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Injection Forging of Solid Asymmetric Branched Components

Technical University of Lisbon - Luis M. Alves, Paulo A. F. Martins
  • Journal Article
  • 16-227-6-898
Published 2013-06-01 by SAGE Publications in United Kingdom
Injection forging allows producing near-net or net-shape asymmetric branched components with geometries that are difficult or impossible to fabricate by means of conventional impression die forging. On the contrary to previous research work in the field that was mainly focused on proposing methodologies for shape classification, systematization of forming defects, definition of workability ranges and evaluation of the overall performance of finite element predictions against experiments, the aims and scope of this article are centered in material flow and forging load requirements that result from double-acting tool concepts with closing spring elements. The presentation includes details on the active tool parts that were utilized for producing solid branched components with different numbers of radial straight legs, on the mechanical characterization of the material and on the numerical simulation and experiments that were performed with selected test cases. Results and observations confirm that double-acting tool concept with closing spring elements is a flexible and efficient manufacturing process for producing injection forged components because it can eliminate the formability problems and defects that are commonly found in…

Force Optimization of Planar 2-DOF Parallel Manipulators With Actuation Redundancy Considering Deformation

Tsinghua Univ. - Jun Wu, Tiemin Li, Boqiang Xu
  • Journal Article
  • 17-227-6-1371
Published 2013-06-01 by SAGE Publications in United Kingdom
Internal force distribution is one of the most important issues for redundantly actuated parallel manipulators. This article presents a novel method for optimizing internal force to minimize the deformation of key components in a parallel manipulator. The dynamic model is first derived, and then an objective function is proposed by giving different weights on internal forces of different components based on its flexibility. The deformation of the component with big flexibility is minimized. A planar 2-DOF parallel manipulator with actuation redundancy is taken as an example to validate the force optimization method. The simulation results show that the deformation of the manipulator with the force optimization method proposed in this article is smaller than that with the traditional method to minimize the norm of driving forces. Thus, the manipulator precision can be improved.

Utilization of Finite Element Analysis to Develop Automotive Components

Aalborg Univ.-Luiz Carlos H. Ricardo
Virginia Tech-Norman E. Dowling
Published 2010-10-06 by SAE International in United States
The finite element method (FEM) is used daily in the automotive industry for such purposes as reducing the time of product development and improving the design based on analysis results, followed by later validation by tests in the laboratory and on the proving ground. This paper will present some of the methodology used to develop automotive components by finite element analysis, including procedures to specialize FEM models to obtain quantitative and qualitative results for systems such as body, chassis, and suspension components, as well as validation of the models by experimental data.
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Examination of Crack Growth Behavior in Induction Hardened Material Under Torsional Fatigue

Toyota Motor Corp.-Masahiro Fujimoto, Atsushi Fujii, Nobuyuki Matsumiya
  • Technical Paper
  • 2010-08-0154
Published 2010-05-19 by Society of Automotive Engineers of Japan in Japan
Induction hardening is widely used for chassis components to add compressive stress there to control crack growth, since wear resistance and fatigue fracture strength are highly required. Therefore, it is crucial that the defect influence is examined with being compressive residual stress on the parts.In this report, the relationship between crack depth and compressive residual stress was evaluated using cylindrical specimen and torsional fatigue test. Consequently, the test results followed CAE obtained in advance. In future, it is necessary to make this method applicable to the produce design to improve vehicle safety performance further.

Application of Advanced High Strength Steel to NVH Components

Bailey Tool & Manufacturing-T. Howard, K. Raghavan, J. Buttles
Published 2009-04-20 by SAE International in United States
Most applications for Dual Phase hot rolled steel have been large components like frame members that yield significant weight savings. Difficulties in secondary forming have limited the range of parts produced. One area with good potential is noise-vibration-harshness components (NVH), since such parts tend to be heavy gauge. Significant weight reduction should be possible through thinner steel without compromising design requirements, also potentially reducing cost as well. Fatigue properties of Dual Phase also match well with these applications. We have successfully produced a multi-stage deep drawn cup for an engine mount using DP590/600 from different steel sources, demonstrating this material can be used for a new group of applications.
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A Practical Design Process to Optimize Fatigue Performance for Chassis Components

ZF Lemforder Corporation-Shawn Zhang, Andrew Chen
Published 2009-04-20 by SAE International in United States
In the chassis component design, meeting fatigue life requirements with minimum weight is one of critical tasks. Currently chassis components are optimized for minimizing the weight while meeting design requirements of stiffness and strength with topology and shape optimization. In early design phase, topology optimization is utilized to create the optimal material layout for the component within the given design space and constraints. Then shape optimization can be used to determine the final design shape with minimum weight. Recent technology advance makes automotive OEMs to shift to durability duty cycle as one of their component design specifications in order to design an efficient component. However, the duty cycle counts or fatigue life requirement can not be easily integrated with the current design optimization process. It is time consuming and involving numerous design iterations to directly consider the fatigue life requirement in the design optimization. In this paper we propose an effective optimization process to include the effect of the fatigue life requirement in shape optimization based on our current design optimization process. Our approach is…
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Improved Efficiency by Use of Sinter-Hardened P/M Automotive Components

Chicago Powdered Metals Products Co.-Thomas J. Miller
Drever Co.-James Groark
Published 2000-03-06 by SAE International in United States
No Abstract Available.
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Fatigue Life Estimation of Chassis Components With Out-Of-Phase Loading

A. Mayer, H. Kötzle
  • Technical Paper
  • 967130
Published 1996-09-16 by Verlag Des Verein Deutscher Ingenieure GmbH in Germany
For reasons of time and cost, extensive tests for evaluating each development loop of chassis components are out of the question in the future. A relative evaluation of the component strength at each development stage is to be achieved by means of simulation. Only the most essential development steps should be verified by means of pertinent on-vehicle and rig testing.To allow a relative comparison of variants in the development process, models of load-time histories, representation of local - mainly multiaxial stresses, will be evaluated with regard to material fatigue using considerations of material behavior and production techniques. It is this step that forms the basis for a mathematical preoptimization of complex components with respect to their geometry and load.The technique is illustrated by means of the rear axle carrier of the Mercedes E class.

Prototyping and Testing of PM Automotive Components

Sintermetal SA-A. Romero
  • Technical Paper
  • 1993-25-0592
Published 1993-09-13 by ISATA - Dusseldorf Trade Fair in United Kingdom
Requirements of the automotive industry for the development of PM automotive components are revised. Methods of PM prototype manufacturing are discussed in view of process and part design aspects and characteristics to be tested. Case studies are presented.

The way ahead for the automotive component industry

Robert Bosch Australia-Hans Hugendubel
  • Technical Paper
  • 1992-10-0021
Published 1992-05-21 by SAE Australasia in Australia
A forecast for the future of the automotive industry in Austrailia is presented by an Economist from Robert Bosch Austrailia, an international component development and supply company. The status of the industry, the need for international cooperation, export potential, competitiveness, technology, and how Bosch fits into the overall equation are subjects which are discussed in further detail. A summary which calls for international cooperation is also included.