Automotive Engineering Commons^™

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Parts, Logan Trimmer

Harrisburg University Other Works

Presentation covering the broad strokes of the project. The goal was to prove the viability of hybrid/additive manufacturing for high stress automotive applications. This project focused on recreating a piston from an old engine to examine if hybrid manufacturing could be used for such applications. On a small scale, hybrid manufacturing was able to be more cost effective if the costs of the equipment and electricity were ignored. The decision to ignore those costs came from the inability to find accurate prices for industrial casting.

Development Of Stronger, More Extrudable 6xxx Series Alloys For Automotive Applications, Eli A. Harma

Dissertations, Master's Theses and Master's Reports

6xxx alloys are widely used in automotive extrusion structures for their high specific strength and formability. Advanced designs require greater formability and strength, creating an opportunity for high-strength, formable alloys. The 6xxx series forms β”-Mg₅Si₆ precipitates during age hardening and develops a fibrous microstructure during extrusion, both strengthening the alloy. Increasing Mg and Si to form more β” decreases formability. Thus, modifying texture can increase strength without reducing formability. Current alloys like 6005A add Mn and Cr to form dispersoids that inhibit recrystallization and promote strengthening textures; however, high Mn and Cr concentrations reduce formability. Replacing Mn …

The Efficacy Of Hybrid Manufacturing For High Stress Automotive Components, Logan Trimmer

Harrisburg University Other Works

The goal of this research was to establish the viability of using hybrid manufacturing for automotive applications. By verifying that high-stress components can be created, it can be assumed that any other lower stress part could be made to match the strength requirements. A limiting factor of adoption for hybrid manufacturing is how new the technology is. Studies on time and cost were performed allowing for comparisons with traditional manufacturing technologies (casting, forging, milling) used in automotive applications. This research utilized a Haas Automation UMC750 5-axis CNC mill with a Meltio laser wire direct energy deposition attachment. Fusion 360 was …

Influence On Shot Peening And Blast Polishing For Rotating Bending Fatigue Strength Of Vacuum Carburized Steel With Circumferential Notch, Yuji Kobayashi, Hayato Taniguchi, Kiyotaka Masaki

15th International Conference on Shot Peening

In order to improve fuel efficiency in automobiles, weight reduction is necessary as well as improving engine efficiency. For transmission gears, thickness reduction is necessary for weight reduction. When the thickness is reduced, the cross-sectional area becomes smaller, and the load stress increases. Therefore, higher fatigue strength is required. Most gears carry out carburizing. Shot peening is often used to improve the fatigue strength of carburized heat-treated parts. After shot peening, compressive residual stress is introduced, but at the same time, surface roughness is increased. Therefore, the processing conditions of shot peening are very important. Blast polishing is a processing …

Adaptation Of Shot Peen Parameters For Gear Geometry, David J. Breuer, Beth Matlock

15th International Conference on Shot Peening

Shot peening is a well established process for the surface enhancement of gearing. Gearing is a primary example of a high cycle fatigue application that can benefit from residual stress enhancement. Designing shot peening parameters to specific gear geometry based on material, heat treatment, and surface finish is a more precise way to achieve better performance outcomes. One of the best tools to assist in the optimal shot peening is x-ray diffraction (XRD) and its ability to measure small differences that can result in significant performance outcomes. XRD residual stress measurements are a direct measurement of elastic strain. The diffraction …

Application Of Burnishing Process Expected To Frictional Heat To Non-Oriented Electromagnetic Steel Sheet, Yuji Kobayashi, Masato Okada

15th International Conference on Shot Peening

Burnishing is a technology used to improve the surface roughness of metals. On the other hand, it is expected that the metal structure near the surface will change due to strong distortion.

The magnetic properties of electromagnetic steel sheets depend on large crystal grains and fine crystals near the surface[1]. In particular, thinner fine crystal grain layers on the surface are expected to reduce iron loss. In this study, the power generation characteristics of Burnished electromagnetic steel sheets were evaluated.

Electromotive force waveform was evaluated by rotating the laminated electromagnetic steel sheets and using a spindle motor. The electromotive force …

The Effects Of Shot Peening Highly Loaded Compression Springs, David J. Breuer

15th International Conference on Shot Peening

The compression spring in this test study is typical of one used in a demanding off-road vehicle suspension. The cyclic loads applied during fatigue tests were severe enough to cause failure in approximately 11,000 cycles without shot peening.

The objectives of this study were the following: (1) Design a compression spring similar to those used in the off-road recreational industry. (2) Design & manufacture a fatigue test stand that could withstand high loads for months of testing. (3) Generate a matrix of shot peening treatments to produce different amounts of residual compressive stress. (4) Measure the shot peening residual compressive …

Potential Of Lidar And Hyperspectral Sensing For Overcoming Challenges In Current Maritime Ballast Tank Corrosion Inspection, Sergio Pallas Enguita, Jiajun Jiang, Chung-Hao Chen, Samuel Kovacic, Richard Lebel

Electrical & Computer Engineering Faculty Publications

Corrosion in maritime ballast tanks is a major driver of maintenance costs and operational risks for maritime assets. Inspections are hampered by complex geometries, hazardous conditions, and the limitations of conventional methods, particularly visual assessment, which struggles with subjectivity, accessibility, and early detection, especially under coatings. This paper critically examines these challenges and explores the potential of Light Detection and Ranging (LiDAR) and Hyperspectral Imaging (HSI) to form the basis of improved inspection approaches. We discuss LiDAR’s utility for accurate 3D mapping and providing a spatial framework and HSI’s potential for objective material identification and surface characterization based on spectral …

Striking A Balance: Market Shock & Responses In Automotive Components Manufacturing, Emma Lane Mcgahey

All Theses

This thesis examines the effects of extreme market shocks on supply chain dynamics within the automotive industry. Through an analysis of demand data from an automotive manufacturer to its component suppliers (January 2018 to May 2024), the study investigates the relationship between market shocks and supply chain responses, providing insights into how auto components inventory management handles downstream responses to market shocks. With supporting public data—from FRED, BLS, and the U.S. Census Bureau resources—we explore two primary relationships: the impact of market shocks on the Average Standard Deviation of Demand (SDO) and the effect of demand variability on expedited pricing …

Engineering Multifunctional Silicon Nanostructures From Biorenewable Cellulose Nanocrystals, Nancy Chen

All Dissertations

The imperative search for alternative materials to address the pressing demand for advance energy storage is underscored by the escalating environmental predicaments. Lithium-ion batteries (LIBs) with graphite anodes have become the benchmark in energy storage; however, they are approaching a saturation point in terms of energy density. Silicon emerges as a promising contender to supplant graphite, owing to its profuse availability, cost-effectiveness, and impressive specific capacity of 4200 mAh g^-1. By integrating silicon anodes, LIBs stand to undergo a radical transformation, markedly diminishing in weight and size, thus heralding a novel wave of compact, lightweight energy storage systems. …

Dynamic Impact Testing And Numerical Analysis Of Non-Proprietary Astm F2656-20 M50 Anti-Ram Barrier Components, Weston Kelley

Department of Mechanical and Materials Engineering: Dissertations, Theses, and Student Research

In a post-9/11 world, hostile actors are using vehicles as weapons to inflict civilian casualties. Pedestrians, vulnerable road users, military personnel, and police may be targeted using a vehicle as a weapon. The United States Department of Defense (DoD) also utilizes Entry Control Facilities (ECFs) which are carefully designed transportation corridors to manage how threat vehicles are able to access military facilities. In 2004, DoD started to upgrade all ECFs using both passive and active barriers. Many anti-ram vehicle barriers were evaluated according to the criteria established in ASTM F2656, but to date few options are available which are (1) …

Finite Element Analysis Of Thermal-Mechanical Instabilities In Nonmetallic Friction Composite Material, Joseph-Shaahu Shaahu

Electronic Theses and Dissertations

Thermal-mechanical instability (TMI) has been a research topic of interest as it focuses a lot on transportation systems. Thermal-mechanical instability was first noticed in railway and experimentally studied with a pin-to-pin or pin-to-surface setup of sliding contact. The topic has been extended into brakes and clutches which are two of the most common sliding systems most susceptible to thermal buckling and thermoelastic instability (TEI), where thermal buckling and thermoelastic instability are two sub-categories of thermal-mechanical instability. Thermal-mechanical instability is an ongoing research to better understand the phenomenon and the limits at which such instability occurs. This work delved into the …

Extending Trailer, Alex Grove

Williams Honors College, Honors Research Projects

The goal of this research project is to revolutionize the convenience in towable transportation. This innovative design aims to enhance the versatility of pull-behind trailers by incorporating an extendable feature, allowing users to effortlessly adjust the length according to their specific needs. Whether navigating tight spaces or accommodating extra cargo, our trailer adapts to diverse situations, providing unmatched flexibility. In addition to its adjustable length, the trailer is engineered to be compactable, addressing the storage constraints often faced by users with limited space. The collapsible design ensures easy storage without compromising on functionality, making it an ideal solution for individuals …

Cfrp Delamination Density Propagation Analysis By Magnetostriction Theory, Brandon Eugene Williams

All Dissertations

While Carbon Fiber Reinforced Polymers (CFRPs) have exceptional mechanical properties concerning their overall weight, their failure profile in demanding high-stress environments raises reliability concerns in structural applications. Two crucial limiting factors in CFRP reliability are low-strain material degradation and low fracture toughness. Due to CFRP’s low strain degradation characteristics, a wide variety of interlaminar damage can be sustained without any appreciable change to the physical structure itself. This damage suffered by the energy transfer from high- stress levels appears in the form of microporosity, crazes, microcracks, and delamination in the matrix material before any severe laminate damage is observed. This …

Life Cycle Energy Assesment Of Advanced Fiber Reinforced Composite Design And Manufacturing Methodologies, Urjit Lad

All Theses

Automotive industry at large is focused on vehicle light-weighting since a 6%-8% increase in fuel efficiency can be achieved with a 10% reduction in vehicle weight [1]. With the growing demand for cost-effective and sustainable light weighting of automobile structures, interest has increased in the application of fiber reinforced plastic (FRP) composites for use in the Body-in-White (BiW), which can account for up to 40% of the total vehicle weight. Traditional FRP composite manufacturing processes like vacuum assisted resin transfer molding, autoclave consolidation or use of automated fiber placement have been successfully used for marine and aerospace applications. However, these …

Design And Development Of A Multi-Material, Cost-Competitive, Lightweight Mid-Size Sports Utility Vehicle’S Body-In-White, Amit M. Deshpande, Rushabh Rajesh Sadiwala, Nathan Brown, Sai Aditya Pradeep, Leon M. Headings, Ningxiner Zhao, Brad Losey, Ryan Hahnlen, Marcelo J. Dapino, Gang Li, Srikanth Pilla

Publications

Vehicle light-weighting has allowed automotive original equipment manufacturers (OEMs) to improve fuel efficiency, incorporate value-adding features without a weight penalty, and extract better performance. The typical body-in-white (BiW) accounts for up to 40% of the total vehicle mass, making it the focus of light-weighting efforts through a) conceptual redesign b) design optimization using state-of-the-art computer-aided engineering (CAE) tools, and c) use of advanced high strength steels (AHSS), aluminum, magnesium, and/or fiber-reinforced plastic (FRP) composites. However, most of these light-weighting efforts have been focused on luxury/sports vehicles, with a relatively high price range and an average production of 100,000 units/year or …

Towards Environmentally Sustainable, High-Performance, Lightweight Composites For Automotive Applications, Jasmin Zamudio Vasquez

Theses and Dissertations

The increasing public demand in the world automotive industry to improve the environmental sustainability of their manufactured vehicles without sacrificing drivers' comfort and safety and the high cost of lightweight materials have driven researchers to reconsider materials used in the automotive application. Thus, this work aims toward the production of environmentally sustainable, high-performance, lightweight composites, utilizing recycled carbon fibers (RCFs) and pyrolyzed tire particles (PTPs) reclaimed from pyro-gasification of CFRP wastes and end-of-life tires (ELTs), respectively, as reinforcements for cardanol-based epoxy resins. The fabricated composites exhibited rubbery-like behavior at 25 °C. Spectroscopic, rheological, physical, thermal, thermomechanical, and mechanical characterizations were …

Numerical Implementation And Validation Of A Viscoelastic-Plastic Material Model For Predicting Curing Induced Residual Stresses In Adhesive Bonded Joints, Akshat Agha, Fadi Abu-Farha

Publications

One of the main challenges in the joining of multi-material components is the assessment of the nature and magnitude of the residual stresses developing in the adhesive bond during the heat curing manufacturing process. Numerical modeling of these residual stresses can provide insights for making informed decisions related to (i) material substrate properties; (ii) adhesive properties i.e., low, medium, or high stiffness; (iii) bondline geometry i.e., bondline width and bead thickness; (iv) curing cycle characteristics; and (v) fixation design i.e., type, spacing, the number of joints. This work presents a cure history-dependent viscoelastic-plastic material description for the modeling of adhesive …

Manipulated Electrochemical Surface Reactions Induced By Oscillatory Electric Potentials On Metal Based Electrodes, Thomas Stone Welles

Dissertations - ALL

This research effort investigates the manipulation of surface electrochemical reactions induced by oscillating electric potentials on the surface of metal-based electrodes. Specifically, this research presents experimental data identifying modified electrochemical surface reactions caused by low magnitude electric potential oscillations on multilayered catalytic membranes and on implanted biometallic alloys. The scope of this effort consists of four major components: (1) perform an exhaustive literature review and analysis of the current understanding in applied surface electrochemistry and develop potential theoretical frameworks by which to interpret the experimental results; (2) identify the electrochemical manipulation via electrical oscillation while reacting nitric oxide on a …

Thermoforming Process Effects On Structural Performance Of Carbon Fiber Reinforced Thermoplastic Composite Parts Through A Manufacturing To Response Pathway, Madhura Limaye, Sai Aditya Pradeep, Anmol Kothari, Sushil Savla, Akshat Agha, Srikanth Pilla, Gang Li

Publications

Thermoforming process of thermoplastic-based continuous CFRP's offer a major advantage in reducing cycle times for large-scale productions, but it can also have a significant impact on the structural performance of the parts by inducing undesirable effects. This necessitates the development of an optimal manufacturing process that minimizes the introduction of undesirable factors in the structure and thereby achieves the targeted mechanical performance. This can be done by first establishing a relationship between the manufacturing process and mechanical performance and successively optimizing it to achieve the desired targets. The current study focuses on the former part, where a manufacturing-to-response (MTR) pathway …

Mechanical Properties Of Nanomodified Hybrid Gfrp Composite Materials, Micah Rop Kimutai

College of Graduate Studies: Theses & Dissertations

The mechanical behavior of the nanomodified hybrid epoxy matrix was investigated in glass fiber reinforced plastics (GFRP). In this study, five nanocomposites enriched with as received halloysite, nanomer I.28E, HNT-APTES, and the hybrid combinations of the two HNTs with the nanomer I.28E were successfully fabricated. To evaluate the effects and morphological characteristics of the individual fillers and the hybrid configurations on the epoxy resin matrix, TGA, DSC, and DMA were analyzed. To understand the effect of the five configurations on the neat GFRP laminate, mode I interlaminar fracture toughness, tensile, and vibration properties were investigated. Electron microscopy testing techniques were …

The Effects Of Molybdenum, Chromium, And Niobium On Gray Iron For Brake Rotor Applications, Matthew Hasbrouck

Dissertations, Master's Theses and Master's Reports

Brake rotor composition and microstructure must be optimized for thermal and mechanical performance to avoid thermal-mechanical cracking, excessive wear, and to reduce noise. Niobium is an element that increases the strength and wear resistance of gray iron; however, the interaction of niobium with other common alloying elements (chromium and molybdenum) is not well understood. Thirteen gray cast iron alloys were produced with varying levels of carbon equivalent (CE), Cr, Mo, and Nb. Bars with four different diameters (8, 14, 22, and 30 mm) were cast from each alloy and microstructural and physical properties such as graphite flake morphology, pearlite spacing, …

Design And Analysis Of One-Piece 10” Carbon Fiber Wheels For Zips Racing Zr20 Formula Sae Racecar, Patrick Kruse, Henry J. Wathen, Jordan J. Hyde, Nicholas D. Dobben, Jordan D. Blake

Williams Honors College, Honors Research Projects

Reducing the weight of a vehicle in racing can substantially improve the vehicle dynamics and general performance capabilities. More specifically, the reduction of the unsprung corner weight can provide noticeable performance gains in handling and responsiveness, leading to a quicker, more agile car due to a lower yawing moment of inertia. Unsprung weight reduction also improves the car’s ability to maintain contact between the tires and the road surface for a more consistent grip. In this project we identified the loads that act on the wheel rims according to the data collected from the sensors in the car’s suspension, and …

Autojack - Hydraulic Powertrain System, Tyce Vu

All Undergraduate Projects

A primary problem for mechanics and automotive enthusiasts is the risk associated with lifting and securing a vehicle with conventional jack stands. Often times, improper jack-stand installation results in the vehicle collapsing unexpectedly, causing injury and/or death. This problem can be minimized through the application of a newly re-designed vehicle lifting system. The conventional method for lifting cars is time consuming and can be unsafe in many circumstances. A better, safer, and more efficient lift design was needed; the AutoJack. The approach of the AutoJack design was entirely focused on the safety of lifting a vehicle. Safety was improved by …

Experimental And Numerical Simulation Of Split Hopkinson Pressure Bar Test On Borosilicate Glass, Mayank K. Bagaria

Dissertations, Master's Theses and Master's Reports

This study is an extension to the design of ceramic materials component exposed to bullet impact. Owing to the brittle nature of ceramics upon bullet impact, shattered pieces behave as pellets flying with different velocities and directions, damaging surrounding components. Testing to study the behavior of ceramics under ballistic impact can be cumbersome and expensive. Modeling the set-up through Finite Element Analysis (FEA) makes it economical and easy to optimize. However, appropriately incorporating the material in modeling makes laboratory testing essential. Previous efforts have concentrated on simulating crack pattern developed during 0.22 caliber pellet impact on Borosilicate glass. A major …

Reinventing The Wheel, Esther K. Unti, Ahmed Z. Shorab, Patrick B. Kragen, Adam M. Menashe

Mechanical Engineering

Reinventing the Wheel selected tires and designed wheels for the 2018 Cal Poly, San Luis Obispo Formula SAE combustion vehicle. Available tire options were evaluated for steady-state and transient performance as well as vehicle integration. A single-piece composite wheel with hollow spokes was designed to meet stiffness, strength, and tolerance requirements. A detailed study of wheel loading and geometric structural efficiency was performed. Finite element analysis was used to iterate the geometry and laminate. A two-piece male mold was designed and machined to manufacture the wheel. Removable silicone inserts were used to create the hollow spokes.

Advances In Automotive Conversion Coatings During Pretreatment Of The Body Structure: A Review, Mark Doerre, Larry Hibbitts, Gabriela Patrick, Nelson K. Akafuah

Institute of Research for Technology Development Faculty Publications

Automotive conversion coatings consist of layers of materials that are chemically applied to the body structures of vehicles before painting to improve corrosion protection and paint adhesion. These coatings are a consequence of surface-based chemical reactions and are sandwiched between paint layers and the base metal; the chemical reactions involved distinctly classify conversion coatings from other coating technologies. Although the tri-cationic conversion coating bath chemistry that was developed around the end of the 20th century remains persistent, environmental, health, and cost issues favor a new generation of greener methods and materials such as zirconium. Environmental forces driving lightweight material selection …

Composite Suspension For A Mass Market Vehicle, Sarah M. Chapiama, Brian Auyeung, Jose Guerrero, Ethan Lau

Mechanical Engineering

Statement of Confidentiality: The complete senior project report was submitted to the project advisor and sponsor. The results of this project are of a confidential nature and will not be published at this time.

A Laboratory Kit For Multimeter Design, Seth Percy, Joshua Perry

Thinking Matters Symposium Archive

The multimeter is an important electrical tool and is a combination of many individual instruments. In practice, common multimeter designs are digital and measure voltage, current, resistance, capacitance, etc., using a single set of probes. Before the digital age, the world relied on analog displays. Some argue that analog displays are outdated technology. However, this overlooks one of the most important characteristics provided by the analog display, which is its ability to provide an instantaneous visual perception. Analog displays are currently used for many applications in aviation and automobiles, demonstrating their continuing usefulness in the field. In the multimeter, the …

Manufacturing A Composite Wheel Prototype Using 3d Printed Molds, Steven Thuening

All Graduate Theses, Dissertations, and Other Capstone Projects

Throughout the evolution of high performance racing, a large emphasis has been on reducing the weight of the vehicle in order to improve its performance. Over the years, new designs and materials have been introduced reducing weight in a variety of different locations. Comparing weight reduced in different areas has shown that some areas are more valuable to reduce than others are. Perhaps one of the most beneficial locations are the wheels. This is because the mass of the wheel is considered unsprung and rotational. Because of this, large improvements towards the reduction of wheel mass have been developed in …