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Identification of Automotive Cabin Design Parameters to Increase Electric Vehicles Range, Coupling CFD-Thermal Analyses with Design for Six Sigma Approach

FCA ITALY S.p.A.-Andrea Alessandro Piovano, Giuseppe Scantamburlo, Massimo Quaglino, Matteo Gautero
  • Technical Paper
  • 2020-37-0032
To be published on 2020-06-23 by SAE International in United States
The ongoing global demand for greater energy efficiency plays an essential role in the vehicle development, especially in case of electric vehicles (EVs). The thermal management of the full vehicle is becoming increasingly important, since the Heating, Ventilation, and Air Conditioning (HVAC) system has a significant impact on the EV range. Therefore the EV design requires new guidelines for thermal management optimization. In this paper, an advanced method is proposed to identify the most influential cabin design factors which affect the cabin thermal behavior during a cool down drive cycle in hot environmental conditions. These parameters could be optimized to reduce the energy consumption and to increase the robustness of the vehicle thermal response. The structured Taguchi’s Design for Six Sigma (DFSS) approach was coupled with CFD-Thermal FE simulations, thanks to increased availability of HPC. The first control factors selected were related to the thermal capacity of panel duct, dashboard, interior door panels and seats. Surface IR emissivity and solar radiation absorptivity of these components were then added to the study. Car glass with absorptive…
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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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Experimental Investigation on Mechanical Properties and Vibration Damping Frequency Factor of Kenaf Fiber Reinforced Epoxy Composite

Hindustan Institute of Technology and Science-Sathish Kumar Rajamanickam, Sivakumar Sattanathan, Deenadayalan Ganapathy, Joshuva Arockia Dhanraj
Sri Krishna College of Engineering and Technology-Vishnuvardhan Ravichandran
Published 2019-10-11 by SAE International in United States
Kenaf Fiber regarded as industrial crop for different applications. It is one of the most important plants cultivated for natural fibers globally. Natural fibers such as kenaf fibers are getting attention of researchers and industries to utilize it in different composites due to its biodegradable nature. In this present investigation mechanical properties, vibration damping frequency factor and thermogravimetric analysis of kenaf fiber reinforced epoxy composite (KFREC) have been evaluated and reported. The tests were conducted with different weight categories of kenaf fiber such as 20%, 25%, 30% and 35%. The effects of fiber content on tensile, flexural, impact strengths, hardness and thermal decomposition properties of the composite were determined. The failure mechanism and damage features of the KFREC were categorized using Scanning Electron Microscope (SEM). The results indicate that the increase in the fiber content decreases the damping vibration factor (ζ) correspondingly. The lowest value of the damping vibration factor was recorded as 0.033 for 35% weight content of Kenaf fiber in the composite. The maximum value of hardness, tensile, flexural, and impact strengths were…
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Design Guidelines for Fiberboard Materials

Textile and Flexible Plastics Committee
  • Ground Vehicle Standard
  • J1774_201909
  • Current
Published 2019-09-25 by SAE International in United States
This document provides information on the various fiberboard products, which are available for automotive application. It is intended to give engineers and designers a better understanding of product usage, characteristics, properties and industry terminology. The following sections cover these topics: 2 General Product Information 3 Design Characteristics 4 Physical/Mechanical Properties 5 Fiberboard Definitions In sections 2, 3 and 4 the fiberboard products are categorized. These sections give an overview of product types, with general information about characteristics and properties. In cases where product categories encompass more than one material or material grade, ranges were established to cover all of the products in that category. The individual companies that supply fiberboard products should be consulted for specific information about a particular product or application.
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Study of the Sliding Door Shaking Problem and Optimization Based on the Application of Euler’s Spiral

SAE International Journal of Vehicle Dynamics, Stability, and NVH

Hunan University, China-Ziming Chen, Luoxing Li, Yunlong Wu
Oushang R&D Center of Changan Automobile Company, China-Wufeng Zhou
  • Journal Article
  • 10-02-03-0014
Published 2018-10-03 by SAE International in United States
This study focuses on the sudden shaking phenomenon of a sliding door passing through a corner. This phenomenon requires attention because shaking during movement can lead to a harsh operation feeling and a short service life. An experiment based on a test setup was conducted, and the sudden change in the acceleration of a sliding door panel was measured. Based on multi-body dynamics (MBD) analysis and a rigid-flexible coupled model of the sliding door system, the cause of the sudden shaking was determined to be the discontinuous curvature of the middle rail trajectory. A transition curve was proposed as the solution for the discontinuous curvature, and Euler’s spiral was applied in the redesign of the middle rail trajectory. Verified by simulations, the results exhibit considerable improvement in sliding door movement stability, with large reductions in the maximum center of mass (CM) acceleration and guide roller impact force.
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In-Situ Characterization of Vibrations from a Door Mounted Loudspeaker

Volvo Car Group-David Lennström
Published 2018-06-13 by SAE International in United States
In the automotive industry, there is an increasing need for gaining efficiency and confidence in the prediction capability for various attributes. Often, one component or sub-system is used in a number of car models of one vehicle platform. Many of these components are potential sources of noise, vibration and squeak and rattle. In order to provide an early prognosis, vibro-acoustic source characterization in combination with the source-to-response transfer behavior are required. This paper describes the process of predicting the vibrational behavior due to a woofer, which could induce squeak and rattle, on a door panel. Blocked forces, determined indirectly in-situ by frequency response functions and operational accelerations, were used for quantifying the source activity. Those forces were in a second step loaded on to a finite element model in order to predict the response when the speaker was mounted to another position in an upcoming car model. Prior to this, comparisons between the measured and simulated response for the same car model were made, with satisfying agreement.
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Trimmed Door Audio Response Hybrid Modeling Assessment

PSA Group-Laurent Gagliardini, Pierre-Emile Chartrain, Olivier Ponte-Felgueras
Vibratec-Aurélien CLOIX
Published 2018-06-13 by SAE International in United States
The door response to audio excitation contributes to the overall performance of a vehicle audio system on several items: acting as a cabinet, it influences the loudspeaker response, but it also radiates unwanted sound through the inner door panel. Associated design issues are numerous, from the loudspeaker design to door structure and inner panel definition. Modeling then appears as an unavoidable tool to handle the acoustic response of the loudspeaker in its actual surrounding as well as the door inner panel radiation.In the low frequency range (<300 Hz), the loudspeaker is conveniently modelled using the classical Thiele&Small 1 D model. The interaction with the door and the acoustic surroundings requires a more detailed Finite Element modeling considering the acoustic loads on both sides of the loudspeaker membrane and the force at the loudspeaker frame interface with the door structure.The proposed hybrid modeling is first assessed by comparison of the computed and the measured membrane’s displacement. An update of the T&S parameters is performed in order to optimize the model. Then, the computed loudspeaker frame displacement and…
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Access System Senses Finger Vibrations to Verify Users

  • Magazine Article
  • TBMG-28531
Published 2018-03-01 by Tech Briefs Media Group in United States

The market for smart security access systems is expected to grow rapidly, reaching nearly $10 billion by 2022. Today's smart security access systems mainly rely on traditional techniques that use intercoms, cameras, cards, or fingerprints to authenticate users. These systems require costly equipment, complex hardware installation, and diverse maintenance needs.

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Interior Automotive Plastic Part Testing

Plastics Committee
  • Ground Vehicle Standard
  • J1717_201707
  • Current
Published 2017-07-13 by SAE International in United States
SAE J1717 is an advisory document suggesting minimum recommended testing, appearance evaluation, and protocol for specifying the recommendations with regard to Singular Unassembled Automotive Interior Trim Parts.
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Aircraft Landing Noise Reduction Liners

  • Magazine Article
  • TBMG-27199
Published 2017-07-01 by Tech Briefs Media Group in United States

NASA Langley Research Center has developed two new implementations of acoustic liners for aircraft noise reduction whereby curved channels within tight spaces can be outfitted to provide noise reduction. The two implementations are flap side edge liners and landing gear door liners for airframe noise reduction. In these applications, the acoustic liner is designed primarily to reduce aircraft noise that occurs during landing, which will help aircraft comply with increasingly stringent airport noise restrictions.