Browse Topic: Forming

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Balancing global and local formability properties through Nb microalloying2026-26-03031/16/2026
David Martin, CBMM Asia Bernardo Barile, CBMM Europe BV Caio Pisano, CBMM Europe BV Automotive high strength steels have specific microstructure-dependent forming characteristics. Global formability is generally associated with high uniform strain values which imply good drawability and stretch forming properties driven by pronounced work hardening. Local formability on the other hand is often measured by various fracture strain values—generally higher in single phase steels. In this respect, the so-called ‘local/global formability map’ concept has been established not only to provide a comprehensive methodology to characterize existing automotive steels but also to enable improvement strategies toward more balanced forming characteristics. Niobium (Nb) microalloying is a powerful tool to achieve both property improvement in general and property balance in particular. More than two decades of research has demonstrated that Nb-induced microstructural optimization is applicable to HSLA
Barile, Bernardo
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-02801/16/2026
This paper presents a comprehensive numerical method intended at developing a coupled process structure simulation that integrates both elastoplastic and anisotropic material behavior for short glass fiber-reinforced injection-molded thermoplastics. Three engineering tools, namely Moldflow, Digimat, and ABAQUS are used in the current numerical methodology to assess material anisotropy and its influence on thermo-mechanical characteristics. The simulation incorporates fiber orientation concerns as well as potential injection molding defects known as weld lines, linking with thermo-mechanical simulations. The behavior of real injection-molded components is computationally represented by the ability to transfer data from injection molding software (Moldflow) to structural software (ABAQUS). Besides, integrating with multi-scale modeling software Digimat as an interface tool, the results of the Moldflow simulations, such as fiber orientations and weld-line properties transmitted directly
T, KALINGA, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Development of a GUI-Based Pitch Sequence Optimization Tool for Tyre Noise Reduction2026-26-03301/16/2026
Minimizing tyre noise is essential for enhancing ride comfort, especially in electric vehicles where the absence of engine noise makes tyre-generated sound more prominent. This work presents the development of a GUI-based pitch sequence optimization tool to support tyre design engineers in generating acoustically optimized tread sequences. The tool operates in two modes: without constraints, where the pitch sequence is optimized freely to reduce tonal noise levels; and with constraints, where specific design rules are applied to preserve pattern consistency and manufacturability. This tool plays a pivotal role in the tire development process, serving as one of the key evaluation criteria for tread pattern approval before mould fabrication. By enabling engineers to generate balanced, low-noise pitch sequences that align with both acoustic targets and engineering constraints, the tool facilitates faster design iterations and smooth integration with downstream processes. Its successful
Sampathraghavan, Lakshmi, Ramarathnam, Krishna Kumar, Mantripragada PhD, Krishna Teja, Ramachandran, Neeraj
Evaluating the Suitability of ADC12 for Sand Casting: Filling, Solidification, and Mechanical Properties2026-26-02961/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Jichkar, Pawan
A numerical approach to optimize the flow characteristics for the enhancement of casting soundness of Al 6061 alloy die-casting2026-26-02841/16/2026
The optimization of flow characteristics such as filling time, flow velocity, viscosity and temperature play a vital role in the die-casting to enhance the casting soundness. Experimental trial and error methods for optimizing the flow characteristics of mold filling are costlier and time-consuming methods. A digital approach could significantly minimize the cost and time for the prediction of the flow characteristics of the casting. Z-Cast Pro is the casting simulation software used for simulating the whole casting process such as filling, solidification etc. This software basically utilizes the finite difference and finite volume approximation techniques to numerically unravel the molten metal flow and solidification equations. In this study, A 3D model of the valve housing is used to analyze the mold-filling behavior through high and low-speed plunger movement of the molten Al 6061 alloy using Z-Cast Pro software version 24. Higher-speed plunger movement required a total mold
Choudhary, Chandan, Subramaniam, Anand, Karle, Manish, Karle, Ujjwala
Incorporation of strain hardening and sheet thinning effects during forming process for an accurate prediction of buckling loads on sheet metal axle parts2026-26-03911/16/2026
In this competitive automotive world, shorter development time and quicker time to market for new models are vital to product success. This can be achieved by digitalization, thereby avoiding over-design of parts and the need for physical prototypes, resulting in cutting down on material and development efforts respectively. In this study, the deviation of load carrying capacity of chassis sheet metal axle links in comparison with hardware testing and simulation results were investigated. A multi-step forming simulation is carried out, which involves simulating all stages of the forming process to accurately predict the plastic strains leading to material strain hardening and thickness distribution leading to thinning. The forming simulation is performed using the anisotropic material model Banabic-Barlat-Comsa (BBC) to capture the anisotropy effects. This model uses several coefficients to precisely characterize the yield surfaces, considering both uniaxial and biaxial yield stresses
R B, Govind, Selvaraj, Nirmal Velgin
Tailgate Stiffness Mitigation and Engineering Strategy for Y-to-Y Tailgate-Mounted Tail Lamp Integration2026-26-04941/16/2026
The tailgate, as the rearmost vehicle opening, plays a pivotal role in defining the rear aesthetic theme while ensuring structural durability and maximizing luggage space. Contemporary automotive design trends highlight an increasing demand for Y-to-Y tailgate-mounted tail lamp configurations, which deliver a bold and dynamic visual appeal. Enhanced by animated lighting features, these designs cater to the preferences of Gen Z customers, becoming a decisive factor in purchasing decisions. However, integrating these complex tail lamp structures introduces significant engineering challenges, including increased X-dimension volume, reduced design space, and intricate mounting schemes constrained by stamping limitations. These factors necessitate the development of innovative joinery strategies and structural definitions to maintain durability targets, including achieving 25,000–30,000 slam cycles without failure, while preserving luggage space. This paper explores a comprehensive approach
Beryl, Joshua, Mohanty, Abhinab, Unadkat, Siddharth, Selvan, Veera
Tolerances Titanium and Titanium Alloy Extruded Bars, Rods, and Shapes AMS2245D (Current)12/9/2025
This specification covers established manufacturing tolerances applicable to titanium and titanium alloy extruded bars, rods, and shapes. These tolerances apply to all conditions, unless otherwise noted. The term "excl" applies only to the higher figure of the specified range.
AMS G Titanium and Refractory Metals Committee
Aluminum Alloy, Extruded Wide Panel Profiles (7150-T77511), 6.4Zn - 2.4Mg - 2.2Cu - 0.12Zr, Solution Heat Treated, Stress-Relieved, Straightened and OveragedAMS4325B (Current)11/21/2025
AMS4325A prohibits unauthorized exceptions (3.7), revises condition (3.2), properties (3.4.5), quality (3.5.1), reports (4.4.1), and identification (5.1.1), and results from a Five-Year Review and update of this specification.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extrusions, 1.0Mg - 0.60Si - 0.28Cu - 0.20Cr (6061-O), AnnealedAMS4160K (Current)11/13/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing.
AMS D Nonferrous Alloys Committee
Aluminum Alloy, Extrusions 4.5Cu - 0.85Si - 0.80Mn - 0.50Mg (2014-T6) Solution and Precipitation Heat TreatedAMS4153N (Current)11/13/2025
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, profiles, and tubing up to 32 square inches (206 cm2) in area (see 8.5).
AMS D Nonferrous Alloys Committee
Scalability, Production, and Application of Stretch Broken Carbon Fiber for Primary Aircraft StructureF-0081-2025-04135/20/2025
The work done in developing stretch broken carbon fiber technology is described. The objectives of the program include the scale up of the process to demonstrate production feasibility, as well as reducing the maximum filament stretch break length to ~50mm/2” or below, less than half of what was achieved on previous programs. The shorter break length is considered to be critical in order to achieve formability into complex geometries. The new stretch break line at Montana State University, BC3, has been commissioned to achieve the required material characteristics and throughput. To date, 6 tows have been successfully stretch broken simultaneously, representing a significant improvement compared with what was achieved on previous programs. Possible geometries and forming evaluation methods are described. Mechanical testing is to be conducted, including both equivalency testing of continuous vs stretch broken carbon fiber and a later minimal level allowables program. It is expected that
Ridgard, Christopher, Ryan, Cecily, Amendola, Roberta, Bajwa, Dilpreet, Cairns, Douglas
Multi-objective Optimization of Rotorcraft Blade Structure with Multi-disciplinary ConstraintsF-0081-2025-03385/20/2025
We extend the previously developed integrated VABS (iVABS) framework for rotor blade structural optimization with an enhanced cross-section template for practical manufacture considerations; these include the introduction of curved spar corners, a continuous wrap-around skin, trailing-edge tabs and a conformal non-structural mass. The added fidelity is exercised on a UH-60A-based outer mold line through three multi-objective optimization case studies, including a case where the cross-sections are optimized independent of each other, and two cases where all the cross-sections are optimized simultaneously with manufacture considerations. It was found that the latter cases produce straight spars that are relatively more practical to manufacture when compared to the first case, while achieving significant reduction of up to 80% in the mismatch of stiffness values, inertia properties, and shear center locations, when compared to the prior work. A subsequent sensitivity analysis of the
Song, Jiwoo, Zhang, Jianhua, Smith, Edward, Haehnel, Robert, Huang, Daning
Evaluation of SBCF and CCF Forming in Complex Shapes via a Unified Defect Scoring IndexF-0081-2025-04085/20/2025
Stretch broken carbon fiber (SBCF) offers enhanced formability as compared to continuous carbon fiber (CCF). However, robust, quantitative evaluation of forming defects remains a challenge. This study introduces a unified formability index (UFI) that integrates multiple defect types, including texture anomalies, bridging, wrinkling, thickness variation, spring-back, and resin distribution variation (RDV), into a single weighted score. Each defect is ranked on a scale of 0-5 using normalized metrics with a tunable parameter, α, allowing users to balance defect magnitude and frequency as desired. The full scoring pipeline is demonstrated for texture defects using measured data, while normalized legacy scores from previous work are used for non-texture defects to enable complete formability index computation. Case studies on three laminates illustrate how variations in α affect both texture scoring and the overall formability index and demonstrate the geometry-agnostic nature of the
Williams, Cooper, Ryan, Cecily, Cairns, Douglas, Ridgard, Christopher, Nelson, Jared
A review of warm forming for steels: History, Methodology and Emerging trends2025-01-88144/1/2025
Many manufacturing techniques and process modifications have been implemented over the years to improve the formability of sheet metals. Warm forming of sheet metals is one such established method. However, it is more commonly and successfully applied to aluminum grades. The reevaluation of less-used metal forming technologies, such as warm forming and sheet hydroforming for steel, is a response to the challenges posed by competitive processes like large castings and the geometry requirements of new BEV parts. By understanding the effects of elevated temperatures (below recrystallization temperatures) on different steel grades and the impact of various heating methodologies, the industry can adapt and optimize these proven techniques for modern applications. This paper is a comprehensive summary of the effect of elevated temperatures on various grades of steel. Different heating techniques, their cycle times and effects on final forming feasibility is contrasted. The effect of
Kella, Caroline, Wormald, Tom, Gatts, Joshua
Maximizing the Potential of TPU Extrusion in Medical Tubing ApplicationsTBMG-5216412/1/2024
Whether for vascular catheters or implantable devices, medical tubing must meet tough standards for flexibility, strength, and biocompatibility. That’s why more manufacturers are turning to thermoplastic polyurethanes (TPUs) that strike the ideal balance between these key properties, making them an excellent choice for high-performance medical tubing. Unlocking the best that TPUs have to offer means optimizing the extrusion process. This article looks at why TPUs are a top pick, the common obstacles in extrusion, and the ways manufacturers can fine-tune their process to get the most out of different grades.
Manufacturing of Thermoplastic Composite Parts with Press Forming TechnologyF-0080-2024-13625/7/2024
Thermoplastic composites are serious competitor for classic epoxy composites. They have comparable properties to epoxy composites, but characterize much lower processing costs. There are several methods of manufacturing the components from thermoplastic composites. One of the most interesting method in terms of efficiency is thermoforming on a press. This technology allows to product of the aircraft parts such as: ribs, brackets, covers, stiffeners. Thermoplastic composites are resistant to most solvents such as grease, oil and aviation fuel. They are also non-flammable and heat-resistant. This all makes them suitable for use in aircraft as upholstery, casing or elements around the tank. PZL Mielec has been developing press thermoforming technologies since 2016 and is the owner of the several patents in this area.
Głodzik, Marcin, Wojtuszewski, Radosław, Farbaniec, Konrad, Sienicki, Jarosław, Banaś, Aleksander, Gałaczyński, Tomasz
Schey’s Tribology in Metalworking: Friction, Lubrication, and WearB-ASM-0572/28/2024
Schey’s Tribology in Metalworking—Friction, Lubrication, and Wear is an update to the seminal text Tribology in Metalworking by John Schey, originally published by ASM International in 1983. The 1983 first edition served as a recognized essential resource for researchers in the fields of manufacturing tribology and metal forming for many decades. This 2023 update preserves the essential information in that first edition but provides a thorough update, including a description of the significant advances in tribological research and detailed information for every metal forming process.
Improving the Sound Transmission Loss of Wire Harness Pass Throughs2025-01-01185/5/2023
Abstract Improving the Sound Transmission Loss of Wire Harness Pass Throughs For years the NVH community has known that openings in the dash sheet metal, such as holes to pass wire harnesses through, create an acoustical weak point that limits the potential noise reduction of the dash insulation system. These pass throughs can also be a source of water leaks into the vehicle’s interior. With the combustible engine and now electric inverter power plants, the need to seal this area is vital. By molding a lightweight barrier that draws through the fiber/absorber interior decoupler and dash sheet metal which mates to a secondary seal molded into an outer engine dash decoupler, the two opposing molded barriers meet in the engine compartment and compress together forming a seal around the wire harness. This male/female molded seal replaces the conventional snap in grommet and eliminates noise/water leaks. The system Sound Transmission Loss (STL) is equivalent to similarly insulated sheet
Check, James, Moritz, Charles
New system for the measurement of sound-insertion loss on small samples: a comparison with ASTM-E2611 and ASTM E90 test procedures2025-01-01165/5/2023
This article follows a companion article presented at the SAE NVC 2021, in which a new system for the measurement on small samples of the normal-incidence Insertion Loss (IL) of multilayers used for the manufacturing of automotive sound package parts was first introduced. In addition to simplifying the evaluation of the sound-insulation of multi-layers used to produce sound-package components, the system aims to overcome the limitations of the test procedure based on the ASTM E2611 standard. In this article, the latter point is demonstrated by comparing the insertion loss results obtained with the new system with those obtained with the test procedure based on the ASTM E2611 standard on a few multilayers commonly used for the manufacturing of automotive sound package parts. Results indicate that the results obtained by means of the newly developed system are more meaningful, practically usable and less prone to edge-effects, compared to those obtained according to the ASTM E2611 test
Ruggeri, Giulio, Bertolini, Claudio
Suction Cup Quality Predication by Digital Image Correlation2023-01-00674/11/2023
Vacuum suction cups are used as transforming handles in stamping lines, which are essential in developing automation and mechanization. However, the vacuum suction cup will crack due to fatigue or long-term operation or installation angle, which directly affects production productivity and safety. The better design will help increase the cups' service life. If the location of stress concentration can be predicted, this can prevent the occurrence of cracks in advance and effectively increase the service life. However, the traditional strain measurement technology cannot meet the requirements of tracking large-field stains and precise point tracking simultaneously in the same area, especially for stacking or narrow parts of the suction cups. The application must allow multiple measurements of hidden component strain information in different fields of view, which would add cost. In this study, a unique multi-camera three-dimensional digital image correlation (3D-DIC) system was designed
Guo, Bicheng, Zheng, Xiaowan, Fang, Siyuan, Yang, Lianxiang
PREDICTION OF OPTIMIZED DESIGN UNDER DYNAMIC LOADS USING ML2022-01-09493/29/2022
The stamped components play important roles in supporting many sub-systems within engine and transmission assembly. In few cases, the stamped components will not meet the design criteria whereas, due to overdesign in few other components, there will be opportunities to reduce the mass. Hence in CAE simulations, it would require to perform multiple iterations to enhance the component design by varying multiple design parameters (such as thickness, bend radius, material, etc.,) as per allowable limit. The conventional process of design enhancements will follow unidirectional parametric changes, though it helps in meeting the design criteria, it would be very difficult to produce the best optimized design within the limited time span. With the aid of Altair-HyperMorph technics, multiple design parameters can be controlled simultaneously, and DOE analyses are performed using Altair-HyperStudy to extract simulated results corresponding to the pre-defined design parameters. These DOE results
S, Siddesh, Nayak, Swarnendu Bikash, Freiman, David
Enhanced Forming Limit for Aluminum Sheet Forming2022-01-02803/29/2022
The enhanced forming limit phenomenon has been studied for steel blanks passing through draw beads. This phenomenon has also been observed in aluminum sheet forming when it passed through a die radius. In this study, the enhanced forming limit of aluminum sheets has been investigated. A set of tools were created to simulate the sheets bending and unbending around the die radii. Two sheet thicknesses of 5182 aluminum strips were pulled through three different die radius. Then, samples were cut from the strips and pulled to failure to test the material under plane strain tension condition. Material thinning was measured and compared to the data of samples of as received materials. The forming strains were also measured with digital image correlation (DIC) for verification. Results showed that the material thinning limit increased after it passed through the die radii. Enhanced forming limit was evaluated and a bending correction factor (BCF) was calculated. The BCF can be used to improve
Chen, Xiaoming (Ming)
An Integrated Approach for Simulation of the RTM Process2022-01-03873/29/2022
In the preform preparation stage of the RTM process, the fabric is draped on the mold along the geometry. Before the filling and warpage analysis, the draping analysis will be performed to get the fabric orientation. Due to the anisotropy of the fabric material, the main direction of the material has a significant influence on the overall flow behavior and warpage of the product. In this study, the advanced simulation approach for the RTM process is demonstrated. The filling and warpage analysis integrate with the draping simulation result from AniForm. The influences of fabric shearing and fiber orientation on the resin flow and warpage in RTM process is studied. With more accurate fabric orientation prediction methods, the accuracy of predicting fabric ply orientation is improved and more accurate infusion and product warpage simulation results can be obtained.
Bora, Anand
INBUILT SANITIZING SPRAYER AT DOOR HANDLE2022-01-04033/29/2022
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
Ultimate Breakage Load Calculation Method of Cold Gas Inflator Burst Disk2022-01-09383/29/2022
For cold gas Inflator, high refinement of ultimate load forecast is one key of Inflator development. At beginning, two methods based on implicit algorithm, Zero Curvature method and RIKS method were used for burst disk hydro-burst test ultimate pressure load calculation. After considering the effect of bursting disk stamping process, comparing with results of real test, the refinement of the two methods were above 97% both. Studying the corresponding relations between displacement and stress matrix of the center point of burst disk by RISK method. It was found that under ultimate load, the third principal stress vs. displacement curve of the central node shown extreme point, and load step of the point was corresponding the one of maximum pressure load. This shown that after reaching the ultimate load, the center of the bursting disc lost stability in the direction of thickness. Based on the status of stress matrix analysis results of RIKS method, and for solving the nonlinear contact
Shan, Jinhui, Wang, Cheng
Local Thermomechanical Processing for Improving Formability of High Strength Aluminum Sheets2022-01-02783/29/2022
Limited room temperature formability hinders the wide-spread use of high strength aluminum alloys in structural body-in-white parts. Stamping or extrusion at warm temperatures or from softer tempers are the current solutions. In this work, our approach is to start with age- and work-hardened sheets from 7xxx, 6xxx, and 5xxx family of alloys and improve their formability using local thermomechanical processing only in the regions demanding highest ductility in the forming processes. The processes used were friction stir processing (FSP) and roller bending-unbending. In both the methods sheets were locally deformed and heated simultaneously without any change in the final sheet geometry or chemistry. Initial results indicated significant deformation in the processed zones with minimal sheet distortion. FSP also resulted in dynamically recrystallized, fine grained (d <5 µm) microstructures in the processed regions with textures significantly different from the base material. This resulted
Nasim, Wahaz, Das, Hrishikesh, Kulkarni, Shank, Rohatgi, Aashish, HERLING, DARRELL, Grant, Glenn, Upadhyay, Piyush, Efe, Mert
Ultra High Pressure sensor with MEMS sensor element mounted on the measurement membrane manufactured by MIM2022-01-02823/29/2022
This paper presents a ultra high pressure sensor composed the measurement membrane manufactured by MIM(Metal Powder Injection Molding). The membrane should be sufficiently deformed within the measuring pressure range and not be broken at the burst pressure. Therefore, in general, the high pressure sensor membrane made of metal using machining methods such as milling and drilling [1]. However, it requires additional process to assembly with other parts and is difficult to make complex structure such as screw. Thus, in this paper, we propose the product and design of the measurement membrane using the MIM method. We have developed the ultra-high pressure sensor capable of measuring to 900 bar.gauge. Figure 1 shows the ultra-high pressure and measurement part. The measurement membrane thickness is 900 ㎛ and diameter is 3.2 mm. The MEMS sensor element mounted on the measuring membrane surface outputs an electrical signal according to the pressure. The electrical circuit with ASIC
Jeon, Myounggun
Impact of chemical blowing agent on polypropylene properties2021-28-020310/1/2021
Weight reduction and material saving goals in automotive applications have led to the processing of thermoplastic polymers by foam injection molding. The density of the foamed polymer can be reduced up to 20%. Whilst, work has been reported on the weight reduction of the foamed polymer by using different types of blowing agent technologies, there has been limited studies in the areas of the sound transmission loss and material dampening properties of these materials. The present study is intended to understand the effect of chemical blowing agent (CBA) on the properties of polypropylene. The molded specimens were characterized against the density, Tensile property, flexural property, Izod impact, heat deflection temperature, differential scanning colorimetry (DSC), thermogravimetric analysis (TGA), Fourier transform infra-red spectroscopy (FT-IR), sound transmission loss (STL) properties as per standard test protocol and cell structures by stereo microscope. Obtained results indicates
Shukla, Sandeep Kumar, Balaji, K V
MOLD IN COLOR PIANNO BLACK PC MATERIAL FOR AUTOMOTIVE EXTERIOR APPLICATION2021-26-02429/22/2021
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
A New Catalyst Technology to overcome Diffusion and Transport Limitations2021-26-02109/22/2021
The purification efficiency of exhaust gas catalysts depends on several factors. One of the most important factors is the diffusivity of the exhaust gases in the catalytic coating layer, especially at moderate to high temperature and space velocity conditions. Porous silica, γ-alumina, zirconia, carbons and many other porous crystalline materials that are commonly used as catalysts and catalyst supports are traversed by a labyrinth of tortuous micro and mesopores. If the connectivity is very low, the labyrinth of pores becomes more difficult to penetrate, increasing the overall “tortuosity” and slowing down the transportation of gas molecules within catalyst layers. A new approach to overcome these diffusion and transport limitations in an exhaust gas catalyst is to create an interconnected network of mesopores and macropores via increase in void fractions within the washcoat components and layers. In this study, various organic and inorganic pyrolyzable pore forming agents (PFAs) were
Gaur, Kanishka, Muthusamy, Vishnuvarthan, Mishra, Sushil, Kukreti, Sumit, Rajan, Bosco, Bartley, Gordon, Trigunayat, Alok
Multiphysics Simulation of Electric Motor NVH Performance with Eccentricity2021-01-10778/31/2021
With the emphasis of electrification in automotive industry, tremendous efforts are made to develop electric motors with high efficiency and power density, and reduce noise, vibration and harshness (NVH). A multiphysics simulation workflow is used to predict the eccentricity-induced noise for GM’s Bolt EV motor. Both static and dynamic eccentricities are investigated along with axial tilt. Analysis results show that these eccentricities play a critical role in the NVH behavior of the motor assembly. Transient electromagnetic (EM) analysis is performed first by extruding 2D stator and rotor sections to form 3D EM models. Sector model is duplicated to form full 360-degree model. Stator is split into three rotated sections to characterize stator skew, and the skew between two sections of rotor and magnets are also modelled. Sinusoidal current is applied and lumped-sum forces on each stator tooth are computed. Next, full 3D structural model is constructed, and EM forces are applied as
Zhang, Henry, Jaura, Ankur, Kumar, Dinesh, Sambharam, Tushar, Zhang, Zheming, He, Song, Zhang, Peng, GSJ, Gautam
Bar, Rod, and Shapes Produced from 30% Glass Fiber Filled Polyamide-Imide (PAI) MaterialAMS3670/4D (Current)5/19/2021
This specification covers molded or extruded bar, rod, and shapes produced from a polyamide-imide (PAI) polymer filled with 30% glass fiber. This is designated as Grade 4 material per AMS3670.
AMS P Polymeric Materials Committee
Molded or Extruded Bar, Rod, and Shapes Produced from 20% Graphite – 3% Polytetrafluoroethylene (PTFE) Filled Polyamide-Imide (PAI) MaterialAMS3670/2C (Current)5/19/2021
This specification covers molded or extruded bar, rod, and shapes produced from a polyamide-imide (PAI) polymer filled with 20% graphite and 3% polytetrafluoroethylene (PTFE). This is designated as Grade 2 material per AMS3670.
AMS P Polymeric Materials Committee
Bars, Rods, and Shapes Produced from Unfilled Polyamide-Imide (PAI) MaterialAMS3670/1C (Current)5/19/2021
This specification covers an unfilled polyamide-imide plastic in the form of molded or extruded bar, rod, and shapes. This is designated as Grade 2 material per AMS3670.
AMS P Polymeric Materials Committee
Bars, Rods, and Shapes Produced from 30% Carbon Fiber Filled Polyamide-Imide (PAI) MaterialAMS3670/5D (Current)5/19/2021
This specification covers molded or extruded bar, rod, and shapes produced from a polyamide-imide polymer filled with 30% carbon fiber. This is designated as Grade 5 material per AMS3670.
AMS P Polymeric Materials Committee
Bar, Rod, and Shapes Produced from 12% Graphite - 3% Polytetrafluoroethylene (PTFE) Filled Polyamide-Imide (PAI) MaterialAMS3670/3C (Current)5/19/2021
This specification covers molded or extruded bar, rod, and shapes produced from a polyamide-imide (PAI) polymer filled with 12% graphite and 3% polytetrafluoroethylene (PTFE). This is designated as Grade 3 material per AMS3670.
AMS P Polymeric Materials Committee
Painless Paper Patch Test for Glucose Levels Uses MicroneedlesTBMG-386413/1/2021
Patches seem to be all the rage these days. There are birth control patches, nicotine patches, and transdermal medicinal patches, just to name a few. Now, a team of researchers at the Institute of Industrial Science, The University of Tokyo, have developed a patch of needles connected to a paper sensor for diagnosing conditions such as prediabetes. Luckily, this patch doesn't multiply the pain and discomfort of a single hypodermic needle. In fact, these microneedles are painless and biodegradable.
4D Printing of Morphing StructuresTBMG-384942/1/2021
Soft robots and biomedical implants that reconfigure themselves upon demand are closer to reality with a new way to print shapeshifting materials. Researchers have developed a method to print objects that can be manipulated to take on alternate forms when exposed to changes in temperature, electric current, or stress.
Linking Materials May Transform Robots Made of RobotsTBMG-385012/1/2021
A method was developed that unifies the construction of varying types of mechanical metamaterials using a discrete lattice, or LEGO-like system, enabling the design of modular materials with properties tailored to their application. These building blocks and their resulting materials could lead to dynamic structures that can reconfigure on their own; for example, a swarm of robots could form a bridge to allow troops to cross a river. This capability would enhance military maneuverability and survivability of warfighters and equipment.
Wafer-Scale Membrane Release ProcessTBMG-384762/1/2021
Precise measurements utilizing sensitive instruments may require thermally managed detectors; therefore, thermal insulation of the detector is essential to its performance. To maintain critical signal-to-noise ratio, there is a need for larger thermal isolation structures. Due to high detector filling fraction limits, these isolation structures may be thinner, less mechanically robust, and more prone to breakage during fabrication.
02-Environmental Sound Impact in Civil Construction WorksSAE-PP-001791/29/2021
The first phase of these projects is the deployment, where several activities of civil construction are developed. The activities in general are developed in consolidated urban areas, treating very often modification of an urbane important installation. Thus, in this initial phase are executed activities of demolition, cleaning, preparing the land, foundation and piling, which are considered noisy for people, causing great discomfort to the existing community around the construction site.
Mutagaana, Festo
Painless Paper Patch Tests Glucose LevelsTBMG-383451/1/2021
Researchers have been trying to develop a practical way to use microneedles — tiny needles less than 1 mm in length — for routine at-home medical monitoring. Microneedles are so short that they stay within the skin and do not make contact with any neurons, meaning that they cause no pain. Rather than extracting blood, they draw up fluid in the skin that contains most of the important biomarkers that blood tests look for. Several types of microneedles exist but until now, making a practical device that quickly analyzes the fluid has proved elusive.
Vote for Medical Design Briefs Product of the Year 2020TBMG-3829012/1/2020
Each month, the editors of Medical Design Briefs choose a Product of the Month that has exceptional technical merit and practical value for MDB’s design engineering readers.
Providing of Sliding Bearings Reliability of Transmissions Gear Wheels of Transport Cars by Optimization of Assembly Tolerances2020-01-22399/15/2020
In the design of gearboxes and transfer boxes of heavy-duty vehicle`s transmissions, sliding bearings are often used as supports for gear wheels. Analysis of the results of statistical processing of gearbox parts failures and transfer boxes of wheeled tractors with a pulling force of 30 kN indicates the need to improve the reliability of the sliding bearings of the gear wheels. Such plain bearings ensure free rotation of the gear wheels in case of the torque transmission absence, and when locked by a clutch, the radial load of the gear wheel is sensed, while operating in the slipping rolling mode. Such units are poorly understood and in the technical literature sources there are no recommendations for their engineering, which often leads to errors when selecting operation gaps and press fitted in gear wheels. The manufacturers of the transmissions assemblies replaced the plain bearings, which in this case are made of metal-ceramic bushes, for roller bearings. Also, the application of
Savchuk, Volodymyr, Kuhtov, Valeriy, Gritsuk, Igor V., Podrigalo, Mikhail, Vychuzhanin, Vladimir, Parsadanov, Igor, Bulgakov, Nickolay, Belousov, Evgen, Vrublevskyi, Roman, Samarin, Oleksandr, Kurnosenko, Daria, Verbovskiy, Valeriy
4D Printing of Morphing StructuresTBMG-373948/1/2020
Soft robots and biomedical implants that reconfigure themselves upon demand are closer to reality with a new way to print shapeshifting materials. Researchers have developed a method to print objects that can be manipulated to take on alternate forms when exposed to changes in temperature, electric current, or stress.
Engineers Design a Reusable, Silicone Rubber Face MaskTBMG-373598/1/2020
Researchers at MIT and Brigham and Women’s Hospital have designed a new face mask that they believe could stop viral particles as effectively as N95 masks. Unlike N95 masks, the new masks were designed to be easily sterilized and used many times.
Correlational Analysis of Speech Intelligibility Tests and Metrics for Speech Transmission20AERP08_098/1/2020
Analysis of the common methods of evaluating the quality and limitations of speech could serve as a resource for users of standard speech intelligibility measurement methods. Army Research Laboratory, Aberdeen Proving Ground, Maryland Speech is a form of language (communication code) that uses vocally produced sounds to convey thoughts, meanings, and feelings. To communicate by speech, speech sounds must be both produced and perceived. Speech production refers to the process by which predetermined vocalized sounds are produced by the talker and organized in sequences forming communication signals. Speech perception is the process by which the listener is able to hear and interpret (understand) the message encoded in the speech signals. The effective design and use of audio communication systems requires some knowledge of the physical properties of speech and the rules that govern the human perception of speech. The two main physical descriptors of speech signal are its sound intensity
Material “Shape-Shifts” in Response to External ForcesTBMG-374788/1/2020
A self-adapting material was developed that can change its stiffness in response to the applied force. This advancement can someday open the door for materials that can self-reinforce to prepare for increased force or stop further damage; for example, a bone implant or a bridge that can self-reinforce where a high force is applied without inspection and maintenance.
The Benefits of Embedding Marker Bands vs. SwagingTBMG-371266/1/2020
In order to identify the location of a catheter tip under fluoroscopy, the use of marker bands is commonplace in medical applications. These bands are typically platinum iridium metals that are easily detectable on the technology used during the surgeries but can also be made of tantalum or gold for certain applications. The marker bands are put on the catheter, either through swaging or embedding, as a shiny indicator to the surgeon of directly where in the body the tip is located as the operation progresses.
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