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Robust assessment of automotive door structure by considering manufacturing variations

FCA Engineering India Pvt. Ltd.-Roshan N. Mahadule
FCA US LLC-Raj Namineni, Parag Nittur
  • Technical Paper
  • 2020-01-0910
To be published on 2020-04-14 by SAE International in United States
The automotive door structure experiences various static and dynamic loading conditions going through an opening and closing operation. A typical swing door is attached to the body with two hinges and a check strap. These mechanisms carry the loads while the door is opened. Similarly, when closing the door, the latch/ striker mechanism along with the seal around the periphery of the door react all loads. Typically, computer aided engineering (CAE) simulations are performed considering a nominal manufacturing (or build) tolerance condition. This results in one loading scenario but it is found that build variations in the various mechanisms mentioned above can result in different loading scenarios which should be evaluated. This paper discusses various tolerances that should be accounted for in the CAE simulations to generate a robust door assembly.
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Quantification of Clamp Loss and Subsequent Loosening of Automotive Hub-Knuckle Joints under Time-Varying Proving Ground Loading

FCA US LLC-Sandip Datta, Parag Nittur
  • Technical Paper
  • 2020-01-0181
To be published on 2020-04-14 by SAE International in United States
Threaded fasteners or bolted joints are used extensively in automotive assemblies. There are standard procedures to evaluate joint performance under block cycles or road loads. The deciding load case for such joint design is slippage analysis of the joint.There are studies done to evaluate the theoretical and experimental behavior of these joints. There are different ways of understanding the interaction between the bolt and the nut under different loading scenarios. However, none have provided a satisfactory method of quantifying bolt loosening or loss of clamp load under cyclic loading, where no slippage is observed.Under varying loads, initial relaxation of the joint is followed by a loss of clamping load. Below a critical value, complete loss of clamping load progresses very rapidly and this results in a loose joint. The loss of clamping load below the critical value happens at a transition stage when both elastic deformations of the bolt as well as external moments contribute to rapid loosening.This study provides an overall understanding of geometric parameters that contribute to sudden loss of clamping load and…