Applications for 3D machine vision are rapidly expanding in a variety of industries for several reasons. The first is that vision systems can lower production costs by increasing yields and/or reducing scrap product and wasted raw material. One example of this would be extruded products from various materials (rubber, plastic, metal), where it’s vital to know as soon as the process goes out of specification.

The Effect of Plasticizers on Vibration Damping in Polyvinyl Chloride (PVC) Formulations

2015-01-22046/15/2015

The ability of various plasticizers to impact the vibration damping properties of polyvinyl chloride (PVC) plastisols was investigated. A material must have good viscoelastic properties in order for it to be an effective vibration damper. However, it is evident that not all viscoelastic materials are good vibration dampers. Consider flexible (plasticized) PVC, for example. PVC formulations demonstrating the same glass transition temperature may have widely different damping capabilities. This presentation will show that the type of plasticizer substantially impacts the damping ability of the final PVC composite. Initially, flexible PVC formulations with varied plasticizers were screened via dynamic mechanical thermal analysis (DMTA) to determine which ones would likely have good damping properties. Formulations which exhibited promising results with DMTA were then tested via an Oberst bar damping test (SAE J1637). Final observations showed that specific plasticizers do promote vibration damping in PVC systems. End use applications for this technology could include PVC plastisols for automotive floor pans and body panels. This presentation will include test results (DMTA and Oberst bar), discussion of correlations between the test results, and some conclusions.

Funderburg, Michael

Optimizing Body Panels for NVH Performance

2015-01-22656/15/2015

Automotive manufacturers are being challenged to come up with radical solutions to achieve substantial (30-35%) vehicle weight reductions without compromising Safety, Durability, Handling, Aero-thermal or Noise, Vibration and Harshness (NVH) performance. Developing light weight vehicle enablers have assumed foremost priority amongst vehicle engineering teams in order to address the stringent Fuel Economy Performance (FEP) targets while facilitating lower CO2 emissions, downsizing of engines, lower battery capacities etc. Body sheet metal panels have become prime targets for weight reductions via gage reduction, high strength steel replacement, lighter material applications, lightening holes etc. Many of these panel weight reduction solutions are in sharp conflict with NVH performance requirements. The main challenge for NVH engineers is to recover panel stiffness and mitigate the potentially increased air-borne as well as structure-borne noise transmissibility thru these lighter panels. This is achievable with a systematic approach to optimizing panel geometry and damping treatment upfront during the body structure development process while also incorporating innovative new light weight solutions for acoustic insulation. This paper describes generic FE based methods to virtually engineer body panels starting with optimization of geometry features followed by efficient damping treatment to meet weight and stiffness targets upfront in the design process. Panel geometry study parameters include panel features such as curvature, form geometry and beads in combination. Mesh morphing to vary panel curvatures coupled with topography methods to optimize features such as bead pattern are used to achieve panel frequencies and FRF targets. Further, a new methodology is introduced to assess panel sensitivities to mid-frequency structure borne noise which is then used to fine tune the panel features for stiffness as well as identification of target panel areas for efficient damping treatment. Also, innovative concepts for weight effective acoustic insulation are referenced.

Balasubramanian, Murali, Shaik, Ahmed

Standardized Dent Resistance Test Procedure

J2575_201504 (Current)4/28/2015

These test procedures were developed based upon the knowledge that steel panel dent resistance characteristics are strain rate dependent. The “quasi-static” section of the procedure simulates real world dent phenomena that occur at low indenter velocities such as palm-printing, elbow marks, plant handling, etc. The indenter velocity specified in this section of the procedure is set to minimize material strain rate effects. The dynamic section of the procedure simulates loading conditions that occur at higher indenter velocities, such as hail impact, shopping carts, and door-to-door parking lot impact. Three dent test schedules are addressed in this procedure. Schedule A is for use with a specified laboratory prepared (generic) panel, Schedule B is for use with a formed automotive outer body panel or assembly, and Schedule C addresses end product or full vehicle testing. These schedules are targeted at sheet steel samples obtained at different points in an auto/steel product development cycle. A multiple schedule approach has been utilized to maximize dent test method flexibility and thereby allow both the steel producers and end users to benefit from a standardized approach. Extrapolating results from one schedule to another, however, may not be valid and could result in erroneous conclusions. For “quasi-static” testing, each test schedule provides a load-displacement curve for a given material, either as-stamped or after assembly, under a prescribed set of conditions such as specified strain state, specimen geometry, boundary conditions, indenter type, etc. In order to obtain the most information about dynamic denting behavior comparable in scope to the quasi-static testing, it is necessary to use high speed measuring and recording equipment. If use of this equipment is cost-prohibitive, other dynamic dent evaluations use a drop weight, pendulum, or air gun to fire a projectile at the test surface. For this latter type of dynamic testing, only the impact energy is calculated and the dent depth measured after impact. This information may be sufficient to measure some aspects of dent resistance in the absence of high-speed measuring and recording equipment, but the indenter speed/energy interaction will not be captured. Uniform methods for calculating panel property characteristics such as stiffness and oil canning load are presented. A format for reporting test results is suggested. Using this procedure, reproducible values of “dent resistance” should be obtained in different laboratories.

Metals Technical Committee

MMLV: Door Design and Component Testing

2015-01-04094/14/2015

The Multi Material Lightweight Vehicle (MMLV) developed by Magna International and Ford Motor Company is a result of a US Department of Energy project DE-EE0005574. The project demonstrates the lightweighting potential of a five passenger sedan, while maintaining vehicle performance and occupant safety. Prototype vehicles were manufactured and limited full vehicle testing was conducted. The Mach-I vehicle design, comprised of commercially available materials and production processes, achieved a 364kg (23.5%) full vehicle mass reduction, enabling the application of a 1.0-liter three-cylinder engine resulting in a significant environmental benefit and fuel reduction. This paper reviews the mass reduction and structural performance of aluminum, magnesium, and steel components for a lightweight multi material door design for a C/D segment passenger vehicle. Stiffness, durability, and crash requirements are assessed. The structure incorporated aluminum sheet, aluminum extrusion, magnesium high pressure vacuum die casting and steel sheet. The multi material components were assembled using structural adhesive bonding (hem and structure), self-pierce rivets (SPRs), single sided rivets, and bolts. The aluminum extrusion and the magnesium casting in the MMLV door were specifically designed to maximize stiffness, reduce part count and maximize mass reduction. To optimize the strength and weight of the MMLV door, a new aluminum intensive structure was developed. The new structure features a unique architecture that uses a multi-cavity aluminum extrusion joined to stamped sheet reinforcements to provide a direct load path between the hinges and the latch. The new structure also utilizes a high pressure vacuum die cast magnesium casting to create the structure at the base of the A-pillar on the front door to achieve the required structural stiffness while reducing components and maximizing the mass reduction. The “barn door” architecture of the inner structure of the door allowed for gage optimization of both the inner and outer stampings, the two largest and heaviest components of the assembly. Overall, the design architecture used in the MMLV doors allowed for a mass reduction of 33% through the use of multi material, gage optimization, and multiple forming technologies, while achieving all of the structural requirements.

Plourde, Larry, Azzouz, Michael, Wallace, Jeff, Chellman, Mari

Re-design of Power Sliding Door Pulley System

2015-01-13124/14/2015

The power sliding door system(PSD) is being equipped in the MPV(Multi-Purpose Vehicle/minivans) vehicle for convenience in the door operation. This study will focus on package space optimization for interior design and overall vehicle packaging for the vehicles equipped with PSD. To optimize the package, investigation for PSD's structure need to be done and the examples of other vehicle maker will be investigated and compared. The study that considers performance and package requirements resulted in a unique PSD design. And finally, this study will show the result vehicle in which the optimized mechanism is applied.

Je, MyoungKwon

Single Cylinder Diesel Engine Mount Configuration for Reduced Vibration in a Three-Wheeled Vehicle

2014-32-012311/11/2014

The diesel power train (engine and transmission) is the most significant mass contributor in a three- wheeled vehicle. High idling vibrations from the engine get transmitted to the structure and the body panels through the engine mounts. Isolation of these vibrations by proper design of rubber mounts is the most effective engineering approach to improve ride quality of vehicle. In the present study, a mathematical model of the powertrain and mount system is developed; with the engine and transmission being assumed to behave as a rigid body (6 degrees-of-freedom) and the compliance comes from the mounts. As a first step, the modes and natural frequencies are obtained. Following this the response to unbalanced inertial forces for an excitation frequency range of 20-60 Hz (1200-3600 rpm) has been obtained. The model is validated by comparing its results with results of previous published research work. Also, motoring experiments are conducted on a baseline configuration to obtain the vibration response at mounts and mode shapes through ODS (Operational Deflection Shape) for validating the math model. A detailed parametric study is conducted and a new combination of mount system design variables were arrived as proposed solution which in comparison with baseline configuration showed that the vibration response reduces by 40% at idling and 60% in the engine operating range. Experiments conducted on the improved design show similar improvement. Thus, using this validated analytical math model, a closer-to-optimal design can be obtained with minimal dependency on iterative experimental methods which are costlier and time consuming.

Kuduva Shanthulal, Vishnu Kumar, Marudachalam, Kannan, Pattabiraman, V, Jabez Dhinagar, S, Padmanabhan, Chandramouli

Sandwich Panels with Corrugated Core - A Lightweighting Concept with Improved Stiffness

2014-01-08084/1/2014

Sandwich panels with high modulus/high strength skin material and low density/low modulus core material have higher stiffness-to-weight ratio than monolithic panels. In this paper, sandwich panels with corrugated core are explored as a lightweighting concept for improved stiffness. The skin and the core materials are a high strength steel, aluminum alloy or carbon fiber-epoxy composite. The core has a triangular corrugation, a trapezoidal corrugation and a rectangular corrugation. The stiffness of the sandwich panels is analytically determined and compared with monolithic panels of equal mass. It is shown that the stiffness of the sandwich panels is 5 to 7 times higher than that of the monolithic panels.

Mallick, Pankaj K., Boorle, Rajesh

Passenger Car Response to Interaction with Tractor-Trailer Steer Tire Lugs

2014-01-04754/1/2014

Performing a reconstruction of sideswipe interactions is difficult due to the lack of permanent crush sustained by the vehicles involved. Previous studies have provided insight into the forces involved in creating various types of damage for vehicle-to-vehicle interactions during a sideswipe interaction. However, these data may not be applicable to the interaction that occurs when a tractor-trailer steer tire is involved. As demonstrated in previous studies, steer tire interaction produces a unique pattern of markings on the struck vehicle by the protruding lugs (wheel stud) of the steer tire. These studies have demonstrated that the pattern of cycloidal marks created by the wheel lugs can be used to calculate the relative speeds of the vehicles. While this is helpful in understanding the relative motion of the vehicles, it does not provide information regarding the forces applied at the point of contact. The purpose of this study is to assess the structural response of passenger cars during a sideswipe event involving a tractor-trailer steer tire. The study consists of quasi-static and dynamic tests performed using a stationary tractor-trailer tire spinning at an equivalent speed of 55 mph. A total of 20 quasi-static tests were performed using 3 separate vehicles by forcing the spinning tire against the side of a stationary vehicle. The force and displacement necessary to cause various levels of damage to the passenger car was measured to develop an understanding of the stiffness response at different locations along the side of the vehicle. A range of contact stiffness was achieved by forcing the tire against areas around the door pillars and at the center of the door panels which produced stiffer and softer responses respectively. A total of 8 dynamic tests were performed by driving the side of the same 3 vehicles against the rotating steer tire. The vehicle acceleration and change in speed (Delta-V) associated with contact were measured. Peak forces during the quasi-static testing ranged from 500 to 2,600 lbs with a range of deflection of 0.5 to 3.6 inches. The data provided by the quasi-static testing can be used to assess the lateral forces applied to passenger vehicles based on the level of damage sustained. The dynamic testing was performed at speeds of 4.5 to 6.5 mph and resulted in peak vehicle accelerations of 0.1 to 1.4 g in the lateral and 0.1 to 0.6 in the forward direction. The patterns created by the wheel studs were similar to those presented in previous studies. The results of the dynamic testing can be used to assess vehicle acceleration based on the severity of the damage observed.

Cormier, Joseph, Freund, Mark "Tony", Bonugli, Enrique, Guzman, Herbert

Automotive Vehicle Body Temperature Prediction in a Paint Oven

2014-01-06444/1/2014

Automotive vehicle body electrophoretic (e-coat) and paint application has a high degree of complexity and expense in vehicle assembly. These steps involve coating and painting the vehicle body. Each step has multiple coatings and a curing process of the body in an oven. Two types of heating methods, radiation and convection, are used in the ovens to cure coatings and paints during the process. During heating stage in the oven, the vehicle body has large thermal stresses due to thermal expansion. These stresses may cause permanent deformation and weld/joint failure. Body panel deformation and joint failure can be predicted by using structural analysis with component surface temperature distribution. The prediction will avoid late and costly changes to the vehicle design. The temperature profiles on the vehicle components are the key boundary conditions used to perform structure analysis. This paper presents an efficient method to predict vehicle body temperature profiles as the vehicle pass through the radiant section of an e-coat and/or paint oven. Transient analysis coupled with geometry movement is used to predict the vehicle body temperature which provides a complete vehicle component temperature map for further structural simulation.

Wu, Yu Hsien, Surapaneni, Sreekanth, Srinivasan, Kumar, Stibich, Paul

Vehicle Body Panel Thermal Buckling Resistance Analysis

2014-01-09264/1/2014

This paper discusses CAE simulation methods to predict the thermal induced buckling issues when vehicle body panels are subjected to the elevated temperature in e-coat oven. Both linear buckling analysis and implicit quasi-static analysis are discussed and studied using a quarter cylinder shell as an example. The linear buckling analysis could produce quick but non-conservative buckling temperature. With considering nonlinearity, implicit quasi-static analysis could predict a relative conservative critical temperature. In addition, the permanent deformations could be obtained to judge if the panel remains visible dent due to the buckling. Finally these two approaches have been compared to thermal bucking behavior of a panel on a vehicle going through thermal cycle of e-coat oven with the excellent agreement on its initial design and issue fix design. In conclusion, the linear buckling analysis could be used for quick thermal buckling evaluation and comparison on a series of proposals. The implicit quasi static analysis is must to conduct to determine if a body panel will buckle or not and how much permanent deformation may remain in any thermal circumstance.

Zhang, Weidong, Guo, Mingchao, Stibich, Paul, Bhandarkar, Ram

Simulating Human Body Touch Automotive Tests Using Industrial Robot & Intelligent Grippers Equipped With Sensors

2013-01-282311/27/2013

All Automotive companies conduct various performance and Endurance tests on automotive bodies, doors by using Pneumatic Actuators. These Actuators can only give linear or rotary motion. Therefore these can neither simulate the complex motion of Human arm nor can they simulate the Force and pressure induced by the Human palm or Human back on the body domain parts. Each test need to have different test setup. This paper discusses how a system of industrial Robot coupled with intelligent Gripper with sensors and feedback signal to robot can be used to simulate the effect of Human touch during testing.

Bhatkar, Hemant R., ramakrishnan, Dakshinamoorthy, B, Venkatasubramanian, Vijayakumar, Narayanan

Structure to Assist in the Prevention of Bimetallic Corrosion of Hybrid Doors

2013-01-03864/8/2013

The use of low-density materials in body panels is increasing as a measure to reduce the weight of the vehicle body. Honda has developed an aluminum/steel sheet hybrid door that is more effective in reducing weight than an all-aluminum door. Because aluminum was used in the door skin, bimetallic corrosion at the connection between the aluminum and the steel sheets represented an issue. It was possible that the difference in the electrical potential of the two metals might promote corrosion at the connection between the aluminum door skin and the steel sheet door panel, in particular at the lower edge of the door, where rainwater and other moisture tend to accumulate, with the result that the appeal of the exterior of the door might decline. To address this issue, a watertight structure realized through the use of a high-ductility sealer was employed in order to help prevent water from infiltrating to the connection between the metals, and steel sheets with a zinc-aluminum-magnesium alloy coating, highly effective in controlling bimetallic corrosion, were employed in the door panels. This produced rust-resistance specifications for the hybrid door able to maintain durability in market use environments. This paper discusses the effect of the zinc-aluminum-magnesium alloy-coated steel sheets in controlling bimetallic corrosion.

Kimura, Shoji

Analysis of Damage Caused to Vehicle Body Panels by Impacting Hail and Various Tools and Objects

2013-01-14384/8/2013

On the 25th December 2011 there was a hail storm in the state of Victoria, Australia, which caused approximately AU$712 million worth of damage. Some of this damage was caused to passenger vehicles. The authors conducted a number of inspections of hail-damaged vehicles as a result of insurance claims being disputed or rejected on the basis that some, or all, of the alleged hail damage was not created by hail but instead created intentionally by the vehicles' owners with the use of different tools and/or objects. As a result of the inspections and investigations of potentially fraudulent claims, the authors conducted a total of 119 tests designed to replicate damage caused to vehicle body panels by impacting hail and to recreate claimed hail damage by using tools and other objects. To do so, the authors created two sizes of hail: Ø20 mm and Ø40 mm hail. A total of 15 impact tests were conducted with Ø20 mm hail. The impact speed for the Ø20 mm hail varied between 75 km/h and 144 km/h, with the average being 113 km/h. A total of 50 impact tests were conducted with Ø40 mm hail. The impact speed for the Ø40 mm hail varied between 66 km/h and 133 km/h, with the average being 101 km/h. The testing impact speeds were generally higher than the terminal velocities of the corresponding hail, so the damage observed is expected to be an over estimation of the actual damage caused by hail. The hail was projected at the test vehicle using a purpose-built projectile launching device that used a sling-like mechanism to project hail in a horizontal direction at a test vehicle. The test vehicle was a white-colored 2001 model Holden Commodore with non-metallic paint. The body panels tested were: bonnet, roof, boot, all four doors, the vehicle pillars and cant rail. High speed cameras were used to determine the impact speed of the hail. Damage was photographed and recorded. In addition to impacting the vehicle with hail, a number of different tools and objects were used to recreate man-made damage. Tools and objects used were: claw hammer (conventional), welding hammer, ball-peen hammer, mason hammer, lead ball sink in a sock, golf ball in a sock, ratchet, breaker bar, crowbar and center punch. The conducted tests revealed the following findings: 1. hail impacting the vehicle body panels will not scratch or mark the paint but the paint may chip if hail impacts the vehicle near a fold or edge of a panel; 2. dents caused by hail will cause the light to move smoothly and continuously across the dent and the light will not "break" or crease; 3. where dents were caused by tools and objects the light will crease into multiple (two or more) distinct areas as it passes over the dent; 4. scratches and/or markings in the paint were identified on dents caused by tools and objects; 5. folds and curves on the panels did not affect the size of the dent caused to the panel; using the same tool and force to impact two different body panels (A-pillar and roof) resulted in dents that were very similar in physical appearance; 6. for the same impact speed the larger Ø40 mm hail caused more damage than the Ø20 mm hail; and 7. for the same size hail the higher impact speed hail caused more damage.

Josevski, Nikola, Sandvik, Andreas, Jones, Chris, Pok, Tandy, Orton, Tia, Richardson, Shane

Weight Reduction of Damping Materials on Vehicle Body Panels by using an Optimization with Sound Pressure Constraints

2012-01-02204/16/2012

This paper presents an optimization method of damping material attached on vehicle body panels incorporated with trimmed body calculation up to 400 Hz. Damping sheets are modeled by using shell elements whose neutral plane are located away from the middle plane of the elements. In this method the offset value must agree with the average of the thicknesses of a panel and a damping sheet attached on it. Therefore, we implement the function that can automatically change the offset values according to the change of the thicknesses of damping sheets during the iterative calculations of optimization. Interior sound pressure levels are employed as the constraint conditions by utilizing the precise acoustic cavity models that have been recently developed. The developed optimization technique is applied to reduce the weight of the damping sheets on the floor panels of a sedan car. The levels of noise transfer functions that are proved to have high contributions to the performance of road noise are constrained in several one-third octave bands. The optimization calculation finds a solution that can achieve 1.5 kg weight reduction after several iterations. Moreover, the vehicle realized the optimal configuration proves to attain the almost the same road noise level as one with the original configuration

Yamamoto, Takashi, Maruyama, Shinichi, Shimada, Hiroshi

Development of Liftgate Hinge-to-Roof Sealing Gasket Material for Uncoated Steel Roof Panels

2011-01-00724/12/2011

The sealing of a lift gate hinge to the body structure is necessary to avoid both the onset of corrosion and to avoid water intrusion into the interior compartment. The hinge-to-body interface typically involves horizontal metal-to-metal surface contact, creating the perfect environment for moisture entrapment and corrosion initiation. The choice of body panel material (uncoated (bare) steel vs. coated (galvanized) steel) drives different sealing approaches especially when considering corrosion avoidance.

Corman, Carl, Yergin, Mark, Kussmaul, Andy, Conrad, Lou, Martin, Gregory

Boundary Condition Effect on the Correlation of an Acoustic Finite Element Passenger Compartment Model

2011-01-0506

4/12/2011

Three different acoustic finite element models of an automobile passenger compartment are developed and experimentally assessed. The three different models are a traditional model, an improved model, and an optimized model. The traditional model represents the passenger and trunk compartment cavities and the coupling between them through the rear seat cavity. The improved model includes traditional acoustic models of the passenger and trunk compartments, as well as equivalent-acoustic finite element models of the front and rear seats, parcel shelf, door volumes, instrument panel, and trunk wheel well volume. An optimized version of the improved acoustic model is developed by modifying the equivalent-acoustic properties. Modal analysis tests of a vehicle were conducted using loudspeaker excitation to identify the compartment cavity modes and sound pressure response to 500 Hz to assess the accuracy of the acoustic models. The optimized acoustic model is also coupled with a structural finite-element model of the trimmed body to evaluate the effect of body panel flexibility on the interior sound pressure response. The optimized acoustic model is found to exhibit the best correlation in terms of the predicted sound pressure FRF response at the passenger compartment interior locations and at the compartment boundary surfaces.

Lee, Sangyun, Park, Kwangseo, Sung, Shung H., Nefske, Donald J.