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Coarse Mesh RIFF Method to Identify the Homogenized Flexural and Shear Complex Moduli of Composite Beams

LAUM-Frédéric Ablitzer, Charles PEZERAT
Sonorhc Technologies-Thibault Wassereau, Jean-Louis GUYADER
  • Technical Paper
  • 2020-01-1579
To be published on 2020-06-03 by SAE International in United States
Facing the increasing use of composite materials regarding their stiffness to mass ratio, industries need to design complex structures. Hence specific methods must developed to predict the vibratory behavior of such materials but also to check their performances in-situ, analyse the presence of flaws or quantify degradation of properties throughout time. This paper describes a method to estimate the flexural and shear complex moduli of composite beams, based on a simple measurement of the transverse displacement on a coarse mesh using a hammer and an accelerometer. The herein depicted approach consists in an adaptation of the corrected finite difference scheme (Leclere et al. 2012) applied to an inverse vibratory method developed by the authors in previous works (Wassereau et al. 2017). The Timoshenko’s equation of motion and the corrected finite difference scheme are the two major key points of the method. The first allows estimation of Young and shear complex moduli simultaneously (sometimes crucial to describe composite beams) but also simplifies the representation of the composite structure by considering it as an homogeneous material, which…
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Experimental Study on Static and Fatigue Behavior of a Short Glass Fiber Reinforced Polypropylene

FCA US LLC-Mingchao Guo, Congyue Wang, Jian Tao, Ramchandra Bhandarkar
InDepth Engineering Solutions-Johnson Joseph
  • Technical Paper
  • 2020-01-0190
To be published on 2020-04-14 by SAE International in United States
One approach of reducing vehicle weight is using composite materials. Fiber reinforced polypropylene is one of the most popular composite materials. To improve accuracy in prediction of durability performance of structures made of this kind of composite material, static and fatigue properties of a 30% fiber reinforced polypropylene have been physically studied. This paper describes details of test coupon design, fabrication and test setup of both quasi static and fatigue tests. In this study, various fiber orientation (0, 20, 90 degrees & knit line), temperature (-40, 23 and 80 degree C), mean stress (R=-1.0, -0.5, -0.2, 0.1 and 0.4) have been considered and the result of the tests discussed.
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A McPherson Lightweight Suspension Arm

Barnem Tecnologie Plastiche Srl-Marcello Chessari
Metal-Stampi di Maccarinelli e Cucchi-Silvia Maccarinelli
  • Technical Paper
  • 2020-01-0772
To be published on 2020-04-14 by SAE International in United States
The paper deals with the design and manufacturing of a McPherson suspension arm made from short glass fiber reinforced polyamide (PA66). The design of the arm and the design of the molds have been made jointly. According to Industry 4.0 paradigms, a full digitalization of both the product and process has been performed.Since the mechanical behavior of the suspension arm strongly depends on constraints which are difficult to be modelled, a simpler structure with well-defined mechanical constraints has been developed. By means of such simple structure, the model for the behavior of the material has been validated. Since the suspension arm is a hybrid structure, the associated simple structure is hybrid as well, featuring a metal sheet with over-molded polymer. The issues referring to material flow, material to material contact, weld lines, fatigue strength, high and low temperature behavior, creep, dynamic strength have been investigated on the simple structure. The detailed understanding gained with the simple structure has been transferred on the actual suspension arm.The McPherson arm has been produced and withstood the technical specifications.
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Electrical Heated Epoxy Tool for Rotational Molding Application

John Deere India Pvt., Ltd.-Sorna Rajendran Gandhi, Amit S Patil
  • Technical Paper
  • 2020-01-0234
To be published on 2020-04-14 by SAE International in United States
The conventional method of making rotational molding part is by heating the cast aluminum mold or sheet metal mold by hot air medium which has its own limitation on energy loss, the other means is by direct heat and cold of mold by passing hot oil/water in the mold to have better energy efficiency but leakage and safety problems associated with pumping pressurized hot oil / Water. There is no solution available for prototyping rotational molding parts using design intended material. The current practice of prototyping with conventional method is expensive and time-consuming. In this work, a simple method is presented to produce a rotational molded part with breakthrough in mold construction, which is Composite Mold Technology (CMT) with glass fiber reinforced epoxy resin built-in with electrical heaters. Project focuses is on proving CMT in comparison with the current production method. CMT reduce the cost by 90% and time to build Protomold by 30%. This electrical heated CMT can be used for new product development (NPD) and very low volume production as the cycle time of the part development was observed very high and life mold is yet to be tested. Deeper study of the life…
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CAE Modeling Static and Fatigue Performance of Short Glass Fiber Reinforced Polypropylene Coupons and Components

FCA US LLC-Congyue Wang, Mingchao Guo, Mohan Shanmugam, Ramchandra Bhandarkar
  • Technical Paper
  • 2020-01-1309
To be published on 2020-04-14 by SAE International in United States
Fiber reinforced polypropylene (FRPP) is a typical anisotropic composite and its material properties highly depend on the fiber orientations within the material. To improve accuracy in prediction of durability performance of structures made of this kind of composite material, simulation of manufacturing process is necessary to obtain distribution of fibers and their orientations at every location of the structure. This paper describes a CAE modeling techniques to simulate 1) injection molding process, 2) static and fatigue performance of coupons and 3) static and fatigue performance of components made of 30% FRPP. Details of CAE model setup, analysis procedures and correlation between analysis and test results are presented. In this study, various fiber orientation (0, 20, 90 degrees & knit line), temperature (-40, 23 and 80 degree C) and mean stress (R=-1.0, -0.5, -0.2, 0.1 and 0.4) have been considered. To demonstrate correlation, battery trays made of this FRPP have been tested subjected to block cycle loads, results of which have been discussed.
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Hybrid Forming - A Novel Manufacturing Technique for Metal-LFT Structural Parts

University of Siegen-Daniel Heidrich, Tobias Kloska, Xiangfan Fang
  • Technical Paper
  • 2020-01-0235
To be published on 2020-04-14 by SAE International in United States
Hybrid structural parts combining aluminum or steel sheets with long glass fiber reinforced thermoplastics (LFT) offer a great opportunity to reduce component weight for automotive applications. But due to high manufacturing cost, metal-LFT hybrid components are still scarcely used in automotive large-scale production. Thus in this work a novel cost- and time efficient manufacturing process for simultaneous metal sheet forming and compression molding of long fiber reinforced thermoplastics to manufacture automotive lightweight components is presented. In this manufacturing process, which is referred to as “Hybrid forming”, a fiber reinforced thermoplastic melt is used as a forming medium in the manner of well-known hydroforming processes. After forming the metal sheet by polymer melt in combination with the rigid die, the melt solidifies and forms a local reinforcement structure in the hybrid component. Since the metal sheet is pre-coated with a bonding agent prior to the forming process, a firmly bonded connection between metal and LFT can be achieved.For proof of concept a longitudinal control arm in a multi-link rear axle is chosen. By utilizing Hybrid forming…
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Composite Suspension Leaf Springs: The Smart Solution

SGL Technologies GmbH-Peter Kuhn
SGL Technologies LLC-William Pinch
  • Technical Paper
  • 2020-01-0991
To be published on 2020-04-14 by SAE International in United States
2020 SAE Congress - Technical Paper Abstract "Smart Solutions for Electric Vehicle Suspensions" Session: Steering, Chassis and Suspension Authors: Peter Kuhn, SGL Technologies GmbH, Meitingen, Germany William D. Pinch, SGL Technologies LLC, Charlotte, NC USA Abstract: Battery Electric Vehicles (BEVs) Programs are becoming the vehicle of choice globally. This is driven by heightened vehicle emissions requirements and improved fuel economy performance. Vehicle requirements will be rolled down to Subsystems and Components. Subsystem requirements will be divided into upper and lower control planes with Kinematic performance targets discussed. Various types of front and rear suspensions will be identified and analyzed including MacPherson & Chapman Strut, Short-Long Arm (SLA), and various Multi-link arrangements. At the component level the use of innovative, lightweight composite materials provides a significant advantage. Besides ensuring technical feasibility, implementation on high volume production vehicles is essential for competing with aluminum and steel materials. Within suspension, Carbon Fiber Reinforced Polymer (CFRP) suspension links as well as lateral and longitudinal leaf springs made from Glass Fiber Reinforced Polymer (GFRP) materials are capable solutions. In addition,…
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new

In-Service Fiber Optic Inspection, Evaluation, and Cleaning, Best Practices, Expanded Beam Termini

AS-3 Fiber Optics and Applied Photonics Committee
  • Aerospace Standard
  • ARP6283/1
  • Current
Published 2020-03-18 by SAE International in United States
This document provides user information on best practice methods and processes for the in-service inspection, evaluation, and cleaning of expanded beam (EB) fiber optic interconnect components (termini, alignment sleeves, and connectors), test equipment, and test leads based on the information provided in AIR6031 and ARP6283. This document provides the user with a decision-making tool to determine if the fiber optic components are acceptable for operation with EB fiber optic termini.
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new

Electrically Non-Conductive Ladder Fall Protection

  • Magazine Article
  • TBMG-36194
Published 2020-03-01 by Tech Briefs Media Group in United States

NASA’s Kennedy Space Center developed an electrically non-conductive ladder fall protection system for the Launch Complex (LC) 39B lightning towers. The towers include a 100-foot fiberglass mast at the top of the tower structure. The fiberglass masts insulate the metallic tower structure from the lightning strike protection system that is housed at the top of the fiberglass masts.

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WIRE, ELECTRICAL, POLYVINYL CHLORIDE INSULATED, PVC-GLASS-POLYAMIDE, TIN-COATED COPPER CONDUCTOR, 600-VOLT, 105 °C

AE-8D Wire and Cable Committee
  • Aerospace Standard
  • AS50861/2A
  • Current
Published 2019-12-05 by SAE International in United States
No Abstract Available.
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Annotation ability available