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Comparison of Different Methods for Panel Dent Resistance Using Numerical Assessment and Influence of Materials Used in Automotive Industry

Tata Technologies Ltd.-Ashish Sathaye, Deepak Srivastava, Manivasagam Shanmugam
  • Technical Paper
  • 2020-01-0483
To be published on 2020-04-14 by SAE International in United States
Conventionally, the automotive outer panels, giving vehicle its shape, have been manufactured from steel sheets. The outer panels are subjected to loads due to wind loading, palm-prints, person leaning on the vehicle, cart hits, and hail stones for example. Consumer awareness about these two panel characteristics: Oilcanning and Dent resistance is increased, which has been observed in recent marketing studies. Apart from perceptive quality, another factor depending on the dent performance is insurance and respective cost implications. Dents can occur due to several reasons such as object hits, parking misjudgement, hail stones etc. Phenomenon can be divided into two types, static and dynamic denting. Static dent case covers scenario wherein interaction with outer panel is mostly quasi-static. Hail stones present dynamic case where object hits a panel with certain kinetic energy. Automotive companies usually perform static dent assessment to cover all the cases. The scope of this paper is to discuss the comparison between two methods and its results using Finite Element Analysis. Influence of panel stiffness on dent resistance is also studied. Panel dent…
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A method to evaluate the acoustic performance of the Pillar filler foam in a Truck cab

ESI North America-Praveen Jayasheela, Ricardo Alvarez
Volvo Group North America-Suresh Patra
  • Technical Paper
  • 2020-01-0505
To be published on 2020-04-14 by SAE International in United States
The truck cab is made of many structural members like a, b, c, hinge - pillar, rocker, roof rails, headliner, quarter panels, cross-members at the floor and other body panels. For an acoustic example, the source energy travels easily from one end to another end through pillars. To reduce these acoustic effects, the filler foams were added inside the pillars. The proper usage of filler design and filler material type produces the optimal sound response at the driver head space location. In this paper, an analytical method is used to evaluate the acoustic performance of the fillers as described above and the method also avoids the expensive full vehicle tests. The statistical energy analysis (SEA) model simulations and post-processing techniques were used to evaluate the results quickly with an acceptable level of accuracy. It has proven that the effect of the foam thickness and foam coverage area of the fillers can be evaluated and helped to achieve the optimal sound response at the driver head location.
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Improving Rough Road NVH by Hydraulic Mount Design Optimization

Maruti Suzuki India, Ltd.-Vivek Singh, Gokulram Seenivasan, Gaurav Gupta, Adheesh Agrawal
  • Technical Paper
  • 2020-01-0422
To be published on 2020-04-14 by SAE International in United States
Vehicle cabin comfort emphasizes a specific image of a brand and its product quality. Low frequency powertrain induced noise and vibration levels are a major contributor affecting comfort inside passenger cabin. Thus, using hydraulic mount is a natural choice. Introduction of lighter body panels coupled with cost effective hydraulic mounts has resulted in some additional noises on rough road surfaces which are challenging to identify during design phase. This paper presents a novel approach to identify two such noises i.e. Cavitation noise and Mount membrane hitting noise based on component level testing which are validated at vehicle experimentally. These noises are encountered at 20~30kmph on undulated road surfaces. Sound quality aspect of such noises is also studied to evaluate the solution effectiveness.
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Laboratory Measurement of Random Incidence Sound Absorption Tests Using a Small Reverberation Room

Acoustical Materials Committee
  • Ground Vehicle Standard
  • J2883_202003
  • Current
Published 2020-03-04 by SAE International in United States
This SAE Recommended Practice describes a laboratory test procedure for measuring the random incidence sound absorption performance of a material or a part in a small size reverberation room by measuring decay rates. The absorption performance may include sound absorption coefficient of the test sample and or the amount of energy absorbed by the test sample. Materials for absorption treatments may include homogeneous materials, nonhomogeneous materials, or a combination of homogeneous, nonhomogeneous, and/or inelastic impervious materials. These materials are commonly installed in the mobility products and in the transportation systems such as ground vehicles, marine products, aircraft, and commercial industry (in industrial and consumer products) to reduce reverberant sound build-up and thus reduce the noise level in the environment by minimizing reflections off of hard surfaces. The test method described herein was developed also to describe a way to measure the absorption performance of a part or a sound package system that will relate to an application. It can be used to rank order materials for application on panels using general automotive steel but also…
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Development and Investigation of Jute/Linen Fibre Reinforced Polymer Composite

BSA Crescent Institute of Science & Technology-Arvinda Pandian, Siddhi Jailani
Published 2019-10-11 by SAE International in United States
In recent automotive era, natural fibre reinforced with thermoset polymer composites have been incorporated by automotive industries especially for interiors, car body panels, dashboards, headliners etc. Natural fibres offer many affirmative qualities such as less weight and cost, especially in reduction of carbon di-oxide which is a major threat to the planet from the automotive sectors. The current work deals with the study of the potential usage of mineral powder (industrial by-product) in polymer. In this paper, hybrid composites with natural fabrics reinforcements and mineral powder as filler to matrix material are developed. The mineral powder used as filler is silica fumes which is a by-product of industries. The hand lay-up methodology is employed to fabricate the composite. The composites with and without mineral filler material are developed. The mechanical properties of the composites are assessed. The mechanical properties of composites with and without mineral filler are compared and their result shows that with addition of filler material, the mechanical properties of the composites are affected. Results disclose that loading of silica fumes increases the…
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Low-Speed Impact Bumper System Test Procedure for Passenger Vehicles

Motor Vehicle Council
  • Ground Vehicle Standard
  • J2319_201910
  • Current
Published 2019-10-03 by SAE International in United States
The scope of this SAE Recommended Practice is restricted to the testing of original equipment on passenger vehicles and to provide for a uniform industry test procedure.
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Standard for Safety Glazing Materials for Glazing Motor Vehicles and Motor Vehicle Equipment Operating on Land Highways - Safety Standard

Glazing Materials Standards Committee
  • Ground Vehicle Standard
  • J3097Z26_201905
  • Current
Published 2019-05-28 by SAE International in United States
Specifications, test methods, and usage provisions for safety glazing materials used for glazing of motor vehicles and motor vehicle equipment operating on land highways.
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Certified Containers for Lower Deck Compartments

AGE-2 Air Cargo
  • Aerospace Standard
  • AS5896
  • Current
Published 2018-10-18 by SAE International in United States
This SAE Aerospace Standard (AS) covers the design, fabrication, performance, and testing requirements for general-purpose, base-restrained, containers requiring airworthiness approval for installation/use in aircraft lower deck compartments. See 10.1 and 10.2.
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Dynamic Stiffness Investigation of an Automotive Body-in-White by Utilizing Response Surface Methodology

Iran University of Science & Technology-Milad Abbasi, Abolfazl Khalkhali
RMIT University-Mohammad Fard
Published 2018-06-13 by SAE International in United States
Noise, vibration, and harshness (NVH) attribute is needed to be included in the vehicle structure design since improving the NVH characteristics enhances the ride quality experienced by the occupants. In this regard, an efficient method was proposed to investigate the structural dynamic response of an automotive body considering low-frequency NVH performances. Moreover, the improvement of an automotive structure under the constraint of NVH behavior was investigated by using the design of experiments (DOEs) method. The DOEs methodology was for screening of the design space and generating approximation models. Here, the thicknesses of panels consisting of a body-in-white (BIW) of an automotive were employed as design variables for optimization, whose objective was to increase the first torsional and bending natural frequencies. Central composite design (CCD) for DOEs sampling and response surface methodology (RSM) were employed to optimize the dynamic stiffness. Moreover, the effects of the selected variables as well as their binary interactions were modeled and the optimum conditions for rigidity improvement were obtained via the RSM. Furthermore, the validity of the proposed optimization scheme was…
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An Application of Acoustic Metamaterial for Reducing Noise Transfer through Car Body Panels

Gwangju Inst. of Science and Technology-Jaesoon Jung, Hyun-Guk Kim, Dong Rak Choi, Semyung Wang
Hyundai Motor Co.-Kyoung-Jin Chang
Published 2018-06-13 by SAE International in United States
This paper presents the design of an additional structure based on acoustic metamaterial (AMM) for the reduction of vibro-acoustic transfer function of a car body panel. As vehicles are lighter and those engine forces are bigger recently, it has become more difficult to reduce the vibration and noise transfer through body panels by using just conventional NVH countermeasures. In this research, a new approach based on AMM is tried to reduce the vibration and noise transfer of a firewall panel. First, a unit cell structure based on the locally resonant metamaterial is devised and the unit cell’s design variables are studied to increase the wave attenuation in the stop band of a dispersion curve, where the Floquet-Bloch theorem is used to estimate the dispersion curve of a two-dimensional periodic structure. Also, the vibration transfer and the vibro-acoustic transfer are predicted in a FE model of meta-plate which is composed of a periodic system of the devised unit cell. Next, the driving point mobility of a meta-plate is tested and its design is updated for the…
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