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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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Realtime Tuning and optimization of EV traction motors with controllers on E-motor testbench

ARAI Academy-Manoj Desai
Automotive Research Association of India-Monishram Venkataram
  • Technical Paper
  • 2019-28-2478
To be published on 2019-11-21 by SAE International in United States
The need for dedicated development of indigenous electric power-train is becoming much essential in the recent times with upcoming trends and policies. Hence, The validation and optimization of the newly developed electric power-train becomes much crucial in order to ensure smooth real world operation. This can be only possible in E-motor test benches with dedicated equipment for thorough evaluation. Also, there are no practical limitations to check the peak characteristics in a controlled laboratory environment. Initially, the motor is setup by mechanically coupling with the dynamo-meter and the controller in the open loop method with constant parameters to check steady state operability without load or external parameters that affect the torque production and speed of the drive. Then progresses to closed loop method incorporating the feedback control and external parameters including torque loading at the shaft from the dynamo-meter. The output torque is primarily estimated from phase currents and forms as the feedback to alter the input to the drives. In closed loop control, the electric power train is run with either speed control or…
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Calculation of Drag Torque Losses by Component of a Transfer Case

Magna Powertrain of America, Inc.-Ricardo Rivera Rodriguez, Carlos Martinez
  • Technical Paper
  • 2019-01-2605
Published 2019-10-22 by SAE International in United States
In recent decades, fuel economy has become a key indicator of an automaker corporate social responsibility and a market differentiation factor, and ultimately it is regulated by government agencies such as EPA through CO2 emissions compliance tests. The light pick-up truck and SUV production share has been increasing in the last few years, being 4-wheel drive capability one of the main features that customers seek. Within the 4-Wheel Drive system, the transfer case has a significant impact to both torque transfer efficiency and parasitic losses. The scope of this paper is to better understand the parasitic losses of a transfer case by the quantification of its individual drag losses by component. At product development phases, one measurement of interest is the system level spin loss which has a target value defined by the automakers, and contribution by component is often neglected if the system has the expected performance. This study summarizes the tests performed on a 2-speed chain driven transfer case, where as a first step, a baseline spin loss measurement was taken, then the…
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Development of Methodology to Determine Toe Geometry of any Vehicle at Its Early Design Stage for Optimum Tyre Life

Mahindra & Mahindra, Ltd.-Nitin Kumar Khanna, Karthik Senthi, Vignesh Natarajan
Published 2019-10-11 by SAE International in United States
Toe setting is one of the major wheel alignment parameters which directly effects handling of a vehicle. Correct toe setting ensures desired dynamic behavior of an automobile like straight line stability, cornering behavior, handling and tire durability. Incorrect setting of toe during design stage significantly deteriorates tire durability and leads to uneven tire wear. In the present scenario of automotive industry, toe setting is majorly an iterative or a trial and error process which is both time consuming and involves higher development cost as there may be instances where 2 to 3 sets of iterations are needed before specification is finalized for production. Therefore, determining optimum toe setting at an early stage of a product development will not only save significant development time but it will also benefit in reducing product validation time and cost. Through this paper an attempt has been made to develop a methodology for deciding toe setting for any vehicle as a first time right approach to cut down on conventional expensive & time consuming iterative approach. In this new methodology…
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Improvement of Mechanical Properties, and Optimization of Process Parameters of AISI 1050 Spheriodized Annealed Steel by Ranking Algorithm

SRM Institute of Science and Technology-Durai Kumaran, Sundar Singh Sivam Sundarlingam Paramasivam, Krishnaswamy Saravanan, Raj Rajendran
Tishk International University-Ganesh Babu Loganathan
Published 2019-10-11 by SAE International in United States
AISI 1050 is used in the production of landing gear, actuators and other aerospace components but their application is limited due to machinability of the material. In any metal cutting operation the features of tools, input work materials, machine parameter settings will influence the process efficiency and output quality characteristics. A significant improvement in process efficiency may be obtained by process parameter optimization that identifies and determines the regions of critical process control factors leading to desired outputs or responses with acceptable variations ensuring a lower cost of manufacturing. This experimental study elucidates the problems and machinability issues like failure of tools and accuracy are found while machining and less output in machining. In the present study of spherodizing heat treatment of AISI 1050 was investigated during the turning operation in CNC lathe, under the consideration of several turning process parameters. The microstructures of the as-received, and heated specimens were investigated by Optical Microscopy (OM). A correlation between various process parameters on the desired response namely surface finish, roundness Material Removal Rate (MRR), power consumption…
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The Future of 3D Printing: From Prototyping to Production

  • Magazine Article
  • TBMG-35370
Published 2019-10-01 by Tech Briefs Media Group in United States

Additive manufacturing, better known as 3D printing, has been evolving for the last 30 years. Now it’s set to enter the mainstream, and evolving technology including new printers and 3D printed metals have the potential to transform manufacturing and logistics across multiple sectors.

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Rose-Inspired Device Collects and Purifies Water

  • Magazine Article
  • TBMG-35276
Published 2019-10-01 by Tech Briefs Media Group in United States

A new device, inspired by a rose, inexpensively collects and purifies water. The device is a new approach to solar steaming for water production — a technique that uses energy from sunlight to separate salt and other impurities from water through evaporation.

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CASTING AROUND FOR lightweight solutions

Automotive Engineering: October 2019

Stuart Birch
  • Magazine Article
  • 19AUTP10_02
Published 2019-10-01 by SAE International in United States

The United Kingdom's Grainger & Worrall is introducing and perfecting “new and imaginative” casting-technologies.

“Get more [efficiency] from less [weight, time, cost],” is a mantra that will be chanted sotto voce by many an automotive designer and engineer facing the latest list of a new vehicle's “requirements.”

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Q&A

Automotive Engineering: October 2019

  • Magazine Article
  • 19AUTP10_16
Published 2019-10-01 by SAE International in United States

Swamy Kotagiri is Magna's chief technology officer and head of the company's Power & Vision segment. Automotive Engineering contributor Sebastian Blanco spoke with him at the 2019 opening of Magna Electronics' new manufacturing facility near Holly, Michigan. There, the company will be consolidating production lines to make and fully test around 12 million automotive-grade cameras a year. Some highlights of our conversation:

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3D Printing: SLS Creates New Potential for Design in Medical Technology

  • Magazine Article
  • TBMG-35366
Published 2019-10-01 by Tech Briefs Media Group in United States

Laser sintering technology enables medical technology designers to print plastic objects for feasibility studies within a very short time. The functional prototypes largely have the same properties as injection-molded parts. EEM AG goes one step further: It manages a balancing act between the production of prototypes and small series.