The automotive industry is facing unprecedented pressure to reduce costs without compromising on quality and performance, particularly in the design and manufacturing. This paper provides a technical review of the multifaceted challenges involved in achieving cost efficiency while maintaining financial viability, functional integrity, and market competitiveness. Financial viability stands as a primary obstacle in cost reduction projects. The demand for innovative products needs to be balanced with the need for affordable materials while maintaining structural integrity. Suppliers’ cost structures, raw material fluctuations, and production volumes must be considered on the way to obtain optimal costs. Functional aspects lead to another layer of complexity, once changes in design or materials should not compromise safety, durability, or performance. Rigorous testing and simulation tools are indispensable to validate changes in the manufacturing process. Marketing considerations are also

Oliveira Neto, Raimundo Arrais, Souza, Camila Gomes Peçanha, Brito, Luis Roberto Bonfim, Guimarães, Georges Louis Nogueira

Deep Learning Approaches to Predict the Life Cycle of Lithium-Ion Batteries in Electric Vehicles

2024-36-0181

12/20/2024

Predictive maintenance is crucial for Industry 4.0, and deep neural networks are a promising approach for predicting the capacity of electric batteries. However, few applications effectively utilize neural networks for this purpose with lithium-ion batteries. In this work, different deep learning models are developed, starting with simple neural networks, dense neural networks, convolutional networks, and recurrent networks. Using a public domain dataset, training, testing, and validation datasets were generated to predict battery capacity as a function of the number of cycles. Despite the limited number of samples in the dataset, deep learning techniques are employed to ensure robust prediction performance. The work presents the loss functions for each iteration of the algorithms and the average absolute error. The models made good generalizations over the test dataset within a short prediction time window. Finally, the work presents an average absolute error below 0.3, ensuring good

Branco, César Tadeu Nasser Medeiros

Hydrogen as a Fuel Cell: A Comparative between the Gas and Liquid State and Storage

2024-36-0128

12/20/2024

It is emerging the need to take action to reduce the greenhouse effect, which is one of the major causes of climate change and environmental disasters that has been occurring frequently in recent decades throughout the planet. The burning of fossil fuels for electricity and energy generation are the main concerns and those that have greater incentives for its reduction, as its by-product of the reaction of burning CO2, which among the greenhouse gases is primarily responsible for its aggravation. The transport sector excels in CO2 emissions, emits about 20% of gas, according to the Intergovernmental Panel on Climate Change (IPCC), a scientific organization linked to the United Nations (UN). A promising solution to reduce the impact of this sector would be the use of hydrogen fuel cell, which if carried out through renewable energies, the electrolysis of hydrogen has zero CO2 emission throughout the cycle. However, one of the biggest challenges to make viable the use of hydrogen as fuel

Alves, Joyce, Silva, Antônio, Paterlini, Bruno, Santos, Felipe, Pedroso, Henrique, Henrique, Pedro, Milani, Pedro

Ground Height and Pitch Angle Influence on the Aerodynamic Behavior of a Production Pickup Truck

2024-36-0011

12/20/2024

The fuel economy performance of road vehicles is one of the most important factors for a successful project in the current automotive industry due to greenhouse effect gases reduction goals. Aerodynamics and vehicle dynamics play key roles on leading the automaker fulfill those factors. The drag coefficient and frontal area of the vehicle are affected by several conditions, where the ground height and pitch angle are very relevant, especially for pickup trucks. In this work, we present a combined study of suspension trim heights and aerodynamics performance of a production pickup truck, where three different loading conditions are considered. The three weight configurations are evaluated both in terms of ground height and pitch angle change considering the suspension and tires deflection and these changes are evaluated in terms of drag coefficient performance, using a Lattice-Boltzmann transient solver. Results are compared with the baseline vehicle at road speed condition, where both

Buscariolo, Filipe Fabian, Terra, Rafael Tedim

Laser Welding Applied to Complex Phase Steel

2024-36-0159

12/20/2024

The development of advanced high-strength steels has become essential in the production of lightweight, safe, and more economical vehicles within the context of the automotive industry. Among the advanced high-strength steels, complex phase steels stand out, characterized by their high formability and high energy absorption and deformation capacity. Laser welding is a technique that applies laser using high energy density as a heat source. It has the advantages that the high welding speed and low heat input compared to other welding methods cause a decrease in deformation, and the narrow width of the weld bead and heat-affected zone allows for the welding of complex parts that would be difficult for other welding methods. Based on a study of a complex phase steel, an analysis was made of the microstructures observed by optical microscopy, the grain boundaries and certain phases contained in this microstructure, as well as the microstructures of each area in the laser welding region

Dias, Erica Ximenes, Reis de Faria Neto, Antonio, Castro, Thais Santos, Martins, Marcelo Sampaio, Santos Pereira, Marcelo

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