Search results for: automotive wire harness

Authors: G. Hemath Kumar, H. Mohit, K. Karthick

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One of the most important issues in the composite technology is the repairing of parts of aircraft structures which is manufactured from composite materials. In such applications and also for joining various composite parts together, they are fastened together either using adhesives or mechanical fasteners. The tensile strength of these joints was carried out using Universal Testing Machine (UTM). A parametric study was also conducted to compare the performance of the hybrid joint with varying adherent thickness, adhesive thickness and overlap length. The composition of the material is combination of epoxy resin and carbon fibre under the method of reinforcement. To utilize the full potential of composite materials as structural elements, the strength and stress distribution of these joints must be understood. The study of tensile strength in the members involved under various design conditions and various joints were took place.

Keywords: carbon fiber, FRP composite, MMC, automotive

Procedia PDF Downloads 377

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

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Nonwoven fabric such as an automobile interior material becomes consists of several material layers required for the sound-absorbing function. Because several material layers, many experimental tuning is required to achieve the target of sound absorption. Therefore, a lot of time and money is spent in the development of the car interior materials. In this study, we present the method to predict the sound-absorbing performance of the various layers with physical properties of each material. and we will verify it with the measured value of a prototype. If the sound absorption can be estimated, it can be optimized without a number of tuning tests of the interiors. So, it can reduce the development cost and time during development

Keywords: automotive interior material, sound absorbing, optimization design, nonwoven fabric

Procedia PDF Downloads 803

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: 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 material 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 a 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: Nguyen Thu Huong, Nguyen Quang Bau

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The Hall Coefficient (HC) and the Magnetoresistance (MR) have been studied in two-dimensional systems. The HC and the MR in Rectangular Quantum Wire (RQW) subjected to a crossed DC electric field and magnetic field in the presence of a Strong Electromagnetic Wave (EMW) characterized by electric field are studied in this work. Using the quantum kinetic equation for electrons interacting with optical phonons, we obtain the analytic expressions for the HC and the MR with a dependence on magnetic field, EMW frequency, temperatures of systems and the length characteristic parameters of RQW. These expressions are different from those obtained for bulk semiconductors and cylindrical quantum wires. The analytical results are applied to GaAs/GaAs/Al. For this material, MR depends on the ratio of the EMW frequency to the cyclotron frequency. Indeed, MR reaches a minimum at the ratio 5/4, and when this ratio increases, it tends towards a saturation value. The HC can take negative or positive values. Each curve has one maximum and one minimum. When magnetic field increases, the HC is negative, achieves a minimum value and then increases suddenly to a maximum with a positive value. This phenomenon differs from the one observed in cylindrical quantum wire, which does not have maximum and minimum values.

Keywords: hall coefficient, rectangular quantum wires, electron-optical phonon interaction, quantum kinetic equation

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

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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

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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

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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

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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: Zahra Alikhani Koopaei

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In the fifth lesson of the third-grade mathematics book, students are introduced to the concept of multiplication. However, some students showed a lack of interest in learning this topic. To address this, a simple electronic multiplication table was designed with the aim of making the concept of multiplication entertaining and engaging for students. It provides them with moments of excitement during the learning process. To achieve this goal, a device was created that produced a bell sound when two wire ends were connected. Each wire end was connected to a specific number in the multiplication table, and the other end was linked to the corresponding answer. Consequently, if the answer is correct, the bell will ring. This study employs interactive and engaging methods to teach mathematics, particularly to students who have previously shown little interest in the subject. By integrating game-based learning and critical thinking, we observed an increase in understanding and interest in learning multiplication compared to before using this method. This further motivated the students. As a result, the intelligent multiplication table was successfully designed. Students, under the instructor's supervision, could easily construct the device during the lesson. Through the implementation of these operations, the concept of multiplication was firmly established in the students' minds. Engaging multiple intelligences in each student enhances a more stable and improved understanding of the concept of multiplication.

Keywords: intelligent multiplication table, design, construction, education, increased interest, students

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

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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

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Authors: Jung-Ho Moon, Tae Kwon Ha

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Continually increasing working temperature and growing need for greater efficiency and reliability of automotive exhaust require systematic investigation into the thermal fatigue properties especially of high temperature stainless steels. In this study, thermal fatigue properties of 300 series austenitic stainless steels have been evaluated in the temperature ranges of 200-800°C and 200-900°C. Systematic methods for control of temperatures within the predetermined range and measurement of load applied to specimens as a function of temperature during thermal cycles have been established. Thermal fatigue tests were conducted under fully constrained condition, where both ends of specimens were completely fixed. Load relaxation behavior at the temperatures of thermal cycle was closely related with the thermal fatigue property.

Keywords: austenitic stainless steel, automotive exhaust, thermal fatigue, microstructure, load relaxation

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Authors: Achim Kampker, Kai Kreiskoether, Johannes Wagner, Sarah Fluchs

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The growing speed of innovation in related industries requires the automotive industry to adapt and increase release frequencies of new vehicle derivatives which implies a significant reduction of investments per vehicle and ramp-up times. Emerging markets in various parts of the world augment the currently dominating established main automotive markets. Local content requirements such as import tariffs on final products impede the accessibility of these micro markets, which is why in the future market exploitation will not be driven by pure sales activities anymore but rather by setting up local assembly units. The aim of this paper is to provide an overview of the concept of decentralized assembly and to discuss and critically assess some currently researched and crucial approaches in production technology. In order to determine the scope in which complementary mobile assembly can be profitable for manufacturers, a general cost model is set up and each cost driver is assessed with respect to varying levels of decentralization. One main result of the paper is that the presented approaches offer huge cost-saving potentials and are thus critical for future production strategies. Nevertheless, they still need to be further exploited in order for decentralized assembly to be profitable for companies. The optimal level of decentralization must, however, be specifically determined in each case and cannot be defined in general.

Keywords: automotive assembly, e-mobility, production technology, release capability, small series assembly

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Authors: Anton Golubkov, Gleb Ermachkov, Aleksandr Smerdin, Oleg Sidorov, Victor Philippov

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Current collection quality is one of the limiting factors when increasing trains movement speed in the rail sector. With the movement speed growth, the impact forces on the current collector from the rolling stock and the aerodynamic influence increase, which leads to the spread in the contact pressure values, separation of the current collector head from the contact wire, contact arcing and excessive wear of the contact elements. The upcoming trend in resolving this issue is the use of the automatic control systems providing stabilization of the contact pressure value. The present paper considers the features of the contemporary automatic control systems of the current collector’s pressure; their major disadvantages have been stated. A scheme of current collector pressure automatic control has been proposed, distinguished by a proactive influence on undesirable effects. A mathematical model of contact strips wearing has been presented, obtained in accordance with the provisions of the central composition rotatable design program. The analysis of the obtained dependencies has been carried out. The procedures for determining the optimal current collector pressure on the contact wire and the pressure control principle in the pneumatic drive have been described.

Keywords: contact strip, current collector, high-speed running, program control, wear

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Authors: D. Chen, H. Daoud, C. Kreiner, U. Glatzel

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Additive Manufacturing (AM) provides promising opportunities to optimize and to produce tooling by integrating near-contour tempering channels for more efficient cooling. To enhance the properties of the produced tooling using additive manufacturing, prototypes should be produced in short periods. Thereby, this requires a small amount of tailored powders, which either has a high production cost or is commercially unavailable. Hence, in this study, an arc spray atomization approach to produce a tailored metal powder at a lower cost and even in small quantities, in comparison to the conventional powder production methods, was proposed. This approach involves converting commercially available metal wire into powder by modifying the wire arc spraying process. The influences of spray medium and gas pressure on the powder properties were investigated. As a result, particles with smooth surface and lower porosity were obtained, when nonoxidizing gases are used for thermal spraying. The particle size decreased with increasing of the gas pressure, and the particles sizes are in the range from 10 to 70 µm, which is desirable for selective laser melting (SLM). A comparison of microstructure and mechanical behavior of SLM generated parts using arc sprayed powders (alloy: X5CrNiCuNb 16-4) and commercial powder (alloy: X5CrNiCuNb 16-4) was also conducted.

Keywords: additive manufacturing, arc spraying, powder production, selective laser melting

Procedia PDF Downloads 109

Authors: Cathy SW. Chow, Kristina Shin, Faming Wang, B. C. L. So

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During some dynamic giant puppet performances, an ergonomically designed load carrier system is necessary for the puppeteers to carry a giant puppet body’s heavy load with minimum muscle stress. A load carrier (i.e. prototype) was designed with two small wheels on the foot; and a hybrid spring device on the knee in order to assist the sliding and knee bending movements respectively. Thus, the purpose of this study was to evaluate the effect of three load carriers including two other commercially available load mounting systems, Tepex and SuitX, and the prototype. Ten male participants were recruited for the experiment. Surface electromyography (sEMG) was used to collect the participants’ muscle activities during forward moving and bouncing and with and without load of 11.1 kg that was 60 cm above the shoulder. Five bilateral muscles including the lumbar erector spinae (LES), rectus femoris (RF), bicep femoris (BF), tibialis anterior (TA), and gastrocnemius (GM) were selected for data collection. During forward moving task, the sEMG data showed smallest muscle activities by Tepex harness which exhibited consistently the lowest, compared with the prototype and SuitX which were significantly higher on left LES 68.99% and 64.99%, right LES 26.57% and 82.45%; left RF 87.71% and 47.61%, right RF 143.57% and 24.28%; left BF 80.21% and 22.23%, right BF 96.02% and 21.83%; right TA 6.32% and 4.47%; left GM 5.89% and 12.35% respectively. The result above reflected mobility was highly restricted by tested exoskeleton devices. On the other hand, the sEMG data from bouncing task showed the smallest muscle activities by prototype which exhibited consistently the lowest, compared with the Tepex harness and SuitX which were significantly lower on lLES 6.65% and 104.93, rLES 23.56% and 92.19%; lBF 33.21% and 93.26% and rBF 24.70% and 81.16%; lTA 46.51% and 191.02%; rTA 12.75% and 125.76%; IGM 31.54% and 68.36%; rGM 95.95% and 96.43% respectively.

Keywords: exoskeleton, giant puppet performers, load carriage system, surface electromyography

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Authors: Juan Manuel Martinez Alvarez, Michele Chiumenti

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This work explores the benefit of the thermo-metallurgical simulation to tackle the Wire Laser Additive Manufacturing (WLAM) of low-carbon steel components. The Finite Element Analysis is calibrated by process monitoring via thermal imaging and thermocouples measurements, to study the complex thermo-metallurgical behavior inherent to the WLAM process of low carbon steel parts.A critical aspect is the analysis of the heterogeneity in the resulting microstructure. This heterogeneity depends on both the thermal history and the residual stresses experienced during the WLAM process. Because of low carbon grades are highly sensitive to quenching, a high-gradient microstructure often arises due to the layer-by-layer metal deposition in WLAM. The different phases have been identified by scanning electron microscope. A clear influence of the heterogeneities on the final mechanical performance has been established by the subsequent mechanical characterization. The thermo-metallurgical analysis has been used to determine the actual thermal history and the corresponding thermal gradients during the printing process. The correlation between the thermos-mechanical evolution, the printing parameters and scanning sequence has been established. Therefore, an enhanced printing strategy, including optimized process window has been used to minimize the microstructure heterogeneity at ArcelorMittal.

Keywords: additive manufacturing, numerical simulation, metallurgy, steel

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Authors: Seyed Esmail Seyedi Bariran, Khairul Salleh Mohamed Sahari

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In multi-echelon supply chain networks, optimal supplier selection significantly depends on the accuracy of suppliers’ performance prediction. Different methods of multi criteria decision making such as ANN, GA, Fuzzy, AHP, etc have been previously used to predict the supplier performance but the “black-box” characteristic of these methods is yet a major concern to be resolved. Therefore, the primary objective in this paper is to implement an artificial intelligence-based gene expression programming (GEP) model to compare the prediction accuracy with that of ANN. A full factorial design with %95 confidence interval is initially applied to determine the appropriate set of criteria for supplier performance evaluation. A test-train approach is then utilized for the ANN and GEP exclusively. The training results are used to find the optimal network architecture and the testing data will determine the prediction accuracy of each method based on measures of root mean square error (RMSE) and correlation coefficient (R2). The results of a case study conducted in Supplying Automotive Parts Co. (SAPCO) with more than 100 local and foreign supply chain members revealed that, in comparison with ANN, gene expression programming has a significant preference in predicting supplier performance by referring to the respective RMSE and R-squared values. Moreover, using GEP, a mathematical function was also derived to solve the issue of ANN black-box structure in modeling the performance prediction.

Keywords: Supplier Performance Prediction, ANN, GEP, Automotive, SAPCO

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Authors: Dario Basile, Manuela De Maddis, Raffaella Sesana, Pasquale Russo Spena, Roberto Maiorano

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Nowadays, the reduction of CO₂ emissions and the decrease in energy consumption are the main aims of several industries, especially in the automotive sector. To comply with the increasingly restrictive regulations, the automotive industry is constantly looking for innovative techniques to produce lighter, more efficient, and less polluting vehicles. One of the latest technologies, and still developing, is based on the fabrication of the body-in-white and car parts through the stamping of Aluminum Tailor Welded Blanks. Tailor Welded Blanks (TWBs) are generally the combination of two/three metal sheets with different thicknesses and/or mechanical strengths, which are commonly butt-welded together by laser sources. The use of aluminum TWBs has several advantages such as low density and corrosion resistance adequate. However, their use is still limited by the lower formability with respect to the parent materials and the more intrinsic difficulty of laser welding of aluminum sheets (i.e., internal porosity) that, although its use in automated industries is constantly growing, remains a process to be further developed and improved. This study has investigated the effect of the main laser welding process parameters (laser power, welding speed, and focal distance) on the mechanical properties of aluminum TWBs made of 6xxx series. The research results show that a narrow weldability window can be found to ensure welded joints with high strength and limited or no porosity.

Keywords: aluminum sheets, automotive industry, laser welding, mechanical properties, tailor welded blanks

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Authors: S. S. Sravanthi, Swati Ghosh Acharyya

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Automotive light weighting is of major prominence in the current times due to its contribution in improved fuel economy and reduced environmental pollution. Various arc welding technologies are being employed in the production of automobile components with reduced weight. The present study is of practical importance since it involves preferential substitution of Zinc coated mild steel with a light weight alloy such as 6061 Aluminium by means of Gas Metal Arc Welding (GMAW) – Brazing technique at different processing parameters. However, the fabricated joints have shown the generation of Al – Fe layer at the interfacial regions which was confirmed by the Scanning Electron Microscope and Energy Dispersion Spectroscopy. These Al-Fe compounds not only affect the mechanical strength, but also predominantly deteriorate the corrosion resistance of the joints. Hence, it is essential to understand the phases formed in this layer and their crystal structure. Micro area X - ray diffraction technique has been exclusively used for this study. Moreover, the crevice corrosion analysis at the joint interfaces was done by exposing the joints to 5 wt.% FeCl₃ solution at regular time intervals as per ASTM G 48-03. The joints have shown a decreased crevice corrosion resistance with increased heat intensity. Inner surfaces of welds have shown severe oxide cracking and a remarkable weight loss when exposed to concentrated FeCl₃. The weight loss was enhanced with decreased filler wire feed rate and increased heat intensity. 

Keywords: automobiles, welding, corrosion, lap joints, Micro XRD

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Authors: Ahlad Neti, Elisa Arch, Martha Hall

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Studies have shown that individuals who use Ankle-Foot-Orthoses (AFOs) have a high level of dissatisfaction regarding their current AFOs. Studies point to the focus on technical design with little attention given to the user perspective as a source of AFO designs that leave users dissatisfied. To design a new AFO that satisfies users and thereby improves their quality of life, the reasons for their dissatisfaction and their wants and needs for an improved AFO design must be identified. There has been little research into the user perspective on AFO use and desired improvements, so the relationship between AFO design and satisfaction in daily use must be assessed to develop appropriate metrics and constraints prior to designing a novel AFO. To assess the user perspective on AFO design, structured interviews were conducted with 7 individuals (average age of 64.29±8.81 years) who use AFOs. All interviews were transcribed and coded to identify common themes using Grounded Theory Method in NVivo 12. Qualitative analysis of these results identified sources of user dissatisfaction such as heaviness, bulk, and uncomfortable material and overall needs and wants for an AFO. Beyond the user perspective, certain objective factors must be considered in the construction of metrics and constraints to ensure that the AFO fulfills its medical purpose. These more objective metrics are rooted in a common medical device market and technical standards. Given the large body of research concerning these standards, these objective metrics and constraints were derived through a literature review. Through these two methods, a comprehensive list of metrics and constraints accounting for both the user perspective on AFO design and the AFO’s medical purpose was compiled. These metrics and constraints will establish the framework for designing a new AFO that carries out its medical purpose while also improving the user experience. The metrics can be categorized into several overarching areas for AFO improvement. Categories of user perspective related metrics include comfort, discreteness, aesthetics, ease of use, and compatibility with clothing. Categories of medical purpose related metrics include biomechanical functionality, durability, and affordability. These metrics were used to guide an iterative prototyping process. Six concepts were ideated and compared using system-level analysis. From these six concepts, two concepts – the piano wire model and the segmented model – were selected to move forward into prototyping. Evaluation of non-functional prototypes of the piano wire and segmented models determined that the piano wire model better fulfilled the metrics by offering increased stability, longer durability, fewer points for failure, and a strong enough core component to allow a sock to cover over the AFO while maintaining the overall structure. As such, the piano wire AFO has moved forward into the functional prototyping phase, and healthy subject testing is being designed and recruited to conduct design validation and verification.

Keywords: ankle-foot orthotic, assistive technology, human centered design, medical devices

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Authors: Tahar Abid, Haoues Ghouss, Abdelhamid Boubertakh

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This present work is focused on the hardening precipitation in two AlMgSi(Cu) automotive body sheets. The effect of pre-aging, aging treatment and 0.10 wt % copper addition on the hardening response was investigated using scanning calorimetry (DSC), transmission electron microscopy (TEM), and Vickers microhardness measurements (Hv). The results reveal the apparition of α-AlFeSi, α-AlFe(Mn)Si type precipitates frequently present and witch remain stable at high temperature in Al-Mg-Si alloys. Indeed, the hardening response in both sheets is certainly due to the predominance of very fine typical phases β' and β'' as rods and needles developed during aging with and without pre-aging. The effect of pre ageing just after homogenization and quenching is to correct the undesirable effect of aging at ambient temperature by making faster alloy hardening during artificial aging.The addition of 0.10 wt % copper has allowed to refine and to enhance the precipitation hardening after quenching.

Keywords: AlMgSi alloys, precipitation, hardening, activation energy

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Authors: Hatice Özbek, Caner Çil, Ahmet Rodoplu

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Automotive lighting is the leading function in the configuration of vehicle architecture. Especially headlights and taillights from external lighting functions are among the structures that determine the stylistic character of the vehicle. At the same time, the fact that lighting functions are related to many other functions brings along difficulties in design. Customers expect maximum quality from the vehicle. In these circumstances, it is necessary to make designs that aim to keep the performance of bulbs with limited working lives at the highest level. With this study, the factors that influence the working lives of filament lamps were examined and bulb explosions that can occur sooner than anticipated in the future were prevented while the vehicle was still in the design phase by determining the relations with electrical, dynamical and static variables. Especially the filaments of the bulbs used in the front lighting of the vehicle are deformed in a shorter time due to the high voltage requirement. In addition to this, rear lighting lamps vibrate as a result of the tailgate opening and closing and cause the filaments to be exposed to high stress. With this study, the findings that cause bulb explosions were evaluated. Among the most important findings: 1. The structure of the cables to the lighting functions of the vehicle and the effect of the voltage values are drawn; 2. The effect of the vibration to bulb throughout the life of the vehicle; 3 The effect of the loads carried to bulb while the vehicle doors are opened and closed. At the end of the study, the maximum performance was established in the bulb lifetimes with the optimum changes made in the vehicle architecture based on the findings obtained.

Keywords: vehicle architecture, automotive lighting functions, filament lamps, bulb lifetime

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Authors: Anna-Lisa Osvalder, Jonas Borell

Abstract:

There are several reasons behind the use, non-use, or inadequate use of personal protective equipment (PPE) in the construction industry. Comfort and accurate size support proper use, while discomfort, misfit, and difficulties to understand how the PPEs should be handled inhibit correct usage. The need for several protective equipments simultaneously might also create problems. The purpose of this study was to analyse the correct usage, comfort, and fit of different types of PPEs used for construction work. Correct usage was analysed as guessability, i.e., human perceptions of how to don, adjust, use, and doff the equipment, and if used as intended. The PPEs tested individually or in combinations were a helmet, ear protectors, goggles, respiratory masks, gloves, protective cloths, and safety harnesses. First, an analytical evaluation was performed with ECW (enhanced cognitive walkthrough) and PUEA (predictive use error analysis) to search for usability problems and use errors during handling and use. Then usability tests were conducted to evaluate guessability, comfort, and fit with 10 test subjects of different heights and body constitutions. The tests included observations during donning, five different outdoor work tasks, and doffing. The think-aloud method, short interviews, and subjective estimations were performed. The analytical evaluation showed that some usability problems and use errors arise during donning and doffing, but with minor severity, mostly causing discomfort. A few use errors and usability problems arose for the safety harness, especially for novices, where some could lead to a high risk of severe incidents. The usability tests showed that discomfort arose for all test subjects when using a combination of PPEs, increasing over time. For instance, goggles, together with the face mask, caused pressure, chafing at the nose, and heat rash on the face. This combination also limited sight of vision. The helmet, in combination with the goggles and ear protectors, did not fit well and caused uncomfortable pressure at the temples. No major problems were found with the individual fit of the PPEs. The ear protectors, goggles, and face masks could be adjusted for different head sizes. The guessability for how to don and wear the combination of PPE was moderate, but it took some time to adjust them for a good fit. The guessability was poor for the safety harness; few clues in the design showed how it should be donned, adjusted, or worn on the skeletal bones. Discomfort occurred when the straps were tightened too much. All straps could not be adjusted for somebody's constitutions leading to non-optimal safety. To conclude, if several types of PPEs are used together, discomfort leading to pain is likely to occur over time, which can lead to misuse, non-use, or reduced performance. If people who are not regular users should wear a safety harness correctly, the design needs to be improved for easier interpretation, correct position of the straps, and increased possibilities for individual adjustments. The results from this study can be a base for re-design ideas for PPE, especially when they should be used in combinations.

Keywords: construction work, PPE, personal protective equipment, misuse, guessability, usability

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Authors: Peter Pomlenyi, Orsolya Semperger, Gergely Hegedus

Abstract:

The purpose of the project is to develop a complex composite component with visible class ‘A’ surface. It is going to integrate more functions, including continuous fiber reinforcement, foam core, injection molded ribs, and metal inserts. Therefore we are going to produce recyclable structural composite part from thermoplastic polymer in serial production with short cycle time for automotive applications. Our design of the process line is determined by the principles of Industry 4.0. Accordingly, our goal is to map in details the properties of the final product including the mechanical properties in order to replace metal elements used in automotive industry, with special regard to the effect of each manufacturing process step on the afore mentioned properties. Period of the project is 3 years, which lasts from the 1st of December 2016 to the 30th November 2019. There are four consortium members in the R&D project evopro systems engineering Ltd., Department of Polymer Engineering of the Budapest University of Technology and Economics, Research Centre for Natural Sciences of Hungarian Academy of Sciences and eCon Engineering Ltd. One of the most important result that we can obtain short cycle time (up to 2-3 min) with in-situ polymerization method, which is an innovation in the field of thermoplastic composite production. Because of the mentioned method, our fully automated production line is able to manufacture complex thermoplastic composite parts and satisfies the short cycle time required by the automotive industry. In addition to the innovative technology, we are able to design, analyze complex composite parts with finite element method, and validate our results. We are continuously collecting all the information, knowledge and experience to improve our technology and obtain even more accurate results with respect to the quality and complexity of the composite parts, the cycle time of the production, and the design and analyzing method of the composite parts.

Keywords: T-RTM technology, composite, automotive, class A surface

Procedia PDF Downloads 119

Authors: Mokhtar Djeddou, Amine Mehel, Georges Fokoua, Anne Tanière, Patrick Chevrier

Abstract:

Commuters' exposure to air pollution, particularly to particle matter, inside vehicles is a significant health issue. Assessing particles concentrations and characterizing their distribution is an important first step to understand and propose solutions to improve car cabin air quality. It is known that particles dynamics is intimately driven by particles-turbulence interactions. In order to analyze and model pollutants distribution inside the car the cabin, it is crucialto examine first the single-phase flow topology and turbulence characteristics. Within this context, Computational Fluid Dynamics (CFD) simulations were conducted to model airflow inside a full-scale car cabin using Reynolds Averaged Navier-Stokes (RANS)approach combined with the first order Realizable k- εmodel to close the RANS equations. To validate the numerical model, a campaign of velocity field measurements at different locations in the front and back of the car cabin has been carried out using hot-wire anemometry technique. Comparison between numerical and experimental results shows a good agreement of velocity profiles. Additionally, visualization of streamlines shows the formation of jet flow developing out of the dashboard air vents and the formation of large vortex structures, particularly in the back seats compartment. These vortex structures could play a key role in the accumulation and clustering of particles in a turbulent flow

Keywords: car cabin, CFD, hot wire anemometry, vortical flow

Procedia PDF Downloads 252

Authors: Jugoslav Jokovic, Tijana Dimitrijevic, Nebojsa Doncov

Abstract:

The goal of this paper is to investigate the possibilities and effectiveness of the TLM (Transmission Line Matrix) method for modelling of up-to-date microstrip antennas with circular geometry that have significant application in modern wireless communication systems. The coaxially fed microstrip antenna configurations with circular patch are analyzed by using the in-house 3DTLMcyl_cw solver based on computational electromagnetic TLM method adapted to the cylindrical grid and enhanced with the compact wire model. Opposed to the widely used rectangular TLM mesh, where a staircase approximation has to be used to describe curved boundaries, precise modelling of circular boundaries can be accomplished in the cylindrical grid irrespective of the mesh resolution. Using the compact wire model incorporated in cylindrical mesh, it is possible to model coaxial feed and include the influence of the real excitation in the antenna model. The conventional and inverted configuration of a coaxially fed circular patch antenna are considered, comparing the resonances obtained using TLM cylindrical model with results reached by the corresponding model in a rectangular grid as well as with experimental ones. Bearing in mind that accuracy of simulated results depends on a relevantly created model, besides structure geometry and dimensions, it is important to consider additional modelling issues, regarding appropriate mesh resolution and a relevant extension of a mesh around the considered structure that would provide convergence of the results.

Keywords: computational electromagnetic, coaxial feed, microstrip antenna, TLM modelling

Procedia PDF Downloads 258

Authors: Abdelfatah Elsenosy, Mahmoud Ebrahim

Abstract:

Background: Distal radius fractures are commonly encountered in orthopedic practice, especially in elderly patients. A number of clinical papers have supported the idea that anatomic restoration of the distal end of the radius is essential to gain superior results. Aim and objectives: The aim of the study is to systematically review the literature for the management of distal end radius in elderly persons (conservative treatment versus percutaneous wire fixation) as regards radiological and functional outcomes. Subjects and methods: Studies were identified from the Medline, Cochrane, EMBASE, and Google Scholar databases were searched until 2019 using combinations of the following search terms: distal radius fracture, conservative treatment, non-operative treatment, and nonsurgical treatment, surgical treatment, operative, elderly, and older. Reference lists of relevant studies were manually searched. Results: There was no statistical significance difference between CI and PKF groups’ frequency of complication in all of the selected studies. Based on the results, we recommend more analysis regarding every parameter of the radiographic and functional results and specific complications related to each fixation need to be accomplished, which requires more Randomized controlled trials (RCTs) with high quality. Conclusion: Surgical treatment seems to be more effective distal radius fracture compared with conservative treatment when the radiographic outcomes were analyzed, and no significant differences were detected in the functional outcomes and complication rate.

Keywords: radius, fracture, surgical, RCTs, conservative, radiographic, outcomes, orthopedic

Procedia PDF Downloads 126

Authors: Ikbal Eski, Turan Gürgenç

Abstract:

After nearly more than a century of research and development, internal combustion engines have become almost perfect. Along with such improvement in internal combustion engines, automotive manufacturers are conducting research on design of alternative fuel vehicles. Nevertheless an ideal interim solution is to increase overall efficiency of internal combustion vehicles. A potential solution to achieve that is using continuously variable transmission system which, despite being an old idea, has recently become a hope for automotive manufacturers. CVT system, by continuously varying speed ratio, raises vehicle efficiency. In this study, fuzzy logic controller is used in speed ratio control of pulley based CVT system.

Keywords: continuously variable transmission system, variator, speed ratio, fuzzy logic

Procedia PDF Downloads 256

Authors: Seyedeh Fatemeh Nabavi, Hamid Dalir, Anooshiravan Farshidianfar

Abstract:

Laser welding is pivotal in modern manufacturing, offering unmatched precision, speed, and efficiency. Its versatility in minimizing heat-affected zones, seamlessly joining dissimilar materials, and working with various metals makes it indispensable for crafting intricate automotive components. Integration into automated systems ensures consistent delivery of high-quality welds, thereby enhancing overall production efficiency. Noteworthy are the safety benefits of laser welding, including reduced fumes and consumable materials, which align with industry standards and environmental sustainability goals. As the automotive sector increasingly demands advanced materials and stringent safety and quality standards, laser welding emerges as a cornerstone technology. A comprehensive model encompassing thermal dynamic and characteristics models accurately predicts geometrical, metallurgical, and mechanical aspects of the laser beam welding process. Notably, Model 2 showcases exceptional accuracy, achieving remarkably low error rates in predicting primary and secondary dendrite arm spacing (PDAS and SDAS). These findings underscore the model's reliability and effectiveness, providing invaluable insights and predictive capabilities crucial for optimizing welding processes and ensuring superior productivity, efficiency, and quality in the automotive industry.

Keywords: laser welding process, geometrical characteristics, mechanical characteristics, metallurgical characteristics, comprehensive model, thermal dynamic

Procedia PDF Downloads 19