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Mechanical Property Evaluation of Paper Honeycomb reinforced Plastics

Hyundai Motor India Engineering PVT LTD-Vignesh balaji S G, Pradeep S, Aakash S K
  • Technical Paper
  • 2019-28-2538
To be published on 2019-11-21 by SAE International in United States
Mechanical Property Evaluation of Paper Honeycomb Reinforced Plastics Vignesh Balaji S G, Pradeep Hyundai Motor India Engineering Pvt. Ltd, Chennai. India Key Words: Paper Honeycomb, Epoxy Composites, Mechanical Properties, Tensile, Impact & Flexural Test Research and/or Engineering Questions/Objective : Composite Materials are widely being used in many engineering applications because of their desirable properties & Cost, Weight Effectiveness. They are widely being used as their Strength-Weight Ratio is Higher than any Other Material. Paper Honeycomb Material is basically a paper made of honeycomb shapes enforced between layers of Glass Mat. This paper deals with the evaluation of Tensile Strength, Flexural (Three-Point Bending) Strength & Flexural Modulus, Impact Strength of Paper Honeycomb Reinforced Epoxy Composites. The Scope of this Material defines the quality of Paper Honeycomb Reinforced Composites which can be used for Automotive Trim Parts. Methodology: Before beginning the tests, the specimens should be prepared and the steps for the preparation of paper honeycomb reinforced epoxy composites are shown below: 1. Mould Preparation 2. Mixing of Epoxy and Hardener with a ratio of 10:1 3.…
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Characterization and Durability of Mold-In-Color Engineering Plastics

Mahindra & Mahindra, Ltd.-Sandeep Kumar Shukla
  • Technical Paper
  • 2019-28-2542
To be published on 2019-11-21 by SAE International in United States
Plastics are prone to photo oxidative and thermal oxidative degradation under usage conditions due to their chemical nature. From sustainability and cost standpoint, there is an increasing focus on Mold-In-Color (MIC) plastic materials. Simultaneously customer’s expectations on the perceived quality of these MIC parts has been increasing with attractive color and glossy appearance. A study was conducted to analyze the product quality and durability aspects over a prolonged exposure to accelerated weathering condition. Material selected for this study were injection molded specimens of ABS and PC/ABS used in automotive passenger vehicles. Comparative analysis was conducted before and after weathering exposure at defined intervals by using the various tools like Fourier Transform infra-red spectrometer (FTIR), thermogravimetric analyzer (TGA) and universal testing machine (UTM), Izod impact tester, dynamic mechanical analyzer (DMA) to understand the impact on their chemical and mechanical properties. This study will be useful in understanding material behavior, durability, performance and product quality.
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LIGHT WEIGHTING OF ADDITIVE MANUFACTURED PARTS FOR AUTOMOTIVE PRODUCTION APPLICATIONS THROUGH TOPOLOGY OPTIMIZATION TECHNIQUES

General Motors Technical Center India-Abhijith Naik, T Sujan, Suraj Desai, Saravanakumar Shanmugam
  • Technical Paper
  • 2019-28-2544
To be published on 2019-11-21 by SAE International in United States
Rapidly enhancing engineering techniques to manufacture components in quick turnaround time have gained importance in recent time. Manufacturing strategies like Additive Manufacturing (AM) are a key enabler for achieving them. Unlike traditional manufacturing techniques such as injection molding, casting etc., AM unites advanced materials, machines, and software which will be critical for Industry 4.0. Successful application of AM involves a specific combination and understanding of these three key elements. In this paper the AM approach used is Fused Deposition Modelling (FDM). Since material costs contribute to 60% of the overall FDM costs, it becomes a necessity to optimize the material consumption of the produced parts. This paper reports case studies of 3D printed parts used in an Automobile plant’s production aids, which utilize computational methods(CAE), topology optimization and FDM constrains (build directions) to manufacture the part in the most optimal way. These methodologies were used to validate the current operating conditions, optimize the design, increase the stiffness of the original part and reduce the material costs. The newly optimized designs were verified by successfully passing…
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MOLD IN COLOR DIAMOND WHITE ASA MATERIAL FOR AUTOMOTIVE EXTERIOR APPLICATION

Mahindra & Mahindra Ltd-Karthik Govindaraj, K V Balaji, Murukesan Vimalathithan, Gandhi Samir, Ladhe Rajesh
  • Technical Paper
  • 2019-28-2562
To be published on 2019-11-21 by SAE International in United States
In this paper, mold in color diamond white ASA material has been explored for front bumper grill, fender arch extension and hinge cover applications. Other than aesthetic requirements, these parts have precise fitment requirement under sun load condition in real world usage profile. Structural durability of the design was validated by virtual engineering. Part design and material combinations with better tooling design iterations were analysed by using mold flow analysis. Complete product performances were validated for predefined key test metrics such as structural durability, thermal aging, cold impact, scratch resistance, and weathering criteria. This part met required specification. This mold in color ASA material-based parts has various benefits such as environmentally friendly manufacturing by eliminating environmental issues of coating, easily recycled, and faster part production because intended color achieved in one step during molding. Also, it lowers overall production energy footprint, less scrap with no secondary painting, and lower final part cost by eliminating secondary operations.
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Design of Additive Manufactured Thermoplastic Component as FMVSS 201U Countermeasure

General Motors Technical Center India-Swaroop Kavi
  • Technical Paper
  • 2019-28-2547
To be published on 2019-11-21 by SAE International in United States
Research and/or Engineering Questing/Objectives: Safety of the occupant in passenger cars is one of the regulatory requirements in many developed countries. This includes upper interior head impact load case of the unbelted occupant during crash (FMVSS 201U) as one of them. During a crash event the occupant head can collide with the interior parts of the vehicle, such as a headliner, pillar trim and other subsequent components in the loading direction. Injury on the head is quantified in terms of the Head Injury Criterion of a crash test dummy (HIC(d)) value which should be less than 1000 per standard. Several ways can be adopted to reduce the HIC(d) value. These include a change in the design of ribs in the safety plastic components, headliner profile change, use of countermeasure foam between headliner and the exterior sheet metal parts, or a combination of any of these to absorb the energy of impact. Recent developments in the field of manufacturing, such as the Additive Manufacturing (AM) method, have provided an opportunity to design and manufacture components with…
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SIMULATION OF SOFTENING AND RUPTURE IN MULTILAYERED FUEL TANK MATERIAL

General Motors Technical Center India-Vijaya Kumar R L, Biswajit Tripathy, Jayaraj Radhakrishnan
  • Technical Paper
  • 2019-28-2557
To be published on 2019-11-21 by SAE International in United States
Research and/or Engineering Questions/Objective Plastic automotive fuel tanks made up of blow molded, multi-layered, high-density polyethylene (HDPE) material can take complex shapes with varying thickness. Accidental drop of fuel tank from a height during handling can lead to development of cracks. Damage can also occur due to an impact during a crash. This can be catastrophic due to flammability of the fuel. The objective of this work is to characterize and develop a failure model for the fuel tank material to simulate damage and enhance predictive capability of CAE for chassis and safety load cases. Methodology Different aspects were considered to develop a characterization and modelling strategy for the HDPE fuel tank. Material properties can be influenced by factors such as, service temperature, rate of deformation, state of stress etc. Hence, samples cut-out from different regions of the fuel tank were subjected to a variety of tests such as tensile test at different strain rates viz. 0.01/s, 0.1/s, 1/s, 10/s and 100/s, compression, shear, flexure and instrumented dart impact tests at different temperatures, -40°C, 23°C…
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Design and Analysis of Natural Fibre Reinforced Epoxy Composites for Automobile Hood

SRM Institute Of Science And Technology-Akhil Kumar Guduru, V N B Prasad Sodisetty, Vidya Prudhvi Sai Katari
  • Technical Paper
  • 2019-28-0086
To be published on 2019-10-11 by SAE International in United States
The need for eco-friendly materials is recently increasing in the automobile and aerospace sectors. Material selection for automobile components is influenced by various factors such as cost, weight and strength. Natural fibers offers various advantages over conventional materials such as environmental friendly, easily available, recyclable and higher specific strength. Among the natural fibers Sisal and Kenaf fibers are selected for present study due to their good mechanical properties and availability. Kenaf fibers have great potential to be used as construction and automotive materials due to their long fibers which are derived from the bast. Sisal fibers do not absorb moisture and possess good impact, sound absorbing properties and high fire resistance properties. Epoxy LY556 is selected as matrix material to bind the combination of these two natural fibers due to its high temperature resistance and adherence to reinforcements. Alkaline treatment was carried out to remove the moisture from the natural fibers. Fabrication of epoxy/Kenaf fibre/Sisal Fibre composite materials of different stacking sequence was carried out by Vacuum Assisted Resin Transfer Molding (VARTM) method. These composites…
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SEAL, BONDED, ALUMINUM ALLOY 6061-T6, AMS4027, MOLD IN GROOVE, NBR RUBBER, AMS-R-7362

A-6C2 Seals Committee
  • Aerospace Standard
  • AS27195B
  • Current
Published 2019-09-03 by SAE International in United States

Scope is unavailable.

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SEAL, BONDED, 302 CORROSION RESISTANT STEEL, AMS5516, MOLD IN GROOVE, FLUOROSILICONE RUBBER, MIL-DTL-25988

A-6C2 Seals Committee
  • Aerospace Standard
  • AS27198C
  • Current
Published 2019-09-03 by SAE International in United States

Scope is unavailable.

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SEAL, BONDED, 302 CORROSION RESISTANT STEEL, AMS5516, MOLD IN GROOVE, FLUOROCARBON RUBBER, AMS7276

A-6C2 Seals Committee
  • Aerospace Standard
  • AS27196C
  • Current
Published 2019-09-03 by SAE International in United States

Scope is unavailable.