Search results for: automotive interior material

Authors: Erhan Çetin, Ali Kurşun, Şafak Aksoy, Merve Tunay Çetin

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The closed form study deal with elastic stress analysis of annular bi-material discs with variable thickness subjected to the mechanical and termomechanical loads. Those discs have many applications in the aerospace industry, such as gas turbines and gears. Those discs normally work under thermal and mechanical loads. Their life cycle can increase when stress components are minimized. Each material property is assumed to be isotropic. The results show that material combinations and thickness profiles play an important role in determining the responses of bi-material discs and an optimal design of those structures. Stress distribution is investigated and results are shown as graphs.

Keywords: bi-material discs, elastic stress analysis, mechanical loads, rotating discs

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Authors: Joseph Fitoussi, Mohammadali Shirinbayan, Abbas Tcharkhtchi

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Due to material flow during processing, short fiber reinforced composites structures obtained by injection or compression molding generally present strong spatial microstructure variation. On the other hand, quasi-static, dynamic, and fatigue behavior of these materials are highly dependent on microstructure parameters such as fiber orientation distribution. Indeed, because of complex damage mechanisms, SFRC structures design is a key challenge for safety and reliability. In this paper, we propose a micromechanical model allowing prediction of damage behavior of real structures as a function of microstructure spatial distribution. To this aim, a statistical damage criterion including strain rate and fatigue effect at the local scale is introduced into a Mori and Tanaka model. A critical local damage state is identified, allowing fatigue life prediction. Moreover, the multi-scale model is coupled with an experimental intrinsic link between damage under monotonic loading and fatigue life in order to build an abacus giving Tsai-Wu failure criterion parameters as a function of microstructure and targeted fatigue life. On the other hand, the micromechanical damage model gives access to the evolution of the anisotropic stiffness tensor of SFRC submitted to complex thermomechanical loading, including quasi-static, dynamic, and cyclic loading with temperature and amplitude variations. Then, the latter is used to fill out microstructure dependent material cards in finite element analysis for design optimization in the case of complex loading history. The proposed methodology is illustrated in the case of a real automotive component made of sheet molding compound (PSA 3008 tailgate). The obtained results emphasize how the proposed micromechanical methodology opens a new path for the automotive industry to lighten vehicle bodies and thereby save energy and reduce gas emission.

Keywords: short fiber reinforced composite, structural design, damage, micromechanical modelling, fatigue, strain rate effect

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Authors: Yutaro Kyuma, Sung-Jun Yoo, Kazuhide Ito

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A commuter bus remains important as a means to network public transportation between railway stations and terminals within cities. In some cases, the boarding time becomes longer, and the boarding rate tends to be higher corresponding to the development of urban cities. The interior environmental quality, e.g. temperature and air quality, in a commuter bus is relatively heterogeneous and complex compared to that of an indoor environment in buildings due to several factors: solar radiative heat – which comes from large-area windows –, inadequate ventilation rate caused by high density of commuters, and metabolic heat generation from travelers themselves. In addition to this, under conditions where many passengers ride in the enclosed space, contact and airborne infectious risk have attracted considerable attention in terms of public health. From this point of view, it is essential to develop the prediction method for assessment of interior environmental quality and infection risk in commuter bus cabins. In this study, we developed a numerical commuter bus model integrated with computer simulated persons to reproduce realistic indoor environment conditions with high occupancy during commuting. Here, computer simulated persons were newly designed considering different types of geometries, e.g., standing position, seating position, and individual differences. Here we conducted coupled computational fluid dynamics (CFD) analysis with radiative heat transfer analysis under steady state condition. Distributions of heterogeneous air flow patterns, temperature, and moisture surrounding the human body under some different ventilation system were analyzed by using CFD technique, and skin surface temperature distributions were analyzed using thermoregulation model that integrated into computer simulated person. Through these analyses, we discussed the interior environmental quality in specific commuter bus cabins. Further, inhaled air quality of each passenger was also analyzed. This study may have possibility to design the ventilation system in bus for improving thermal comfort of occupants.

Keywords: computational fluid dynamics, CFD, computer simulated person, CSP, contaminant, indoor environment, public health, ventilation

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Authors: El Korchi Ayoub, Cherif Raef

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Interior noise in vehicles is an essential factor affecting occupant comfort. Over recent decades, much work has been done to develop simulation tools for vehicle NVH. At the medium high-frequency range, the statistical energy analysis method (SEA) shows significant effectiveness in predicting noise and vibration responses of mechanical systems. In this paper, the evaluation of the sound pressure level (SPL) inside an automobile cabin has been performed numerically using the statistical energy analysis (SEA) method. A test car cabin was performed using a monopole source as a sound source. The decay rate method was employed to obtain the damping loss factor (DLF) of each subsystem of the developed SEA model. These parameters were then used to predict the sound pressure level in the interior cabin. The results show satisfactory agreement with the directly measured SPL. The developed SEA vehicle model can be used in early design phases and allows the engineer to identify sources contributing to the total noise and transmission paths.

Keywords: SEA, SPL, DLF, NVH

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Authors: A. Mostaani, M. P. Pereira, B. F. Rolfe

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The increasing application of Advanced High Strength Steel (AHSS) in the automotive industry to fulfill crash requirements has introduced higher levels of wear in stamping dies and parts. Therefore, understanding wear behaviour in sheet metal forming is of great importance as it can help to reduce the high costs currently associated with tool wear. At the contact between the die and the sheet, the tips of hard tool asperities interact with the softer sheet material. Understanding the deformation that occurs during this interaction is important for our overall understanding of the wear mechanisms. For these reasons, the scratching of a perfectly plastic material by a rigid indenter has been widely examined in the literature; with finite element modelling (FEM) used in recent years to further understand the behaviour. The ‘wear mode diagram’ has been commonly used to classify the deformation regime of the soft work-piece during scratching, into three modes: ploughing, wedge formation, and cutting. This diagram, which is based on 2D slip line theory and upper bound method for perfectly plastic work-piece and rigid indenter, relates different wear modes to attack angle and interfacial strength. This diagram has been the basis for many wear studies and wear models to date. Additionally, it has been concluded that galling is most likely to occur during the wedge formation mode. However, there has been little analysis in the literature of how the material behaviour and deformation conditions associated with metal forming processes influence the wear behaviour. Therefore, the first aim of this work is first to use a commercial FEM package (Abaqus/Explicit) to build a 3D model to capture wear modes during scratching with indenters with different attack angles and different interfacial strengths. The second goal is to utilise the developed model to understand how wear modes might change in the presence of bulk deformation of the work-piece material as a result of the metal forming operation. Finally, the effect of the work-piece material properties, including strain hardening, will be examined to understand how these influence the wear modes and wear behaviour. The results show that both strain hardening and substrate deformation can change the critical attack angle at which the wedge formation regime is activated.

Keywords: finite element, pile-up, scratch test, wear mode

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Authors: B. P. G. Figueira, I. C. Pinto, D. Ferro, F. C. M. Zacharias

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The absenteeism at work constitutes in a temporary absence of labor functions resulting from various reasons, bringing damage to production, increasing costs of care and overburdening other workers, has its principal cause due to illness, often due exposure to several risks in the workplace. This study aims to know, identify and analyze the types and causes of absenteeism, such as the frequency at which it occurs by professional category, for employment contract and days not worked in Emergency Care Public in a city in the interior of São Paulo. We conducted exploratory and descriptive study with a quantitative approach, with nursing professionals, after selection of inclusion criteria was reached a universe of 208 subjects, the data collected are for the years from 2010-2013. Research has shown that the professional category of nursing assistant had 88,11% of total absenteeism, absenteeism lasting 1 day was the with the highest frequency, the women were responsible for 74,80% of absenteeism disease. It was concluded that absenteeism shall be monitored to plan control actions, establishing better political for the management of human resources, because it can be an aggravating factor in the quality of care.

Keywords: absenteeism; nursing; emergency medical services, human resource

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Authors: Y. Shamas, S. Imanzadeh, A. Jarno, S. Taibi

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Silt-based construction material is acknowledged since forever and lately received the researchers’ attention more than before as being an ecological and economical alternative for typical cement-based concrete. Silt-based material is known for its worldwide availability, cheapness, and various applications. Some rules should be defined to obtain a standardized method for the use of raw earth as a modern construction material; but first, its mechanical properties should be precisely studied to better understand its behavior in order to find new aspects in making it a better competitor for the cement concrete that is high energy-demanding in terms of gray energy. Some researches were performed on the raw earth material to enhance its characteristics as strength and ductility for their importance and their wide use for various materials. Yet, many other mechanical properties can be used to study the mechanical behavior of raw earth materials such as Young’smodulus and toughness. Studies concerning the toughness of material were rarely conducted previously except for metals despite its significant role associated to the energy absorbed by the material under loading before fracturing. The purpose of this paper is to restate different toughness definitions used in the literature and propose a new definition.

Keywords: silt-based material, raw earth concrete, stress-strain curve, energy, toughness

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Authors: Joelle Al Fakhoury, Emilio Sassine, Yassine Cherif, Joseph Dgheim, Emmanuel Antczak

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Hollow block masonry is the most used building technology in the Lebanese context. These blocks are manufactured in an artisanal way and have unknown thermal properties; their overall thermos-physical performance is thus unknown and also poorly investigated scientifically in both single wall and also double wall configurations. In this work, experimental measurements and numerical simulations are performed for a better understanding of the heat transfer in masonry walls. This study was realized using an experimental setup consisting of a masonry hollow block wall (0.1m x 1m x 1m) and two heat boxes, such that each covers one side of the wall. The first is a reference box having a constant interior temperature, and the other is a control box having an adjustable interior temperature. At first, the numerical model is validated using an experimental setup; then 3D numerical analyzes are held in order to investigate the effect of the air gap, the mortar joints, and the plastering on the thermal performance of masonry walls for a better understanding of the heat transfer process and the recommendation of suitable thermal improvements.

Keywords: masonry wall, hollow blocks, heat transfer, wall instrumentation, thermal improvement

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Authors: Ipei Sato, Naonori Shibata, Shoji Matsumoto, Naruhito Matsumoto

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Friction stir welding (FSW) has been widely used in the automotive, aerospace, and high-tech industries due to its superiority in mechanical properties after joining. In order to achieve a good quality joint by friction stir welding (FSW), it is necessary to secure an advanced angle (usually 3 to 5 degrees) using a dedicated FSW machine and to join on a highly rigid machine. On the other hand, although recently, a new combined machine that combines the cutting function of a conventional machining center with the FSW function has appeared on the market, its joining process window is small, so joining defects easily occur, and it lacks reproducibility, which limits its application to the automotive industry, where control accuracy is required. This has limited the use of FSW machines in the automotive industry, where control accuracy is required. FSW-only machines or hybrid equipment that combines FSW and cutting machines require high capital investment costs, which is one of the reasons why FSW itself has not penetrated the market. Synchronized stir welding, a next-generation joining technology developed by our company, requires no tilt angle and is a very cost-effective method of welding. It is a next-generation joining technology that does not require a tilt angle, does not require a complicated spindle mechanism, and minimizes the load and vibration on the spindle, temperature during joining, and shoulder diameter, thereby enabling a wide range of joining conditions and high-strength, high-speed joining with no joining defects. In synchronized stir welding, the tip of the joining tool is "driven by microwaves" in both the rotational and vertical directions of the tool. The tool is synchronized and stirred in the direction and at the speed required by the material to be stirred in response to the movement required by the material to be welded, enabling welding that exceeds conventional concepts. Conventional FSW is passively stirred by an external driving force, resulting in low joining speeds and high heat input due to the need for a large shoulder diameter. In contrast, SSW is characterized by the fact that materials are actively stirred in synchronization with the direction and speed in which they are to be stirred, resulting in a high joining speed and a small shoulder diameter, which allows joining to be completed with low heat input. The advantages of synchronized stir welding technology in terms of basic mechanical properties are described. The superiority of the basic mechanical properties of SSW over FSW was evaluated as a comparison of the strength of the joint cross section in the comparison between FSW and SSW. SSW, compared to FSW, has tensile strength; base metal 242 MPa/217 MPa after FSW 89%, base metal 242 MPa/225 MPa after SSW 93%. Vickers hardness; base metal 75.0HV/FSW; 57.5HV 76% SSW; 66.0HV 88% (weld center), showing excellent results. In the tensile test, the material used was aluminum (A5052-H112) plate 5 mm thick, and the specimen was dumbbell-shaped, 2 mm thick, 4 mm wide, and 60 mm long. Measurements were made at a loading speed of 20%/min (in accordance with Z 2241:2022). Tensile testing machine: INSTRON Japan, model: INSTRON 5982. Vickers hardness was measured on a 5 mm thick specimen of A5052 tempered H112 with a width of 15 mm at 0.3 pitch (in accordance with JIS Z 2244:2020). Vickers tester: FUTURE-TECH Model: FM-300.

Keywords: FSW, SSW, synchronized stir welding, requires no tilt angles, running peak temperature less than 100 degrees C

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Authors: David Downey

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With the introduction of additive manufacturing (3D printing) to produce titanium (Ti6Al4V) components in the medical/aerospace and automotive industries, intricate geometries can be produced with virtually complete design freedom. However, the consideration of microstructural anisotropy resulting from the additive manufacturing process becomes necessary due to this design flexibility and the need to print a geometric shape that can consist of numerous angles, radii, and swept surfaces. A femoral knee implant serves as an example of a 3D-printed near-net-shaped product. The mechanical properties of the printed components, and consequently, their machinability, are affected by microstructural anisotropy. Currently, finish-machining operations performed on titanium printed parts using selective laser melting (SLM) utilize the same cutting tools employed for processing wrought titanium components. Cutting forces for components manufactured through SLM can be up to 70% higher than those for their wrought counterparts made of Ti6Al4V. Moreover, temperatures at the cutting interface of 3D printed material can surpass those of wrought titanium, leading to significant tool wear. Although the criteria for tool wear may be similar for both 3D printed and wrought materials, the rate of wear during the machining process may differ. The impact of these issues on the choice of cutting tool material and tool lifetimes will be discussed.

Keywords: additive manufacturing, build orientation, microstructural anisotropy, printed titanium Ti6Al4V, tool wear

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Authors: Seyed Esmail Seyedi Bariran, Laysheng Ewe, Amy Ling

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Since supplier selection appears as a vital decision, selecting supplier based on the best and most accurate ways has a lot of importance for enterprises. In this study, a new Artificial Intelligence approach is exerted to remove weaknesses of supplier selection. The paper has three parts. First part is choosing the appropriate criteria for assessing the suppliers’ performance. Next one is collecting the data set based on experts. Afterwards, the data set is divided into two parts, the training data set and the testing data set. By the training data set the best structure of GEP and ANN are selected and to evaluate the power of the mentioned methods the testing data set is used. The result obtained shows that the accuracy of GEP is more than ANN. Moreover, unlike ANN, a mathematical equation is presented by GEP for the supplier selection.

Keywords: supplier selection, automotive supply chains, ANN, GEP

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Authors: Mădălina Elena Mavrodin, Gabriela Andreea Despescu, Gheorghe Lăzăroiu

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Long term trend of global warming has brought a very deep interest in climate change, which is due most likely to increasing concentrations of anthropogenic greenhouse gases. 0f these, particular attention is paid to carbon dioxide, which has led in desire for obtaining carbon footprint products. Automotive industry is one of the world’s most important economic sectors with a great impact over the environment through all range of activities. Its impact over the environment has been studied, researcher trying as much as possible to reduce it and to offer environmental friendly solution for the using, but also manufacturing cars. In the global endeavour to meet the international commitments in order to reduce the greenhouse gas emissions, many companies integrate environmental issues into their management systems, with potential effects in their entire production chains. Several tools and calculators have been developed to measure the environmental impact of a product in the life cycle perspective of the whole product chain. There were a lot of ways to obtain the carbon footprint of driving a car, but the total carbon footprint of a car includes also the carbon footprint of all the components and accessories. In the automotive industry, one of the challenges is to calculate the carbon footprint of a car from ‘cradle to grave’; this meaning not only for driving the car, but also manufacturing it, so there can be an overview over the entire process of production.

Keywords: carbon footprint, global warming potential, greenhouse gases, manufacture, plastic air ducts

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Authors: Yong-Jun Jeon, Hyung-Pil Park, Min-Jae Song, Baeg-Soon Cha

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Following the recent trend of having increased demand in producing lighter-weight car bodies for improvement of automobile safety and gas mileage, there is a forming method that makes use of hot-stamping technique, which satisfies all conditions mentioned above. Hot-stamping is a forming technique with advantages of excellent formability, good dimensional precision and others since it is a process in which steel plates are heated up to temperatures of at least approximately 900°C after which forming is conducted in die at room temperature followed by rapid cooling. In addition, it has characteristics of allowing for improvement in material strength through achievement of quenching effect by having simultaneous forming and rapid cooling of material of high temperatures. However, there is insufficient information on the changes in material strength according to changes in material temperature with regards to material heating method and forming process in hot-stamping. Accordingly, this study aims to design and press die for T-type product of the scale models of the center pillar and to understand the changes in material strength in relation to changes in forming methods of hot-stamping process. Thus in order to understand the changes in material strength due to quenching effect among the hot-stamping process, material strength and material forming precision were to be studied while varying the forming and forming method when forming. For test methods, material strength was observed by using boron steel that has boron additives, which was heated up to 950°C, after which it was transferred to a die and was cooled down to material temperature of 400°C followed by air cooling process. During the forming and cooling process here, experiment was conducted with forming parameters of 2 holding rates and 3 flange heating rates wherein changing appearance in material strength according to changes forming method were observed by verifying forming strength and forming precision for each of the conditions.

Keywords: hot-stamping, formability, quenching, forming, press die, forming methods

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Authors: Jasna Prester, Najla Podrug, Davor Filipović

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Manufacturing companies invest a significant amount of sales into material resources for production. In our sample, 58% of sales is used for manufacturing inputs, while only 24% of sales is used for salaries. This means that if a company is looking to reduce costs, the greater potential is in reduction of material costs than downsizing. This research shows that manufacturing companies in Croatia did realize material savings in last three years. It is also shown by which technologies they achieved materials cost savings. Through literature research, we found research gap as to which technologies reduce material consumption. As methodology of research four regression analyses are used to prove our findings.

Keywords: Croatia, materials savings strategies, technologies, return on sales

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Authors: C. Malça, P. Gonçalves, N. Alves, A. Mateus

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Regardless of the manufacturing process used, subtractive or additive, material, purpose and application, produced components are conventionally solid mass with more or less complex shape depending on the production technology selected. Aspects such as reducing the weight of components, associated with the low volume of material required and the almost non-existent material waste, speed and flexibility of production and, primarily, a high mechanical strength combined with high structural performance, are competitive advantages in any industrial sector, from automotive, molds, aviation, aerospace, construction, pharmaceuticals, medicine and more recently in human tissue engineering. Such features, properties and functionalities are attained in metal components produced using the additive technique of Rapid Prototyping from metal powders commonly known as Selective Laser Melting (SLM), with optimized internal topologies and varying densities. In order to produce components with high strength and high structural and functional performance, regardless of the type of application, three different internal topologies were developed and analyzed using numerical computational tools. The developed topologies were numerically submitted to mechanical compression and four point bending testing. Finite Element Analysis results demonstrate how different internal topologies can contribute to improve mechanical properties, even with a high degree of porosity relatively to fully dense components. Results are very promising not only from the point of view of mechanical resistance, but especially through the achievement of considerable variation in density without loss of structural and functional high performance.

Keywords: additive manufacturing, internal topologies, porosity, rapid prototyping, selective laser melting

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Authors: Venkatesh Krishna Murthy

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The era before government-regulated automotive designs gave us some astonishing vehicles that are well worth to keep on the road. The fact that restoring an automobile in 2015 does not mean it will perform like one designed in 2021. This is one of the reasons that manufacturers continue to turn to vintage hardware for future enhancements in their vehicles. Now we need to understand that a modern chassis could possibly allow manufacturers to give vintage performance cars a level of braking capability, compatibility with tires, chassis rigidity, suspension sophistication, and steering response, an experience only racers got until now. However, half a century of advancements in engineering can have a great impact on design in any field, and the automotive realm which holds no exception. In the current situation, a growing number of companies offer chassis and braking components to onboard manufacturers to retrofit contemporary technology for their vintage vehicles to modernize them at the foundation level. The recent question arises on performance on lithium batteries, as opposed to simply bolting upgraded components, for ex. lithium batteries with graphene as superconductive material to enhance performance, an area deeply investigated. Serving as the “bones” of the vehicle, the chassis and frame play a central role in dictating how that automobile will perform. While the desire to maintain originality is alluring for many, the benefits of a modern chassis are vast. In some situations, it also allows builders to put cars back on the road that might otherwise be too far gone. “There’s a couple of different factors at play here – one of them being that these older cars from the ’40s, ’50s, and ’60s have seen a lot of weather and a lot of road miles over the years, more often than not,” says Craig Morrison of Art Morrison Enterprises.

Keywords: hybrid electric vehicles, internet of things, lithium graphene batteries, classic car chassis

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Authors: Mohannad Mayyas, Farshid Pahlevani, Veena Sahajwalla

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Automotive shredder residue (ASR) is an industrial waste, generated during the recycling process of End-of-life vehicles. The large increasing production volumes of ASR and its hazardous content have raised concerns worldwide, leading some countries to impose more restrictions on ASR waste disposal and encouraging researchers to find efficient solutions for ASR processing. Although a great deal of research work has been carried out, all proposed solutions, to our knowledge, remain commercially and technically unproven. While the volume of waste materials continues to increase, the production of materials from new sustainable sources has become of great importance. Advanced ceramic materials such as nitrides, carbides and borides are widely used in a variety of applications. Among these ceramics, a great deal of attention has been recently paid to Titanium nitride (TiN) owing to its unique characteristics. In our study, we propose a new sustainable approach for ASR management where TiN nanoparticles with ideal particle size ranging from 200 to 315 nm can be synthesized as a by-product. In this approach, TiN is thermally synthesized by nitriding pressed mixture of automotive shredder residue (ASR) incorporated with titanium oxide (TiO2). Results indicated that TiO2 influences and catalyses degradation reactions of ASR and helps to achieve fast and full decomposition. In addition, the process resulted in titanium nitride (TiN) ceramic with several unique structures (porous nanostructured, polycrystalline, micro-spherical and nano-sized structures) that were simply obtained by tuning the ratio of TiO2 to ASR, and a product with appreciable TiN content of around 85% was achieved after only one hour nitridation at 1550 °C.

Keywords: automotive shredder residue, nano-ceramics, waste treatment, titanium nitride, thermal conversion

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Authors: O. Eren, L. Zakar

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Recycling steel building components is key to the sustainability of a structure’s end-of-life, as it is the most economical solution. In this paper the effects of usage of recycled steel material in tall buildings aspects are investigated.

Keywords: building, recycled material, steel, structure

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Authors: Justyna Rybicka, Ashutosh Tiwari, Shane Enticott

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In the age of automation and computation aiding manufacturing, it is clear that manufacturing systems have become more complex than ever before. Although technological advances provide the capability to gain more value with fewer resources, sometimes utilisation of the manufacturing capabilities available to organisations is difficult to achieve. Flexible manufacturing systems (FMS) provide a unique capability to manufacturing organisations where there is a need for product range diversification by providing line efficiency through production flexibility. This is very valuable in trend driven production set-ups or niche volume production requirements. Although FMS provides flexible and efficient facilities, its optimal set-up is key in achieving production performance. As many variables are interlinked due to the flexibility provided by the FMS, analytical calculations are not always sufficient to predict the FMS’ performance. Simulation modelling is capable of capturing the complexity and constraints associated with FMS. This paper demonstrates how discrete event simulation (DES) can address complexity in an FMS to optimise the production line performance. A case study of an automotive FMS is presented. The DES model demonstrates different configuration options depending on prioritising objectives: utilisation and throughput. Additionally, this paper provides insight into understanding the impact of system set-up constraints on the FMS performance and demonstrates the exploration into the optimal production set-up.

Keywords: discrete event simulation, flexible manufacturing system, capacity performance, automotive

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Authors: Alaa Fezai, Anuj Sharma, Wolfgang Mueller-Hirsch, André Zimmermann

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Viscoelastic materials have been widely used in the automotive industry over the last few decades with different functionalities. Besides their main application as a simple and efficient surface damping treatment, they may ensure optimal operating conditions for on-board electronics as thermal interface or sealing layers. The dynamic behavior of viscoelastic materials is generally dependent on many environmental factors, the most important being temperature and strain rate or frequency. Prior to the reliability analysis of systems including viscoelastic layers, it is, therefore, crucial to accurately predict the dynamic and lifetime behavior of these materials. This includes the identification of the dynamic material parameters under critical temperature and frequency conditions along with a precise damage localization and identification methodology. The goal of this work is twofold. The first part aims at applying an inverse viscoelastic material-characterization approach for a wide frequency range and under different temperature conditions. For this sake, dynamic measurements are carried on a single lap joint specimen using an electrodynamic shaker and an environmental chamber. The specimen consists of aluminum beams assembled to adapter plates through a viscoelastic adhesive layer. The experimental setup is reproduced in finite element (FE) simulations, and frequency response functions (FRF) are calculated. The parameters of both the generalized Maxwell model and the fractional derivatives model are identified through an optimization algorithm minimizing the difference between the simulated and the measured FRFs. The second goal of the current work is to guarantee an on-line detection of the damage, i.e., delamination in the viscoelastic bonding of the described specimen during frequency monitored end-of-life testing. For this purpose, an inverse technique, which determines the damage location and size based on the modal frequency shift and on the change of the mode shapes, is presented. This includes a preliminary FE model-based study correlating the delamination location and size to the change in the modal parameters and a subsequent experimental validation achieved through dynamic measurements of specimen with different, pre-generated crack scenarios and comparing it to the virgin specimen. The main advantage of the inverse characterization approach presented in the first part resides in the ability of adequately identifying the material damping and stiffness behavior of soft viscoelastic materials over a wide frequency range and under critical temperature conditions. Classic forward characterization techniques such as dynamic mechanical analysis are usually linked to limitations under critical temperature and frequency conditions due to the material behavior of soft viscoelastic materials. Furthermore, the inverse damage detection described in the second part guarantees an accurate prediction of not only the damage size but also its location using a simple test setup and outlines; therefore, the significance of inverse numerical-experimental approaches in predicting the dynamic behavior of soft bonding layers applied in automotive electronics.

Keywords: damage detection, dynamic characterization, inverse approaches, vibration testing, viscoelastic layers

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Authors: Timur Mukhametkaliyev

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The earthen material possesses low compression strength, and it is highly sensitive to the water content. Different binders can be added (Portland cement or lime) to improve the durability and the mechanical characteristics of earthen material, but the production of these binders has high embodied energy and results in an increase in world CO₂ emission. Geopolymers are binders which can be synthesized at low temperature in alkaline solutions from raw materials consisting of amorphous aluminosilicates. Geopolymers are an attractive substitution of Portland cement and can be used as an excellent stabilization for earthen material. In this study, earthen material stabilized with geopolymer binder for use in construction 3D printing was developed. Construction 3D printing offers freedom of design, waste minimisation, customisation, reduced labour, and automation. For successful 3D printing, the properties of used material are the most important aspects because they require adaptability for extrusion and controlled time of hardening for the binder.

Keywords: 3D printing, building construction, geopolymer, architecture

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Authors: Moulay Smaïne Ghembaza, Mokhtar Dadouch, Nour-Said Ikhlef

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Soil treatment is to make use soil that does not have the characteristics required in a given context. We limit ourselves in this work to the field of road earthworks where we have chosen to develop a local material in the region of Sidi Bel Abbes (Algeria). This material has poor characteristics not meeting the standards used in road geo technics. To remedy this, firstly, we were trying to improve the Proctor Standard characteristics of this material by mechanical treatment increasing the compaction energy. Then, by a chemical treatment, adding some cement dosages, our results show that this material classified A1h a increase maximum dry density and a reduction in the water content of compaction. A comparative study is made on the optimal properties of the material between the two modes of treatment. On the other hand, after treatment, one finds a decrease in the plasticity index and the methylene blue value. This material exhibits a change of class. Therefore, soil class CL turned into a soil class composed CL-ML (Silt of low plasticity). This observation allows this material to be used as backfill or sub grade.

Keywords: treatment of soil, cement, subgrade, Atteberg limits, classification, optimum proctor properties

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Authors: Zulfiye Ahan, Mustafa Dogu, Elcin Yilmaz

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The use of nonwoven textile materials in many application areas is rapidly increasing thanks to their versatile performance properties. The automotive industry is one of the largest sectors in the world with a potential market of more than 2 billion euros for nonwoven textile materials applications. Lightweight materials having higher mechanical performance, better sound and heat insulation properties are of interest in many applications. Since the usage of nonwoven surfaces provides many of these advantages, the demand for this kind of materials is gradually growing especially in the automotive industry. Nonwoven materials used in lightweight vehicles can contain economical and high strength thermoplastics as well as durable components such as glass fiber. By bringing these composite materials into foam structure containing micro or nanopores, products with high absorption ability, light and mechanically stronger can be fabricated. In this respect, our goal is to produce thermoplastic composite nonwoven by using nonwoven glass fiber fabric reinforced polypropylene (PP). Azodicarbonamide (ADC) was selected as a foaming agent and a thermal process was applied to obtain porous structure. Various foaming temperature ranges and residence times were studied to examine the foaming behaviour of the thermoplastic composite nonwoven. Physicochemical and mechanical tests were applied in order to analyze the characteristics of composite foams.

Keywords: composite nonwoven, thermoplastic foams, foaming agent, foaming behavior

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Authors: Tahani Farah, Hanène Souli, Jean-Marie Fleureau, Guillaume Kermouche, Jean-Jacques Fry, Benjamin Girard, Denis Aelbrecht

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In this work, the bio-clogging of two soils with different granulometries is presented. The durability of the clogging is also studied under cycles of hydraulic head and under cycles of desaturation- restauration. The studied materials present continuous grain size distributions. The first one corresponding to the "material 1", presents grain sizes between 0.4 and 4 mm. The second material called "material 2" is composed of grains with size varying between 1 and 10 mm. The results show that clogging occurs very quickly after the injection of nutrition and an outlet flow near to 0 is observed. The critical hydraulic head is equal to 0.76 for "material 1", and 0.076 for "material 2". The durability tests show a good resistance to unclogging under cycles of hydraulic head and desaturation-restauration for the "material 1". Indeed, the flow after the cycles is very low. In contrast, "material 2", shows a very bad resistance, especially under the hydraulic head cycles. The resistance under the cycles of desaturation-resaturation is better but an important increase of the flow is observed. The difference of behavior is due to the granulometry of the materials. Indeed, the large grain size contributes to the reduction of the efficiency of the bio-clogging treatment in this material.

Keywords: bio-clogging, granulometry, permeability, nutrition

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Authors: Hasan Muslemani, Jeffrey Wilson, Xi Liang, Francisco Ascui, Katharina Kaesehage

Abstract:

This paper aims to examine consumer behaviour towards, and the willingness to adopt, green steel use in the automotive sector, in order to identify potential barriers and opportunities for its widespread adoption. Semi-structured interviews were held with experts from global, regional and country-specific industry associations and automakers. The analysis shows there is a new shift towards lifecycle thinking in the sector, although these efforts have been voluntary and driven by customer and employee pressures rather than regulation. The paper further appraises possible demand for green steel within different vehicle types (based on size and powertrain), and shows that manufacturers of electric heavy-duty vehicles are most likely to adopt green steel in the first instance, given the amount of incorporated steel in the vehicles and the fact that lifecycle emissions lie predominantly in their manufacturing phase. A case for green advanced higher-strength steels (AHSS) can also be made in light-duty passenger vehicles, which may mitigate competition from light-weight alternative materials in terms of cost and greenness (depending on source and utilisation zones). This work builds on a wide sustainability-related literature in the automotive sector and highlights areas in need of urgent action if the sector as a whole were to meet its Paris Agreement climate targets, in particular a need to revisit current CO2 performance regulations to include Scope 1 and Scope 2 emissions, engage in educational green marketing campaigns, and explore innovative market-based mechanisms to bridge the gap between relatively-low carbon abatement costs of steelmaking and high abatement costs of vehicle manufacturing.

Keywords: Green steel, Consumer behaviour, Automotive industry, Environmental sustainability

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Authors: Alexander Kospach, Fabian Benezeder, Jürgen Abraham

Abstract:

E-mobility poses new challenges for inverters (e.g., higher switching frequencies) in terms of thermal behavior and thermal management. Due to even higher switching frequencies, thermal losses become greater, and the cooling of critical components (like insulated gate bipolar transistor and diodes) comes into focus. New manufacturing methods, such as 3D printing, enable completely new pin-fin structures that can handle higher waste heat to meet the new thermal requirements. Based on the geometrical specifications of the industrial partner regarding the manufacturing possibilities for 3D printing, different and completely new pin-fin structures were numerically investigated for their hydraulic and thermal behavior in fundamental studies assuming an indirect liquid cooling. For the 3D computational fluid dynamics (CFD) thermal simulations OpenFOAM was used, which has as numerical method the finite volume method for solving the conjugate heat transfer problem. A steady-state solver for turbulent fluid flow and solid heat conduction with conjugate heat transfer between solid and fluid regions was used for the simulations. In total, up to fifty pinfin structures and arrangements, some of them completely new, were numerically investigated. On the basis of the results of the principal investigations, the best two pin-fin structures and arrangements for the complete module cooling of an automotive inverter were numerically investigated and compared. There are clear differences in the maximum temperatures for the critical components, such as IGTBs and diodes. In summary, it was shown that 3D pin fin structures can significantly contribute to the improvement of heat transfer and cooling of an automotive inverter. This enables in the future smaller cooling designs and a better lifetime of automotive inverter modules. The new pin fin structures and arrangements can also be applied to other cooling applications where 3D printing can be used.

Keywords: pin fin heat sink optimization, 3D printed pin fins, CFD simulation, power electronic cooling, thermal management

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Authors: Achim Kampker, Heiner Hans Heimes, Mathias Ordung, Jan-Philip Ganser

Abstract:

In the past years, the automotive industry has changed significantly. Innovative mobility concepts have become more important, and electric vehicles see a chance of replacing vehicles with combustion engines in the long term. However, the coming years will be characterized by coexistence. In this context, there are two possible production scenarios: One the one hand, electric vehicles could be manufactured in bespoke assembly lines. Concerning the uncertainty regarding sales figures development, this alternative boasts a high investment risk. Therefore, an integrated assembly building upon existing structures also seems a feasible solution. This empirical study aims at validating hypotheses concerning theoretical and practical challenges of the integrated production in the final assembly. In order to take a test of approaches of the research by analyzing censored feedback of professionals, these hypotheses are validated in the framework of an expert study. For this purpose, hypotheses have been generated on the basis of a requirements analysis and a concept specification. Thereupon, a list of question has been implemented and deduced from the hypotheses to execute an online- and written-survey and interviews with professionals. The interpretation and evaluation of the findings includes an inter-component comparison for the electric drivetrain. Furthermore, key drivers for a sufficient integrated product and process design are presented.

Keywords: automotive industry, final assembly, integrated manufacturing, product and process development

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Authors: M. Sazali Said, Rahim Jamian, Shahrizan Yusoff, Shahruzaman Sulaiman, Jum'Azulhisham Abdul Shukor

Abstract:

This case study focuses on the role of Universiti Kuala Lumpur Malaysian Spanish Institute (UniKL MSI) to produce technologist in order to reduce the shortage of skilled workers especially in the automotive industry. The purpose of the study therefore seeks to examine the effectiveness of Technical Education and Vocational Training (TEVT) curriculum of UniKL MSI to produce graduates that could immediately be productively employed by the automotive industry. The approach used in this study is through performance evaluation of students attending the Industrial Training Attachment (INTRA). The sample of study comprises of 37 students, 16 university supervisors and 26 industrial supervisors. The research methodology involves the use of quantitative and qualitative methods of data collections through the triangulation approach. The quantitative data was gathered from the students, university supervisors and industrial supervisors through the use of questionnaire. Meanwhile, the qualitative data was obtained from the students and university supervisors through the use of interview and observation. Both types of data have been processed and analyzed in order to summarize the results in terms of frequency and percentage by using a computerized spread sheet. The result shows that industrial supervisors were satisfied with the students’ performance. Meanwhile, university supervisors rated moderate effectiveness of the UniKL MSI curriculum in producing graduates with appropriate skills and in meeting the industrial needs. During the period of study, several weaknesses in the curriculum have been identified for further continuous improvements. Recommendations and suggestions for curriculum improvement also include the enhancement of technical skills and competences of students towards fulfilling the needs and demand of the automotive industries.

Keywords: technical education and vocational training (TEVT), industrial training attachment (INTRA), curriculum improvement, automotive industry

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Authors: Chao Yu, Qing-Guo Wang, Dan Zhang

Abstract:

The outlier detection problem for dynamic systems is formulated as a matrix decomposition problem with low-rank, sparse matrices and further recast as a semidefinite programming (SDP) problem. A fast algorithm is presented to solve the resulting problem while keeping the solution matrix structure and it can greatly reduce the computational cost over the standard interior-point method. The computational burden is further reduced by proper construction of subsets of the raw data without violating low rank property of the involved matrix. The proposed method can make exact detection of outliers in case of no or little noise in output observations. In case of significant noise, a novel approach based on under-sampling with averaging is developed to denoise while retaining the saliency of outliers and so-filtered data enables successful outlier detection with the proposed method while the existing filtering methods fail. Use of recovered “clean” data from the proposed method can give much better parameter estimation compared with that based on the raw data.

Keywords: outlier detection, system identification, matrix decomposition, low-rank matrix, sparsity, semidefinite programming, interior-point methods, denoising

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Authors: C. A. Barros, Ana P. Barroso

Abstract:

Any industrial company needs to determine the amount of variation that exists within its measurement process and guarantee the reliability of their data, studying the performance of their measurement system, in terms of linearity, bias, repeatability and reproducibility and stability. This issue is critical for automotive industry suppliers, who are required to be certified by the 16949:2016 standard (replaces the ISO/TS 16949) of International Automotive Task Force, defining the requirements of a quality management system for companies in the automotive industry. Measurement System Analysis (MSA) is one of the mandatory tools. Frequently, the measurement system in companies is not connected to the equipment and do not incorporate the methods proposed by the Automotive Industry Action Group (AIAG). To address these constraints, an R&D project is in progress, whose objective is to develop a web and cloud-based MSA tool. This MSA tool incorporates Industry 4.0 concepts, such as, Internet of Things (IoT) protocols to assure the connection with the measuring equipment, cloud computing, artificial intelligence, statistical tools, and advanced mathematical algorithms. This paper presents the preliminary findings of the project. The web and cloud-based MSA tool is innovative because it implements all statistical tests proposed in the MSA-4 reference manual from AIAG as well as other emerging methods and techniques. As it is integrated with the measuring devices, it reduces the manual input of data and therefore the errors. The tool ensures traceability of all performed tests and can be used in quality laboratories and in the production lines. Besides, it monitors MSAs over time, allowing both the analysis of deviations from the variation of the measurements performed and the management of measurement equipment and calibrations. To develop the MSA tool a ten-step approach was implemented. Firstly, it was performed a benchmarking analysis of the current competitors and commercial solutions linked to MSA, concerning Industry 4.0 paradigm. Next, an analysis of the size of the target market for the MSA tool was done. Afterwards, data flow and traceability requirements were analysed in order to implement an IoT data network that interconnects with the equipment, preferably via wireless. The MSA web solution was designed under UI/UX principles and an API in python language was developed to perform the algorithms and the statistical analysis. Continuous validation of the tool by companies is being performed to assure real time management of the ‘big data’. The main results of this R&D project are: MSA Tool, web and cloud-based; Python API; New Algorithms to the market; and Style Guide of UI/UX of the tool. The MSA tool proposed adds value to the state of the art as it ensures an effective response to the new challenges of measurement systems, which are increasingly critical in production processes. Although the automotive industry has triggered the development of this innovative MSA tool, other industries would also benefit from it. Currently, companies from molds and plastics, chemical and food industry are already validating it.

Keywords: automotive Industry, industry 4.0, Internet of Things, IATF 16949:2016, measurement system analysis

Procedia PDF Downloads 180