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Automotive Dimensional Quality Control with Geometry Tree Process

FCA US LLC-James Cole, Yuqin Wang, Robert Bertucci
  • Technical Paper
  • 2020-01-0480
To be published on 2020-04-14 by SAE International in United States
Geometry Tree is a term describing the product assembly structure and the manufacturing process for the product. The concept refers to the assembly structure of the final vehicle (the Part Tree) and the assembly process and tools for the final product (the Process Tree). In the past few years, the Geometry Tree-based quality process was piloted in the FCA NAFTA region and has since evolved into a standardized quality control process. In the Part Tree process, the coordinated measurements and naming convention are enforced throughout the different levels of product sub-assemblies and measurement processes. The Process Tree, on the other hand, includes both prominently identified assembly tools and the mapping of key product characteristics to key assembly tools. The benefits of directly tying critical customer characteristics to actual machine components that have a high propensity to influence them is both preventive and reactive. This article describes the integrated Geometry Tree quality process and how it has been implemented at the FCA vehicle assembly plants and in the dimensional data management system.
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Phenolic SMC for Automotive Fire Resistance

Hexion Inc.-Ian Swentek, Cedric A. Ball, Stephen Greydanus, Kameswara Rao Nara
  • Technical Paper
  • 2020-01-0771
To be published on 2020-04-14 by SAE International in United States
Phenolic resins that meet REACH compliance and contain lower free-formaldehyde are safer to handle, compound, and mold. These resin systems do not contain any styrene or require any fillers to achieve their rated fire resistance. A commercial phenolic sheet-molding compound (SMC) is presented that achieves a 2-minute cycle time and addresses the unique requirements in an electrified vehicle architecture. This new SMC material includes all the industrially relevant considerations including material processing, shelf life, and surface finish. Other topics such as material hybridization and comparison to incumbent materials also discussed. The resin system uses a water-based phenolic resole which is acid-cured. This chemistry presents several unique challenges and opportunities for the industry such as managing formulation pH and appropriate methods for quality control. A demonstrator battery cover highlights the superior fire performance, impact resistance, and light weighting that is achieved with this resin technology. The phenolic SMC formulation is compatible with already established engineering fibers and textiles resulting in low-shrink, creep-resistant composites. The mechanical performance demonstrates strength and impact energy absorption greater than cast aluminum,…
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Reconciling Simultaneous Evolution of Ground Vehicle Capabilities and Operator Preferences

FCA US LLC-Christopher Slon
Oakland University-Vijitashwa Pandey
  • Technical Paper
  • 2020-01-0172
To be published on 2020-04-14 by SAE International in United States
An objective evaluation of ground vehicle performance is a challenging task. This is further exacerbated by the increasing level of autonomy, dynamically changing the roles and capabilities of these vehicles. In the context of decision making involving these vehicles, as the capabilities of the vehicles improve, there is a concurrent change in the preferences of the decision makers operating the vehicles that must be accounted for. Decision based methods are a natural choice when multiple conflicting attributes are present, however, most of the literature focuses on static preferences. In this paper, we provide a sequential Bayesian framework to accommodate time varying preferences. The utility function is considered a stochastic function with the shape parameters themselves being random variables. In the proposed approach, initially the shape parameters model either uncertain preferences or variation in the preferences because of the presence of multiple decision makers. We consider this utility distribution as the prior and update it to a posterior with feedback that can be acquired from actual system use. The framework improves the utility function and thereby…
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Parametric Study of Spring-Back Effects in Deep Drawing by Design of Experiment

University of Detroit Mercy-Ramzi S. Youssif, Mostafa Mehrabi
  • Technical Paper
  • 2020-01-0750
To be published on 2020-04-14 by SAE International in United States
Deep drawing is a sheet metal forming process in which metal blank is radially drawn into a forming die by the mechanical action of the punch. Dimensional tolerances and their variations are important aspects of quality control issues in this forming operation. In this regard, the spring-back effect is an inherent phenomenon that directly affects the final dimensions of the part produced. This research work is focused on analysis and control of spring-back in deep drawing processes. It is mainly focused on design and implementation/simulation of control strategies to minimize that. In this regard, the impact of various process parameters such as lubrication, punch speed, punch and die nose radius, and blank holding force is studied through design of experiment methodology. In particular, this study is focused on the design and development of various control strategies to minimize spring back in this process. An experimental set up is designed and developed to facilitate this research. This paper presents some of the experimental results obtained from this study.
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Leading Women in Engineering & Science: Anne F. Booth, Owner/President, Booth Scientific Sterilization and Quality System Professionals

  • Magazine Article
  • TBMG-36291
Published 2020-03-01 by Tech Briefs Media Group in United States

What led you to choose science and/or engineering as a career, particularly in the medical device field?

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Inspection of Worn Involute Splines

EG-1 Aerospace Propulsion Systems Support Equipment
  • Aerospace Standard
  • ARP1111A
  • Current
Published 2020-02-03 by SAE International in United States
This concept for measuring worn splines provides a direct wear depth dimension by utilizing the unworn involute surface as a contact point from which to measure the depth of wear on the spline tooth at the pitch diameter. Fig. 1 shows spline wear patterns and pitch diameter gaging points.
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Implementing an Aerospace Factory OF THE FUTURE

Aerospace & Defense Technology: February 2020

  • Magazine Article
  • 20AERP02_04
Published 2020-02-01 by SAE International in United States

Companies across a wide range of segments are introducing Industry 4.0 (i4.0) technology at a rapid pace, turning the next-generation vision of manufacturing - the Factory of the Future - into reality. Many of the advances in this transformation have been in highly automated industries such as vehicle manufacturing. Conversely, the aerospace industry, with its staged approach to assembling aircraft, satellites and other products, has only begun to investigate how i4.0 technologies can improve operations, throughput, quality control and cost challenges.

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Implementing an Aerospace Factory of the Future

  • Magazine Article
  • TBMG-36056
Published 2020-02-01 by Tech Briefs Media Group in United States

Companies across a wide range of segments are introducing Industry 4.0 (i4.0) technology at a rapid pace, turning the next-generation vision of manufacturing — the Factory of the Future — into reality. Many of the advances in this transformation have been in highly automated industries such as vehicle manufacturing. Conversely, the aerospace industry, with its staged approach to assembling aircraft, satellites and other products, has only begun to investigate how i4.0 technologies can improve operations, throughput, quality control and cost challenges.

AS9100D Overview

  • Professional Development
  • PD631833
Published 2020-01-08

Developed by SAE International, AS9100D is a quality management standard applicable to the aviation, space, and defense industry. It includes ISO 9001:2015 quality management system requirements and specifies additional aviation, space and defense industry requirements, definitions, and notes. The requirements specified in this standard are complementary (not alternative) to customer and applicable statutory and regulatory requirements.

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Forgings, Steel For Aircraft/Aerospace Equipment

AMS E Carbon and Low Alloy Steels Committee
  • Aerospace Material Specification
  • AMS6400A
  • Current
Published 2019-12-02 by SAE International in United States
This specification establishes requirements for steel forgings of any shape or form from which finished parts are to be made (See 8.2, 8.3, & 8.4). This specification covers steel forgings suitable for use in the construction of aircraft/aerospace equipment
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