Production of Integrated Automotive Part in High Pressure Diecasting Process Using Salt Core

A new concept of salt core, a melting temperature of which is lower than the solidus temperature of cast alloy,was introduced to produce an integrated casting part having a complicated inner shape or requiring under-cut in high pressure die casting or squeeze casting process. A salt core, named a fusible core in this paper because the salt core can be easily extracted just as holding at a temperature under a solidus temperature of a casting alloy, was developed and applied to produce a fuel control part for automotive GDI engine in high pressure diecasting machine. A different salt material of a lower melting temperature than that of A1 alloy was mixed with a different ceramic particulate to improve a thermo-physical property of fusible core. The thermo-physical property of the fusible core was measured and a weight faction of the ceramic particulate was optimized. The selected core materials were poured in metallic mold by gravity to produce a fusible core for a fuel control part for automotive GDI engine. The fuel control part, which the fusible core was included inside, was successful to fabricate in a conventional diecasting machine with no melting of fusible core during casting.

Development and application of magnesium alloy parts for automotive OEMs:A review

China is currently vigorously implementing the“energy conservation and emission reduction”and“dual carbon”strategies.As the most resource-advantaged light metal material in China,Magnesium(Mg)alloy is progressively expanding its application in automobile,rail transportation,aerospace,medical,and electronic products.Chongqing University,Shanghai Jiaotong University,and Australian National University have conducted extensive research on the preparation,properties,and processes of Mg alloys.In the past 20 years,the proportion of Mg alloy in the automotive industry has gradually expanded,whereas currently the design and development of Mg alloy parts for automobiles has rarely been reported.Thus,the application models and typical parts cases of Mg alloy are summarized mainly from the four systems of the whole vehicle(body system,chassis system,powertrain system,interior,and exterior system).Subsequently,two actual original equipment manufacturers(OEM)cases are used to introduce the development logic of reliable die-cast Mg alloy,including forward design,formability analysis,process design analysis,structural redesign,manufacturing,and testing,aiming to share the methods,processes,and focus of attention of automotive OEMs for developing Mg alloy parts to enhance the confidence and motivation of applying Mg alloy in automotive field.Eventually,the multiple challenges faced by Mg alloy materials are sorted out and how to face these challenges are discussed.National policies and regulations,environmental protection and energy saving,and consumer demand will continue to promote the application of Mg.

Influence of the Coolant Flow Containing Silver Nanoparticles (Ag) from an Aqueous Solution Based on Ethylene Glycol (EG50%) on the Thermal-Hydraulic Performance of an Automotive Radiator

A theoretical analysis of the influence of the flow of a coolant containing silver nanoparticle (Ag) in an automotive radiator is presented. The coolant fluid is composed of water or an aqueous solution of Ethylene-Glycol (EG50%) and silver nanoparticles. Ethylene glycol (EG) has been used in automobile radiators for many years due to its compatibility with metals and its anti-cooling properties. Silver nanoparticles are being incorporated into the development of high-precision surgical equipment. It is shown that the rate of heat transfer increases significantly using silver nanoparticles and ethylene glycol and water. There is a maximum for heat exchange between fluids in all analyzed coolant flows—the maximum moves to higher airflow rates when the coolant flow rate is increased. However, the energy dissipation in the stream also increases, but the relationship between the energy dissipated in the flow and the energy transferred in the form of heat is low, which justifies the use of silver nanoparticles and ethylene glycol, or silver nanoparticles and water as a coolant in the automotive vehicle radiator.

A CFD-DEM-Wear Coupling Method for Stone Chip Resistance of Automotive Coatings with a Rigid Connection ParticleMethod for Non-Spherical Particles

The stone chip resistance performance of automotive coatings has attracted increasing attention in academic and industrial communities.Even though traditional gravelometer tests can be used to evaluate stone chip resistance of automotive coatings,such experiment-based methods suffer from poor repeatability and high cost.The main purpose of this work is to develop a CFD-DEM-wear coupling method to accurately and efficiently simulate stone chipbehaviorof automotive coatings inagravelometer test.Toachieve this end,an approach coupling an unresolved computational fluid dynamics(CFD)method and a discrete element method(DEM)are employed to account for interactions between fluids and large particles.In order to accurately describe large particles,a rigid connection particle method is proposed.In doing so,each actual non-spherical particle can be approximately described by rigidly connecting a group of non-overlapping spheres,and particle-fluid interactions are simulated based on each component sphere.An erosion wear model is used to calculate the impact damage of coatings based on particlecoating interactions.Single spherical particle tests are performed to demonstrate the feasibility of the proposed rigid connection particle method under various air pressure conditions.Then,the developed CFD-DEM-wear model is applied to reproduce the stone chip behavior of two standard tests,i.e.,DIN 55996-1 and SAE-J400-2002 tests.Numerical results are found to be in good agreement with experimental data,which demonstrates the capacity of our developed method in stone chip resistance evaluation.Finally,parametric studies are conducted to numerically investigate the influences of initial velocity and test panel orientation on impact damage of automotive coatings.

Research on Feature Matching Optimization Algorithm for Automotive Panoramic Surround View System

In response to the challenges posed by insufficient real-time performance and suboptimal matching accuracy of traditional feature matching algorithms within automotive panoramic surround view systems,this paper has proposed a high-performance dimension reduction parallel matching algorithm that integrates Principal Component Analysis(PCA)and Dual-Heap Filtering(DHF).The algorithm employs PCA to map the feature points into the lower-dimensional space and employs the square of Euclidean distance for feature matching,which significantly reduces computational complexity.To ensure the accuracy of feature matching,the algorithm utilizes Dual-Heap Filtering to filter and refine matched point pairs.To further enhance matching speed and make optimal use of computational resources,the algorithm introduces a multi-core parallel matching strategy,greatly elevating the efficiency of feature matching.Compared to Scale-Invariant Feature Transform(SIFT)and Speeded Up Robust Features(SURF),the proposed algorithm reduces matching time by 77%to 80%and concurrently enhances matching accuracy by 5%to 15%.Experimental results demonstrate that the proposed algorithmexhibits outstanding real-time matching performance and accuracy,effectivelymeeting the feature-matching requirements of automotive panoramic surround view systems.

ProTSA: A Testing Process for Automotive Software Domain

This study evaluates the development of a testing process for the automotive software domain, highlighting challenges stemming from the absence of adequate processes. The research demonstrates the application of Design Science Research methodology in developing, an automotive software testing process—ProTSA, using six functional testing modules. Additionally, the study evaluates the benefits of implementing ProTSA in a specific Original Equipment Manufacturer (OEM) using an experimental single-case approach with industry professionals’ participation through a survey. The study concludes that combining testing techniques with effective communication and alignment is crucial for enhancing software quality. Furthermore, survey data indicates that implementing ProTSA leads to productivity gains by initiating tests early, resulting in time savings in the testing program and increased productivity for the testing team. Future work will explore implementing ProTSA in cybersecurity, over-the-air software updates, and autonomous vehicle testing processes. .

Discussion on the Free Quenching Heat Treatment Process of Automotive Leaf Springs

Free quenching of automotive leaf springs is a new technology that has gradually started to be applied in the industry in China in recent years.Only a few manufacturers are applying it in the industry.Through more than half a year of on-site practice,the changes in the hot forming of spring plates before free quenching have been explored,and finally a heat treatment process that meets the production requirements of our company has been developed,achieving normal production.

基于Windows Automotive的导航系统设计

本文采用S3C2440A和Windows Automotive 5.0设计了一种汽车导航系统。在硬件方面,给出了S3C2440A和LCD、GPS芯片的接口电路。在软件方面,详细介绍了驱动程序和操作系统的开发方法,并在Visual Studio 2005中成功开发了该系统的GPS信号测试程序。实验结果表明,该系统导航功能良好、可以运行多种导航软件、具有一定的汽车运行状况监控功能。

App@Automotive

美国已经有了一种基于微软Windows 7和RObotics Develolaer Studio的软件开发平台可以访问车辆性能数据、网络服务、语音识别、语音合成、社交网络平台等互联网服务以及Windows Azure云计算环境，汽车已经有了作为智能终端的条件，而众多应用程序登陆这个新兴的平台也已可以预计。

Recycling of automotive aluminum

With the global warming of concern,the secondary aluminum stream is becoming an even more important component of aluminum production and is attractive because of its economic and environmental benefits.In this work,recycling of automotive aluminum is reviewed to highlight environmental benefits of aluminum recycling,use of aluminum alloys in automotive applications,automotive recycling process,and new technologies in aluminum scrap process.Literature survey shows that newly developed techniques such as laser induced breakdown spectroscopy(LIBS) and solid state recycling provide promising alternatives in aluminum scrap process.Compared with conventional remelting and subsequent refinement,solid state recycling utilizing compression and extrusion at room or moderate temperature can result in significant energy savings and higher metal yield.

Ignition Pattern Analysis for Automotive Engine Trouble Diagnosis Using Wavelet Packet Transform and Support Vector Machines

Engine spark ignition is an important source for diagnosis of engine faults.Based on the waveform of the ignition pattern,a mechanic can guess what may be the potential malfunctioning parts of an engine with his/her experience and handbooks.However,this manual diagnostic method is imprecise because many spark ignition patterns are very similar.Therefore,a diagnosis needs many trials to identify the malfunctioning parts.Meanwhile the mechanic needs to disassemble and assemble the engine parts for verification.To tackle this problem,an intelligent diagnosis system was established based on ignition patterns.First,the captured patterns were normalized and compressed.Then wavelet packet transform（WPT） was employed to extract the representative features of the ignition patterns.Finally,a classification system was constructed by using multi-class support vector machines（SVM） and the extracted features.The classification system can intelligently classify the most likely engine fault so as to reduce the number of diagnosis trials.Experimental results show that SVM produces higher diagnosis accuracy than the traditional multilayer feedforward neural network.This is the first trial on the combination of WPT and SVM to analyze ignition patterns and diagnose automotive engines.

New development of powder metallurgy in automotive industry

The driving force for using powder metallurgy(PM)mostly relies on its near net-shape ability and cost-performance ratio.The automotive application is a main market of PM industry,requiring parts with competitive mechanical or functional performance in a mass production scale.As the automobile technology transforms from traditional internal combustion engine vehicles to new energy vehicles,PM technology is undergoing significant changes in manufacturing and materials development.This review outlines the challenges and opportunities generated by the changes in the automotive technology for PM.Low-cost,high-performance and light-weight are critical aspects for future PM materials development.Therefore,the studies on PM lean-alloyed steel,aluminum alloys,and titanium alloy materials were reviewed.In addition,PM soft magnetic composite applied to new energy vehicles was discussed.Then new opportunities for advanced processing,such as metal injection molding(MIM)and additive manufacturing(AM),in automotive industry were stated.In general,the change in automotive industry raises sufficient development space for PM.While,emerging technologies require more preeminent PM materials.Iron-based parts are still the main PM products due to their mechanical performance and low cost.MIM will occupy the growing market of highly flexible and complex parts.AM opens a door for fast prototyping,great flexibility and customizing at low cost,driving weight and assembling reduction.

Modeling Method of Automotive Body CAN/LIN Nets Application Protocol Based on Object-oriented Colored Petri Net

Recently automotive nets are adopted to solve increasing problems in automotive electronic systems.Technologies of automotive local area network from CAN and LIN can solve the problems of the increasing of wire bunch weight and lack in module installation space.However,the multilayer automotive nets software becomes more and more complex,and the development expense is difficult to predict and to keep in check.In this paper,the modeling method of hierarchical automotive nets and the substitution operation based on object-oriented colored Petri net(OOCPN) are proposed.The OOCPN model which analyzes the software structure and validates the collision mechanism of CAN/LIN bus can speed the automobile system development.First,the subsystems are divided and modeled by object-oriented Petri net(OOPN).According to the sets of message sharing relations,the message ports among them are set and the communication gate transitions are defined.Second,the OOPN model is substituted step by step until the inner objects in the automotive body control modules(BCM) are indivisible and colored by colored Petri net(CPN).And the color subsets mark the node messages for the collision mechanism.Third,the OOCPN model of the automotive body CAN/LIN nets is assembled,which keeps the message sets and the system can be expanded.The proposed model is used to analyze features of information sharing among the objects,and it is also used to describe each subsystem real-time behavior of processing messages and implemental device controllers operating,and puts forward a reasonable software framework for the automotive body control subsystem.The research can help to design the communication model in the automotive body system effectively and provide a convenient and rapid way for developing the logical hierarchy software.

DISPLACEMENT CONTROL AND KINETIC ANALYSIS OF A NOVEL VARIABLE DISPLACEMENT COMPRESSOR FOR AUTOMOTIVE AIR CONDITIONER

A novel variable displacement compressor (VDC) for automotive air conditioner (AAC) is introduced, which inherits the advantages of common wobble plate type VDC. It has fewer parts and makes less noise, and instead of pneumatic valve the displacement is controlled by electronic control valve. In order to know the control mechanism well and get a good control effect, a mathematical model for the variable displacement mechanism is developed according to the geometrical and kinematical information of the compressor. Using the model, the effect of relevant parameters on variable displace control is estimated. It is helpful to make the optimum decision in the flow control of AAC. As the novel displacement control device, the structure and control rule of electronic control valve is introduced. It can get better effect than the conventional pneumatic valves. And by using this new electronic control device, the optimum systemic control of AAC is available.

Semi-solid moulding:Competition to cast and machine from forging in making automotive complex components

The very latest technique for impeller manufacture is called semi-solid moulding(SSM).Cummins Turbo Technologies Limited,together with Aluminum Complex Components Inc,developed SSM compressor wheels as a way of achieving cost and durability performance somewhere between that of cast and machined from solid(MFS) aluminium alloy wheels.Experimental results show SSM material has a superior microstructure and mechanical properties over cast and comparable to MFS materials.Component testing including durability testing,using accelerated speed cycle tests,proves SSM compressor wheels emerge as being significantly more durable than cast equivalents and approaching that of MFS impellers.Further challenges for semi-solid processing in manufacture of other complex components and other materials in automotive industry in terms of both cost and durability are also discussed.

Conceptual design of oil palm fibre reinforced polymer hybrid composite automotive crash box using integrated approach

A hybrid conceptual design approach was introduced in this study to develop a conceptual design of oil palm polymer composite automotive crash box(ACB). A combination of theory of inventive problem solving(TRIZ), morphological charts and biomimetics was applied where the foremost requirements in terms of the material characteristics, function specifications, force identification, root cause analysis, geometry profile and design selection criteria were considered. The strategy was to use creations of nature to inspire five innovative conceptual designs of the ACB structure and the AHP method was applied to perform the pairwise analysis of selecting the best ACB conceptual design. A new conceptual design for a composite ACB was conceived bearing in mind the properties of natural fibre, unlike those of conventional materials such as steel alloys and aluminium alloys. The design with the highest ranking(26.6 %) was chosen as the final conceptual design, which was the one with a honeycomb structure for the outermost profile, reinforced with a spider web structure inside the part, supported by fibre foam structure extracted from the woodpecker sponge tissue at the centre to maximize the energy absorption capability. The new design could solve the problem of bending collapse which is a major cause of failure to absorb maximum impact energy for ACB during collision. However, the final conceptual design will still need several modifications for production and assembly purposes, which will be completed in a further study.

V2X-Communication Assisted Interference Minimization for Automotive Radars

With the development of automated driving vehicles, more and more vehicles will be fitted with more than one automotive radars, and the radar mutual interference will become very significant. Vehicle to everything (V2X) communication is a potential way for coordinating automotive radars and reduce the mutual interference. In this paper, we analyze the positional relation of the two radars that interfere with each other, and evaluate the mutual interference for different types of automotive radars based on Poisson point process (PPP). We also propose a centralized framework and the corresponding algorithm, which relies on V2X communication systems to allocate the spectrum resources for automotive radars to minimize the interference. The minimum spectrum resources required for zero-interference are analyzed for different cases. Simulation results validate the analysis and show that the proposed framework can achieve near-zero-interference with the minimum spectrum resources.

Application of shortened heat treatment cycles on A356 automotive brake calipers with respective globular and dendritic microstructures

Since the automotive industry has many possible applications for semi-solid metal (SSM)-high-pressure die casting (HPDC) parts, the newly developed heat treatment cycles, as well as the traditional heat treatment cycles, were applied to A356 brake calipers cast using a LK DCC630 HPDC machine.Vickers hardness measurements at a cross section of the brake calipers were performed, indicating that similar values can be obtained when using the significantly shorter heat treatment cycles.Finally, the typical tensile properties that can be obtained for SSM-HPDC A356 brake calipers are compared with those manufactured by gravity die casting.Results indicate that the differences in microstructures (globular or dendritic) do not have a noteworthy effect on the heat treatment response.This implies that the short heat treatment cycles originally developed for globular SSM-HPDC A356 castings can be successfully applied to dendritic liquid A356 castings too.

WEAR FAILURE MECHANISM AND MULTI-IMPACT PROPERTY OF AUTOMOTIVE ENGINE CHAIN

The multi-impact characteristics and failure mechanism of two kinds of automotive engine chain made in China are studied through engine assembly and road-drive tests. The worn surface morphologies of rubbing area between pin, bush and roller are also analyzed based on scanning electron microscope. The results show that the main wear mechanism of automotive engine chain is fatigue wear, and its failure mechanism is the forming, extending and flaking of cracks on top layer of pin and bush. In addition, the material, hot-treatment method and shaping technique for roller have a great influence upon the resistance to multi-impact. Ensuring sufficient strength and plasticity of roller, as well as adopting suitable shaping technique are the effective method to increase its resistance to multi-impact.

Application and failure evaluation of ferritic stainless steels for automotive exhaust systems

In recent years, with attention paid to global environmental problems, there have been requirements for continuous improvement of automobile fuel economy and exhaust gas purification rate. The properties of the ferritic stainless steels （FSS） used to make automobile parts have been improved. This paper introduces the construction of automotive exhaust systems and describes their main failure behaviors and corrosion evaluation procedures.