Browse Topic: Exterior trim and molding

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Abrasion Resistance Testing - Vehicle Exterior Graphics and Pin StripingJ1847_202101 (Current)1/7/2021
This SAE Recommended Practice applies to the abrasion resistance testing of decorative tapes, graphics, and pin striping. It may also have relevance to certain vehicle labels and plastic wood grain film. The resistance to abrasive damage is judged qualitatively by its effect on the legibility, pattern, and color of the graphic marking. This recommended practice is intended as a guide toward standard practice but may be subject to frequent change to keep pace with experience and technical advances. This should be kept in mind when considering the use of this recommended practice.
Materials, Processes and Parts Council
Paint and Trim Code LocationJ2235_201910 (Current)10/24/2019
This SAE Recommended Practice is designed to provide readily accessible paint and trim code information on all passenger vehicles, lightweight trucks, and vans in a way that minimizes the time and effort required to locate and effectively use that information for body repair, parts ordering, vehicle maintenance, and information systems.
Motor Vehicle Council
Improving Cancer Screening by DesignTBMG-3307510/1/2018
Every year, 50,000 Americans die from colorectal cancer, a common cancer that is easy to detect and can be effectively treated if caught in its earliest stages. Unfortunately, 38 percent of Americans eligible for screening are not being screened. This article explores how one company addressed this need by designing a home sample collection kit that would increase colorectal cancer screening rates.
Toyota rethinks THE FLAGSHIP17AUTP11_0211/1/2017
The 2018 Lexus LS moves to twin-turbo V6 power and piles on the takumi. Toyota has engineered a complete road-to-roof redo of its flagship Lexus LS sedan, dropping the V8 engine in favor of a twin-turbo V6, adding Aisin's new 10-speed planetary automatic and retaining a hybrid-electric powertrain option-and that's just the beginning. The 2018 model marks the fifth generation of the luxury sedan that rocked the luxury-sedan establishment almost 30 years ago. While the LS has represented less than 2% of the brand's U.S. sales in recent years, its significance to Toyota exceeds its sheer numbers. Chief Engineer Toshio Asahi and his team began work on the new LS500 and hybrid LS500h in late 2011. One key goal was to attract a younger buyer with what Asahi calls “Brave Design,” picking up the Lexus family ‘spindle’ grille theme and developing a longer, more muscular exterior form. Lowering the hood by 1.2 in (30.5 mm), the decklid by 1.6 in (40.6 mm) and dropping the roof 0.6 in (15 mm) versus the 2017 LS helps the new version look more ground-hugging as well.
Sessions, Ron
Effect of PVC Skin and Its Properties on Automotive Door Trim Inserts2017-01-04923/28/2017
Plastic plays a major role in automotive interiors. Till now most of the Indian automobile industries are using plastics mainly to cover the bare sheet metal panels and to reduce the weight of the vehicle along with safety concerns. Eventually Indian customer requirement is changing towards luxury vehicles. Premium look and luxury feel of the vehicle plays an equal role along with fuel economy and cost. Interior cabin is the place where aesthetics and comfort is the key to attract customers. Door Trims are one of the major areas of interiors where one can be able to provide premium feeling to the customer by giving PVC skin and decorative inserts. This paper deals with different types of PVC skins and its properties based on process constraints, complexity of the inserts. Door trim inserts can be manufactured by various methods like adhesive pasting, thermo-compression molding and low pressure injection molding process etc. Considering process feasibility and PVC skin manufacturing constraints, it will be a challenge to decide the specifications of the PVC skin to achieve good quality product. The objective of this paper is to review the effect of PVC skin & its properties on door trim inserts using Low pressure injection molding and discuss steps involved in selecting the appropriate PVC skin.
Beera, Mahendra, Pahuja, Dinesh, Kapila, Arpit, Handa, Rajat, Raina, Sandeep
A Study on New Approach of Optimization for the Automotive Plastic Interior Parts2015-01-04764/14/2015
Carmakers have tried to lower the vehicle weight for raising fuel efficiency. This trend involves a trade-off with the vehicle stiffness. In automobile interior parts, the thickness has needed to be decreased for the weight reduction but this makes the stiffness worse. A new approach for improving the stiffness due to the weight reduction is required and various optimization methods at early development stage have been introduced currently. However, it is difficult to apply optimization for the interior parts since many interior parts' structures generally depend on the design. But as studying the structure in detail, we discovered some factors that affect the performance without depending on design. The door trim is selected for optimization item because it has many characteristics of automobile interior parts. In our case study, the factors that improve the performance of door trim without changing design are considered as fastener position and flange rib layout. The optimization process for door trim was established. Size optimization is used for Fastener position and Topology optimization is used for Flange rib layout. As a result, the 1st mode frequency is improved by about 5% and thermal displacement is reduced by about 25% in comparison with the initial model.
Jo, Hyunkwon, Kim, Youngseung, Lee, Hyunchul, Park, Hyunmin, Song, Suckin
Five Bonding Techniques of Side Door Trim Insert Skin Decoration2014-01-10234/1/2014
Interiors of past vehicles were created to satisfy specific functions with appearance being a secondary consideration, but in the present & future market with ever increasing vehicle luxury, decoration of vehicle has become a prime focus in automobile industry along with the safety & economy. Automotive interiors have evolved over the years from a collection of trims covering bare sheet metal panels to add quality & richness of interior cabin, ultimately delivering greater value to customers. One such area in interiors is Side door trims serving the dual purpose of functionality and creating a pleasing environment too. The aesthetic appeal to the Side door trim is added usually through a Door trim insert having a decorative skin pasted on to the plastic base. And the selection of pasting technique for pasting decorative film on to the plastic base insert is a challenge for an automotive interior designer. The objective of this paper will be to review technologies available for manufacturing Door trim inserts with decorative skins, and discuss a direction toward selecting an appropriate pasting technique with cost effectiveness. In automotive industry, for Side door trim insert decoration, five bonding techniques are used ranging from Adhesive pasting, Thermo compression molding using natural fiber reinforced PP, Pressure lamination, Kimikomi, and Low pressure injection molding, all these will be discussed in this paper. A brief synopsis of the advantages and disadvantages of each process including cost effectiveness, design considerations, shape & complexity of Door trim inserts, Door trim insert skin types & their physical property requirements, process considerations and its testing methods are covered. In addition to this, the necessary tooling investment will also be discussed in this paper.
Pahuja, Dinesh, Kapila, Arpit, Haldar, Sanjay, Raina, Sandeep
Procedure for Visual Evaluation of Interior and Exterior Automotive TrimJ361_201308 (Historical)8/14/2013
This SAE Recommended Practice applies to parts and materials used in vehicle manufacture which are intended to be acceptable color matches to a specified standard. This document is intended for use with parts or materials which are opaque or nearly so. Materials covered by this document include topcoat paint finishes, interior soft trim, interior and exterior hard trim, and exterior film and flexible trim.
Textile and Flexible Plastics Committee
An Experimental Study on Flow Pattern of Door Trim Speaker Grille Shape2013-01-13694/8/2013
Recently the automotive industry has focused on reducing product development time to correspond with the customer's demands. Especially when quickly changed. The decreased product development time shortens the quality assurance period. It makes difficult to guarantee the quality of the products. The improved quality assurance is required so that customer's expectations are actually higher quality than in the past. Most automotive interior parts are manufactured by using plastic. It is very sensitive to focus on quality, because it is exposed to a passenger's sight. So automotive interior companies make full use of injection molding CAE in an effective ways to reduce costs and reduce elements of poor quality. This paper suggests a methodology that improves reliability for injection molding analysis in grille shapes of door trim. And it involves an experimental analysis of flow pattern in speaker grille shapes. To analyze it, use an authentic mold of speaker grilles in door trim and Mold flow software.
Yang, Heeseung, Jo, Hyunkwon, Jang, Ikkeun, Park, Hyunmin, Yoon, Sungyun, KIM, Heejoong
Enhanced Light Weight Frontal Crash Box Design for Low Speed and Insurance Tests2013-26-00231/9/2013
Single body architecture designed for various global markets and subjected to varied load cases is a challenge for Body in White (BIW) engineers. Optimization of structural design to meet regulatory, insurance and assessment requirements is an iterative and time consuming task. With focus on reduction of vehicle's damageability and ease of repairability Original Equipment Manufactures (OEM), insurance companies and Research Council for Automobile Repairs (RCAR) [1] are striving for better designs. A space constraint crash box structure installed behind the bumper plays a significant role in absorption of energy, before transmitting to longitudinal rails. In this study, crashworthiness of a multipurpose crash box for a hatch segment vehicle is presented with the various design of experiments conducted with a focus on light weighting, cost and ease of manufacturing. Possible cross sectional shapes that connect to common platform crash rails were tested with numerical simulations to obtain the energy absorption capacity and the mean load. In case of the simple axial crush, a section with maximum effective width within the ridge lines showed higher mean load and energy absorption without damaging the longitudinal members. Major constraint was to restraint the crash box tower from rapid time bound buckling and collapsing with an allowable intrusion for reduction of damageability. The simplified vehicle model was analyzed for an effective and reliable design method of a crash box, comparing the performance of a full car model and a single crash box model. Further to keep costs low for both domestic and export requirements, sectional modulus was optimized to a single design.
Cheni, Ravi Kiran, Sinha, Abhishek, Narayan, Shinoj
Characterization of Mechanical Behavior of Thermoplastics with Local Deformation Measurement2012-01-00404/16/2012
In quasi-static tension and compression tests of thermoplastics, full-field strain distribution on the gage section of the specimen can be captured using the two-dimensional digital image correlation method. By loading the test specimens made of a talc-filled and impact-modified polypropylene up to tensile failure and large compressive strains, this study has revealed that inhomogeneous deformation within the gage section occurs quite early for both test types. This leads to the challenge of characterizing the mechanical properties - some mechanical properties such as stress-strain relationship and fracture strain could depend on the measured section length and location. To study this problem, the true stress versus true strain curves determined locally in different regions within the gage length are compared. The results show that, for the tension test, the stress-strain curve seems independent of regions within the gage section, but the local fracture strain increases as the length of the measurement region is reduced. For the compression test, the large transverse expansion of the material in the middle of the gage section causes the specimen surface to become shorter and bulged out in the late stage of the tests, which makes the test result only reliable when the longitudinal strain is smaller than 0.2. A possible inverse-engineering method is proposed for identifying the true material response at a large compressive deformation. It is also shown that the ratio of longitudinal strain to transverse strain is different between tension and compression tests. This difference is not addressed in any existing material models in the finite element software LS-DYNA.
Gu, Gongyao, Lin, Shaoting, Xia, Yong, Zhou, Qing, Lin, Chin-Hsu
Aerodynamic Development of the Newly Developed Electric Vehicle2011-39-72305/17/2011
This paper explains the specific measures taken to develop the body and underfloor of the newly developed Electric Vehicle for the purpose of reducing drag. Additionally, the headlamps and fenders were designed with innovative shapes to reduce wind noise that occurs near the outside mirrors. As a result of utilizing the aerodynamic advantages of an electric vehicle to maximum effect, The newly developed Electric Vehicle achieves a class-leading drag coefficient and interior quietness.
Ishihara, Yuji, Takagi, Hitoshi, Asao, Kazuya
Procedure for Visual Evaluation of Interior and Exterior Automotive TrimJ361_201006 (Historical)6/16/2010
This SAE Recommended Practice applies to parts and materials used in vehicle manufacture which are intended to be acceptable color matches to a specified standard. This document is intended for use with parts or materials which are opaque or nearly so. Materials covered by this document include topcoat paint finishes, interior soft trim, interior and exterior hard trim, and exterior film and flexible trim. Purpose The intent of this document is to precisely specify procedures for the visual evaluation of appearance of colored materials or parts incorporated in the manufacture of vehicles. The document provides a consistent engineering practice for the determination of visual color difference between materials or parts of the same or like materials. A suitable fixture providing daylight, fluorescent, and horizon lighting conditions is necessary for this evaluation.
Textile and Flexible Plastics Committee
Effects of Material Type, Surface Roughness, Compressibility, Shape, Gender, Age and Sense Modality on Perception of Automotive Interior Materials2010-01-06824/12/2010
This paper presents the results of an experimental study conducted to evaluate the effects of four material characteristics and two driver characteristics on the perception of automotive interior materials. The perceptual characteristics of the materials were measured using two sensing conditions, namely, visual sensing only and combined visual and tactile sensing. The experiments were conducted using the Taguchi's L16 orthogonal array with seven independent variables, namely material type, surface roughness, compressibility, driver's age, driver's gender, and sensing method. Twenty-four subjects participated in the experiments. Each subject was asked to evaluate four treatment combinations and provide ratings using seven 5-point semantic differential scales. In addition, physical measurements were made on surface roughness, coefficient of friction, and compressibility. This paper presents the results and discussion of a) the correlation models developed between the seven factors chosen for the Taguchi experiment and the subjective data and b) the relationship developed between the subjective rating and the measured physical characteristics measurements.
Sarma, Vishnuvardhan, Bhise, Vivek, Mallick, Pankaj
Fiberboard Test ProcedureJ315_201003 (Current)3/2/2010
This SAE Standard provides test methods for determining the critical characteristics of basic or finished fiberboard products. Where applicable, methods of test developed by SAE and ASTM have been referenced.
Textile and Flexible Plastics Committee
Simple Test Method for Squeak & Rattle Evaluation of Door Trim by Using Statically Repeated Loading Robot Arm2009-01-21125/19/2009
Recently, major car maker is specified squeak and rattle test method for subsystems or components by objective method. Generally these test method is focused on vibration environmental conditions. Especially, door trim which is located close to occupant is required additional test for squeak and rattle which is produced by occupant's interaction with door trim. To evaluate this condition, generally it can be tested by subjective method such as striking or pushing and twisting several positions of door trim. Dosing so is very time consuming and including variation results as different decisions. So, this paper suggest a new approach for evaluating squeak and rattle which is relating occupant contacting conditions to interior part, especially interior door trim. Multi-axis robot arm is examined to push automatically several points of door trim. Subjective response index for noise is checked at each point and compared with objective values which are evaluated by acceleration level of vibration. Results on subjective and objective method show that they have similar trend at each test point and is thus to adapt to new test method.
Lee, Hyunchul, Park, Hyunmin, Na, Hyunghyun, Kim, Jongsoo, Jeon, Ohhwan, Jang, Ikkeun
Development and Validation of Utility Matrix for Automotive Interiors in Real World Usage2009-26-00721/21/2009
As the real world usage profile of customers is becoming increasingly dynamic the need for more utility features in interior parts of vehicle has increased. The main purpose of the study is to analyze how the changing customer style actually influences the volume requirement of the utility spaces i.e. at the glove box, console door pocket etc. In the present study, an exhaustive list of utilities, and a utility matrix based on the user characteristics for automotive interiors is developed. Based on customer reviews on the web and expert opinions, seven user profiles were defined. The selection matrix is arrived at by using the usability index, accessibility index and the disbursement index. The matrix is evaluated using statistical methods and validated for real world usage. The selection matrix is used to identify relatively important utility features and preferred locations in automotive interior parts.
Rajamohan, B. K., Partha, Siddharth, Sathish Baba, S.
Simplified Side Impact Test Methodologies for Door Interior Trim Armrest in Automotive Vehicle2007-01-37228/5/2007
The complete evaluation of the side vehicle structure and occupant protection is only possible by the full-scale side impact crash test. But auto part manufactures, such as door trim makers can't conduct the test especially when the vehicle is under developing process. And important information and components for estimating crash performance is restricted. With the proposed design procedure for the door trim by a simple impact test method was demonstrated to evaluate the abdominal injury. In addition to simple test, Euro-NCAP test result that is conducted by referenced full-scale test in Korea is compared with several test results. In conclusion, this simple test method have similar trend for abdominal injury index so that it is possible to present guidelines of door armrest design to carmaker at the early stages of vehicle program development.
Lee, Hyunchul, Park, Hyunmin, Na, Hyunghyun, Kim, Jongsoo, Jeon, Ohhwan, Jang, Ikkeun, Younghan, Youn
A Value Analysis Tool for Automotive Interior Door Trim Panel Materials and Process Selection2007-01-04534/16/2007
This paper describes a computerized value analysis tool (VAT) developed to aid automotive interior designers, engineers and planners to achieve the high levels of perceived quality of materials used in automotive door trim panels. The model requires a number of inputs related to types of materials, their manufacturing processes and customer perceived quality ratings, costs and importance of materials, features located in different areas of the door trim panel, etc. It allows the user to conduct iterative evaluation of total cost, total weighted customer perceived quality ratings, and estimates of perceived value (perceived quality divided by cost) for different door trim areas as well as the entire door trim panel. The VAT, thus, allows value and cost management related to materials and processing choices for automotive interiors. The model computes two parallel estimates of perceived values-one from the material supplier's viewpoint and the other from the customer and OEM's viewpoint. From OEM's viewpoint, the model uses the actual consumer ratings of different door trim materials. And, from the supplier's viewpoint, the model uses ratings based on the supplier's internal experts that are familiar with the OEM's design needs (e.g. radii, fit tolerances), manufacturing process complexities, and costs. The tool is developed using Microsoft Excel and its unique features/advantages include: i) Interactive with graphical outputs, ii) Ability to quickly reconfigure virtual door trim models for evaluation of different combinations of technologies or material choices, iii) Drive for early technology decisions so early design clays can be optimized for particular choices, iv) Improved cost management process, v) Provide records for all completed virtual builds, and v) Involvement of OEMs in early planning and decision making. The paper also presents a comparative analysis of six different door trim panels from recent production vehicles and provides distributions of costs, perceived quality ratings, and overall values. The analysis, thus, supports the usefulness of the overall concept of the VAT to help achieve higher levels of perceived quality at a given/target cost.
Onkar, Sonal, Hayes, Marc, Dalpizzol, Jim, Dowd, James, Bhise, Vivek D.
Load Path Considerations for Side Crash Compatibility2007-01-11764/16/2007
Heavier, larger pickups and SUVs are bound to encounter lighter, smaller passenger vehicles in many future accidents. As the fleet has evolved to include more and more SUVs, their frontal structures are often indistinguishable from pickup fronts. Improvements in geometric compatibility features are crucial to further injury prevention progress in side impact. In corner crashes where modern bullet passenger car (PC) bumpers make appropriate geometrical overlap with target PC rocker panels, concentrated loads sometimes disrupt foam and plastic bumper corners, creating aggressive edges. In situations where sliding occurs along the structural interface, these sharp edges may slice through doors, panels and pillars. End treatments for such bumper beams should be designed to reduce this aggressive potential. The experimental comparison presented here demonstrates that load path compatibility can provide a means by which severe door intrusion due to oblique corner impacts may be reduced without severe weight penalties to the vehicles involved.
Warner, Charles Y., Warner, Mark H., Benson, Nathan H.
Ford GT Body Engineering - Delivering the Designer's Vision in 24 Months2004-01-12533/8/2004
The objective was to engineer a world-class supercar body that faithfully reproduces the 2002 Concept and pays homage to the 1960's road racer. The car had to be designed, developed and launched in 24 months, while meeting tough requirements for function, weight, occupant package and aerodynamics. Challenging features such as the cantilevered door, “clamshell” engine decklid and a deeply contoured hood were to be included. This paper will discuss how a dedicated team of enthusiasts can have a flexible approach to the engineering process, material selections and manufacturing processes to achieve the designer's vision in 24 months (Figure 1).
Clarke, William, Gunner, Jon
Acoustic and Tactile Transfer Functions Measurements on Automotive Development2003-01-356911/18/2003
The NVH perception of a vehicle customer is the sum of contributions from various forces and its paths, structure and airborne. Each contribution is the product of an input force and body sensitivity. The tactile and acoustic transfer functions measurements determine how much of the input forces will reach to the costumer. Input points are suspension systems, powertrain and exhaust attachment points. Equivalent stiffness of these points is also determined on this test. This metric is used on target settings or to optimize body structure design at an early stage.
Ferraz, Fábio G., Cherman, André L., Soares, Rodrigo H.
Trend of Regulation in Korea & Introducing Activities of Renault Samsung Motors for Recycling2003-01-288110/27/2003
The status of recycling in Korea was reviewed, including the status of ELV(End-Life-Vehicle) and activities of the recycling industry. Also the Korean regulation for recycling was explained, focusing the unique system of Korea. Hereby, the unique system means that all the car makers have to summit the report which shows their activity of the design improvement for recycling to the government in annual year. Finally, the development items and contents was introduced, which RSM(Renault-Samsung Motors) are tackling. These items were selected on the basis of Renault-Nissan Alliance's policy which promotes increasing recycle rate and eliminating the hazardous materials.
Kim, Sun-Woong, OONO, Masashi
CAE Virtual Door Slam Test for Plastic Trim Components2003-01-12093/3/2003
Visteon has developed a CAE procedure to qualify plastic door trim assemblies under the vehicle door slam Key Life Test (KLT) environments. The CAE Virtual Door Slam Test (VDST) procedure simulates the environment of a whole door structural assembly, as a hinged in-vehicle door slam configuration. It predicts the durability life of a plastic door trim sub-assembly, in terms of the number of slam cycles, based on the simulated stresses and plastic material fatigue damage model, at each critical location. The basic theory, FEA methods and techniques employed by the VDST procedure are briefly described in this paper. Door trim project examples are presented to illustrate the practical applications and their results, as well as the correlation with the physical door slam KLTs. The successful application of CAE virtual KLT has demonstrated that VDST can reduce product development time and cost, by evaluating and improving the durability of plastic door trim components at early design stage, before a prototype is made and physically tested.
Su, Hong, Dunn, Chuck, Krajcirovic, Alex
Procedure for Visual Evaluation of Interior and Exterior Automotive TrimJ361_200301 (Historical)1/30/2003
This SAE Recommended Practice applies to parts and materials used in vehicle manufacture which are intended to be acceptable color matches to a specified standard. This document is intended for use with parts or materials which are opaque or nearly so. Materials covered by this document include topcoat paint finishes, interior soft trim, interior and exterior hard trim, and exterior film and flexible trim. Purpose The intent of this document is to precisely specify procedures for the visual evaluation of appearance of colored materials or parts incorporated in the manufacture of vehicles. The document provides a consistent engineering practice for the determination of visual color difference between materials or parts of the same or like materials. A suitable fixture providing daylight, fluorescent, and horizon lighting conditions is necessary for this evaluation.
Textile and Flexible Plastics Committee
Low cost - High Performance2002-01-12893/4/2002
Dohnt, Werner
Performance Improvement in Leak Noise Reduction2002-01-12383/4/2002
One of the most important quality required for luxury vehicle is quieter cabin. Up to the present, for its improvement, various countermeasures have been carried out. For example, additional weather-strips were added around door for noise reduction and quieter engines were developed. But, with all these performance improvements, local leak noise becomes major remaining. In order to achieve quieter vehicles, the noise has to be stopped by every possible means. In this report, performance improvement in noise reduction is studied by connecting both ends of inner belt weather-strip and glass run. And the influence of connecting portion for glass sliding durability is evaluated.
Goto, Teruhito, Kawai, Katsunori
Cost Savings Via Process Simplification for Painted Exterior Trim Operations - Utilizing Solid Core Bakeable Acrylic Tape2002-01-02753/4/2002
Streamlining the process of producing painted automotive exterior trim products is possible by using a heat resistant tape to serve a dual role of masking and attachment for automotive exterior trim assembly. This is obtained by using a solid core acrylic attachment tape instead of a foamed core acrylic tape. Cost savings are obtained by eliminating the masking aspects of the manufacturing process made redundant by the application of solid core acrylic tape before painting. This paper addresses practicality issues and shows technical feasibility in accordance with automotive specifications here.
Drath, David J.
Economic Analysis of Two Different Door Architectures2001-01-304510/16/2001
In the past, materials selection for automotive components has been managed on a part-by-part basis. As a result, the economics of these selections have often been reduced to comparing material price/property ratios, rather than technological options. More recently, the debate around modular designs and their advantages and disadvantages has shifted the emphasis towards a higher level viewpoint that deals with more complex systems. This approach provides the opportunity to search for new combinations of product architecture and materials that may exploit specific material advantages better than the classic part-by-part replacement. This paper presents the results of an economic analysis for two different door designs. The door designs differ both with regards to their product architectures and with regards to the materials they employ. The economic analysis considers the following process steps: parts fabrication, subassembly, paint, and final assembly (trim) for two production scenarios. The case study reveals several findings. First, the analysis concludes that both door designs offer a potential economic advantage depending on the final production volume. Specifically, the conventional design is considered more appropriate for high volume production, whilst the alternative design is more cost effective at production volumes typical of niche and derivative vehicles. Second, since the choice of design architecture has an influence on all sub systems, meaningful comparisons between the architectures may be made only through the adoption of comprehensive cost models. For example, the case study demonstrates that the choice of certain product architectures can help mitigate disadvantages caused by higher input material costs. Finally, the case study finds that the cost savings from ‘commonization’ of components vary depending on the base production volume.
Fixson, Sebastian K., Blanchard, Patrick J.
Several steps toward recoveryAUTOMAY01_035/1/2001
Making new vehicles out of old vehicles-as well as discarded carpeting-enables automakers to do the right thing for the environment society, and their balance statements. In what appears to have been an accurate portent of things to come, 50% of the automotive engineers and designers who planned to attend the SAE 2000 World Congress cited cost reductions as the industry's top concern, up 19% from the previous year. Also, 50% of the survey respondents of the DuPont Automotive/SAE International survey identified cost as the most important quality automakers seek when choosing a supplier. In the year since the survey was conducted-and especially in the past six months-automakers have not been reticent about requesting cost cuts from suppliers; it may not be a stretch to now put those cost-concern figures at 100%. “The focus on cost reduction has reached its highest level in the last six years,” said Walter Fields, Vice President, DuPont Automotive Engineering Materials. “The trend toward systems integration has certainly helped drive out cost and improve performance, but the key to long-term, sustainable growth for the industry revolves around enhancing overall value-chain relationships.
Broge, Jean L.
Development of a Power Window Switch with Improved Ergonomics2001-01-00533/5/2001
This paper explains a methodology to develop a Power Window Switch (PWS) that is easy to operate. Many PWS knobs use a pivot movement. The most popular shapes are: 1.Pull-up/Push-down, 2.Rocker, and 3. Toggle. In the Pull-up/Push-down PWS, the knob motion matches the window motion. Since the design of the knob prevents an object or a part of clothing from catching, and pulling the knob up, potential injury from the window coming up is avoided. The knob top surface of the pull up PWS is pushed down to open the window, and the knob front surface is pulled up to close it. One weakness of this design is that the operating finger posture changes each time the window direction changes, the finger will often become tired with the repetitive posture changes. Another weakness of the Pull-up/Push-down PWS is the flush top surface of the knob to the bezel. The size of the knob and corresponding finger well limits the size of the finger and length of the fingernail.
Shinzato, Takashi, Hayakawa, Hideaki, Nishikawa, Masato, Matsuoka, Eiji
Life cycle costing tool development for design decision2000-05-02176/12/2000
The objective of this study is to develop a design decision support tool that incorporates life cycle costing including the environmental effects of a system. A life cycle costing that incorporates the effects of the environment is essential to support the design decisions required during today''s product or system developments. Since the international environmental standards (ISO 14000 Series) were issued in the early 1990s, the leading companies in the automotive industry have been developing integrated assessment methodologies. These methodologies attempt to integrate cost, quality, environment and other related areas into the total life cycle assessment of a system. Therefore, it is important to develop a tool that integrates all information concerning the product in the early stages of development. It is also appropriate to support the decision-making in selecting the best design alternatives. The tool can minimize the trade-off between technical performance and cost parameters using an integrated database that includes all relevant information. The development approach is based on the Activity Based Costing (ABC) that is essential for new management culture of modern enterprises. The tool adopts the object-oriented software structure and utilizes the Unified Modeling Language (UML) to model the architecture. From a technical point of view, the tool can be utilized at early stages of development in order to assess the life cycle cost to get a higher level of productivity. A door trim example of LCA and the environment costing results was demonstrated to present the concept.
Park, Jong-Chae, Choi, Hong-Kyu, Park, Young-Won, Ha, Jong Bae, Cho, Hee Wook, Kim, Jae Hwan
Form Trim Inject: A New Technology for Exterior Parts Decoration2000-01-11693/6/2000
To improve the decoration of exterior automotive parts, we developed a new technology called Form - Trim - Inject (FTI). FTI is a very low cost investment process based on Insert Molding. Films can be produced either by roller coating / induction process or co-extrusion process. This article shows some results concerning aspect and glossiness that we observed during many trials which were necessary to develop a new knowledge on this technology. Any color, surface appearance and any graphic can be achieved by using FTI. FTI is also a very good answer to V.O.C. issues
Hilmarcher, Olivier, Gille, Denis
All Olefinic Interiors-What Will It Take To Happen?2000-01-06323/6/2000
TPO is getting wider acceptance for automotive applications. An exterior application like a fascia is a very good example. Interiors are still a challenge due to many reasons including overall system cost. For interior applications, “all-olefin” means it mainly consists of three materials: TPO skin, cross-linked olefinic-based foam and PP substrate. The driving force for TPO in Europe is mainly recyclability while in the USA, it is long-term durability. This paper describes the key limitations of the current TPO systems which are: poor grain retention of TPO skin, shrinkage in-consistency of the skin, high cost of priming (or other treatments) and painting of the skin, lower process window of the semi-crystalline TPO material during thermoforming or In-mold lamination / Low pressure molding, high cost of the foam, low tear strength of the foam for deep draw ratio etc. The paper shows the different ways of manufacturing the all olefinic parts which are: thermoforming over PP substrate, different Low pressure molding with in-mold lamination techniques, expanded PP foam process, slush molding etc. The limitations for each process and suggestions to overcome the disadvantages will be discussed to make all olefinic TPO interior parts viable and cost effective. The possibility of reducing the overall system cost will also be discussed such as: general information on formulation development to reduce the skin thickness for thermoforming, how to improve the properties of foam to reduce the thickness without affecting the formability and resiliency, value added recyclability of the skin/foam offal from production, and improving the paint efficiency etc.
Shah, Suresh, Kakarala, Norm
Bifunction HID Headlamp Systems - Reflection and Projection Type2000-01-04293/6/2000
For headlamps whose low beam function is equipped with High Intensity Discharge (HID) technology, a high beam counterpart of equal lighting performance is presented which fits in the constructional space available in modern cars. The new Bifunction HID system allows the use of HID technology for both low and high beam in the same reflector, utilizing the same bulb and electronic control unit. Bifunction HID technology on the basis of reflection as well as projection type systems will be presented in this paper. An overview of the regulation guidelines for world wide application of this new technology is given. The main aspects of the switching mechanisms and their effects on the light distributions are discussed and compared.
Boebel, Doris, Eichler, Heike, Hebler, Verena
Concept to Production: Continuous Surface Keypad Switch1999-01-04133/1/1999
The objective of this paper is to impart the challenges presented and the solutions derived to transform an artist's rendering into a production driver's door switch to be used in the interior of a high profile sports car. The challenges took many forms throughout the process, from data translation and packaging, to the final decorative issues. The results are a finished product providing a new approach to automotive interior switch design. It incorporates a low profile, continuous plane keypad with “soft touch” feel, tactile feedback, and integrated back lighting.
Decker, Earl L., Ziemkiewicz, David J., Ross, Joseph R.
Practical Considerations in Determining High Strain Rate Material Properties9811362/23/1998
Material testing standards for quasi-static rates are relatively well established. The increasing need for high strain rate material properties is now focusing the engineering community's attention on the test methods used to generate data. Differences in procedures and analysis may yield information in apparent conflict with other published data. The lack of industrial standards for high strain rate testing makes it vital that the end-user understands the valid applications and limitations of high strain rate material data. Current test methods, proper specimen selection, strain measurement methods, data analysis techniques, and interpretation of high strain rate data are reviewed.
Hill, Susan I., Sjöblom, Peter
Procedure for Visual Evaluation of Interior and Exterior Automotive TrimJ361_199604 (Historical)4/1/1996
This SAE Recommended Practice applies to parts and materials used in vehicle manufacture which are intended to be acceptable color matches to a specified color standard. This document is intended for use with parts or materials which are opaque or nearly so. Materials covered by this document include topcoat paint finishes, interior soft trim, interior and exterior hard trim, and exterior film and flexible trim. The intent of this document is to precisely specify procedures for the visual evaluation of appearance of colored materials or parts incorporated in the manufacture of vehicles. The document provides a consistent engineering practice for the determination of visual color difference between materials or parts of the same or like materials. A suitable fixture providing daylight, fluorescent, and horizon lighting conditions is necessary for this evaluation.
Textile and Flexible Plastics Committee
New Inverted Force Molding® Technology Reduces Manufacturing Costs up to 30%9602882/1/1996
Recently there has been a strong move to develop technologies aimed at reducing injection molding clamp forces. While these processes claim lower clamp pressures, “low pressure molding,” correctly defined, is much more versatile. Not a single action, but multiple functions.
Hettinga, Siebolt
Simulation Techniques in the Analysis of Variation9511194/1/1995
The use of computer simulation in analyzing the effect of variation needs to be timely and accurate in its analysis. It must be capable of analyzing all definable processes during all phases of a product life cycle. This paper describes the process of Variation Simulation Modeling (VSM) used at General Motors - Truck Platforms that has significantly increased the effectiveness and usage of this technology.
Pettypiece, Cheryl L.
GUIDELINES FOR USAGE OF STAINLESS STEEL AND BIMETAL FOR EXTERIOR AUTOMOTIVE BRIGHT TRIMJ1755_199501 (Historical)1/1/1995
The scope of this SAE Recommended Practice is to give guidelines for design, processing, and material selection for stainless steel and bimetal exterior automotive moldings.
Metals Technical Committee
A Study of the Color Change of Automotive Coatings Subjected to Accelerated and Natural SAE Weathering Tests for Exterior Materials Durability9408563/1/1994
Exposure of automobile exterior materials such as coatings in the South Florida environment has become the de facto standard for testing their durability. In the early thirties, testing sites were established in this location by the automotive industry. Each automobile manufacturer applied different exposure techniques for their own acceptance criteria. SAE J1976 was developed in 1989 to standardize the various exposure types, however, the document still contains radically different test rack designs. Even though the Florida exposure tests have not changed extensively the coatings have become much more durable. Today's service life expectation of more than 5 years means that the coating cannot be tested to failure in the Florida environment and allow the developer to bring a new technology to the marketplace in a timely and competitive manner. This has led to the use of accelerated tests to speed up the exposure process. There are several alternative tests specified by SAE including xenon arc Weather-Ometer® (SAE J1960), Fresnel reflector device (SAE J1961) and fluorescent testing device (SAE J2020). The study reported here was carried out to draw conclusions regarding differences between the outdoor test racks designs and their relationship to the accelerated test methods, in order to identify the accelerated test providing the best correlation to Florida. Specimens were donated by three automotive coating manufacturers, representing a combination of coating types and colors in the form of coated test panels. Seventy specimens were exposed per test method. Performance evaluations including the measurement of color, were conducted several times during the exposure testing. Comparative color change data is reported for all of the test methods and statistical comparisons are made between each. the results showed that the best correlation was achieved when the light source most closely matched sunlight. All of the outdoor tests correlated well with each other.
Verma, Monica, Crewdson, Lesley F. E.
Polyurethane Structural Foam for Automotive Spoiler Applications9404373/1/1994
Recent developments have shown that polyurethane structural foam materials work well in exterior trim applications. In the past, these materials had been considered mainly for interior applications. However, new designs in spoilers have shown that they are also an excellent choice for exterior trim components as well. In reviewing these spoiler programs, physical properties, processing, and design advantages will be discussed. By using the polyurethane structural foam process, spoilers can be molded which are single components, are light-weight, and have good physical properties. These materials also require less postfinishing and can be painted with conventional paints.
Symosko, Gene
Slow-Moving Vehicle Identification EmblemJ943_199306 (Historical)6/10/1993
This SAE Standard establishes emblem dimensional specifications, performance requirements, related test procedures, and mounting requirements. This unique identification emblem shall be used only on machines which are designed for and travel at rates of speed less than 40 km/h (25 mph). The identification emblem shall supplement but not replace warning devices such as tail lamp regulators or flashing lights and shall not be used to identify stationary objets or stopped vehicles and/or machines. The dimensions and color patterns of the emblem have been established as a unique identification and shall not be altered to permit advertising or other markings on the face of the emblem, except as permitted in 3.2. The purpose of this standard is to establish specifications which define a unique identification emblem to be used only for slow-moving vehicles when operated or traveling on highways.
Agricultural Tractor Standards Committee (ATSC)
U.V. Stable, Chemical and Abrasion Resistant Organic Coating for Polymers9001822/1/1990
The successful implementation of polycarbonate for automotive headlamp applications, required the development of specialized coatings. These coatings are required to offer superior ultraviolet as well as scratch resistance. Initially, silicone-based products were the only products available. However, in the last several years, alternative technologies have been developed including organic baking enamels and U.V. - Curable products. This paper will discuss the available technologies as well as the advantages and disadvantages of each. Future trends in lighting and coating advancements will also be highlighted.
Bossmann, Mark J.
Manufacturing and Handling Techniques Used in the Assembly of Polished Commercial Aircraft8909254/1/1989
The use of polished aluminum fuselage skins has been a standard on U.S. commercial jet transport aircraft for decades. Increasingly stringent environmental regulations for paint stripping combined with fuel and maintenance savings allows consideration of flying polished non-painted aircraft. Boeing, McDonnell Douglas and Embraer currently manufacture commercial aircraft with polished alclad aluminum fuselages. Commercial airlines such as American Airlines, USAir, Eastern, Northwest and ASA fly non-painted fleets. These customers require the aircraft to be delivered with a polished appearance incorporating minimum fleet graphics. The manufacturing of polished aircraft requires unique production and handling procedures to fabricate all exterior panels with identical color match and reflectivity. This paper compliments previous papers on the economic advantages of non-painted planes and transition procedures from painted to non-painted aircraft. (1)* The various procedures used to produce and protect the valuable skin material from the plant to delivery of the fully assembled aircraft will be fully explored. THE COMPLEXITY OF PRODUCING an entire fuselage with aesthetically pleasing and uniform appearance is enormous. Airframe fabrication ranges from severly stretch-formed to substantially chem-milled parts, requiring special mill fabrication. Tailor made practices for the exterior aluminum skins allow for consistent manufacturing results while maintaining an extremely constant finish for the fuselage. As an example, Northrop Corporation has produced the fuselage of the 747 since inception of the program. The improvements in handling and manufacturing of the aluminum skins have advanced through the years. Even the 747, with its massive fuselage resembles a mirror-like surface with color-matched and defect-free panels. The integrity of the aluminum can only be sustained by careful manufacturing techniques. Implementation of these standards often raise the entire consciousness of quality needs for other components of the aircraft. The attention given to equipment, parts handling, techniques and awareness has helped reduce reject and rework levels while raising the quality of all parts produced. The result to the fleet purchaser is an aircraft with unmatched quality. The overall economic savings by flying unpainted aircraft are ever increasing. The cost of jet fuel savings alone for a 747 is nearly $200,000/year with fuel at $.50/gallon (see Figure 1). Additional savings of faster maintenance schedules, elimination of strip/repaint cycles and ease of inspection also support the operation of a polished non-painted fleet. Specifically, painted surfaces tend to develop filiform corrosion. During Eastern Airlines conversion to unpainted aircraft, filiform corrosion was noticed on aircraft as new as three years old. Since conversion to unpainted aircraft, Eastern's rate of filiform corrosion has been reduced to near zero. (2) The recent air worthiness directive's (AD) by the FAA, requiring stripping and eddy current testing of rivets for early model 737's, points out clearly the potential for increased inspection of the world's rapidly aging fleet. The cost to strip the 100 737's involved in the inspection is nearly 60 million dollars. (3) The ability to eddy current test and inspect the affected areas is greatly facilatized by starting with a surface that does not require the initial stripping.
Skluzak, Dell F., Whicker, Jerry T.
New Developments in Materials and Fabrication Processes for Automotive Interior Trim Skin Materials8905882/1/1989
Automotive interiors consist of sandwich type components (e.g., instrument panel, door trim, headliner); hard trim (e.g., pillar trim) and functional solid components (e.g., load floor, seat backs, etc.) The intermaterials competition among new processes for fabricating these 3 types of components were described previously (1)*. This paper examines new developments specifically in the area of skin materials used for the sandwich type interior trim components.
O'Malley, Mitra, Eller, Robert
Fabrication of Interior Door Trim Using Ceramic Dies8803412/1/1988
To produce high quality appearance interior parts, precise pattern forming or gloss reduction of three-dimensional door trim cover materials are utilized. In the preparation of formed trim cover using polyvinyl chloride (PVC), prior pattern forming on original cover material or post-pattern forming with vacuum forming dies are employed. In the latter case, the die is usually made of epoxy resin. Although vacuum holes are prepared on the resin die as necessary, the lack of uniformity in air permeability causes inferior pattern transferability. In this development, special porous ceramic die is used as die material so that trim cover material can be evenly sucked through the fine pores on its surface. As a result, a door trim forming die of superior pattern transferability has realized. The features of this- die are as follows. 1) The addition of metal powder, metal fiber, and binder to the ceramic powder has achieved well balanced air permeability, compressive strength, and dimensional change rate. 2) The uniform, high air permeability can produce deep and precise grain and stitching pattern (patterns) transfer with a low surface gloss rate. A work area with a stable surface quality can also be secured. 3) A shorter lead time of manufacturing and lower die making cost have achieved.
Ikeda, Tsugio, Kimura, Hiroshi, Yamaguchi, Hiroshi, Nishikawa, Kazuyuki
Materials For Automotive Interior Door Trim Panels8803382/1/1988
This paper reviews the different materials used to manufacture interior door panels and trim. A brief synopsis of the advantages and disadvantages of each material and its fabrication process along with material selection criteria and future advances are presented.
Misra, Subodh C., Palasek, Roy A.
Comparative Corrosivity of the Automotive Environment8601082/1/1986
Field corrosion tests conducted in Boston, Dallas, Detroit, and Montreal during the winter of ′84-′85 are described. Results show that the Northeast, plagued by acidic precipitation and heavy road salt use, is very aggressive. Galvanizing was effective in greatly reducing corrosion of bare auto-body steel.
Turcotte, R., Baboian, R.
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