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Stiffness Simulation Techniques and Test Correlations in Automotive Interior Cockpit Systems (IP, Door Trim and Floor Console Assembly)

Chrysler Corp.-Tim Potok
Chrysler India Automotive Pvt, Ltd.-Mohammed K Billal, Vinothkumar Subramani
Published 2014-04-01 by SAE International in United States
An automotive cockpit module is a complex assembly, which consists of components and sub-systems. The critical systems in the cockpit module are the instrument panel (IP), the floor console, and door trim assemblies, which consist of many plastic trims. Stiffness is one of the most important parameters for the plastic trims' design, and it should be optimum to meet all the three functional requirements of safety, vibration and durability. This paper presents how the CAE application and various other techniques are used efficiently to predict the stiffness, and the strength of automotive cockpit systems, which will reduce the product development cycle time and cost. The implicit solver is used for the most of the stiffness analysis, and the explicit techniques are used in highly non-linear situations. This paper also shows the correlations of the CAE results and the physical test results, which will give more confidence in product design and reduce the cost of prototype testing.
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Transient Thermal Modeling of Power Train Components

SAE International Journal of Passenger Cars - Mechanical Systems

Chrysler Corp.-Fu-Long Chang
Chrysler Group-Masuma Khandaker
  • Journal Article
  • 2012-01-0956
Published 2012-04-16 by SAE International in United States
This paper discusses simplified lumped parameter thermal modeling of power train components. In particular, it discusses the tradeoff between model complexity and the ability to correlate the predicted temperatures and flow rates with measured data. The benefits and problems associated with using a three lumped mass model are explained and the value of this simpler model is promoted. The process for correlation and optimization using modern software tools is explained. Examples of models for engines and transmissions are illustrated along with their predictive abilities over typical driving cycles.
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Thermal Shock Resistance of Standard and Thin Wall Ceramic Catalysts

Chrysler Corp.-M.J Brady
Corning, Inc.-S. T. Gulati, M.E. Zak, L.F. Jones
Published 1999-03-01 by SAE International in United States
Thin wall ceramic catalysts offer improved performance by way of faster light-off, lower back pressure and higher FTP efficiency than standard ceramic catalysts. These advantages are attributed to their lower thermal mass, larger open frontal area and higher geometric surface area. This paper will focus on their physical durability, notably their thermal shock resistance.The critical physical properties which influence thermal shock resistance - namely modulus of rupture, elastic modulus and coefficient of thermal expansion - will be examined over a wide range of operating temperatures for both standard (400/6.5) and thin wall catalyst supports (600/4.3 and 400/4.5) with stable high temperature washcoat systems. These data help evaluate the thermal shock capability of each system via computation of thermal shock parameter. The validity of such computations is tested against the thermal shock data from oven test. The agreement between thermal shock parameter and oven test data is found to be good. It shows that thin wall ceramic catalysts with high temperature compatible washcoat system possess more than adequate thermal shock resistance.
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Effect of Valve-Cam Ramps on Valve Train Dynamics

Chrysler Corp.-David Eovaldi, James Westbrook, Ronald L. Stene
Worcester Polytechnic Institute-Robert L. Norton
Published 1999-03-01 by SAE International in United States
Testing of an OHC valve train with hydraulic lash adjuster in which the valve displacements, velocities and accelerations were measured and analyzed in both time and frequency domains, coupled with analysis of the frequency content of the valve acceleration function and its ramps, show that traditional designs of the opening and closing ramps used on some IC engine valve cams can exacerbate vibration in the follower system causing higher levels of spring surge and noise. Suggestions are made for improvement to the design of the beginning and ending transitions of valve motion which can potentially reduce dynamic oscillation and vibration in the follower train.
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Application of Design and Development Techniques for Direct Injection Spark Ignition Engines

Chrysler Corp.-C. R. Glaspie, J. R. Jaye, T. G. Lawrence, T. H. Lounsberry, L B. Mann, J. J. Opra, D. B. Roth, F.-Q. Zhao
Published 1999-03-01 by SAE International in United States
Gasoline direct injection technology is receiving increased attention among automotive engineers due to its high potential to reach future emission and fuel economy goals. This paper reports some of the design and development techniques in use at Chrysler as applied to four-stroke Direct Injection Spark Ignition (DISI) engines. The spray characteristics of Chrysler's single-fluid high-pressure injector are reported. Tools used in the design process are identified. Observations of the in-cylinder fuel/air mixing process using laser diagnostic techniques and Computational Fluid Dynamics (CFD) are described. Finally, combustion and emissions characteristics using Design of Experiment (DoE) tests are presented.
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Life Cycle Inventory of a Generic U.S. Family Sedan Overview of Results USCAR AMP Project

Chrysler Corp.-Susan Yester
Aluminum Association-Steven D. Pomper
Published 1998-11-30 by SAE International in United States
The United States Automotive Materials Partnership Life Cycle Assessment Special Topics Group (USAMP/LCA) has conducted a Life Cycle Inventory (LCI) using a suitable set of metrics to benchmark the environmental (not cost) performance of a generic vehicle, namely, the 1995 Intrepid/Lumina/Taurus. This benchmark will serve as a basis of comparison for environmental performance estimates of new and future vehicles (e.g. PNGV).The participants were Chrysler Corporation, Ford Motor Company, General Motors, The Aluminum Association, The American Iron and Steel Institute, and the American Plastic Council.The study was strictly a life cycle inventory. The approach was to quantify all suitable material and energy inputs and outputs, including air, water, and solid wastes. The inventory covered the entire life cycle; from raw material extraction from the earth, to material production, parts manufacture, vehicle assembly, use, maintenance, recovery/recycling, and disposal. For credibility purposes, the inventory was independently peer reviewed.This paper presents an overview of the USCAR AMP LCI of a generic vehicle that took approximately five years from conception to the final report. This paper is one of six…
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An Analysis of the Vehicle End-of-Life in the United States

Chrysler Corp.-Susan G. Yester
Centro de Calidad Ambiental, ITESM-Alberto Bustani, Patrick W. Mackay, Berenice Ramirez
Published 1998-11-30 by SAE International in United States
This paper presents an analysis of the Vehicle End of Life (VEOL) trends in the United States based on the VEOL model developed by the Vehicle Recycling Partnership (VRP), a consortium between Chrysler Corporation, Ford Motor Company and General Motors. The model, developed interactively with the VRP by the Center for Environmental Quality (CEQ) at the Instituto Tecnológico y de Estudios Superiores de Monterrey (ITESM), accounts for the economic and the material transfer interactions of stakeholders involved in the VEOL process; the insurance valuation, salvage pool, dismantling, rebuilding, maintenance and repair, shredding, and landfilling [Bustani, et al., 1998].The scenarios analyzed using the VEOL model consider regulations from Europe as well as the U.S. market factors and business policies. The model recognizes the importance of materials choices during vehicle design by tracking twenty-four different materials, classified as plastics, non ferrous metals, ferrous metals and other materials, and twenty six assemblies such as base engine, transmission, fuel tank and body shell.Three scenarios are analyzed using the VEOL Model: the first is directed to understanding the effect of…
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Life Cycle Management of Hydraulic Fluids and Lubricant Oils at Chrysler

Chrysler Corp.-Jody Bailiff, David H. Ehlfeldt
Franklin Associates, a Service of McLaren/Hart-William E. Franklin
Published 1998-11-30 by SAE International in United States
A systematic life cycle management (LCM) approach has been used by Chrysler Corporation to compare existing and alternate hydraulic fluids and lubricating oils in thirteen classifications at a manufacturing facility. The presence of restricted or regulated chemicals, recyclability, and recycled content of the various products were also compared. For ten of the thirteen types of product, an alternate product was identified as more beneficial.This LCM study provided Chrysler personnel with a practical purchasing tool to identify the most cost effective hydraulic fluid or lubricant oil product available for a chosen application on an LCM basis.
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The Chrysler “Quick Shift Neon” Automanual Transmission Project

Chrysler Corp.-Kim M. Lyon
Published 1998-11-16 by SAE International in United States
Formula One motorsport competition, ever seeking increases in powertrain responsiveness and efficiency, has utilized electronically-shifted manual transmissions for nearly a decade. With the advent of this technology for passenger car usage ( for example the Magneti Marelli “Selespeed” system), new levels of powertrain electronic control become possible. At the same time, world-wide emission and fuel economy standards have driven powertrain designers to seek transmissions that are multi-faceted; able to offer manual transmission levels of driveline efficiency while simultaneously offering the ability to be automatically controlled.This paper will document a 1995-1996 Chrysler advanced powertrain concept study that culminated in a fully driveable, fully automatic, manual 5 speed transmission Neon coupe. The particular difficulties of electronically managing clutch control, gearshift synchronization, and synchronization duration will be scrutinized while detailed data traces will chronicle their successful resolution. In the end, a unique electro-mechanical control system was devised which allows electronic selection and control of a power-interrupted shift, manual transmission and dry friction clutch, affording heretofore unachievable levels of powertrain efficiency.
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Self-Excited Vibrations During Engagements of Dry Friction Clutches

Chrysler Corp.-Christopher C. Bostwick
Eaton Corp.-Andrew Szadkowski
Published 1998-11-16 by SAE International in United States
During the starting of the vehicle, the friction clutch engagement sometimes generates judder. Judder prevents vehicles from starting smoothly, harms the ride comfort, and may produce damage to the drivetrain components. This unpleasant phenomenon, which often manifests in the form of noisy torsional vibrations of the drivetrain or a violent surging of starting vehicles, is an example of the many annoying problems that automotive engineers have been experiencing since the car was invented.Engineers and scientists have identified some causes of transient torsional oscillations connected to judder. Vibrations generated by the clutch facings when a special type of relationship between the friction coefficient and sliding speed occurs account for the most important source of judder. Other potential judder sources are: misalignments in the drivetrain that may induce fluctuating pressure between sliding components, some thermoelastic phenomena on contact surfaces, and/or torsional excitations from the engine and universal joint in the presence of special resonant conditions.The present paper concentrates on a research of selfexcited vibrations that are generated by a special type of friction force identified by an…
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