Browse Topic: Body structures

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Necessity of Body Torsional Rigidity of Personal Mobility Vehicles (PMVs) with an Inward Tilting Mechanism2024-32-001304/18/2025
In traditional four-wheeled automobiles, the imbalance between the roll moment, which is the product of the centrifugal force during a turn acting on the center of gravity and the height of the center of gravity, and roll stiffness, which is the product of the left-right difference in tire vertical load and the tread width and commonly used among automotive suspension engineers, of the front and rear sections necessitates body torsional rigidity. However, there is a lack of specific cases and guidelines for constructing the body structure of three-wheeled PMVs (Personal Mobility Vehicles) with a tilting mechanism from the perspective of vehicle dynamics characteristics. In this paper, the basic considerations related to the dynamics of such three-wheeled PMVs are investigated. We use the term “torsional rigidity” to refer to the stiffness as the torsional deformation of the body itself, and the term “roll stiffness” to refer to the moment that counteracts the roll moment during a turn
Haraguchi, Tetsunori, Kaneko, Tetsuya
Technical Paper
Fatigue Analysis of Motorcycle Rear Swing Arm on Different Road Surfaces2024-32-004604/18/2025
The rear swing arm, a crucial motorcycle component, connects the frame and wheel, absorbing the vehicle’s load and various road impacts. Over time, these forces can damage the swing arm, highlighting the need for robust design to ensure safety. Identifying potential vulnerabilities through simulation reduces the risk of failure during the design phase. This study performs a detailed fatigue analysis of the swing arm across different road conditions. Data for this research were collected from real-vehicle experiments and simulation analyses, ensuring accuracy by comparing against actual performance. Following CNS 15819-5 standards, road surfaces such as poorly maintained, bumpy, and uneven roads were tested. Using Motion View, a comprehensive multi-body dynamic model was created for thorough fatigue analysis. The results identified the most stress-prone areas on the swing arm, with maximum stress recorded at 109.6N on poorly maintained roads, 218.3N on bumpy surfaces, and 104.8N on
Chiou, Yi-Hau, Hwang, Hsiu-Ying, Huang, Liang-Yu
Technical Paper
Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions2024-32-003804/18/2025
The arc welding process is essential for motorcycle frames, which are difficult to form in one piece because of their complex shapes, because a single frame has dozens of joints. Many of the damaged parts of the frames under development are from welds. Predicting the strength of welds with high reliability is important to ensure that development proceeds without any rework. In developing frames, CAE is utilized to build up strength before prototyping. Detailed weld shapes are not applicable to FE models of frames because weld shapes vary widely depending on welding conditions. Even if CAE is performed on such an FE model and the evaluation criteria are satisfied, the model may fail in the actual vehicle, possibly due to the difference between CAE and actual weld bead geometry. Therefore, we decided to study the extent to which the stresses in the joint vary with the variation of the weld bead geometry. Morphing, a FE modeling method and design of experiment method, was utilized to
Hada, Yusuke, Sugita, Hisayuki
Technical Paper
Analysis of the Effect of Combination Frame Flexibility on Weave Modes2024-32-004904/18/2025
The weave mode of a motorcycle is known to be affected by the flexibility of the vehicle frame. The weave mode has been shown to be more unstable in the 10-DOF model than in the 4-DOF model. However, it is not clear why the weave mode would be unstable, given the six different frame flexibilities. In this study, the authors analyzed the stability of the weave mode in a 4-DOF model when the same was integrated with two types of frame flexibilities. In the vehicle specifications used in the analysis, the combination of the bending flexibility of the front forks and the torsional flexibility of the main frame destabilizes the weave mode. The analysis results show that the phase delay of the front tire lateral force is caused by the phase delay of the steering angle. The combined bending flexibility of the front forks and the torsional flexibility of the main frame results in a large phase lag in the steering angle.
Haraoka, Reiya, Katayama, Tsuyoshi, Yoshino, Takahiko
Technical Paper
Background Filtering and Target Detection for Traffic Objects with Roadside LiDAR Point Cloud Data2025-01-719303/19/2025
Roadside perception technology is an essential component of traffic perception technology, primarily relying on various high-performance sensors. Among these, LiDAR stands out as one of the most effective sensors due to its high precision and wide detection range, offering extensive application prospects. This study proposes a voxel density-nearest neighbor background filtering method for roadside LiDAR point cloud data. Firstly, based on the relatively fixed nature of roadside background point clouds, a point cloud filtering method combining voxel density and nearest neighbor is proposed. This method involves voxelizing the point cloud data and using voxel grid density to filter background point clouds, then the results are processed through a neighbor point frame sequence to calculate the average distance of the specified points and compare with a distance threshold to complete accurate background filtering. Secondly, a VGG16-Pointpillars model is proposed, incorporating a CNN
Liu, Zhiyuan, Rui, Yikang
Technical Paper
Test GV 162025JTEST162025 (Current)01/06/2025
test
Ground Vehicle European Prospect Committee
Technical Standard
3D-Printed Reactor Core Makes Solar Fuel Production More EfficientTBMG-5219312/01/2024
In recent years, engineers at ETH Zurich have developed the technology to produce liquid fuels from sunlight and air. In 2019, they demonstrated the entire thermochemical process chain under real conditions for the first time, in the middle of Zurich, on the roof of ETH Machine Laboratory. These synthetic solar fuels are carbon neutral because they release only as much CO2 during their combustion as was drawn from the air for their production. Two ETH spin-offs, Climeworks and Synhelion, are further developing and commercializing the technologies.
Magazine Article
OMNI-DIRECTIONAL AUTONOMOUS GUIDED VEHICLE (AGV) WITH WIRELESS NAVIGATION2024-01-343611/15/2024
ABSTRACT Automatic guided vehicles (AGV) have made big inroads in the automation of assembly plants and warehouse operations. There are thousands of AGV units in operation at OEM supplier and service facilities worldwide in virtually every major manufacturing and distribution sector. Although today’s AGV systems can be reconfigured and adapted to meet changes in operation and need, their adaptability is often limited because of inadequacies in current systems. This paper describes a wireless navigated (WN) omni-directional (OD) autonomous guided vehicle (AGV) that incorporates three technical innovations that address the shortfalls. The AGV features consist of: 1) A newly developed integrated wireless navigation technology to allow rapid rerouting of navigation pathways; 2) Omnidirectional wheels to move independently in different directions; 3) Modular space frame construction to conveniently resize and reshape the AGV platform. It includes an overview of the AGVs technical features
Cheok, Ka C, Radovnikovich, Micho, Fleck, Paul, Hallenbeck, Kevin, Grzebyk, Steve, Vanneste, Jerry, Ludwig, Wolfgang, Garner, Robert
Technical Paper
Developing Customer Loss Function for Door Opening Angle in Passenger Cars: Balancing the Ergonomic Performance between “Entry/Exit (Ingress/Egress) Accommodation” and Door Reachability15-17-03-001407/27/2024
Abstract Occupant packaging is one of the key tasks involved in the early architectural phase of a vehicle. Accommodation, as a convention, is generally considered related to a car’s interior. Typical roominess metrics of the occupant like hip room, shoulder room, and elbow room are defined with the door in its closed condition. Several other roominess metrics like knee room, leg room, head room, and the like are also specified. While all the guidelines are defined with doors in their closed condition, it is also important to consider the dynamics that exist while the occupant is entering the vehicle. This article expands the traditional understanding of occupant accommodation beyond conventionally considering the vehicle interior’s ability to accommodate anthropometry. It broadens the scope to include dynamic conditions, such as when doors are opened, providing a more realistic and practical perspective. As a luxury car manufacturer, it is important to ensure the best overall customer
Rajakumaran, Sriram, Sreenivas, Kalyan
Journal Article
Coupled FEM-DEM for determination of payload distribution on Tipper load body2024-26-025501/16/2024
Tippers used for transporting blue metal, construction and mining material is designed with different types of load body to suit the material being carried, capacity and its application. Structural strength verification of load body of tipper is conducted using FEM, by modelling forces due to payload as a pressure function on the panels of the load body. Determining the pressure function on panels is a challenge owing to the complexity of modelling large volume of granular payload using conventional FE methods. Hence, typically the spatial variation of pressure is assumed. The Discrete Element Method (DEM) allows the modelling of granular materials such as gravel, wet or dry sand, coal, etc., taking into account its flow and interaction with the structure holding them. DEM has the ability to numerically calculate displacements and rotations of finite particles. Also, automatically perform contact detection for particle assembly. DEM uses a discrete approach that is very well suited for
Sadasivam, Sivasankaran, Loganathan, Ekambaram, Mahalingam, Manikandan
Technical Paper
SUV Multi-Link Rigid Axle Control Links Optimization for Ride and Handling Improvement2024-26-004801/16/2024
In automotive world, role of suspension system is to absorb vibrations from the road, and to provide stability while vehicle is going over bumps or uneven roads, cornering, acceleration and braking etc. For body on frame SUVs which are typically characterized by high center of gravity, it is quite critical to find best balance in ensuring stability of the vehicle and having comfortable ride performance. Rigid axle rear suspension is quite typical choice in such vehicles, wherein lower and upper control links are two important components subjected to lateral, longitudinal, and vertical loads. These links allow the vehicle to move smoothly throughout the entire range of suspension travel. Kinematics and compliance optimization of these links is major factor in definition of ride-handling performance of the vehicle. The present study describes key challenges and methodology to define position as well as orientation of control links, where-in multiple inter-related handling and comfort
Hussain, Inzamam, Jani, Harshil, Rasal, Shraddhesh, Asthana, Shivam, ahire, Manoj, Jadhav, Prashant, Lenka, Visweswara, Vellandi, Vikraman
Technical Paper
INTEGRATION AND OPTIMIZATION OF GENEVA MECHANISM IN THE CAR DOOR HANDLE2024-26-028501/16/2024
The car door handle is an essential component of any vehicle, as it plays a crucial role in providing access to the cabin and ensuring safety of the passenger. The primary function of the car door handle is to allow entry and exit from the vehicle while preventing unauthorized access. In addition to this, car door handles also play a critical role in ensuring passenger safety by keeping the door closed during accidents or when there is a significant amount of G-force acting on the vehicle. A typical car door handle comprises several components including the structure, cover, Bowden lever, bracket, pins and other child parts. The structure provides the ergonomics and rigidity for grabbing the handle, while the cover gives the handle an aesthetic appearance. The Bowden lever facilitates the unlatching of the door and the intermediate parts ensure that the handle operates smoothly. The position of the Bowden lever is crucial for the unlatching process and for keeping the door closed
Kumar, Vinayak
Technical Paper
Experimental Evaluation of Metro Rail Bogie Frame through Bench Testing2024-26-032501/16/2024
Bogie frame is a main skeleton and structural member in railway system which is carrying all the loads such as Suspensions, Axles, wheels, car body, Motor, Gear box etc. The frame is subjected the exceptional and service stresses in Vertical, Longitudinal, Lateral and twist directions throughout the service life which should be withstand for a life span of 30 years without failure. The objective of this work is to estimate the structural integrity of the Metro rail bogie frame .This paper is the outcome of bench testing of metro rail bogie frame with the application of multiaxial loading in static and dynamic campaign through which stress data is collected with strain gauge sensors and correlated with the FEA results at design stage. This helps to verify and evaluate the design and validate the quality of metro rail frame as per the requirement specified in EN13749 European standard in early design stages.
Tormal, Uday Bapurao
Technical Paper
Countermeasures for Low Frequency Boom noise Reduction in Electric Vehicle2024-26-021401/16/2024
Electric vehicles are much quieter than IC engine powered vehicles due to less mechanical components and absence of combustion. The lower cabin noise in electric vehicles make customers sensitive to even small disturbance in vehicle. Road boom noise is one of the major concerns to which the customers are sensitive in electric vehicles. The test vehicle is a front wheel driven compact SUV powered by electric motor. In normal plain road, noise levels are acceptable but when the vehicle has been driven on coarse road, the boom noise is perceived, and the levels are objectionable. Multi reference Transfer path Analysis (MTPA) is conducted to identify the path through which maximum forces are entering the body. Based on MTPA, modifications are proposed on the suspension bushes and the noise levels were assessed. Operational deflection shape (ODS) analysis is conducted on entire vehicle components like suspension links, sub frame, floor, roof, and doors to identify the deflection pattern of
S, Nataraja moorthy, Rao, Manchi, Raghavendran, Prasath, Selvam, Ebinezer
Technical Paper
An experimental approach to investigate the FEAD cover failure & its design optimization.2024-26-037101/16/2024
In automotive Front End Accessory Drives (FEAD), the crankshaft supplies power to accessories like alternators, pumps, etc. FEAD undergoes forced vibration due to crankshaft excitation, dynamic tension fluctuations can cause the belt to slip on the accessory pulleys. By considering the criticality of the system, when engine mounting is longitudinally to the vehicle which makes it directly exposed to the air flow containing foreign particles which may cause the damage to the FEAD system and deteriorate the intended functionality. FEAD cover is introduced in the system to enhance belt-pully system functionality by restricting the entry of foreign particles during engine operation. This paper contains study of FEAD cover failure and provide the stepwise approach to capture such issue during novel model development for 4 cylinder naturally aspirated engine during engine bench testing. Failure mechanism was studied using various methodology such as CAE and G-Load measurement to identify the
PATEL, HARDIK MANUBHAI, KUMAR, NITISH, Chand, Subhash, Gupta, Vineet
Technical Paper
Effect of environmental factors on the function of an Automotive Luggage Cover of a passenger vehicle – A case study2024-26-022801/16/2024
Abstract: - Automobile OEMs, universally, have always given high priority to the Luggage Area of the vehicle. Luggage Area primarily includes a Load Floor (the load bearing part), Side & Rear garnishes & the Luggage Shelf (or the Parcel Tray) for covering the luggage. The Parcel Tray makes the Luggage Area look neat and aesthetically appealing & is occasionally also used for carrying small items like files, papers, cushion, tissue box etc. The article under consideration in this paper is a Luggage Cover made from thermoplastic composite such as PP-Compounds (with Glass-fiber or Wood-powder), with rotating hinges towards the cabin side. Such types of Covers are predominantly in use in many markets including India. In the vehicle, the Luggage shelf is suspended on the Side Trims or Garnishes & has an elastomer interface with the back Door. The back door tends to be opened and closed in frequent intervals and the elastomer tends to harden with time. This leads to increased load on
Sreejith, M P, Khandelwal, Lokesh, Sandilya, Arnab, Natu, Mandar R, Ray, Amulya Kali, Handa, Rajat
Technical Paper
Comprehensive Analysis and Optimization of Door Closing Sound Quality of a Heavy Truck2025-01-006605/05/2023
Based on the objective and subjective experiment and finite element analysis, the influencing factors on the door closing sound quality of a heavy-duty truck is analyzed and optimized. Results show that the loudness and sharpness can be reduced apparently by increasing stiffness and damping of the door. The sound quality can be enhanced by increasing the pressure release area, which can decrease the air resistance of dooring closing. By adding holes on the inner liner and changing the pressure release location, the dooring closing air resistance is reduced from 289 Pa to 181 Pa. In terms of the rebound sound, the sound level is positively relative to the door closing force. Increasing the protrusion height and decreasing the stiffness of the vibration absorber of the handle can improve the rebound sound quality. Optimizing the absorbers on both ends and adding damping material can decrease the loudness by 47.8%, reduce the cavity sound, dismiss the trembling and improve the compact
Wang, Jian, Zhang, Yongshen, Feng, Lei, Xie, Chenhao, Lin, Jiewei, Sun, Changchun
Technical Paper
Excavator exterior noise contribution analysis using angle-based operational acoustic load synthesis.2025-01-006205/05/2023
Since earth moving machines (EMM) are subject to exterior noise (EN) regulations, OEMs need to develop mitigation solutions from an early design stage. It is challenging to predict solution effectiveness at early design stage. Excavators are distinct compared to other EMM as their upper frame rotate while keeping lower frame fixed. ISO 6395(2) or EC/2000/14(1) require EMMs to follow specific operating maneuvers where noise sources change their position, directivity, and speed along the operating cycle. These conditions pose challenges in performing noise contribution analysis as a function of angular position and operating condition. Authors successfully demonstrated Acoustic source quantification and contribution analysis for linearly moving EMMs. However, excavator pose data processing challenges due to angular motion. This work demonstrates the use of frequency domain ASQ for operational acoustic source quantification and use of frequency domain virtual prototype sub structuring
Vesikar, Prasad Balkrishna, Haynes, Timothy, Aquino Arriaga, Adrian Antonio, Drabison II, John, Chaduvula, Prasanna
Technical Paper
Active Control of Engine Order Noise for Heavy-duty Trucks: Using the Genetic Algorithm for the Optimization of Error Microphone Arrangement2025-01-001305/05/2023
The arrangement of error microphones for a vehicle active noise control (ANC) system is no trivial work, especially for heavy-duty trucks due to the dilemma resulted from the large volume of the cab and the limited number of microphones accepted by most manufacturers in the auto industry. Most ANC developers resort to trial and error, which is not only a heavy workload given the amount of interested working conditions to be test, but also does not guarantee to yield the optimum noise cancellation performance. In this paper, the authors proposed an error microphone selection methodology using a genetic-algorithm (GA) -based mechanism. The target vehicle was a heavy-duty truck with a six-piston diesel engine, and two scenarios were particularly interested, i.e. driver & copilot and driver & one passenger sleeping on the berth. We first arranged eight microphones at different locations in the cab, five on the headrests, two on the B pillars and one at the head position of the sleeping
Wang PhD, Jian, Ling, Zihong, Zhang, Zhe, Cai, DeHua, lv, Xiao, Zhang, Ming, Gao, GuoRan
Technical Paper
Evaluation of Automotive Closure Design for High Frequency Acoustics Performance2025-01-004905/05/2023
A good NVH environment in a vehicle plays an important role in attracting a large customer base in the automotive market. Hence, NVH has been given significant priority while considering automotive design. NVH performance is monitored using simulations early during the design phase and testing in later prototype stages in the automotive industry. Meeting NVH performance targets possesses a greater risk related to design modifications in addition to the cost and time associated with the development process. Hence, a more enhanced and matured design process involves Design Point Analysis (DPA), which is essentially a decision-making process in which analytical tools derived from basic sciences, mathematics, statistics, and engineering fundamentals are used to develop a product model that better fulfills the predefined requirement. This paper shows the systematic approach of conducting a Design Point Analysis-level NVH study to evaluate the acoustic performance of vehicle door systems in
Ranade, Amod A., Shirode, Satish, Miskin, Atul, Mahamuni, Ketan, Shinde, Rahul, GHAN, PRAVIN, Choudhury, Ashok
Technical Paper
The applications of Acoustic Black Holes to attenuation of Coach/Bus Frame Structure Vibrations2025-01-006505/05/2023
Abstract An acoustic black hole (ABH) is a structure whose cross-sectional thickness decreases exponentially to zero, and the phase velocity and group velocity of wave propagation in those structure acoustic black holes decrease as the thickness decreases until they are zero. ABH produce some very magical physical phenomena. For example, because the wave velocity decreases to zero, the wave can never reach the center of the ABH, so the wave propagation in the acoustic black hole has neither refraction nor reflection; that is to say the vibration wave will not go through the acoustic black hole. As a result, the wave energy is concentrated in the center of the ABH. The arrangements of those acoustic black holes in the structures could change the directions of the vibrational wave propagation in the structures at NVH engineers’ wills. These amazing phenomena could play a magical role in reducing structural vibration, structural noise radiation and structure-borne noise. Basic structures
Huang, Xianli
Technical Paper
A Study on the Subwoofer Rattle Noise Analysis and System Target Setting2025-01-009005/05/2023
Rattle noise from electrical sound systems is becoming one of the prominent issues for automakers as it directly affects the perception of customers about vehicle quality. Recent times, quality sound system is prerequisite for automotive passenger vehicles. And, in the whole sound systems subwoofer forms dominant part of sound output. However, sub-woofer rattle noise problem sometimes occurs in small and midsize SUV. Generally, sub woofers are located inside rear quarter area (back side of the quarter panel), due to the limitation in the available space. Mainly rattle is noise resulting from physical impact of two parts due to vibrations when relative displacement is bigger than gap of two parts, it occurred in 50-100Hz, which is main excitation range of sub-woofer. In this study, we analyze the sub-woofer structural vibration analysis for five sample vehicles based on the test and correlation. However, the present sub-woofer system model has limitation in determining the level of this
Thota, Jagadeesh, Choi, Seungchan, Park, Jong-Suh
Technical Paper
Localisation of Ultra-short Sound Emissions from Automotive Components by Using the Sound Field Scanning Method2025-01-009205/05/2023
Design verification and quality control of automotive components require the analysis of the source location of ultra-short sound events, for instance the engaging event of an electromechanical clutch or the clicking noise of the aluminium frame of a passenger car seat under vibration. State-of-the-art acoustic cameras allow for a frame rate of about 100 acoustic images per second. Considering that most of the sound events introduced above can be far less than 10ms, an acoustic image generated at this rate resembles an hard-to-interpret overlay of multiple sources on the structure under test along with reflections from the surrounding test environment. This contribution introduces a novel method for visualizing impulse-like sound emissions from automotive components at 10x the frame rate of traditional acoustic cameras. A time resolution of less than 1ms eventually allows for the true localization of the initial and subsequent sound events as well as a clear separation of direct from
Rittenschober, Thomas
Technical Paper
Thin, Stretchable Biosensors Could Make Surgery SaferTBMG-4649309/01/2022
A research team developed bio-inks for biosensors that could help localize critical regions in tissues and organs during surgical operations. The ink is biocompatible and provides a user-friendly design with workable time frames of more than one day. Simultaneous recording and imaging could be useful during heart surgery in localizing critical regions and guiding surgical interventions such as a procedure for restoring normal heart rhythms.
Magazine Article
Modeling and analysis of dynamic hysteresis behavior of an automatic tensioner2022-01-074903/29/2022
The automatic tensioner of the engine front end accessory drive system was taken as a study object, and the mechanical structure and working principle of the automatic tensioner were analyzed. The dynamic hysteresis behavior test of tensioner torque-angular displacement was carried out, and the effects of different excitation frequencies and excitation amplitudes on the hysteresis behavior of tensioner were analyzed. Based on the modified Dahl hysteresis model, the identification method of tensioner model parameters and method of hysteresis behavior in the stick and slip process were proposed. Based on the established model and the identified model parameters, the hysteresis behavior of the tensioner were calculated, and the calculation model accuracy was verified with the test results. The influence of the hysteresis curve transition area exponent on the automatic tensioner behavior was studied. The dynamic behaviors of the engine front end accessory drive system were simulated using
Wan, Lixiang, Wang, Haoran, Ding, Quanyu
Technical Paper
Saddle type structure design for electric vehicle2022-01-087603/29/2022
Abstract: Electric vehicle are likely to gain market share in near future as technology is getting evolved and cost of ownership is also reducing. Focus on pure electric vehicle is need of an hour and vehicle manufacturers are investing heavily on future trends. Conventional vehicle has BIW front end which is used to protect from crash. With recent development in vehicle architecture, it is learned that secondary load path can be created with help of saddle structure to and there can be huge weight saving in BIW front end which still can meet safety norms. Saddle structure is also helping to have idealistic engine mount locations in vehicle. A & B mount can be packaged exactly on TRA (Torque Roll Axis) to get the best NVH performance. With saddle type structure all three mount can be weight carrying member and easy to handle high torque. This paper explains how saddle type structure is beneficial for crash point view and engine mounting system best performance, Keywords: - Engine
Deshmukh, Sagar
Technical Paper
INBUILT SANITIZING SPRAYER AT DOOR HANDLE2022-01-040303/29/2022
It is specially designed for people who have to travel by a cab or a car during COVID 19 pandemic. We can get rid of portable sanitizers inside car. This technology mainly focuses on the benefit of people to sanitize their hands along with their belongings before entering into the car during pandemic. We are planning to implement our products on door handles of the cars. This technology comprises of Press button request switch, Car's Door handle, Controller, Motor Driver, Sensor & Pump. Whenever the request switch is pressed for sanitizing, communication signal will be sent to the controller to enable disinfection mode. The controller then activates the motor driver, which is responsible for Pump operation. The pump then sprays the sanitizing fluid through the nozzle at door handle and the belongings can be sanitized. In parallel, controller enables the sensor into monitoring mode for detecting the disinfection mode and thereby communicating to controller. Motor driver will be turned
Mani, Megala
Technical Paper
An Engineering Approach to Consider Stress Concentrations in Fatigue Life Predictions on Automotive Body Structures 2022-01-030103/29/2022
This paper proposes a new procedure for more accurate durability predictions on the edges of structural components especially on notch regions. Current CAE procedures based on elemental stress often require iterative mesh refinement to correlate predictions to experimental cracking on the edges of components. The new proposed procedure is based on element nodal stress. It is first studied theoretically on a rectangular plate with different element sizes and options and demonstrates an improvement over elemental stress methods. It is then studied on multiple examples of experimental cracks and successfully predicts issues where current elemental stress methods do not. In addition, it avoids the iterative mesh refinement associated with current methods. In summary, the new method based on nodal stress is more accurate, more efficient, and improves first time through capability on the edges of structural components.
Zhang, Weidong, Pankaj, Ananta, Archak, Vijay, Guo, Mingchao
Technical Paper
Manufacturing and Joining Considerations for Upper Body Structures Made in Ultra-High Strength 7075 Aluminium Alloys2022-01-028403/29/2022
To date ultra-high strength aluminium alloys, such as AA7075, were used predominantly in aerospace industry where high cost and manufacturing challenges can be forgiven due to high value lightweighting potential of the material. This made the aerospace manufacturing techniques inaccessible to mainstream automotive industry. HFQ technology was developed to enable low cost high volume manufacture of high and ultra-high strength aluminium alloys opening up new lightweighting opportunities for automotive industry. The remining challenge was to develop and prove out a reliable joining technology for 7XXX series alloys. This paper discusses the linking of the HFQ manufacturing considerations, SPR joining and vehicle body thermal treatment required to process 7XXX made safety cell for EV vehicles.
Szegda, Damian
Technical Paper
A Study to Reduce the Minimum Distance of the Vehicle Sensor’s Detecting Range Using a Prior Estimation Method2022-01-008303/29/2022
As autonomous driving vehicles are developed, automotive makers start focusing on implementing new door types, such as a falcon wing door or a B-pillarless dual sliding door, which could be one of the best-selling points. To make these doors electrically operate, applying advanced sensors like a RADAR or an Ultrasonic sensor is almost mandatory. Without these sensors, the door could be easily damaged or the customers could be seriously injured. Due to physical limitation, however, every sensor has a noise in nearby area and has a specification of the minimum detection range, which causes us not to be able to precisely detect the object in close area. If the controller cannot detect the precise distance of the object, the door could malfunction, since it could misidentify the obstacles. In this paper, we propose a method to minimize the minimum detection range by applying a prior estimation scheme. Without changing any sensor mechanisms, we can use this method if the door electrically
Kim, Junhyuk, Choi, Jae Hong, Je, Myoung Kwon, Ku, Bon Hyeok
Technical Paper
CAE driven light weighting of automotive hood using multiple loadcase optimization 2022-01-095503/29/2022
In the automotive industry the requirement for low emissions has led to the demand for lightweight vehicle structures. Light weighting can be achieved through different iterative approaches but is usually time consuming. Current paper highlights deployment of the multi-objective optimization approach for light weighting. This work involves developing a process for multi-objective optimization (MOO) for vehicle durability system, in this case Hood. The main goal is to minimize the weight of a Hood assembly by meeting strength and stiffness targets. The design variable considered in the study is thickness of the panels. Design constraints were set for Stress and Stiffness based on DVP requirement. Optimization workflow is setup in modeFRONTIER with design objective as minimizing weight of hood. Using the Design of Experiments (DOE) data response surfaces are generated using different algorithms for prediction of the structural performance parameters such as displacement, modal frequency
Kangde, Suhas
Technical Paper
Investigations of Honeycomb and Foam structures of Automotive Front rails During Frontal crashes and its affinity with Optimum Energy Absorption2022-01-104903/29/2022
Energy dissipation in frontal crash of the vehicles normally occurs through the deformation in the engine compartment zone and especially on longitudinal front rails. In this article, the details of the crash tests is presented which involves an interpretation of the damage profiles and understanding the origin of the stiffness coefficients in main particular member which is front rails of a passenger vehicle. Moreover, the present experimental work is used to estimate the energy dissipated during deformation based on crush measurements. Furthermore, it explains the implementation of experimental test to investigate the influence of design characteristics on the deformation behavior of the proposed front rails. The current experimental work deals with the influences of geometric shape modifications of conventional steel members with flange configurations compared to honeycomb structures and structural foam with the same members length. The observations in this work led to conclude the
Elhussieny, Sayed Abbas, Oraby, Walid
Technical Paper
Influence of Manufacturing Processes on the Structural behavior of Truck Frame Rail Sections2022-01-091403/29/2022
The sequence of manufacturing processes involved in the making of ladder shaped truck frame rail assembly leave certain amount of manufacturing and assembly imperfections in the form of plastic deformation and residual stresses in some areas of frame rail ‘C’ sections. The plastic deformation and the resulting residual stress should not be allowed to cross the safer limit as it would affect the structural behaviour of the frame rail while interacting with the externally induced loading stresses from extreme road operating conditions. If the combined stress level crosses the yield limit of the frame material, it may lead to premature failure of frame rail much before it gives the expected life. One such manufacturing induced premature failure in a truck frame rail assembly during proving ground trials was studied in detail using experimental analyses and presented in this paper. As part of this study, the local material crowding due to plastic deformation occurring at certain sections
K, Chinnaraj, KR, Balaji, Gopal, Gopi
Technical Paper
Check Strap Optimization for Door Vibration Reduction in Opening and Closing Maneuvers2022-01-091903/29/2022
In swing door design, the check strap plays an important role since it assists the door opening and closing maneuvers and stops the door in case of extra opening events. Computer-Aided-Engineering is extensively used to simulate door opening and closing events for designing the door structure in terms of durability performance and closing effort. However, in customer perspective, other phenomena related to check strap subsystem need to be investigated, as the onset of door vibration in opening and closing phase. This paper describes a methodology, based on the Finite Element approach, able to simulate the opening and closing maneuver of a swing door, including detailed check strap mechanism through a sequential implicit-explicit strategy. Such methodology can reproduce in virtual door vibrations caused by check strap operation. Since this oscillatory phenomenon could be potentially unacceptable in terms of perceived quality, a component optimization may be necessary. The methodology
Mennillo, Serena, DUNI, EFTHIMIO, Audano, Livio
Technical Paper
A Development of Spindle drive power trunk lid system with Optimizing Actuating noise2022-01-091603/29/2022
The power trunk lid system is a device that automatically opens and closes the trunk lid using a motor, for the purpose to improve user’s convenience. The technology was applied only to high-priced large cars such as Equus and Genesis, but in line with increasing preference for high convenience features, the scope of application is gradually expanding to semi-large and mid-size vehicles. Accordingly, the need to secure profitability through cost reduction emerged, and we developed a power trunk lid system using a spindle drive. Spindle drives can reduce costs by optimizing the required motor specifications compared to conventional swing arm drives, and are lightweight and easy to assemble. However, since a planetary gear with a high gear ratio is used and the rotational speed of the motor is generally high, it has a relatively low characteristic in terms of actuating noise. When we first applied the spindle drive type power trunk lid system to GL3 model (the successor of YG), to reduce
lim, Kyeongjun
Technical Paper
Design and Analysis of a 110cc All-Terrain Vehicle(ATV) for BAJA SAE India Competition2022-01-044803/29/2022
The capacity to handle tough undulated terrain is the most important aspect of developing an All-Terrain vehicle. We get the opportunity to design and manufacture our buggy and race it against other collegiate teams throughout the country thanks to BAJA SAE. Our vehicle is designed to operate under adverse driving conditions with ease. It can endure excessive loads and impacts throughout the event. Our design has been brainstormed, debated, tested, and verified based on various Automobile literature, FEA Analysis, physical testing, and experience gained over 7 years of manufacturing ATV. This year we have prioritized driver's ergonomics and maximum utilization of space in the roll-cage. The most important aspect of designing an ATV is to make it robust and aggressive. Goals set this year were specifically targeted towards making our vehicle agile around the corners while keeping it sturdy and durable on the track. Also this year we have tried to reduce the overall weight (curb weight
Dutta, Ayushman, Ratan, Anmol
Technical Paper
Driveline Parking Brake Test Procedure for Medium Duty VehiclesJ2690_202110 (Current)10/28/2021
This SAE Recommended Practice establishes uniform test procedures for friction based parking brake components used in conjunction with hydraulic service braked vehicles with a gross vehicle weight rating greater than 4500 kg (10 000 lb). The components covered in this document are the primary actuation and the foundation park brake. Various peripheral devices such as application dashboard switches or indicators are not included. These test procedures include the following: a Brake Related Tests 1 Brake Functional Performance 2 Brake Dynamic Torque Performance 3 Brake Corrosion Resistance 4 Brake Endurance with Torque 5 Brake Endurance without Torque 6 Vibration Resistance 7 Brake Ultimate Static Load 8 Brake Lining Wear Adjuster Function b Actuation Related Tests 1 Mechanical Actuator Functional Performance 2 Mechanical Actuator Endurance 3 Mechanical Actuator Quick Release 4 Mechanical Actuator Ultimate Load 5 Spring Apply Actuator Functional Performance 6 Spring Apply Actuator
Truck and Bus Hydraulic Brake Committee
Recommended Practice
Customer usage profile based Luggage compartment development at concept phase2021-28-015310/01/2021
The SAE J1100 based standard cargo volume index methods and predefined luggage objects are very specific to United States population. The European luggage volume calculation and standard luggage calculations are primarily based on DIN and ISO standards. Luggage volume declaration by manufacturers are based on any of these methods. The calculations are complicated and there is a possibility of declaring different values for similar luggage compartments. The major purchase decision of vehicle is based on its luggage capacity and current methods are very limited to make an intelligent decision by a customer. Market specific customer usage patterns for luggage requirements and protecting them in vehicle architecture upfront in concept stage is important to retain the market position and buying preference of customers. The usage patterns is collected from customer clinics and marketing inputs. These patterns are used to build virtual luggage models representing the actual luggage at
Radakrishnan, Rambabu, BALAKRISHNAN, Mohanraj
Technical Paper
SCV Chassis Performance Optimization through Parametric Beam Modelling & Simulation2021-28-018310/01/2021
In automotive product development, design and development of the chassis plays an important role since all the internal and external loads pass through the vehicle chassis. Durability, NVH, Dynamics as well as overall vehicle performance is dependent on the chassis structure. Even though passenger vehicle chassis has a ladder frame or a monocoque construction, small commercial vehicle chassis is a hybrid chassis with the cabin welded to the ladder frame. As mileage is critical for sale of SCVs, making a light-weight chassis is also important. This creates a trade-off between the performance and weight which needs to be optimized. In this study, a parametric beam model of the ladder frame & the cabin of the vehicle is created in COMSOL Multiphysics. The structure has been parameterized into the long member & crossmember geometry and sections. The model calculates the first 12 natural frequencies, global stiffness, and weight. It has been validated and further used for optimization study
THANAPATI, ALOK Ranjan, Bhalerao, Mihir, Deshmukh, Chandrakant, Krishnan, Hareesh
Technical Paper
MOLD IN COLOR PIANNO BLACK PC MATERIAL FOR AUTOMOTIVE EXTERIOR APPLICATION2021-26-024209/22/2021
Aesthetics contribute significantly to the customer buying decision of an automobile. This is traditionally achieved through painting. Sustainability and cost challenges have led automakers to look at substituting painting through molded-in color polymers in decorative bezels like pillar appliques. These appliques and bezels have a unique mix of material requirements that include color tone, gloss, stiffness, scratch resistance and weathering. Polycarbonates are an interesting class of polymers that has potential to meet these challenging requirements. This paper reports the work done in evaluating a polycarbonate compound in piano black shade to meet the functional and aesthetic requirements. The results prove that the material can substitute painting thereby resulting in significant cost savings.
Govindaraj, Karthik, Vimalathithan, Murukesan, Balaji, K V, Samir, Gandhi, hebbar, vinayak
Technical Paper
Brake Groan Noise Investigation and Optimization Strategy for Passenger Vehicles2021-26-030109/22/2021
Groan is a low frequency noise generated when moderate brake pressure is applied between the surfaces of the brake disc and the brake pad at a low-speed condition. Brake groan is often very intense and can cause large numbers of customer complaints. During a groan noise event, vehicle structure and suspension components are excited by the brake system and result in a violent event that can be heard and felt during brake application. The cause of noise is friction variation of stick-slip phenomenon between friction material and disc. This paper discusses the approach for prediction and mitigation of brake groan noise for passenger vehicles having disc brakes. To identify the brake groan noise frequency, vehicle testing with operating condition for reproducing the groan noise is carried out and also impact frequency response analysis is performed to identify natural frequency of each chassis component like brake, suspension stud, lower control arm, knuckle etc. The finite element corner
Doundkar, Vikas, Iqbal, Shoaib
Technical Paper
Door Seal Behavior Prediction and Enhancement in Performance Using Digital Simulation2021-26-038709/22/2021
Automotive door seal has an important function which is used extensively where interior of the vehicle is sealed from the environment. It must be functional and cohesive with the body design of the vehicle. Poor door seal system design will cause water leakage, wind noise, hard opening or closing of doors, gap and flushness issue which impair customer’s satisfaction of the vehicle. Moreover, improper design of seal can lead to difficulty in installation of door seal on body panel. The design prudence and manufacturing process are important aspect for the functionality and performance of sealing system. However, the door sealing system involves many design and manufacturing variables. At the early design stage, it is difficult to quantify the effect of each of the multiple design variables. As there are no physical prototypes during rubber profile beading-out stages, engineers need to carry out non-linear numerical simulations that involve complex phenomena as well as static and dynamic
Hursad, Tushar Haridas, Patil, Sanjay
Technical Paper
Hybrid Laminated Panels Addressing Acoustic Issues in Vehicles2021-01-108608/31/2021
Laminated steel body panels are used in different applications in vehicles, such as dash panels and wheel wells. A part made out of laminated steel has the potential to provide structure-borne noise reduction and also improve the airborne noise reduction of the part compared to a monolithic part. The use of laminated steel has been more critical when there are deep draws on the part as the deep draws cause localized resonances which degrade the acoustic performance significantly. However, due to lightweighting demands, hybrid laminated panels, commonly known as acoustic patch laminates have become very attractive. This paper discusses the damping and sound transmission loss performances of a dash panel part with monolithic, laminated, and acoustic patch panels. The paper discusses the damping performance below 1000 Hz, including the data analysis process and the effectiveness of the acoustic patch laminates for both structure borne and airborne noise studies including coincidence dip
Saha, Pranab, Patil*, Sagar, Figueroa**, Antonio, Telenko, Michael
Technical Paper
CONNECTOR, RECEPTACLE, ELECTRIC THRU BULKHEAD, WALL MOUNTING FLANGE, SERIES I (CLASS E)AS31391-TEST-REC (Historical)06/22/2021
AE-8C1 Connectors Committee
Technical Standard
CONNECTOR, RECEPTACLE, ELECTRIC THRU BULKHEAD, WALL MOUNTING FLANGE, SERIES I (CLASS E)AS31391 (Current)06/22/2021
AE-8C1 Connectors Committee
Technical Standard
SAE TOMORROW TODAY: Lifting the Hood on the Engineering of Ford Motor Company's Mustang Mach-E1312705/21/2021
Introduced 57 years after the launch of its iconic namesake, the Mustang Mach-E reinvented the game and has been named the 2021 North American Utility Vehicle of the Year. On this episode, Ron Heiser, Mustang Mach-E Chief Engineer with the Ford Motor Company, joins us to talk about the vehicle's origins, engineering, reductive design, as well as the pending release of the Ford Mustang E-GT.
Hineman, Marcie
Podcast
Metamaterials R&D TARGETS NVH ABATEMENT21AUTP05_0405/01/2021
Nissan readies its lightweight acoustic solution for 2022 production - will Hyundai follow? Acoustics engineers have a broad variety of materials from which to choose for reducing noise, vibration and harshness (NVH) in vehicles. But their selection often comes with a measurable downside: added mass. It's not uncommon for a new vehicle to gain 100 lb (45 kg) or more during development as various absorbers, reflective barriers and absorber-barrier combinations - typically baked-on mastics, blankets, injected foams and acoustic glazing - are brought to bear. In an era where “lightweighting rules” and engineers are rewarded on a per-gram basis for cutting vehicle weight, materials researchers are betting on new developments to win the NVH-versus-mass battle. So-called metamaterials offer significant promise here, with a potential added benefit of being less costly than the traditional NVH solutions used by OEMs.
Brooke, Lindsay
Magazine Article
Felling Head Terminology and NomenclatureJ1272_202103 (Current)03/01/2021
This SAE Standard is intended to describe the basic types of felling heads, including those with bunching capabilities, that are attachments to a self-propelled machine. Only the major components that are necessary to describe the functions of the felling head, and to apply the principles of the standard are included. Illustrations used are not intended to include all existing felling heads or to describe any particular manufacturer’s variation.
MTC4, Forestry and Logging Equipment
Technical Standard
Nissan's 2021 Rogue is a COVID beater21AUTP02_1402/01/2021
Nissan staff truly pulled out the stops to get the all-new 2021 Rogue into the market during the global pandemic. Rogue is the company's best-selling product in North America, by far - a testament to a well-considered overall package that designers, engineers and product planners have steadily evolved and improved since the model's launch in 2007. Now in its third generation (coded T33), the latest Rogue is underpinned by Nissan's C/D-segment architecture that shares more geometries with Sentra, itself a vastly upgraded and improved vehicle for 2021. “Last March, I was reviewing our program schedules and it looked like everything was going to get delayed due to Covid,” said Chris Reed, executive VP of R&D at Nissan Technical Center in Farmington, Mich. “At this time, we had delays in other programs due to a ‘development overload’ situation between suppliers and prototypes. The hatches were being battened down.
Brooke, Lindsay
Magazine Article
SAE TOMORROW TODAY: Building Next-Gen Electric Vehicles From the Ground Up with Lucid Motors1287611/25/2020
Small but mighty. That's the future of electric vehicles. As Lucid Motors prepares to launch its first vehicle, Lucid Air, next spring, the company will also be proving that passengers don't have to sacrifice luxury, power and space for efficiency and innovation. We spoke with Eric Bach, Vice President of Hardware Engineering at Lucid Motors, to get a look "under the hood" and understand the technology that's transforming how we think about electric vehicles. Discover how Lucid Motors' competitive nature launched the company into the racing scene, how miniaturization plays a key role in Lucid Air's innovation and how customers can harness the vehicle's electric technology to power life beyond the car itself.
Hineman, Marcie
Podcast
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