Browse Topic: Stamping

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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
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
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
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
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
Bake Hardening Behavior of DP, TBF, and PHS Steels with Ultimate Tensile Strengths Exceeding 1 GPa2020-01-05364/14/2020
Third generation advanced high strength steels (AHSS) have been developed combining high strength and formability, allowing for lightweighting of vehicle structural components. These AHSS components are exposed to paint baking operations ranging in time and temperature to cure the applied paint. The paint baking treatment, combined with straining induced from part forming, may lead to increased in-service component performance due to a strengthening mechanism known as bake hardening. This study aims to quantify the bake hardening behavior of select AHSS grades. Materials investigated were press hardenable steels (PHS) 1500 and 2000; transformation induced plasticity (TRIP) aided bainitic ferrite (TBF) 1000 and 1200; and dual phase (DP) 1000. The number designations of these grades refer to minimum as-received ultimate tensile strengths in MPa. Paint baking was simulated using industrially relevant times and temperatures from 15 to 60 min and 120 to 200 °C, respectively. Samples were
Blesi, Brandon W., Smith, Charles, Matlock, David K., De Moor, Emmanuel
Metal Stamping: Converting Parts for Cost SavingsTBMG-3537210/1/2019
In today’s world of medical device manufacturing, cost pressures are very real. At the same time, cost savings can be just as real, especially when companies examine their manufacturing processes for greater efficiencies. One area that is gaining particular attention is metal stamping of previously machined, metal injection-molded, or laser-cut parts.
Installation Procedures - Pin/Plug Expansion TypeAIR3277 (Current)8/15/2019
E-25 General Standards for Aerospace and Propulsion Systems
Why Reel-to-Reel Molding Might Be Right for Medical ComponentsTBMG-344485/1/2019
Reel-to-reel insert molding can prove a more efficient process for design engineers when it comes to lowering assembly costs. The process is best suited for products that require dimensional stability and need to function in harsh environments, such as drug-delivery device parts and components.
A Non-Contact Overload Identification Method Based on Vehicle Dynamics2019-01-04904/2/2019
The vehicle overload seriously jeopardizes traffic safety and affects traffic efficiency. At present, the static weighing station and weigh-in-motion station are both relatively fixed, so the detection efficiency is not high and the traffic efficiency is affected; the on-board dynamic weighing equipment is difficult to be popularized because of the problem of being deliberately damaged or not accepted by the purchaser. This paper proposes an efficient, accurate, non-contact vehicle overload identification method which can keep the road unimpeded. The method can detect the vehicle overload by the relative distance (as the characteristic distance) between the dynamic vehicle's marking line and the road surface. First, the dynamics model of the vehicle suspension is set up. Then, the dynamic characteristic distance of the traffic vehicle is detected from the image acquired by the calibrated camera based on computer vision and image recognition technology. The data error caused by the
Zhou, Daolin, Tan, Gangfeng, Ding, Yiran, Yu, Shimin, Ma, Xiaofei, Wang, Shuai, Wang, Zhenyu
2018 Create the Future Design Contest: Automotive/Transportation Category WinnerTBMG-3331911/1/2018
Using Touchscreens in a Rotorcraft EnvironmentF-0074-2018-127425/14/2018
ABSTRACT This paper describes the flight test of a mounted touchscreen device in a UH-60 helicopter. The device assists crew chiefs in their fuel management tasks and provides situational awareness information regarding the route/flight plan, map data, external camera displays, publications and aircraft system information. The touchscreen tested was a 10.5" display and used Projected Capacitive for touch input. It was surrounded by 28 bezel switches. Eight current crew chiefs performed tasks using the device in flight. The participants wore gloves. Flight test evaluation results show that the subjects used and preferred the bezel switches over soft buttons on the touchscreens. Results also show that 16% percent of touchscreen presses required multiple presses to register the touch. Vibration did not appear to cause a problem with using the touchscreen. Gloves did present a problem in using the Projected Capacitive touchscreen.
Schutte, Paul
Replacing Press Hardenable Steel with 980 MPa Generation 3 Steel for Automotive Pillars2018-01-01174/3/2018
Press hardenable ultra high strength steel (UHSS) is commonly used for automotive components to meet crash requirements with minimal mass addition to the vehicle. Press hardenable steel (PHS) is capable of forming complex geometries with deep sections since the forming takes place at elevated temperatures up to 900 degrees Celsius (in the Austenitic phase). This forming process is known as hot-stamping. The most commonly used PHS grade is often referred to as PHS1500. After hot-stamping, it is typically required to have a yield strength greater than 950 MPa and a tensile strength greater than 1300 MPa. Most automotive design and material engineers are familiar with PHS, the hot-stamping process, and their capabilities. What is less known is the capability of 3rd Generation advanced high strength steels (AHSS) which are cold stamped, also capable of forming complex geometry, and are now in the process of, or have recently completed, qualification at most automotive manufacturers. This
McKune, Paul, Khutorsky, Alex, Butala, Kapil
Finite Element Analysis and Test Correlation for Pressing and Staking of Planetary Gear Pinion Shaft2018-01-04814/3/2018
During the assembly process of planetary gears, the pinion shaft is initially pressed in to the planetary carrier and then staking is performed to fix the pinion shaft to the carrier. The main purpose of the staking process is to prevent the movement of the pinion shaft during transmission operation. During assembly there should be minimal distortion of the assembly. The press-in process, pinion shaft and carrier are subjected to extremely high frictional loading due to the interference fit. The staking process permanently deforms the pinion shaft top and bottom ends, forming a protrusion that holds the shaft in position. The pinion shaft needs to sustain operational loads exerted by helical planetary gears, which tend to push the carrier flange out of position during operation. Staking length, staking force and interference between shaft and carrier hole are the critical parameters, which determine the maximum axial force that the pinion shaft can withstand. Finite element (FE
S, Sujeendran, Palani, Selvakumar, Li, Da Wei, Srinivasan, Balajikumar, Lai, Jerry, Ziada, Youssef
Effects of AHSS Sheared Edge Conditions on Crash Energy Absorption in Component Bend Test2018-01-01134/3/2018
Edge fracture of advanced high strength steels (AHSS) can occur in both the stamping process and the crash event. Fracture due to poor sheared edge conditions in the stamping process was reduced with a recently developed optimal shearing process for AHSS. Currently, the improvement in the energy absorption due to the improved edge condition during crashes performed under different loading conditions had not been closely verified. The purpose of this study is to design and build a miniature component of AHSS and a three-point bending test for investigating the influence of various conditions of the sheared edge on the energy absorption in crashes. AHSS including DP600, TRIP780, DP980 and DP1180 were selected in the study. A small channel component was developed and fabricated using DP980 to simulate key features of the B-pillar. The exposed non-constrained, as-sheared edge was subject to stretch bending forces in three-dimensional space during the three-point bending test. Two bottom
Shih, Hua-Chu, Chen, Guofei
Effect of E-Modulus Variation on Springbackand a Practical Solution2018-01-06304/3/2018
Springback affects the dimensional accuracy and final shape of stamped parts. Accurate prediction of springback is necessary to design dies that produce the desired part geometry and tolerances. Springback occurs after stamping and ejection of the part because the state of the stresses and strains in the deformed material has changed. To accurately predict springback through finite element analysis, the material model should be well defined for accurate simulation and prediction of stresses and strains after unloading. Despite the development of several advanced material models that comprehensively describe the Bauschinger effect, transient behavior, permanent softening of the blank material, and unloading elastic modulus degradation, the prediction of springback is still not satisfactory for production parts. Dies are often recut several times, after the first tryouts, to compensate for springback and achieve the required part geometry. In this study, the effect of Young’s modulus (E
Fallahiarezoodar, Ali, Goertemiller, Cliff, Katre, Aanandita, Altan, Taylan
Spring Assistance (Energy-Swing) in an Electro Mechanical Brake2017-01-25179/17/2017
On Electro-Mechanical Brakes (EMB) spring-support can be necessary for releasing the brake without electrical energy. Advantageous brake-configurations can make use of the spring over the whole actuation range during engage and release. Such optimized spring support is known as “energy-swing. Under loss-less conditions the spring force could be in permanent equilibrium with the force required to press the pad, i.e. the brake could be controlled without actuation energy. In reality this will not be fully achievable as actuation losses and different operational conditions need to be covered. Still, significant advantages can be gained. The EMB of Vienna Engineering (VE) fulfills a key condition for energy-swing as it facilitates using the spring for engage- and release-support. Car brakes must release automatically when power is off. Consequently, spring-induced engage-support must always be smaller than release-forces and release-support must ensure overcoming mechanical resistance. The
Putz, Michael Herbert, Zipper, Thomas
An Optimization Model for Reallocating Stamped Parts2017-01-02443/28/2017
We describe an optimization model developed by Ford Motor Company to reallocate stamped parts between facilities when business conditions change. How can the business meet new targets when demand starts to exceed existing capacity? Likewise, how can it respond when demand is lower than expected? Sometimes the business can reduce costs by transferring production to a different location or by outsourcing parts. We describe in this paper how mathematical optimization can identify solutions that balance both logistical and outsourcing costs. We explain the algorithm and demonstrate with a small example how it recommends sourcing plans that minimize cost.
Lyon, Joshua, Park, Junheung, Fradkin, Yakov, Tornabene, Jeff
Extensional Rheology: New Dimension of Characterizing Automotive Fluids2017-01-03643/28/2017
This paper describes the basic principles of extensional rheometry, and the successful application to a variety of automotive fluids, including gear lubricants, paints, and forming lubricants. These fluids are used under very complex flow fields containing strong extensional (elongational) components. While exact derivation of extensional viscosities involves sophisticated theories, the measurement of liquid filament break-up time can provide fruitful information. Gear lubes showed different break-up time according to the kinematic viscosities. Addition of viscosity modifier (acrylic copolymer) significantly increased the breakup time, whereas surfactants had little effect. Clearcoat paint sample increased the breakup time, perhaps due to the deterioration. The waxy stamping lubricant showed remarkable change in the extensional properties as the temperature is raised. The extensional data obtained showed the promise of the technique to understand the performance of these fluids in
Ohtani, Hiroko, Ellwood, Kevin, Pereira, Gustavo, Chinen, Thiago, Selvasekar, Siddharthan
Modeling and Simulation of Compression Molding Process for Sheet Molding Compound (SMC) of Chopped Carbon Fiber Composites2017-01-02283/28/2017
Compression molded SMC composed of chopped carbon fiber and resin polymer which balances the mechanical performance and manufacturing cost presents a promising solution for vehicle lightweight strategy. However, the performance of the SMC molded parts highly depends on the compression molding process and local microstructure, which greatly increases the cost for the part level performance testing and elongates the design cycle. ICME (Integrated Computational Material Engineering) approaches are thus necessary tools to reduce the number of experiments required during part design and speed up the deployment of the SMC materials. As the fundamental stage of the ICME workflow, commercial software packages for SMC compression molding exist yet remain not fully validated especially for chopped fiber systems. In the present study, SMC plaques are prepared through compression molding process. The corresponding simulation models are built in Autodesk Moldflow with the same part geometry and
Li, Yang, Xu, Hongyi, Dahl, Jeffrey, Zeng, Danielle, Su, Xuming, Mirdamadi, Mansour, Chen, Zhangxing
Brake Insulator Damping Measurement ProcedureJ3001_201604 (Current)4/20/2016
This procedure is applicable to modes from 500 and 13,000 Hz. The parameters measured with this procedure are defined as the damping factor, ξ for first nine vibration modes of the beam. The measurement will be done in free-free conditions and with temperature.
Brake NVH Standards Committee
An Investigation of Deformation Effects on Phase Transformation in Hot Stamping Processes2016-01-03614/5/2016
To reduce the fuel consumption as well as to improve the crash safety of vehicles, the usage of hot stamping parts is increasing dramatically in recent years. Aisin Takaoka has produced hot stamping parts since 2001 and has developed various technologies related to Hot Stamping. In an actual hot stamping process, parts with insufficient strength could be produced sometimes at a prototyping phase, even under the proper forming conditions. In order to understand these phenomena, in this paper, phase transformation in a boron steel 22MnB5 under various cooling rates were investigated and the effects of pre-strain conditions on the phase transformations were characterised. Uniaxial tensile specimens were stretched under isothermal conditions to different strain levels of 0-0.3, at strain rates of 0.1-5.0/s and deformation temperatures of 650-800°C. A dilatometer was used to measure the dimensional changes of the specimen to rationalize the phase transformation of the boron steel during
Matsumoto, Takeki, Li, Nan, Shi, Xin, Lin, Jianguo
Surface Generation speeds composites throughput with one-shot stamp-forming process16MEIP03_213/1/2016
Surface Generation is working with research group WMG, an academic department of the University of Warwick, and AGC AeroComposites to develop new composite press-forming processes for automotive and aerospace manufacturers. Surface Generation, a U.K.-based provider of advanced carbon-fiber processing technologies, is developing new press-forming mold faces that incorporate its patented PtFS (Production to Functional Specifications) technology for the production of high-performance thermoplastic composite components. By integrating Surface Generation's active thermal management technologies into the mold face itself, WMG and AGC are able to continuously adapt heating and cooling levels for each mold area and process stage in real time. The companies believe that this enhanced capability will improve both the quality and throughput of compression molding applications.
Gehm, Ryan
Automation System Retrofit Transforms 175-Ton Hydraulic Forming PressTBMG-239472/1/2016
Southern Manufacturing Group (SMG) of Morrison, TN, makes automotive components and industrial valves. In 2012, the automation system for its 175-ton hydraulic forming press received electrical damage resulting from a lightning strike (Figure 1). Purchasing a new hydraulic forming press would be prohibitively expensive — in the range of hundreds of thousands of dollars. Therefore, SMG needed a company that could repair the forming press in a short timeframe to maintain its production schedule.
Surface Generation speeds composites throughput with one-shot stamp-forming process16AUTP02_072/1/2016
Surface Generation is working with research group WMG, an academic department of the University of Warwick, and AGC AeroComposites to develop new composite press-forming processes for automotive and aerospace manufacturers. Surface Generation, a U.K.-based provider of advanced carbon-fiber processing technologies, is developing new press-forming mold faces that incorporate its patented PtFS (Production to Functional Specifications) technology for the production of high-performance thermoplastic composite components. By integrating Surface Generation's active thermal management technologies into the mold face itself, WMG and AGC are able to continuously adapt heating and cooling levels for each mold area and process stage in real time. The companies believe that this enhanced capability will improve both the quality and throughput of compression molding applications.
Gehm, Ryan
Surface Generation speeds composites throughput with one-shot stamp-forming process16OFHP02_062/1/2016
Surface Generation is working with research group WMG, an academic department of the University of Warwick, and AGC AeroComposites to develop new composite press-forming processes for automotive and aerospace manufacturers. Surface Generation, a U.K.-based provider of advanced carbon-fiber processing technologies, is developing new press-forming mold faces that incorporate its patented PtFS (Production to Functional Specifications) technology for the production of high-performance thermoplastic composite components. By integrating Surface Generation's active thermal management technologies into the mold face itself, WMG and AGC are able to continuously adapt heating and cooling levels for each mold area and process stage in real time. The companies believe that this enhanced capability will improve both the quality and throughput of compression molding applications.
Gehm, Ryan
AS2512 Stamping for Arm (Filler Cap)AS2512-3 (Current)12/4/2015
No scope available.
Engine and Airframe Technical Standards Committee (TSC)
Methods for Determining Plastic Deformation in Sheet Metal StampingsJ863_201504 (Current)4/28/2015
This SAE Recommended Practice describes methods for determining plastic deformation encountered in the forming or drawing of sheet steel.
Metals Technical Committee
Design For Six Sigma (DFSS) for Optimization of Stamping Simulation Parameters to Improve Springback Prediction2015-01-05824/14/2015
Springback prediction for stamped components is a challenging task for Automotive Industry. Automotive Manufacturers are working to reduce the springback effect of sheet metal stampings caused due to elastic behavior of materials with the help of changes to manufacturing process and part geometry. Recent development in Finite Element Analysis (FEA) studies made it possible for the industry to rely on stamping simulation. There is always a gap between the springback predicted from stamping simulation and the actual stamped part. Currently FEA techniques are trying to close this gap. The objective of this study is to minimize this gap using DFSS method for predicting the springback and optimizing the simulation parameters with the help of LS-Dyna FEM tool. The behavior of material with different simulation parameters has been studied in this paper and the ones that best correlate with actual data are identified. The amount of springback is virtually measured for the stamped part with and
Bhuyan, Deepak Ranjan, Netapalli, Sreekanth, Dev, Sathya, Srinivasan, Soundarya
Innovative Door Design for Commercial Vehicles2014-01-24119/30/2014
Design of body structures for commercial vehicles differs significantly from automotive due to government, design and usage requirements. Specifically, heavy truck doors are not required to meet side impact requirements due to their height off the ground as compared to automobiles. However, heavy truck doors are subjected to higher loads, longer life, and cannot experience permanent deformation from overload events. Aluminum has been used intensively in commercial vehicle doors and cab structures for over 50 years by several different manufacturers in North America. It has been only in the last few years that aluminum has appeared in automotive door structures other than in high-end luxury vehicles. Commercial vehicle customers are expecting the same features found in premium automobiles resulting in opportunities to learn from each other's designs. In order to optimize the strength and weight of a commercial vehicle door, a new aluminum intensive structure was developed. The new
Auger, Marc, Plourde, Larry, Trumbore, Melissa, Manuel, Terry
The Influence of Vacuum Booster Design Parameters on Brake Pedal Feel2014-01-24999/28/2014
Brake pedal feel characteristic is determined by the structural and kinetic parameters of the components of the brake system. As the servo power component of the brake system, vacuum booster has a significant influence on the brake pedal feel. In this paper, a brake system model for brake pedal feel which has a detail vacuum booster mathematical description is established in the software MATLAB/Simulink. The structure gaps, spring preload, friction force and reaction disc characteristics of vacuum booster are considered in this model. A brake pedal feel bench test under different input velocity and vacuum pressure is completed in order to validate the prediction of the model. Finally, based on the assessment index in pedal travel, pedal force and master cylinder pressure three-quadrant diagram, the influence of vacuum booster design parameters such as structure gaps, spring preloads, press plate and press ring areas, diaphragm effective area and reaction disc stiffness on the brake
Zhang, Lijun, Ruan, Cheng, Meng, Dejian
Redundant Sensors Improve Precision and ReliabilityTBMG-201908/1/2014
Some machine processes, such as presses, can require extreme accuracy in applying and holding force on an object. A popular way to measure force is via load cells. But what do you do when the accuracy required by a particular application is higher than that guaranteed by the load cell manufacturer?
Development of Thermoplastic Composite Cones for Helicopter Tail Boom ApplicationF-0070-2014-95605/20/2014
Thermoplastic composites offer many attractive characteristics such as no shelf life, high fracture toughness, high temperature resistance, recyclability etc. The short coming of thermoplastic composites is their high viscosity, even at processing temperature. Due to the high viscosity, techniques for the manufacturing of thermoplastic composite have been limited to molding processes such as compression molding, high temperature stamping, where high temperature, high pressure and long duration are used. The advent of automated fiber placement machine brings forward possibilities to manufacture of large thermoplastic composite components. This is due to the fact that heating and compaction is done on the go directly on the surface of the substrate, and the flexibility of the feeding head to conform to the shape of the mold. It is in the spirit of exploration for new manufacturing possibilities that Bell Helicopter has supported an inter industry- university project for the development
Hoa, Suong, Shadmehri, Farjad, Cai, Xiao, Simpson, Jeff, Hojjati, Mehdi, Hubert, Pascal, Quinlan, Erin, Beaulieu, Pierre, Dion, Michel
Experimental Evaluation of the Quench Rate of AA70752014-01-09844/1/2014
The aluminum alloy 7075-T6 has the potential to be used for structural automotive body components as an alternative to boron steel. Although this alloy shows poor formability at room temperature, it has been demonstrated that hot stamping is a feasible sheet metal process that can be used to overcome the forming issues. Hot stamping is an elevated temperature forming operation in which a hot blank is formed and quenched within a stamping die. Attaining a high quench rate is a critical step of the hot stamping process and corresponds to maximum strength and corrosion resistance. This work looks at measuring the quench rate of AA7075-T6 by way of three different approaches: water, a water-cooled plate, and a bead die. The water-cooled plate and the bead die are laboratory-scale experimental setups designed to replicate the hot stamping/die quenching process. The results verify that water is the most superior form of quenching, i.e. above 1000°C/s, the bead die quench rate is impressive
Keci, Aledoni, Harrison, Nia R., Luckey, S. George
Designing and Building Dies for Higher Strength Steel Stampings2014-01-09864/1/2014
The application of advanced high-strength steels with ultimate tensile strengths of approximately 800 MPa is now well established within the automotive stamping industry. Current trends point to growth in higher strength applications with tensile strengths exceeding 1200 MPa. Due to their higher strength and greater springback after forming, producing high-strength steel stampings and their tools requires special attention. Effective processing methods are required that address problems specific to these materials, including: selection of an optimum stamping process and related equipment, solving formability problems, controlling springback, and selecting appropriate die steels and coatings for optimal tool life. As automakers strive to meet 2025 CAFÉ requirements of 54.5 miles per gallon, the demand for higher strength steel stampings will increase among lower tier automotive suppliers. These companies tend to be contract manufacturers and tool & die shops that are well established
Ulintz, Peter J.
Application of Structure Optimization Method to Dynamic Tuning2014-01-04114/1/2014
The understeer of vehicle is desired for the vehicle's handling performance, and the roll rate of rear suspension is one of the key characteristics to achieve the understeer performance. A proper roll rate of the rear suspension is required to assure a certain level of understeer. Generally, in the vehicle dynamic tuning process, several methods are available for improving understeer performance, e.g., changing the hard-points of suspensions, adjusting stiffness of bushings, etc. On the other hand, structure optimization of components can be used in some case to improve the performance. In this paper, the optimization method is applied to the twist beam of rear suspension. The change in local geometry by optimized design leads to appropriate adjustment of the roll rate. Finally the vehicle understeer performance reaches design target.
Qu, Yuan, Hongbin, Wang, Zhang, Dechao, Zhang, Linbo, Wu, Shen
On Modeling the Hot Stamping of High Strength Aluminum Sheet2014-01-09834/1/2014
This paper documents the finite element (FE) analysis of a hot stamping process for high strength aluminum sheet. In this process a 7075 blank, heated above its solvus temperature, was simultaneously die quenched and stamped in a room temperature die to form a B-pillar outer reinforcement. Two modeling approaches have been investigated: an isothermal mechanical model and a non-isothermal coupled thermo-mechanical model. The accuracy of each approach was assessed by comparing the predicted strain and thickness distributions to experimental measurements from a formed panel. The coupled thermo-mechanical model provided the most accurate prediction.
Ilinich, Andrey, Luckey, S. George
Integrated CAE Methods for Perceived Quality Assurance of Vehicle Outer Panels2014-01-03664/1/2014
Oil canning and initial stiffness of the automotive roofs and panels are considered to be sensitive customer ‘perceived quality’ issues. In an effort to develop more accurate objective requirements, respective simulation methods are continuously being developed throughout automotive industries. This paper discusses a latest development on oil canning predictions using LS-DYNA® Implicit, including BNDOUT request, MORTAR contact option and with the stamping process involved, which resulted in excellent correlations especially when it comes to measurements at immediate locations to the feature lines of the vehicle outer panels. Furthermore, in pursuit of light-weighting vehicles with thinner roofs, a new CAE method was recently developed to simulate severe noise conditions exhibited on some of developmental properties while going through a car wash. This paper introduces such a method to discuss Fluid Structure Interaction (FSI) approach using an Arbitrary Lagrangian Eulerian (ALE
Jang, Jaehyuk
Hot Stamping of a B-Pillar Outer from High Strength Aluminum Sheet AA70752014-01-09814/1/2014
This work demonstrates the feasibility of hot stamping a B-pillar outer panel from aluminum alloy 7075. AA7075 is characterized by a high strength to weight ratio with yield strengths comparable to those of DP and TRIP advanced high strength steels. Applications using AA7075 have typically been limited to the aerospace industry due to the high variable cost associated with forming and joining of these materials. A primary key to implementation in the automotive industry is the development of metal forming methods that produce non-compromised stamped parts at automotive manufacturing volumes and costs. This work explores the feasibility of die quenching a hot blank within a cold die as a means of delivering high strength aluminum sheet parts. A die made from kirksite was used to evaluate the hot stamping process for a B-pillar outer. After the forming/quenching operation, the parts were subjected to an artificial aging process to regain the properties of the T6-temper. The results show
Harrison, Nia R., Luckey, S. George
A Fastener Analysis Addressing Various Types of Misfit and Its Damage Life Calculations2013-01-23129/17/2013
In a fastening system when there is a small misalignment of the holes, the holes are enlarged to align the axes and a next size fastener is used to fit the joint. But when the misalignment is large then the enlargement need to be proportionally large. In this case a bushing is press fit onto the hole to handle the fastening. If we press fit a bushing, it generates residual stresses in the panel. These residual stresses reduce the damage life of the components on which the bushings were press fit. In the aircraft engine nacelle components the damage life is very critical in various failure conditions such as fan blade out condition, wind milling and bird strike. It increases the flight time in these events. Here four different case studies were considered to study the damage life of the aircraft components made of Aluminum or composite material. Case-study 1 (Aluminum panel and full ring bushing): A knock down factor to the damage life for the component material (Aluminum - in this case
Anandan, Vailore
Development of Low Cost Fuselage Frames by Resin Transfer Molding2013-01-23259/17/2013
This paper presents work on the development of a low cost fuselage C-frame for aircraft primary structure using a Light Resin Transfer Molding (RTM) process. Compared to labor intensive hand layup prepreg technologies, Light RTM offers some substantial advantages by reducing infrastructure requirements such as hydraulic presses or autoclaves. Compared to Prepreg, Light RTM tooling creates two finished surfaces, which is an advantage during installation due to improved dimensional accuracy. The focus of this work was to develop means of achieving high fiber volume fraction structural frames using low cost tooling and a low volume manufacturing strategy. In this case a three piece Light RTM mold was developed using an internal mandrel. To achieve the strength requirements, a combination of crimped and non-crimped fabrics were selected for the reinforcing preform. This made it possible to reduce the number of flat patterns by more than 8 times, saving layup time compared to the prepreg
Salek, Hasan, Trudeau, Paul
Test Slabs, Acrylonitrile Butadiene (NBR-H) Medium-High Acrylonitrile, 65 - 75AMS3217/1B (Historical)9/16/2013
This specification covers a standard acrylonitrile butadiene (NBR-H) rubber stock with medium-high acrylonitrile content in the form of molded test slabs.
AMS CE Elastomers Committee
Synthetic Resin Plastic Sealers, Nondrying TypeJ250_201307 (Current)7/9/2013
The material desired under this recommended practice is a synthetic resin plastic sealer of the nondrying, nonbleeding, and noncorrosive type that may be extruded to the specified size and used as a medium for producing a water tight seal between 2 pressed steel sections or between rubber and steel.
Materials, Processes and Parts Council
Die Wear Estimation in Automotive Sheet Metal Stamping2013-01-11714/8/2013
Automotive industry's migration to usage of HSS (High Strength Steels), AHSS (Advance High Strength Steels) from conventional steels for their low weight and high strength properties has had its significant effects on die wear. The unpredictability of die wear can pose manufacturing issues, for example, undesirable tool life. Hence die wear has been gaining immense attention and lot of research work has been carried out to provide a die wear prediction method. This paper focuses on the method of estimating wear mathematically based on the mechanics behind die wear phenomenon. This is also an effort to study wear on die for an automotive component in critical areas for which the amount of wear are calculated. This study is further to be correlated with production data from die maintenance record, explicit measurement of die wear, etc., to validate the estimation.
Balakrishnan, Praveen Balaj, Dev, Sathya, Bhuyan, Deepak, Syed, Parvez, Thokala, Sarin Babu
Integrating Manufacturing Pre-Stress in FEA Based Road Load Fatigue Analysis2013-01-12044/8/2013
Most manufacturing and assembly processes like stamping, clamping, interference fits introduce a pre-stress condition in components or assemblies. Very often these stresses are high enough and alter the mean stress state resulting in significant effect on fatigue life performance and thus cannot be ignored. If the pre-stress is compressive, it will increase the allowable stress range and improve fatigue life performance; on the other hand if these stresses are tensile, they will decrease the allowable stress range resulting in a degradation of fatigue life. At times it becomes critical to effectively introduce the pre-stress condition in order to accurately represent the stress state in an FEA based durability simulation. Accounting for the pre-stress state in FEA based constant amplitude loading fatigue life simulation is relatively straight forward, but when it comes to random variable amplitude multi-channel loads simulation, the problem becomes more complicated. In this paper, a
Qin, Wenxin
Simulation on the Vibration Characteristics of Elliptical Gears17-227-4-8194/1/2013
Elliptical gear drive is a typical non-circular gear drive, which can be used to transmit a variable-ratio rotation and power simultaneously. To date, elliptical gears are commonly used in automatic machinery, pumps, flow meters and printing presses. However, the vibration characteristics of elliptical gears have not been clarified yet. Due to the non-uniform rotation, the vibration of elliptical gear demonstrates particular characteristics, which should be paid attention to in practical application. This article presents a simulation method on the vibration characteristics of elliptical gears. The torsional vibration simulation model of elliptical gears is established and the simulation program is developed. The particular gear mesh characteristics of elliptical gears are determined and both the inertial effects of the driving and driven sides of elliptical gears are taken into account in the simulation program. By means of the simulation program, two elliptical gear pairs which are a
Liu, Xing, Nagamura, Kazuteru, Ikejo, Kiyotaka
Design and Research of a Novel Type of Mechanical Presses Driven by Three Servo Motors in Parallel17-227-3-5803/1/2013
A novel type of mechanical presses design driven by three servo motors in parallel is proposed to develop high stamping capacity based on the theory of generalized function sets, and then is improved to enhance its practicability in engineering practice. The inverse and forward kinematics analyses are conducted later. Based on the fuzzy probability theory, the computing method of fuzzy reliability of kinematic accuracy of slider is then obtained. Finally, with a set of optimized length parameters of the presses given, the fuzzy reliability is calculated, on the basis of which a typical deep-drawing process is simulated.
Huang, Xun, Ma, Chunxiang, Wu, Suxing, Wang, Qian, Wang, Zhibo, Gao, Feng
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