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2015-04-27
Article
The BZ-Marker from Markator is suitable for CNC machining centers to generate a durable marking on many different kinds of materials.
2015-04-27
Standard
AMS03_3
This SAE Standard specifies the requirements for the application of sprayed metal coatings of aluminum, zinc, or aluminum-zinc based alloys for the protection of aluminum alloys against corrosion. It does not cover the metal spraying of aluminum armour materials, which should be treated in accordance with the requirements of Def Stan 08-39.
2015-04-27
Standard
AMS03_4
This SAE Standard specifies the special treatments and precautions that are to be observed when protective and other surface treatments are applied to items, including springs, made from steel of specified maximum tensile strength exceeding 1450 MPa. The requirements of this Standard qualify those in process specifications and override the latter where there is conflict. The Standard also gives advice on design, manufacture, and preparation of items prior to cleaning and protection.
2015-04-27
Standard
AMS03_2
This SAE Standard specifies processes for the cleaning of metal surfaces to remove any extraneous or undesirable material or deposits at any stage of manufacture, storage or service and for the preparation of these surfaces for further treatment. Any necessary stress-relieving treatments are also included. This Standard does not override special preparatory procedures specified in individual Defence Standards, Defence Specifications, DTD Process Specifications, DG Ships Specifications and Naval Defence Standards. It also does not cover cleaning operations associated with the maintenance of internal combustion engines, the preliminary removal of heavy deposits of oil, grease, or dirt accumulated during operational service, preparations for welding and the cleaning of electrical contacts.
2015-04-17
Article
Delcam will launch in May the 2015 R2 version of its PowerSHAPE Pro software, which includes new options for reverse engineering as well as improvements to speed up and simplify the editing of product designs to make them more suitable for manufacture.
2015-04-16
Article
mycon developed a new coating system that is suitable for coating and painting longer parts, e.g., wires, belts, tubes, rods, and profiles.
2015-04-16
WIP Standard
AMS6440S
This specification covers a low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.
2015-04-16
WIP Standard
AMS6479D
This specification covers a special aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.
2015-04-16
WIP Standard
AMS6444M
This specification covers a premium aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.
2015-04-15
WIP Standard
AMS2451/9C
This specification covers the requirements for brush plating of zinc-nickel by electrodeposition.
2015-04-15
Standard
AIR5367
This SAE Aerospace Information Report (AIR) provides information related to machining of composite materials, components and structures. This document is intended to supplement the machining processes and guidelines provided in OEM repair manuals and structural repair manuals. It is not intended to supersede the approved data provided in OEM repair documents.
2015-04-15
Book
“Spotlight on Design” features video interviews and case study segments, focusing on the latest technology breakthroughs. Viewers are virtually taken to labs and research centers to learn how design engineers are enhancing product performance/reliability, reducing cost, improving quality, safety or environmental impact, and achieving regulatory compliance. Just how prevalent is the problem of counterfeit electronic parts? What are the consequences of using sub-par components in safety or mission critical systems? The Federal Aviation Administration estimates that 2% of the 26 million airline parts installed each year are counterfeit, accounting for more than 520,000 units, maybe more.
2015-04-14
Technical Paper
2015-01-1313
Donald Jasurda
Abstract The effects of thermal expansion and gravity on assembly processes in automotive manufacturing can and often do cause unexpected variation. Not only do these effects cause assembly issues, they can also create non-conformance and warranty problems later in the product lifecycle. Using 3D CAD models, advances in simulation allow engineers to design out these influences through a combination of tooling, process and tolerance changes to reduce costs. This whitepaper examines the process of simulating the effect of both thermal expansion and gravity on automotive structures. Using real life examples, a number of solutions were determined and tested in a simulated environment to reduce product variation and account for unavoidable environmental variation.
2015-04-14
Technical Paper
2015-01-0715
Terry Lynn Chapin, Van Thomas Walworth
Abstract Balancing the fill sequence of multiple cavities in a rubber injection mold is desirable for efficient cure rates, optimized cure times, and consistent quality of all molded parts. The reality is that most rubber injection molds do not provide a consistent uniform balanced fill sequence for all the cavities in the mold - even if the runner and cavity layout is geometrically balanced. A new runner design technique, named “The Vanturi Effect”, is disclosed to help address the inherent deficiencies of traditional runner and cavity layouts in order to achieve a more balanced fill sequence. Comparative analysis of molded runner samples reveals a significant and positive improvement in runner and cavity fill balancing when the Vanturi Effect is integrated into the runner design.
2015-04-14
Technical Paper
2015-01-0497
Monika Filiposka, Ana M. Djuric, Waguih ElMaraghy
Abstract Gantry robots are mainly employed for applications requiring large workspace, with limited higher manipulability in one direction than the others. The Gantries offer very good mechanical stiffness and constant positioning accuracy, but low dexterity. Common gantries are CNC machines with three translational joints XYZ (3DOF) and usually with an attached wrist (+3DOF). The translational joints are used to move the tool in any position in the 3D workspace. The wrist is used to orient the tool by rotation about X, Y and Z axis. This standard kinematic structure (3T3R) produces a rectangular workspace. In this paper a full kinematic model for a 6DOF general CNC (gantry) machine is presented, along with the Jacobian matrix and singularity analysis. Using Denavit-Hartenberg convention, firstly, the general kinematic structure is presented, in order to assign frames at each link. The forward kinematic problem is solved using Maple 17 software.
2015-04-14
Technical Paper
2015-01-0499
Nagarjun Jawahar, Sangamitra Manoharan, Harish Chandran
Abstract Material energy and cost minimization has been the need of the hour off late. The work aims at designing a micro gripping device which has suitable application in bio medical industry; specifically surgical operation of comminuted fracture using CAE software. Being a combination of an inverter and a clip, the ability of the compliant mechanism to be used as a gripper as well as positioner constitutes its rare versatility. The compliant mechanisms are single-piece structures, having no backlash as in case of rigid-body, jointed mechanisms and comparatively cheaper to manufacture. Designed in MATLAB R2008a using the concept of topological optimization, modeled in AutoCAD Mechanical 2011 and analyzed in ANSYS Workbench 13.0; the mechanism is initially designed with a geometrical advantage of 2. The MATLAB code which is an improvement of the 99 line code written by O.
2015-04-14
Technical Paper
2015-01-0506
Toshiyuki Kondo, Shinichiro Watanabe, Nobuhiro Nanba
Abstract Today, conventional requests for automation and modern requests for flexibility in handling product diversity and changes in production volume regarding assembly operation are increasing. In order to satisfy those, the “Innovative Automation Cell” (Refer to Figure 1) has been proposed as an innovative assembly production system in lieu of an assembly line operation, which has been continuing with the use of automatic conveyance. Furthermore, technical developments were implemented, such as “Real-time Position Attitude Correction Technology” and “High-speed Emergency Recovery System”, as well as “Assembly Operation Support System”, to make an easy system for an operator, so as to minimize reduction of run rate in mass production practices. This article addresses the concept of the “Innovative Automation Cell”, the details of the developed technology, the effects of introduction to mass production, and future issues.
2015-04-14
Technical Paper
2015-01-0505
Miguel Angel Reyes Belmonte, Colin D. Copeland, Drummond Hislop, George Hopkins, Adrian Schmieder, Scott Bredda, Sam Akehurst
Abstract Pressure and temperature levels within a modern internal combustion engine cylinder have been pushing to the limits of traditional materials and design. These operative conditions are due to the stringent emission and fuel economy standards that are forcing automotive engineers to develop engines with much higher power densities. Thus, downsized, turbocharged engines are an important technology to meet the future demands on transport efficiency. It is well known that within downsized turbocharged gasoline engines, thermal management becomes a vital issue for durability and combustion stability. In order to contribute to the understanding of engine thermal management, a conjugate heat transfer analysis of a downsized gasoline piston engine has been performed. The intent was to study the design possibilities afforded by the use of the Selective Laser Melting (SLM) additive manufacturing process.
2015-04-14
Technical Paper
2015-01-0507
Taro Nakamura
Abstract During the planning of Honda's new plant in Ogawa Japan, which is the new benchmark for developed countries power train plants, there was a project requirement established for a significant reduction in initial investment. In order to improve the competitive edge of module machines, which is the foundation of Honda's existing powertrain machining lines, Honda targeted a reduction in the number of module machines through concurrent machining of multiple workpieces, and minimization of transfer time. By developing exclusive jigs for cylinder heads and blocks, this project was able to meet the original project reduction requirements. In addition, Honda was able to shorten the loading and unloading times of a module machine by developing an exclusive transfer machine specifically for cylinder heads.
2015-04-14
Technical Paper
2015-01-0582
Deepak Ranjan Bhuyan, Sreekanth Netapalli, Sathya Dev, Soundarya Srinivasan
Abstract Springback prediction for stamped components is a challenging task for Automotive Industry. Automotive Manufacturers are working to reduce the springback effect of sheet metal stampings caused due to elastic behavior of materials with the help of changes to manufacturing process and part geometry. Recent development in Finite Element Analysis (FEA) studies made it possible for the industry to rely on stamping simulation. There is always a gap between the springback predicted from stamping simulation and the actual stamped part. Currently FEA techniques are trying to close this gap. The objective of this study is to minimize this gap using DFSS method for predicting the springback and optimizing the simulation parameters with the help of LS-Dyna FEM tool. The behavior of material with different simulation parameters has been studied in this paper and the ones that best correlate with actual data are identified.
2015-04-14
Technical Paper
2015-01-0551
Qiuren Chen, Haiding Guo, John V. Lasecki, John Hill, Xuming Su, John J. Bonnen
Abstract The fatigue strength and failure behavior of A5754-O adhesively bonded single lap joints by a hot-curing epoxy adhesive were investigated in this paper. The single lap joints tested include balanced substrate joints (meaning same thickness) and unbalanced substrate joints, involving combinations of different substrate thicknesses. Cyclic fatigue test results show that the fatigue strength of bonded joints increase with the increasing substrate thickness. SEM and Energy Dispersive X-ray (EDX) were employed to investigate the failure mode of the joints. Two fatigue failure modes, substrate failure and failure within the adhesive were found in the testing. The failure mode of the joint changes from cohesive failure to substrate failure as the axial load is decreased, which reveals a fatigue resistance competition between the adhesive layer and the aluminum substrate.
2015-04-14
Technical Paper
2015-01-0545
Jeong Kyun Hong
Abstract As the automotive industry seeks to remove weight from vehicle chasses to meet increased fuel economy standards, it is increasingly turning to composites and aluminum. In spite of increasing demands for quality aluminum alloy spot welds that enable more fuel efficient automobiles, fatigue evaluation procedures for such welds are not well-established. This article discusses the results of an evaluation Battelle performed of the fatigue characteristics of aluminum alloy spot welds based on experimental data and observations from the literature. In comparison with spot welds in steel alloys, aluminum alloy spot welds exhibit several significant differences including a different hardness distribution at and around the weld, different fatigue failure modes, and more. The effectiveness and applicability of the Battelle structural stress-based simplified procedure for modeling and simulating automotive spot welds has previously been demonstrated by Battelle investigations.
2015-04-14
Technical Paper
2015-01-1371
Samuel T. Bartlett
Abstract With the many model variations produced on the same production line because of increasing power train options, fuel efficiency targets, performance and customer demands we saw limitations with our existing suspension mount equipment. Layout options were limited due to guided shifts and transfers. Large supporting frame work took up valuable floor space. Model wheelbase sizes and suspension pallets were limited to the model requirements of the original equipment. We needed an adaptable system to install the engine/front suspension assemblies and the rear suspension assemblies. We found a solution by utilizing the capabilities of 6-axis industrial robots to make the core components of the equipment simpler; many of the functions of a traditional machine can now be accomplished by the robot. We were able to vary install position to optimize handling characteristics and accommodate the model-to-model varieties on the same production line.
2015-04-14
Technical Paper
2015-01-1299
Rod Emery
Abstract - Sustainable Manufacturing: Beyond Turning the Lights Off There is increasing pressure for manufacturers to go “green.” Automotive OEMs are improving their own sustainability practices and demanding environmental accountability from their vendors. Sustainable manufacturing is defined by the U.S. Department of Commerce as the creation of manufactured products using processes that: 1 Minimize negative environmental impacts2 Conserve energy and natural resources3 Are safe for employees, communities and consumers4 Are economically sound Installing low-energy lighting and adding recycling bins have had a positive effect, but manufacturers must take a comprehensive view of sustainability to have a continuing impact. This white paper will address some “out of the box” methods to improve sustainability of automotive assembly.
2015-04-14
Technical Paper
2015-01-1297
Harveer Singh Pali, Naveen Kumar, Yahaya Alhassan, Amar Deep
Abstract Biodiesel production has been getting global awareness since Petroleum prices are escalating continuously. As biodiesel is gaining considerable demand, standards are vital for its commercialization and market introduction. Feedstocks availability has posed serious challenges, thus the need for non-edible and unexplored feedstocks has risen. In Indian context, Biodiesel is produced using sal seed oil which is potentially available in Indian forest as a non-edible feedstock. The present paper deals with the production optimization using design of experiments and fuel property characterization of Sal biodiesel (sal methyl esters). Transesterification process parameters like catalyst concentration (% w/w), Oil to Methanol molar ratio, reaction time (min) and reaction temperature (°C) were considered the significance factors and the response was taken as the Yield (% w/w). Experiment matrix with several combinations of factors was generated.
2015-04-14
Technical Paper
2015-01-1723
Dieter Gabriel, Thomas Hettich
Abstract Fuel economy legislation is requiring further improvements to piston friction reduction as well as additional gains in thermal efficiency. A piston material change from aluminum to steel is enabling advancements in both demands. Furthermore, steel material properties lead to increased piston strength, robustness and durability. All this can be achieved at a lower compression height compared to an aluminum reference piston. Therefore, piston mass can be reduced despite the increase in material density. Since steel pistons require cooling of the combustion bowl region and the ring belt just like the aluminum counterpart, MAHLE implemented a new innovative metal joining technology by using laser welding to generate a cooling gallery. The TopWeld® concept offers design flexibility which cannot be matched by any other welding process.
2015-04-14
Technical Paper
2015-01-1725
Gerhard Konrad Flores
Abstract The use of form honing contributes to energy efficiency of modern internal combustion engines, especially to the reduction of CO2. Until now the production of internal combustion engines has required cylindrical bores with high shape and surface quality. This machined macro form is not maintained for the function of the engine due to mechanical and thermal influences. During operation they cause complex distortion mechanisms which significantly deviate from the desired cylinder form. Therefore Gehring developed a form honing process that does not produce the cylindrical bore form as its goal, but gives instead the expected cylindrical deformations having the quasi cylindrical bore geometries under specific operational conditions. Furthermore the current development of form honing considers the friction of the piston skirt of the cylinder operation temperature with specific clearance in the lower part of the bore.
2015-04-14
Technical Paper
2015-01-1612
Wei Liu, Gangfeng Tan, Jiafan Li, Xin Li, Fuzhao Mou, Yongqiang Ge
Abstract The hydraulic retarder is a significant auxiliary braking device [1] for the heavy duty vehicle. Traditionally, cooling circulatory system of the hydraulic retarder was coupled with the engine cooling system [2], and the thermal energy of the transmission medium would be cooled by the engine radiator ultimately. For this scheme, radiator's spare heat removal capacity could be fully utilized whereas the cooling system is very complicated and is hard to maintain. Furthermore, the corresponding of thermal management system lags behind the power change of the retarder. In this research, integrated cooling evaporation system is developed for the hydraulic retarder, which makes the cooling water contact with the transmission medium through the stator wall, so that it can rapidly response to the thermal variation of the retarder, keep the stability of the oil temperature and meanwhile reduce the risk of cooling medium leakage.
2015-04-14
Technical Paper
2015-01-0459
Vesna Savic, Louis Hector, Hesham Ezzat, Anil Sachdev, James Quinn, Ronald Krupitzer, Xin Sun
Abstract This paper presents an overview of a four-year project focused on development of an integrated computational materials engineering (ICME) toolset for third generation advanced high-strength steels (3GAHSS). Following a brief look at ICME as an emerging discipline within the Materials Genome Initiative, technical tasks in the ICME project will be discussed. Specific aims of the individual tasks are multi-scale, microstructure-based material model development using state-of-the-art computational and experimental techniques, forming, toolset assembly, design optimization, integration and technical cost modeling. The integrated approach is initially illustrated using a 980MPa grade transformation induced plasticity (TRIP) steel, subject to a two-step quenching and partitioning (Q&P) heat treatment, as an example.
2015-04-14
Technical Paper
2015-01-0475
Truong Nguyen, John Bell
Abstract Modern automotive electrical and electronic architecture is comprised of the battery and charging system, power distribution boxes, electronic control units, electrical devices, grounds, and the means of connecting all of these together - the wire harness or Electrical Distribution System (EDS). As automotive electrical content and complexity increases, it becomes imperative to optimize the weight, size, cost, and manufacturability of a vehicle [1]. In terms of an EDS, the most potential gain can be realized if the EDS supplier and vehicle Original Equipment Manufacturer (OEM) work together during the advanced electrical & electronic architecture development and packaging design process. Traditionally, the electrical content, harness partitioning, and packaging locations are designed by the vehicle OEM with limited advanced input from the EDS supplier.
Viewing 31 to 60 of 20004

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