Design and Application of a Hot Dip Simulator

<div class="htmlview paragraph">Based on long time engineering research and dedicated collaborations with industry, a new welding software, SORPAS, has been developed for <b>s</b>imulation <b>o</b>f <b>r</b>esistance <b>p</b>rojection <b>a</b>nd <b>s</b>pot welding processes applying the powerful finite element method (FEM).</div> <div class="htmlview paragraph">In order to make the software directly usable by engineers and technicians in industry, all of the important parameters in resistance welding are considered and automatically implemented into the software. With the specially designed graphic user interface for Windows, engineers (even without prior knowledge of FEM) can quickly learn and easily operate and utilize the software. All industrial users, including welding engineers from DaimlerChrysler, Volkswangen, PSA Peugeot Citroen, VOLVO, Siemens, ABB and so on, have started using the software just after taking a one-day training course.</div> <div class="htmlview paragraph">With the user-friendly facilities for flexible geometric design of work pieces and electrodes as well as process parameter settings similar to real machine settings, the software has been readily applied in industry for supporting product development and process optimization. After simulation, the dynamic process parameters are graphically displayed. The distributions of temperature, current, stress and deformation in the materials are displayed in color, which can be animated like slow-motion video. The software has been extensively verified and today applied in various industries including automotive, electronics and other metal processing industries as well as welding equipment manufacturers.</div>

<div class="htmlview paragraph">The distributed control system for the automotive audio equipment supported by digital LSI is described. Since the introduction of microcomputer, the operability of the automotive entertainment has been improved by employing the central control system. However, the central control system will not be able to follow the recent increase of the entertainment components such as compact disk player (CD), digital audio tape recorder (DAT), direct broadcasting system (DBS). The distributed control system under the bus structure reduces the load of the controllers and the wire count for interconnecting the components.</div> <div class="htmlview paragraph">In this paper, perspective of modem, digital signal processor (DSP) and microcomputer which are the key devices of the distributed control system is also described. DSP will change the configuration of the audio components completely.</div>

<div class="section abstract"><div class="htmlview paragraph">Hybrid electric vehicle (HEVs) represents a promising approach to reduce vehicle fuel consumption and exhaust emissions. However, due to the electric motor (EM) assistance, the engine load could be reduced and intermittent operation of engine is realizable in HEVs powertrain system. Consequently, the HEV powertrain heating-up process and engine fuel consumption will be changed accordingly.</div><div class="htmlview paragraph">Therefore, the influences of the EM power and battery capacity on the hybrid powertrain heating-up process and the engine fuel consumption will be analyzed, and 2 methods for optimizing the heating-up process by applying the auxiliary heaters (AHs) and the modification of the energy management strategy are represented.</div><div class="htmlview paragraph">The application of AHs can improve engine efficiency during heating-up; the controlling of the power flow from the AHs to the ICE cooling system is of special important. Accordingly, a thermal and energy management strategy (TEMS) is introduced in this paper to find a balance between fuel consumption and heating-up.</div><div class="htmlview paragraph">The TEMS is based on model predictive control (MPC) and dynamic programming (DP). MPC analyzes the forthcoming vehicle speed profile, calculates the power requirement and controls the AH accordingly. A cost function is then formulated based on the battery SOC and other driving conditions. DP solves the objective function and optimizes the power distribution between electric motor and engine.</div><div class="htmlview paragraph">The effects of the two methods are demonstrated by simulation in Matlab/Simulink. Simulation results are compared to demonstrate the optimized heating-up process.</div></div>

<div class="htmlview paragraph">Full service supply and concurrent engineering are the wave of the future in powertrain development. Launching a new automotive engine requires a fast and efficient development program for both the first engine and the transition into mass production. This paper presents a case study utilizing Soligen's Direct Shell Production Casting (DSPC <sup>®</sup>) to integrate the development of a new aluminum intake manifold and the launch of the mass production tooling, eliminating long lead times and costs as well as potential geometrical inconsistencies from incongruous manufacturing phases.</div> <div class="htmlview paragraph">DSPC is a rapid casting process which makes conventional prototype casting obsolete. DSPC works by producing ceramic casting molds with integral cores, directly from CAD files without the need for patterns and core boxes. Using DSPC in the design phase enables engineers to test multiple design iterations in various alloys concurrently, expediting and improving the design phase. Additionally, DSPC's reliance on CAD files provides for stringent configuration control, assuring that all design changes are properly documented.</div> <div class="htmlview paragraph">In the transition to mass production, the CAD files of the approved cast parts are converted into production tooling CAD files and subsequently cast as net shape tools. Working with the mass production foundry, these tools are launched onto the production lines. In this way, Soligen manages the maintenance of part continuity, accuracy and timeliness.</div> <div class="htmlview paragraph">The case study in this paper describes a manifold launch with permanent molds for annual production of 1,000,000 manifolds. The whole process was paperless and driven by the CAD file (prototypes, gating simulation, permanent (steel) molds and core boxes, and final machining).</div> <div class="htmlview paragraph">By basing all production on the CAD file and DSPC technology, a smooth and cost effective transition from prototype to mass production could be guaranteed. This successful transition has proven to shorten time-to-market and dramatically Improve profitability.</div>

<div class="htmlview paragraph">The effect of post heating on the powdering resistance of the galvannealed steel sheet was investigated. Four types of substrates, i.e., Al-killed, Mn and P added, interstitial-free Nb-added (Nb-IF) and interstitial-free Ti-added (Ti-IF), were used. The powdering resistance of the galvannealed steel sheet was evaluated by a draw bead tester which simulated considerably the practical press forming.</div> <div class="htmlview paragraph">It is found that relatively low temperature post heating from 250 to 420°C improves the powdering resistance of the galvannealed steel sheet. Generally the increase of iron content in the coating detriorates the powdering resistance. Although the iron content in the coating is increased by the post heating, in some cases, the powdering resistance after post heating is almost the same campared to that of the as-received specimen.</div> <div class="htmlview paragraph">The results of X-ray diffraction analysis reveal that X-ray diffraction peaks of the post heated specimens become sharper compared to those of the as-received specimen. This phenomenon suggests that the internal stress of the coating induced by high temperature galvannealing treatment in the conventional continuous galvanizing line, is decreased by the post heating at rather low temperature.</div>

The main process variables to produce galvanized dual phase (DP) steel sheets in continuous galvanizing lines are time and temperature of intercritical austenitizing (tIA and TIA), cooling rate (CR1) after intercritical austenitizing, holding time at the galvanizing temperature (tG) and finally the cooling rate (CR2) to room temperature. In this research work, the effects of CR1, tG and CR2 on the ultimate tensile strength (UTS), yield strength (YS), and elongation (EL) of cold rolled low carbon steel were investigated by applying an experimental central composite design and a multivariate regression model. A multi-objective optimization and the Pareto Front were used for the optimization of the continuous galvanizing heat treatments. Typical thermal cycles applied for the production of continuous galvanized AHSS-DP strips were simulated in a quenching dilatometer using miniature tensile specimens. The experimental results of UTS, YS and EL were used to fit the multivariate regression model for the prediction of these mechanical properties from the processing parameters (CR1, tG and CR2). In general, the results show that the proposed multivariate model correctly predicts the mechanical properties of UTS, YS and %EL for DP steels processed under continuous galvanizing conditions. Furthermore, it is demonstrated that the phase transformations that take place during the optimized tG (galvanizing time) play a dominant role in determining the values of the mechanical properties of the DP steel. The production of hot-dip galvanized DP steels with a minimum tensile strength of 1100 MPa is possible by applying the proposed methodology. The results provide important scientific and technological knowledge about the annealing/galvanizing thermal cycle effects on the microstructure and mechanical properties of DP steels.

<div class="section abstract"><div class="htmlview paragraph">In order to reduce CO₂, Electric Vehicles (EV) and Hybrid Vehicles (HV) are effective. Those types of vehicles have powertrains from conventional vehicles. Those new powertrains drastically improve their efficiency from conventional vehicles keeping the same or superior power performance. On the other hand, those vehicles have an issue for thermal energy shortage during warming up process. The thermal energy is very large, and seriously affects the fuel economy for HV and the mileage for EV.</div><div class="htmlview paragraph">In this paper, we propose VHDL-AMS multi-domain simulation technique for the estimation of the vehicle performance at the concept planning stage. The VHDL-AMS is IEEE and IEC standardized language, which supports not only multi-domain (physics) but also encryption. The common modeling language and encryption standard is indispensable for full-vehicle simulation.</div><div class="htmlview paragraph">By the VHDL-AMS modeling, the fuel economy, the effect of heat energy recovery from the exhaust gas, and the power performance are discussed for HV. The fuel economy was estimated using LA#4 driving pattern and the base simulation model validation result was that simulation was 22.0 km/L and measurement was 21.7 km/L (error 1.4%). The energy management using an exhaust gas heat exchange system realized 10.3% fuel consumption improvement during warming up. As for the power performance, the simulated acceleration time of 0-100 km/h was 11.12 sec and the measured vehicle time was 11.27 sec. The error between simulation and actual measurement result was 1.4%.</div><div class="htmlview paragraph">We showed that the application of VHDL-AMS multi-domain HV simulation is effective for the vehicle concept planning. Since the HV model uses embedded real control software, the VHDL-AMS modeling can be used as SIL at system control development stage.</div></div>

<div class="htmlview paragraph"><b>S</b>EVERAL major problems that confront the man who has charge of a fleet of automotive vehicles are analyzed by the author, who states that they deserve closer scrutiny and more intensive study. Their solution lies in evolution, which requires time, and their continued discussion by the Society is imperative. They are problems not only of the transportation executive but of the entire industry.</div> <div class="htmlview paragraph">Centralized control of a company's equipment is discussed, its advantages are enumerated, the ideal organization and procedure are outlined, the difficulties to be anticipated are listed and a procedure for installing such a system is proposed. The author recognizes that, where the automotive activities of a gigantic company are spread over a wide territory, application of an ideal system of centralized control is very difficult.</div> <div class="htmlview paragraph">Consideration is given to the relationships between the transportation executive and the motor-vehicle manufacturer. These are the relations of buyer and seller, yet a peculiar need of the automotive industry is that buying and selling be conducted on a high professional plane and in a spirit of tolerance born of intelligent appreciation of the other man's problem. The transportation industry demands salesmen who not only know specifications and prices but who have pleasing personalities and a superior knowledge of highway transportation and the capabilities of equipment to serve specific purposes. The author believes that the transportation executive can do much to improve the quality of salesmen.</div> <div class="htmlview paragraph">Selection of the right unit for a specific service depends upon a clear and definite understanding between buyer and seller of all the facts of the case and implies technical ability on the part of both. Therefore a questionnaire form is proposed, with the recommendation that it be approved by the Society and its use by transportation executives and manufacturers be urged. The author also suggests the desirability of a super-committee of representatives of trade associations, sponsored by the Society, for the purpose of discussing important problems that are common to the operator and the manufacturer.</div> <div class="htmlview paragraph">Finally, the relations between the transportation executive and his superior are discussed, the qualifications the fleet superintendent should have are enumerated and the responsibility of the higher company executive for the efficient and economical operation of the fleet is set forth. A plea is made for such executives to devote sufficient time to become acquainted with the transportation-executive's problems and to give him sufficient authority, recognition and compensation so that he can accomplish real transportation economies.</div>

<div class="htmlview paragraph">The application of Computer-Aided Engineering is accelerating product design, process design, and prototype development for conversion of suspension steel fabrications to aluminum castings. Development cycle-time reduction is achieved by sharing a consistent CAE model among the system designers, component designers, and process development engineers.</div> <div class="htmlview paragraph">The CAE tools being utilized include Solid Modeling tools for geometry definition and manipulation, linear FEA for evaluating strength and stiffness, and non-linear heat-transfer for modeling the casting solidification. One of the major breakthroughs in cycle-time reduction for the CAE efforts is the utilization of automatic mesh-generation technology.</div> <div class="htmlview paragraph">The component geometry is simultaneously developed by product and casting engineers, so that the manufacturability issues are addressed up-front. Preliminary stress and solidification FEA are conducted in parallel to generate a more optimal geometry. This same geometric model is later used to create Laminated Object Model (LOM) Rapid prototypes. The tooling for the prototype sand-castings is produced from the LOM.</div> <div class="htmlview paragraph">Early prototypes are produced as sand-castings, allowing shortest possible lead-times, and permitting the maximum possible time for design optimization through Finite Element Analysis.</div> <div class="htmlview paragraph">Examples of successful aluminum conversions, and the tools and technologies enabling these successes, as well as lessons learned are presented.</div>

<div class="section abstract"><div class="htmlview paragraph">At part load and wide open throttle operation with stratified charge and lean mixture conditions the Direct Injection Spark Ignition (DISI) engine offers similar efficiency levels compared to compression ignition engines</div><div class="htmlview paragraph">The present paper reports on results of recent studies on the impact of the in-cylinder processes in DISI engines e. g. the injection, the in-cylinder flow, the mixture preparation and the ignition on the combustion, the energy conversion and the exhaust emission behavior. The analyses of the spray behavior, of the in-cylinder flow during compression as well as of the flame propagation have been carried out applying advanced optical measurement techniques. The results enable a targeted optimization of the combustion process with respect to engine efficiency and exhaust emissions. The benefits of an increase in fuel injection pressures up to 100 MPa are discussed. The investigations have been mainly performed in a single cylinder research engine featuring a spray-guided injection process with central injector location. The considered operating range includes part load conditions with both stratified and homogeneous mixture preparation as well as full load operation with homogeneous mixture preparation. The results obtained from the research work are very promising and hence a 4-cylinder production engine is modified to operate with a suitable injection system with rail pressures in the range of 50 MPa to 60 MPa.</div><div class="htmlview paragraph">Additionally, irregular combustion events in the full load regime such as knocking combustion and low speed pre-ignition have been investigated in a 4-cylinder DISI production engine. The results support the development of mitigation strategies for both engine knock and low speed pre-ignition (LSPI).</div></div>

<div class="section abstract"><div class="htmlview paragraph">New process development of forging component requires in-depth knowledge and experience related to the process. Also it requires number of physical trials to arrive at optimum process and initial billet dimensions. With the help of reliable computer simulation tool, it is possible to optimize the complete forging process and billet dimensions. Simulation provides much more insight about the process and possible forging defects. This saves considerable time and money.</div><div class="htmlview paragraph">This paper describes about a complete forging process designed for a complex component. With the help of metal forming simulation software, complete forging process was simulated and optimized. Forging defects were removed during optimization of the process. Billet weight optimization was also carried out. Deciding the preforming shape of the billet was the main challenge. An innovative pre-forging shape was arrived which resulted in eliminating one process stage. The entire forging process was optimized in such a way to maintain required grain flow and complete filling of cavity with maximum yield.</div><div class="htmlview paragraph">Initial billet to final component weight ratio obtained was 0.87. The position of billet was optimized in such a way that it gives minimum wastage of material in flash. The optimized process was implemented and simulation results were validated with actual trials. Simulation results found in good correlations with manufactured sample.</div></div>

A control unit that put forward a set of PLC as core has been proposed to solve the problems of slow response speed, large overshoot, and poor anti-interference ability and time lag in the temperature control system of automobile airbag hot extrusion equipment. Fuzzy adaptive PID control strategy is applied to realize the temperature control system of airbag hot extrusion equipment, which can accurately control the temperature of hot pressing furnace, monitor, diagnose and feedback regulation. Through the comparison of simulation and experiment, it is proved that the fuzzy adaptive PID controller proposed has the advantages of excellent dynamic performance, good robustness and high temperature control accuracy compared with the traditional PID controller, and the performance of the temperature control system of hot extrusion equipment has been improved.

The quality of the sand core directly affects the quality of the casting during the casting process. The establishment of an information link between the sand core and the casting can realize the traceability of sand core production and process data in the casting production. The technology can be used when casting defects related to the sand core occur and quickly respond to the causes and optimize the manufacturing process of the sand core making process. This article describes the necessity of establishing a traceability process for sand core making information and introduces a traceability process of sand core information in casting production to ensure that each sand core has its own production process information, which is for product quality management and process optimization. It provides information supervision and promotes the development of intelligent casting manufacturing technology and management technology.

<div class="htmlview paragraph">A 1977 Buick V-6 engine and a 1981 Ford Granada automobile were equipped with heat exchangers to transfer energy from the exhaust gases to the cooling water after cold starts in order to shorten engine warm-up periods and improve fuel economy. A parallel concern was the time required to reach satisfactory heat delivery to the passenger compartment.</div> <div class="htmlview paragraph">The Buick engine was investigated in the laboratory. The Ford automobile was tested during driving over a 12.4 km length of freeway and over an 8.6 km test route including both in-town and highway segments. Prior to each test run the engines were exposed to ambient air for at least 8 hours at temperatures ranging from −26° C to + 2° C.</div> <div class="htmlview paragraph">The use of the heat exchangers resulted in average reductions of fuel consumption of 2.8% during a 7 minute warm-up period for the engine, and of 2.2% for the autombile when tested on the above test routes. The corresponding times for the coolant in the automobile compartment heater to reach maximum temperature were reduced by 16% and 7%. While fuel savings were achieved, their economic value is questionable, particularly in light of a possible retrofit of an existing automobile with an exhaust-to-coolant heat exchanger and the necessary control equipment.</div>

<div class="htmlview paragraph">Car seats with a variety of adjustments and massage systems are available in many cars. It could increase comfort. In a vehicle, particularly a car, it is difficult to increase comfort by variation in posture, since the person has to concentrate on traffic conditions and steering. A car seat has to support the body, since various forces occur, such as acceleration, slowing down and lateral forces. The driver / passenger is well supported by the car seat, and spends a certain time there in an unchanged position. Due to these facts it is meaningful to integrate a massage activity system (MAS) into a car seat. In this way, it is possible to devote oneself fully to the task of driving and the surrounding traffic. A MAS can take control of revitalising and changing the sitting position of the car occupants. Until now, the effect of the use of massage systems and additional equipment such as lumbar support on the intervertebral discs has never been studied.</div> <div class="htmlview paragraph">For this experiment a pressure sensor was implanted with a canula in the middle of an intervertebral disc of a voluntary subject. In this way the local pressure in the disc was measured in an automobile with a massage system in the seat.</div> <div class="htmlview paragraph">All measurements were taken in an ideal seat position. In this position the pressure in the disc was very low (0.5bar).</div> <div class="htmlview paragraph">From these results we are able to improve our knowledge about extra equipment and massage systems and the subsequent reaction of the discs.</div>