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The effects of contamination on commercial trucks rear suspension springs durability

Ford Motor Company-Milton Monteverde Belli, Amilcar Tyrrell Tavares
Suspensys-Eugenio Noro, Graebin Matheus
  • Technical Paper
  • 2019-36-0083
Published 2020-01-13 by SAE International in United States
On current competitive scenario for road load transportation in Brazilian market, the operational costs should be reduced as much as possible. The suspension system commonly used on road commercial trucks is based on leaf spring use and Hotchkiss concept for axle locating devices. The use of leaf springs without bolt attachment eyelets are still common for rear suspension systems. When using the leaf spring with direct contact to the brackets, wear plates are placed between them to work as wear elements due to the friction between the parts. The friction will cause wear on the parts, and the wear plate is designed to suffer the damages of this friction instead of the leaf spring, being the cheapest element and can be easily replaced. When the system works on a severe contamination environment with high levels of grit and dirt, the degradation of the parts are accelerated. With a considerable amount of grit between the wear plate and the leaf spring, the damage caused on the leaf surface is increased and lead to a spring failure…
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Buzz Avoidance on Sunroof Light Sunshades: Design and Validation

Ford Motor Company-Douglas Demori, Marcos Paulo de Oliveira, Rosiane Viegas
MSX International-Douglas França
  • Technical Paper
  • 2019-36-0148
Published 2020-01-13 by SAE International in United States
Sunroof is placed in certain high-end vehicles to give user a better driving experience. All automakers are searching alternatives to reduce weight and cost in the vehicle, in which sunroofs are also impacted. Some alternatives are already applied, as a honeycomb paper used in some sunshades that presents benefits, as less weight and with a good cost reduction. Although, due the reduced weight for this part produced in this material, it shows more susceptibility to reproduce the vibration that vehicle propagates in movement, especially in bad condition roads. The sunroof assembly is dependent of the roof reinforcement and roof skin, but in this special case, the validation could be done in the components itself because the interaction of the sunshades is directly dependent of the other sunroof parts, as rails and front frame. These buzz noise in lights sunshades is perceptible when it is almost or totally close, since lighter material vibrates freely without rail anchorage, then clashing against the front frame surface. Considering the package, the key point is to design the sunshade to…
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Microstructural Characterization of Hot Stamped Parts After Partial Hardening

BENTELER Automotive-Tiago Santos Pinheiro
  • Technical Paper
  • 2019-36-0113
Published 2020-01-13 by SAE International in United States
Hot forming is a process that has been on the spotlight of body-in-white recent developments, globally it was estimated that around 500 million parts would be produced in 2018. During the process, a blank of a 22MnB5 steel is heated, above 900 °C, in the austenite field, formed and quenched in the pressing machine, with the goal of producing a part with ultimate tensile strength (UTS) around 1500 MPa, achieved by a fully martensitic microstructure. However, from the point of view of crashworthiness, not all body in white components benefit from a fully martensitic microstructure. Alternative process routes have been proposed to achieve properties that are tailored to the part’s final application. In one of these process variants, known as partial hardening, the blank is heated in a furnace that operates with two parallel zones, each at a different temperature (one zone between 650 and 750 °C and one between 900 and 930°C), resulting in the blank having two main zones with different final temperatures, and a transition zone between them. This difference in temperature…
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Robustness Design to Avoid Noise on Exterior Handle System

Ford Motor Company-Douglas Demori, Júlio Magalhães, Cristiane Carla Gonçalves, Helano Santos
  • Technical Paper
  • 2019-36-0137
Published 2020-01-13 by SAE International in United States
Squeak and rattle are two undesirable occurrences during component operation and during vehicle driving condition, resulting in one of the top complains from costumers. One common grievance could happen during the user exterior handle operation and during side door closing. The exterior handle system during the operation could generate a squeak between interface parts, if materials and geometric tolerances was not been carefully designed. Also, vibration generated during door closing effort, might generate squeak between parts since the reinforcement for exterior handle touches the outer sheet metal internally. For this reason several guidelines might be included to avoid potential noise condition for this system during vehicle lifetime as correct material reduce friction between parts, taking into consideration the geometric condition between parts. Plus, coupling system on handles two pieces should also be evaluated to avoid squeak during use. Not less important, if required anti-shock material system may be applied to eliminate a clash produced between parts during excessive vibration. It is extremely important to evaluate the environment that the vehicle will be exposed since the…
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Optimization and Numerical Simulation Applied to Design of Stamping Dies

Federal University of Sao Joao del Rei – UFSJ-Otavio Andrade, Marcio Eduardo Silveira
  • Technical Paper
  • 2019-36-0142
Published 2020-01-13 by SAE International in United States
The stamping process is commonly used, it is easily found in vehicles manufacturing. The stamping tool is composed by elements such as: die, punch, drawbeads and blankholder. The objective of this paper is to improve the structural stiffness and to reduce the weight of die through numerical optimization. Usually are used standardized stamping tool's parts that follows standard guidelines. The only part of stamping tool considered in the methodology was the die, other parts like punch and blankholder can also be optimized. A vehicle hood was designed in CAD and after that it was exported to CAE to start the simulations, the first step was the die generation. After that, a stamping process was simulated and the contact forces in the die were extracted and then applied in the control volume designed in CAD. Finally, the constraints, objectives and parameters were changed, so the topological optimization was generated. The results were interpreted and a layout were design in CAD following the pattern given by the optimization. Two different load cases are applied to the die…
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ACCESSORY, NUT, CONNECTOR MOUNTING, SLOTTED, HEXAGON, CONNECTOR, ELECTRICAL, CIRCULAR, HIGH DENSITY, QUICK DISCONNECT, ENVIRONMENT RESISTING (SERIES 1 OR 2)

AE-8C1 Connectors Committee
  • Aerospace Standard
  • AS81511/20A
  • Current
Published 2020-01-06 by SAE International in United States

Scope is unavailable.

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Coupling Assembly, Hydraulic Self Sealing, Quick Disconnect

G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
  • Aerospace Standard
  • AS1709B
  • Current
Published 2020-01-06 by SAE International in United States

This specification covers the requirements for aircraft, hydraulic, self-sealing, quick disconnect couplings, for use in Type II hydraulic systems (-65 to +275 °F temperature range) as defined by AS5440.

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Pin, Straight, Headed, .2499 Diameter, Uns S41800

E-25 General Standards for Aerospace and Propulsion Systems
  • Aerospace Standard
  • AS9845C
  • Current
Published 2020-01-06 by SAE International in United States

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Male Ferrule, Threadless - Flexible, Fixed Cavity, Self-Bonding, Butt Welded

G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
  • Aerospace Standard
  • AS7516C
  • Current
Published 2020-01-06 by SAE International in United States

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PIN, STRAIGHT, HEADLESS, DOWEL - CORROSION AND HEAT RESISTANT STEEL (UNS S66286), STANDARD AND OVERSIZE

E-25 General Standards for Aerospace and Propulsion Systems
  • Aerospace Standard
  • AS9390D
  • Current
Published 2019-12-27 by SAE International in United States

Scope is unavailable.