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Design and Sustainability Assessment of Lightweight Concept for an Automotive Car Module

Benteler-Joern Toelle
Toyota Motor Europe-Martin Kerschbaum
  • Technical Paper
  • 2020-37-0033
To be published on 2020-06-23 by SAE International in United States
Recently sustainability has become a priority for industry production. This issue is even more valid for the automotive sector, where Original Equipment Manufacturers have to address the environmental protection additionally to traditional design issues. Against this background, many research and industry advancements are concentrated in the development of lightweight car components through the application of new materials and manufacturing technologies. The paper deals with an innovative lightweight design solution for the bumper system module of a B-segment car. The study has been developed within the Affordable LIght-weight Automobiles AlliaNCE (ALLIANCE) project, funded by the Horizon 2020 framework programme of the European Commission. A bumper demonstrator, that is currently in series production and mainly consists of conventional aluminum materials, is re-engineered making use of 7000 series aluminum alloys. The design alternatives are described and assessed regarding the achieved weight saving. The study is complemented by a sustainability assessment of the different modules performed through the Life Cycle Assessment methodology. The analysis takes into account production, use and End-of-Life stages and the results are expressed in terms…
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CAE Support to Vehicle Audio Installation Issues

Volvo Car Corporation-Andrzej Pietrzyk
  • Technical Paper
  • 2020-01-1575
To be published on 2020-06-03 by SAE International in United States
Audio CAE is an emerging area of interest for a vehicle OEM, despite the fact that the development of the audio system is often left to a specialized supplier. Especially the questions regarding early stages of the vehicle design, like choosing the possible positions for speakers, deciding the installation details that can influence the visual design, and integration of the low frequency speakers with the body & closures structure, are of interest. Therefore, at VCC, the development of the CAE methodology for audio applications has been undertaken. The long term goal is to enable performing subjective evaluation of sound in a virtual car, and integrating audio evaluation in the NVH simulator. The key to all CAE applications is the loudspeaker model made available in the vibro-acoustic software used within the company. Such a model has been developed, implemented and verified in different frequency ranges and different applications. The applications can be divided into the low frequency ones (concerning the installation of woofers and subwoofers), and the middle/high frequency ones (concerning the installation of midrange and…
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Effects of On-Road Conditions on HVAC Noise

Univ. Of Erlangen-Nuremberg-Andreas Logdesser, Stefan Becker
  • Technical Paper
  • 2020-01-1555
To be published on 2020-06-03 by SAE International in United States
Noise inside the passenger cabin is made up of multiple sources. A significant reduction of the major sound sources such as the engine, wind and tire noise helped to improve the comfort for passengers. As a consequence, the HVAC sound (heating, ventilation and air-conditioning) is unmasked as a primary noise source inside the passenger cabin and has to be taken into consideration when designing passenger cabin sound. While HVAC sound is often evaluated at stop, the most common situation of its use is while driving. In case of fresh air as mode of operation, the HVAC system is coupled to the environment through the air intake. Any change in the boundary conditions due to on-road driving events and gusts of wind affects the flow field in the HVAC system and in turn influences HVAC noise. This study investigates the effect of mass flow and pressure fluctuations on the HVAC noise. In a first step, major influences on the HVAC system are identified in an on-road test. For further investigation, the HVAC system is analyzed in…
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A Design and Optimization Method for Pedestrian Lower Extremity Injury Analysis with the aPLI Model

Changan Automobile Co., Ltd.-Ruyi Chen
Chongqing University-Yue Fu, Huijie Xu, Guan Lin, Zhenfei Zhan, Ping Wang
  • Technical Paper
  • 2020-01-0929
To be published on 2020-04-14 by SAE International in United States
As pedestrian protection tests and evaluations have been officially incorporated into new C-NCAP, more stringent requirements have been placed on pedestrian protection performance. In this study, in order to reduce the injury of the vehicle front end structure to the pedestrian's lower extremity during the collision, the advanced pedestrian legform impactor (aPLI) model was used in conjunction with the finite element vehicle model for collision simulation based on the new C-NCAP legform test evaluation regulation. This paper selected the key components which have significant influences on the pedestrian's leg protection performance based on the CAE vehicle model, including front bumper, front-cover plate, upper impact pillar, impact beam and lower support plate, to form a simplified model and conducted parametric modeling based on it. Then, the variable correlation analysis was carried out on the sample results obtained from the design of experiment (DOE), and the contribution analysis of design variables to the injury measures was discussed. The sample variables and responses were also used to construct the approximate models for further optimization studies. Taking the pedestrian…
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N&V Component Structural Integration and Mounted Component Durability Implications

General Motors LLC-Mark Stebbins, Joseph Schudt
  • Technical Paper
  • 2020-01-1396
To be published on 2020-04-14 by SAE International in United States
Exterior component integration has presented competing integration challenges for suitable exterior styling, safety, N&V structural feel and component durability balanced performances. Industry standard practice of N&V vehicle mode mapping uses vehicle source, path and receiver considerations for component mode frequency placement. Mounted component mode frequency performance can have an influence on structural feel and durability performances. Component integration headwinds have increased with additional nonstructural component styling content, component size, component mass and added sensor modules. Based on first principles, the effective mass of exterior mounted components are increased due to the geometric overhang from structure. Component input vibration levels are compounded due to the cantilevered nature as well as relative positioning to the suspension and propulsion vehicle source inputs locations. Examples of vehicle end mounted components include but are not limited to headlamps, side mirrors, end gates, bumpers and fascia. Our goal is to establish basic expectations for the behavior of these systems, and ultimately to consolidate our existing rational and approaches that can be applied to such integrated systems. The focus of this paper…
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Application of Laminated Steels for Stamped Bumpers

FCA US LLC-Eric Edwin Herz
Material Sciences Corp.-Justin Putti, Matt Murphy
  • Technical Paper
  • 2020-01-1055
To be published on 2020-04-14 by SAE International in United States
Light-weight solutions for stamped steel components that exhibit the same or similar appearance properties for purposes of authentic feel and perception to customers will play a critical role as the goal of reaching maximum fuel efficiency for large vehicles continues. This paper outlines the potential uses for laminated steel or “MSC Smart Steel®” in large stamped steel bumpers that would normally be stamped with thick sheet metal in order to meet vehicle level functional objectives. The paper presents the investigation of the one for one drop in capabilities of MSC Smart Steel® material to existing stamping dies, special processing considerations while manufacturing, vehicle level performance comparisons, and class “A” coating options and process needs. Most of all, it will highlight the significant vehicle weight saving benefits and opportunities as compared to current production stamped steel bumpers.
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Recommendations for Children’s Snowmobile

Snowmobile Technical Committee
  • Ground Vehicle Standard
  • J1038_202001
  • Current
Published 2020-01-15 by SAE International in United States
This SAE Recommended Practice establishes the test procedures, performance requirements, and criteria necessary to evaluate minimum safety and reliability requirements of a children's snowmobile as identified in 1.2.
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Paint and Trim Code Location

Motor Vehicle Council
  • Ground Vehicle Standard
  • J2235_201910
  • Current
Published 2019-10-24 by SAE International in United States
This SAE Recommended Practice is designed to provide readily accessible paint and trim code information on all passenger vehicles, lightweight trucks, and vans in a way that minimizes the time and effort required to locate and effectively use that information for body repair, parts ordering, vehicle maintenance, and information systems.
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Design of Lightweight Composites for Vehicle Front End Energy Management of Bumper Beam

Indian Institute of Technology-Balasubramanian Muthiah, Velmurugan Ramachandran
Mahindra & Mahindra, Ltd.-Praveen Kumar, Sarma Sr Akella, Ayan Chakraborty, Shankar M Venugopal
Published 2019-10-11 by SAE International in United States
Application of advance composites in place of the various conventional materials such as steel can give significant weight and performance advantages. The application of composites is now finding it’s way in the automotive industry due to the growing requirement of the lightweight solutions and high strength to weight ratio. However, their low mechanical properties have limited their application in automotive structural components. The study presented here is focused on the explicit dynamic analysis of a bumper beam and advance composites are used for the study. Different configurations and designs of the bumper are considered to be able to make a comparative study of the stress and deformation levels. The analysis was done in coherence to the Euro NCAP tests and the offset frontal impact analysis was done. The boundary conditions were aligned with the real time impact conditions for proper prediction of the results. Based on stress, deformation, specific strength and weight, the replacing materials for existing steel bumper are considered and the corresponding energy absorption are calculated. Laminated composites such as Glass, Carbon and…
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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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