It is found that the methodology used in this study could predict the interior wind noise induced by the exterior aerodynamic excitation in industry.

Keywords: wind noise, computational fluid dynamics, finite element method, passenger car

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Authors: Shun-Tong Chen, Wei-Ping Huang, Hong-Ye Yang, Ming-Chieh Yeh, Chih-Wei Du

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This study presents a novel versatile high-precision integrated micromachining system that combines contact and non-contact micromachining techniques to machine intricate micro-parts precisely. Two broad methods of micro fabrication-1) volume additive (micro co-deposition), and 2) volume subtractive (nanometric flycutting, ultrafine w-EDM (wire Electrical Discharge Machining), and micro honing) - are integrated in the developed micromachining system, and their effectiveness is verified. A multidirectional headstock that supports various machining orientations is designed to evaluate the feasibility of multifunctional micromachining. An exchangeable working-tank that allows for various machining mechanisms is also incorporated into the system. Hence, the micro tool and workpiece need not be unloaded or repositioned until all the planned tasks have been completed. By using the designed servo rotary mechanism, a nanometric flycutting approach with a concentric rotary accuracy of 5-nm is constructed and utilized with the system to machine a diffraction-grating element with a nano-metric scale V-groove array. To improve the wear resistance of the micro tool, the micro co-deposition function is used to provide a micro-abrasive coating by an electrochemical method. The construction of ultrafine w-EDM facilitates the fabrication of micro slots with a width of less than 20-µm on a hardened tool. The hardened tool can thus be employed as a micro honing-tool to hone a micro hole with an internal diameter of 200 µm on SKD-11 molded steel. Experimental results prove that intricate micro-parts can be in-situ manufactured with high-precision by the developed integrated micromachining system.

Keywords: integrated micromachining system, in-situ micromachining, nanometric flycutting, ultrafine w-EDM, micro honing

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Authors: Monique Joyce L. Disamburum, Nicole C. Faustino, Ashley Angela A. Fazon, Jessie F. Rubonal

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Traditional jeepneys contribute significantly to air pollution in the Philippines, negatively affecting both the environment and people. In response, the researchers investigated Sphagnum moss which has high adsorbent properties and can be used as a filter. Therefore, this research aims to create a muffler filter additive to reduce the smoke density emitted by traditional jeepneys. Various materials, such as moss, cornstarch, a metal pipe, bolts, and a papermaking screen frame, were gathered. The moss underwent a blending process with a cornstarch mixture until it achieved a pulp-like consistency, subsequently molded using a papermaking screen frame and left for sun drying. Following this, a metal prototype was created by drilling holes around the tumbler and inserting bolts. The mesh wire containing the filter was carefully placed into the hole, secured by two bolts. In the final phase, there were three setups, each undergoing one trial in the LTO emission testing. Each trial consisted of six rounds of purging, and after that the average smoke density was measured. According to the findings of this study, the filter aided in lowering the average smoke density. The one layer setup produced an average of 1.521, whereas the two layer setup produced an average of 1.082. Using One-Way Anova, it was demonstrated that there is a significant difference between the setups. Furthermore, the Tukey HSD Post Hoc test revealed that Setups A and C differed significantly (p = 0.04604), with Setup C being the most successful in reducing smoke density (mean difference -1.4128). Overall, the researchers came to the conclusion that employing Sphagnum moss as a filter can lower the average smoke density released by traditional jeepneys.

Keywords: sphagnum moss, Jeepney filter, smoke density, Jeepney emission

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Authors: Amruta Rout, Golak Bihari Mahanta, Gunji Bala Murali, Bibhuti Bhusan Biswal, B. B. V. L. Deepak

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The use of industrial robots for performing welding operation is one of the chief sign of contemporary welding in these days. The weld joint parameter and weld process parameter modeling is one of the most crucial aspects of robotic welding. As weld process parameters affect the weld joint parameters differently, a multi-objective optimization technique has to be utilized to obtain optimal setting of weld process parameter. In this paper, a hybrid optimization technique, i.e., Principal Component Analysis (PCA) combined with fuzzy logic has been proposed to get optimal setting of weld process parameters like wire feed rate, welding current. Gas flow rate, welding speed and nozzle tip to plate distance. The weld joint parameters considered for optimization are the depth of penetration, yield strength, and ultimate strength. PCA is a very efficient multi-objective technique for converting the correlated and dependent parameters into uncorrelated and independent variables like the weld joint parameters. Also in this approach, no need for checking the correlation among responses as no individual weight has been assigned to responses. Fuzzy Inference Engine can efficiently consider these aspects into an internal hierarchy of it thereby overcoming various limitations of existing optimization approaches. At last Taguchi method is used to get the optimal setting of weld process parameters. Therefore, it has been concluded the hybrid technique has its own advantages which can be used for quality improvement in industrial applications.

Keywords: robotic arc welding, weld process parameters, weld joint parameters, principal component analysis, fuzzy logic, Taguchi method

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Authors: Elif Kalkanli, Constantinos Soutis

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The use of textile preform in the advanced fields including aerospace, automotive and marine has exponentially grown in recent years. These preforms offer excellent advantages such as being lightweight and low-cost, and also, their suitability for creating different fiber architectures with different materials whilst improved mechanical properties in certain aspects. In this study, a novel honeycomb core is developed by a 3Dweaving process. The assembly of the layers is achieved thanks to innovative weaving design. Polyester yarn is selected for the 3D woven honeycomb core (3DWHC). The core is used to manufacture a sandwich panel with 2x2 twill glass fiber composite face sheets. These 3DWHC sandwich panels will be tested in three-point bending. The in-plane and out-of-plane (through-the-thickness) mechanical response of the core will be examined as a function of cell size in addition to the flexural response of the sandwich panel. The failure mechanisms of the core and the sandwich skins will be reported in addition to flexural strength and stiffness. Possible engineering applications will be identified.

Keywords: 3D woven, assembly, failure modes, honeycomb sandwich panel

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Authors: Hossein Keshtkar, Ali Nasiri Toosi

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With the growing concerns about gasoline environmental pollution and also the need for a more widely available fuel source, natural gas is finding its way to the automotive engines. But before this could happen industrially, simulations of natural gas direct injection need to take place to maximize and optimize power output. KIVA is one of the most powerful tools when it comes to engine simulation. Widely accepted by both researchers and the industry, KIVA an open-source code, offers great in-depth simulation and analyzation. KIVA can compute complex phenomena’s which can occur inside the chamber before, whilst and after ignition. One downside to KIVA, is its in-capability of simulating gaseous injections, making it useful for only liquidized fuel. In this study, we developed a numerical code, to enable the simulation of gaseous injection within the KIVA code. By introducing our code as a subroutine, we modified the original KIVA program. To ensure the correct application of gaseous fuel injection using our modified KIVA code, we simulated two different cases and compared them with their experimental data. We concluded our modified version of KIVA’s simulation results came in very close to those measured experimentally.

Keywords: gaseous injections, KIVA, natural gas direct injection, numerical code, simulation

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Authors: Watcharapan Sukkerd, Teeradej Wuttipornpun

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This paper aims to present non-population search algorithms called tabu search (TS), simulated annealing (SA) and variable neighborhood search (VNS) to minimize the total cost of capacitated MRP problem in multi-stage assembly flow shop with two alternative machines. There are three main steps for the algorithm. Firstly, an initial sequence of orders is constructed by a simple due date-based dispatching rule. Secondly, the sequence of orders is repeatedly improved to reduce the total cost by applying TS, SA and VNS separately. Finally, the total cost is further reduced by optimizing the start time of each operation using the linear programming (LP) model. Parameters of the algorithm are tuned by using real data from automotive companies. The result shows that VNS significantly outperforms TS, SA and the existing algorithm.

Keywords: capacitated MRP, tabu search, simulated annealing, variable neighborhood search, linear programming, assembly flow shop, application in industry

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Authors: Seyfullah Madakbas, Hatice Birtane, Memet Vezir Kahraman

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In this study, we aimed to synthesize and characterize polyhedral oligomeric silsesquioxanes containing polyimide nanocomposite. Polyimide nanocomposites widely have been used in membranes in fuel cell, solar cell, gas filtration, sensors, aerospace components, printed circuit boards. Firstly, polyamic acid was synthesized and characterized by Fourier Transform Infrared. Then, polyhedral oligomeric silsesquioxanes containing polyimide nanocomposite was prepared with thermal imidization method. The obtained polyimide nanocomposite was characterized by Fourier Transform Infrared, Scanning Electron Microscope, Thermal Gravimetric Analysis and Differential Scanning Calorimetry. Thermal stability of polyimide nanocomposite was evaluated by thermal gravimetric analysis and differential scanning calorimetry. Surface morphology of composite samples was investigated by scanning electron microscope. The obtained results prove that successfully prepared polyhedral oligomeric silsesquioxanes are containing polyimide nanocomposite. The obtained nanocomposite can be used in many industries such as electronics, automotive, aerospace, etc.

Keywords: polyimide, nanocomposite, polyhedral oligomeric silsesquioxanes

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Authors: Dengyu You, Alireza Kashani

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This study explores the potential of 3D concrete printing in manufacturing prefabricated staircases. The applications of 3D concrete printing in large-scale construction could enhance the industry’s implementation of the Industry 4.0 concept. In addition, the current global challenge is to achieve Net Zero Emissions by 2050. Innovation in the construction industry could potentially speed up achieving this target. The 3D printing technology offers a possible solution that reduces cement usage, minimises framework wastes, and is capable of manufacturing complex structures. The performance of the 3D concrete printed lightweight staircase needs to be evaluated. In this study, the staircase is designed using computer-aided technologies, fabricated by 3D concrete printing technologies, and tested with Australian Standard (AS 1657-2018 Fixed platforms, walkways, stairways, and ladders – design, construction, and installation) under a laboratory environment. The experiment results will be further compared with the FEM analysis. The results indicate that 3D concrete printing is capable of fast production, reducing material usage, and is highly automotive, which meets the industry’s future development goal.

Keywords: concrete 3D printing, staircase, sustainability, automation

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Authors: Achim Kampker, Heiner Hans Heimes, Mathias Ordung, Nemanja Sarovic

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A key component of the drive train of electric vehicles is the lithium-ion battery system. Among various other components, such as the battery management system or the thermal management system, the battery system mostly consists of several cells which are integrated mechanically as well as electrically. Due to different vehicle concepts with regards to space, energy and power specifications, there is a variety of different battery systems. The corresponding assembly lines are specially designed for each battery concept. Minor changes to certain characteristics of the battery have a disproportionally high effect on the set-up effort in the form of high change-related costs. This paper will focus on battery systems which are made out of battery cells with a prismatic format. The product architecture and the assembly process will be analyzed in detail based on battery concepts of existing electric cars and key variety-causing drivers will be identified. On this basis, several measures will be presented and discussed on how to change the product architecture and the assembly process in order to reduce change-related costs.

Keywords: assembly, automotive industry, battery system, battery concept

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Authors: H. Ucar, U. Aridogan

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Composite structures become intriguing for the design of aerospace, automotive and marine applications due to weight reduction, corrosion resistance and radar signature reduction demands and requirements. Studies on piezoelectric ceramic transducers (PZT) for diagnostics and health monitoring have gained attention for their sensing capabilities, however PZT structures are prone to fail in case of heavy operational loads. In this paper, we develop a piezo-based Glass Fiber Reinforced Polymer (GFRP) composite finite element (FE) model, validate with experimental setup, and identify the applicability and limitations of PZTs for a marine application. A case study is conducted to assess the piezo-based sensing capabilities in a representative marine composite structure. A FE model of the composite structure combined with PZT patches is developed, afterwards the response and functionality are investigated according to the sea conditions. Results of this study clearly indicate the blockers and critical aspects towards industrialization and wide-range use of PZTs for marine composite applications.

Keywords: FRP composite, operational challenges, piezoelectric transducers, FE modeling

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Authors: Safa Boudhaouia, Mohamed Amen Gahbiche, Eliane Giraud, Wacef Ben Salem, Philippe Dal Santo

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Multi-point forming (MPF) and asymmetric incremental forming (ISF) are two flexible processes for sheet metal manufacturing. To take advantages of these two techniques, a hybrid process has been developed: The Multipoint Incremental Forming (MPIF). This process accumulates at once the advantages of each of these last mentioned forming techniques, which makes it a very interesting and particularly an efficient process for single, small, and medium series production. In this paper, an experimental and a numerical investigation of this technique are presented. To highlight the flexibility of this process and its capacity to manufacture standard and complex shapes, several pieces were produced by using MPIF. The forming experiments are performed on a 3-axis CNC machine. Moreover, a numerical model of the MPIF process has been implemented in ABAQUS and the analysis showed a good agreement with experimental results in terms of deformed shape. Furthermore, the use of an elastomeric interpolator allows avoiding classical local defaults like dimples, which are generally caused by the asymmetric contact and also improves the distribution of residual strain. Future works will apply this approach to other alloys used in aeronautic or automotive applications.

Keywords: incremental forming, numerical simulation, MPIF, multipoint forming

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Authors: Saima Yaqoob

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Due to advancement in technologies and cutting cost competition, especially in manufacturing business, organizations are now becoming more focused toward achieving exceptional quality standards with low manufacturing cost. In this concern, many process improvement strategies are becoming popular in the way of increasing productivity and output. Lean manufacturing principles are among one of them, increasingly used for improving productivity by reducing wastages. Many success factors are involved in lean implementation. But, the role of senior management is most important in developing the lean culture in an organization. Purpose of this study is to investigate the perception of executive level management related to the successful implementation of lean practices and its comparison with the existing practices in the organization. In order to collect data, survey questionnaire comprised of eight statements rendering the critical success factors were sent to the top management of fifty (50) automotive manufacturing companies of Karachi. After analyzing their feedbacks, the trend of lean manufacturing principles and the commitment of senior management toward its implementation was identified in the manufacturing industries of Karachi, Pakistan.

Keywords: lean manufacturing, process improvement, senior management, perception, involvement, waste reduction

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Authors: S. P. Jordan, G. Christian, S. P. Jeffs

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Modern composite materials are increasingly being chosen in replacement of heavier metallic material systems within many engineering fields including aerospace and automotive industries. The increasing push towards satisfying environmental targets are fuelling new material technologies and manufacturing processes. This paper will introduce materials and manufacturing processes using metal matrix composites along with manufacturing processes optimized at Alvant Ltd., based in Basingstoke in the UK which offers modern, cost effective, selectively reinforced composites for light-weighting applications within engineering. An overview and introduction into modern optimized manufacturing methods capable of producing viable replacements for heavier metallic and lower temperature capable polymer composites are offered. A review of the capabilities and future applications of this viable material is discussed to highlight the potential involved in further optimization of old manufacturing techniques, to fully realize the potential to lightweight material using cost-effective methods.

Keywords: aluminium matrix composites, light-weighting, hybrid squeeze casting, strategically placed reinforcements

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Authors: Victoria Yu. Garnova, Vladimir G. Merzlikin, Sergey V. Khudyakov, Valeriy A. Tovstonog, Svyatoslav V. Cheranev

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Long-term scientific forecasts confirm that diesel engines still will be the basis of the transport and stationary power in the near future. This is explained by their high efficiency and profitability compared to other types of heat engines. In the automotive industry carried basic researches are aimed at creating a new generation of diesel engines with reduced exhaust emissions (with stable performance) determining the minimum impact on the environment. The application of thermal barrier coatings (TBCs) and especially their modifications based on semitransparent ceramic materials allows solving this problem. For such researches, the preliminary stage of testing of physical characteristics materials and coatings especially with semitransparent properties the authors proposed experimental operating innovative radiative-and-convective cycling simulator. This setup contains original radiation sources (imitator) with tunable spectrum for modeling integral flux up to several MW/m2.

Keywords: environment saving, radiative and convective cycling simulator, semitransparent ceramic coatings, imitator radiant energy

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Authors: Orhan Kurtuluş, Cüneyt Yavuz

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The end of the line controls of the finished products in the automotive industry is important. The control that has been conducted with the manual methods for the sliding doors tracks is not sufficient and faulty products cannot be identified. As a result, the customer has the faulty products. In the scope of this study, the design criteria of the PLC integrated modular end of line control unit has been examined, designed and manufactured to make the control of the 10 different track profile to 2 different vehicles with an objective to minimize the salvage costs by obtaining more sensitive, certain and accurate measurement results. In the study that started with literature and patent review, the design inputs have been specified, the technical concept has been developed, computer supported mechanic design, control system and automation design, design review and design improvement have been made. Laser analog sensors at high sensitivity, probes and modular blocks have been used in the unit. The measurement has been conducted in the system and it is observed that measurement results are more sensitive than the previous methods.

Keywords: control unit design, end of line, modular design, sliding door system

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Authors: Cansu Kandemir, Marco Franchino

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To attain sustainability goals, the manufacturing industries must assess and improve their processes, adopt the latest technologies, and ensure minimal environmental impact. Ongoing debates claim that the definition of sustainability and its assessment is vague. Companies struggle with understanding which processes they should prioritise and necessitate a methodology to aid decision-making. For that reason, our investigation focused on defining a prioritisation guide to help to manufacture engineers identify areas of a facility to prioritise de-carbonisation efforts based on existing sources of data. The authors at the University of Sheffield Advanced Manufacturing Research Centre (AMRC) worked with a range of major businesses, including Food and Drink (Moy Park), Automotive (Nissan), Aerospace and Defence (BAE, Meggitt, Leonardo, and GKN) and Technology (Accenture and Intellium AI). Collected information has been integrated into a prioritisation guide framework that helps process comparison and decision-making. The framework developed in this study aims to ensure that companies have guidance on where to focus their efforts whilst striving to fulfil their environmental and societal obligations.

Keywords: decision making, sustainability, carbon emissions, manufacturing

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Authors: Sireesha Tamada, Debraj Bhattacharjee, Pranab K. Dan, Prabha Bhola

Abstract:

The most important component in an automotive transmission system is the gearbox which controls the speed of the vehicle. In an automatic transmission, the right positioning of actuators ensures efficient transmission mechanism embodiment, wherein the challenge lies in formulating the number of actuators associated with modelling a gearbox. Data with respect to actuation and gear shifting sequence has been retrieved from the available literature, including patent documents, and has been used in this proposed heuristics based methodology for modelling actuation sequence in a gear box. This paper presents a methodological approach in designing a gearbox for the purpose of obtaining an optimal shifting sequence. The computational model considers factors namely, the number of stages and gear teeth as input parameters since these two are the determinants of the gear ratios in an epicyclic gear train. The proposed transmission schematic or stick diagram aids in developing the gearbox layout design. The number of iterations and development time required to design a gearbox layout is reduced by using this approach.

Keywords: automatic transmission, gear-shifting, multi-stage planetary gearbox, rank ordered clustering

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Authors: İmren Öztürk Yılmaz, Abdullah Yasin Bilici, Yasin Atalay Candemir

Abstract:

The system consists of 4 main elements: motion system, image acquisition system, image processing software, and control interface. The parts coming out of the production line to enter the image processing system with the conveyor belt at the end of the line. The 3D scanning of the produced part is performed with the laser scanning system integrated into the system entry side. With the 3D scanning method, it is determined at what position and angle the parts enter the system, and according to the data obtained, parameters such as part origin and conveyor speed are calculated with the designed software, and the robot is informed about the position where it will take part. The robot, which receives the information, takes the produced part on the belt conveyor and shows it to high-resolution cameras for quality control. Measurement processes are carried out with a maximum error of 20 microns determined by the experiments.

Keywords: quality control, industry 4.0, image processing, automated fault detection, digital visual inspection

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Authors: Un-Hwan Park, Jun-Hyeok Heo, In-Sung Lee, Tae-Hyeon Oh, Dae-Gyu Park

Abstract:

Automotive interior material consisting of several material layers has the sound-absorbing function. It is difficult to predict sound absorbing coefficient because of several material layers. So, many experimental tunings are required to achieve the target of sound absorption. Therefore, while the car interior materials are developed, so much time and money is spent. In this study, we present a method to predict the sound absorbing performance of the material with multi-layer using physical properties of each material. The properties are predicted by Foam-X software using the sound absorption coefficient data measured by impedance tube. Then, we will compare and analyze the predicted sound absorption coefficient with the data measured by scaled reverberation chamber and impedance tubes for a prototype. If the method is used instead of experimental tuning in the development of car interior material, the time and money can be saved, and then, the development effort can be reduced because it can be optimized by simulation.

Keywords: multi-layer nonwoven, sound absorption coefficient, scaled reverberation chamber, impedance tubes

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Authors: Hyo Lim Kang, Tae An Kim, Seung Ho Han

Abstract:

A 3-way reversing valve has been used in automotive washing machines to remove remaining oil and dirt on machined engine and transmission blocks. It provides rapid and accurate changes of water flow direction without any precise control device. However, due to its complicated bottom-plug shape, a cavitation occurs in a wide range of the bottom-plug in a downstream. In this study, the cavitation index and POC (percent of cavitation) were used to evaluate quantitatively the cavitation phenomena occurring at the bottom-plug. An optimal shape design was carried out via parametric study for geometries of the bottom-plug, in which a simple CAE-model was used in order to avoid time-consuming CFD analysis and hard to achieve convergence. To verify the results of numerical analysis, a flow visualization test was carried out using a test specimen with a transparent acryl pipe according to ISA-RP75.23. The flow characteristics such as the cavitation occurring in the downstream were investigated by using a flow test equipment with valve and pump including a flow control system and high-speed camera.

Keywords: cavitation, flow visualization test, optimal shape design, percent of cavitation, reversing valve

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Authors: Clara Luwe, Oliver Harness, Helena Meally, Kim Martin, Alexandra Harrington

Abstract:

Background: The role of ‘Renal Specialist Podiatrist’ originated in 2022 due to prevailing evidence of patients with diabetes and end-stage renal disease (ESRD) on haemodialysis (HD) and active ulcerations that were at higher risk of rapid deterioration, foot-related hospital admissions, and lower limb amputations. This role started in April 2022 with the aim of screening all patients on haemodialysis and instigating preventative measures to reduce serious foot related complications. Methods: A comprehensive neurovascular foot assessment was completed to establish baseline vascular status and identify those with peripheral arterial disease (PAD) for all patients on HD. Individual’s foot risk was stratified, advice and education tailored and issued. Identifying all diabetes patients on HD as high-risk for diabetic foot complications. Major Findings: All patients screened revealed over half of the caseload had diabetes, and more than half had a clinical presentation of PAD. All those presenting with ulcerations had a diagnosis of diabetes. Of the presenting ulcerations, the majority of these ulcers predated the renal specialist post and were classified as severe >3 SINBAD Score. Since April’22, complications have been identified quicker, reducing the severity (SINBAD<3 or below), and have improved healing times, in line with the national average. During the eight months of the role being in place, we have seen a reduction in minor amputations and no major amputations. Conclusion: By screening all patients on haemodialysis and focusing on education, early recognition of complications, appropriate treatment, and timely onward referral, we can reduce the risk of foot Diabetic foot ulcerations and lower limb amputations. Having regular podiatry input to stratify and facilitate high-risk, active wound patients across different services has helped to keep these patients stable, prevent amputations, and reduce foot-related hospital admissions and mortality from foot-related disease. By improving the accessibility to a specialist podiatrist, patients felt able to raise concerns sooner. This has helped to implement treatment at the earliest possible opportunity, enabling the identification and healing of ulcers at an earlier and less complex stage (SINBAD <3), thus, preventing potential limb-threatening complications.

Keywords: renal, podiatry, haemodialysis, prevention, early detection

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