Abstract: The paper presents the influence of non-metallic inclusions on the multi-stage forging process and the mechanical properties of the dodecagon socket bolt used in the automotive industry. The detected metallurgical defect was so large that it directly influenced the mechanical properties of the bolt and resulted in failure to meet the requirements of the mechanical property class. In order to assess the defect, an X-ray examination and metallographic examination of the defective bolt were performed, showing exogenous non-metallic inclusion. The size of the defect on the cross section was 0.531 mm in width and 1.523 mm in length; the defect was continuous along the entire axis of the bolt. In analysis, a finite element method (FEM) simulation of the multi-stage forging process was designed, taking into account a non-metallic inclusion parallel to the sample axis, reflecting the studied case. The process of defect propagation due to material upset in the head area was analyzed. The final forging stage in shaping the dodecagonal socket and filling the flange area was particularly studied. The effect of the defect was observed to significantly reduce the effective cross-section as a result of the expansion of the defect perpendicular to the axis of the bolt. The mechanical properties of products with and without the defect were analyzed. In the first step, the hardness test confirmed that the required value for the mechanical class 8.8 of both bolt types was obtained. In the second step, the bolts were subjected to a static tensile test. The bolts without the defect gave a positive result, while all 10 bolts with the defect gave a negative result, achieving a tensile strength below the requirements. Tensile strength tests were confirmed by metallographic tests and FEM simulation with perpendicular inclusion spread in the area of the head. The bolts were damaged directly under the bolt head, which is inconsistent with the requirements of ISO 898-1. It has been shown that non-metallic inclusions with orientation in accordance with the axis of the bolt can directly cause loss of functionality and these defects should be detected even before assembling in the machine element.
Abstract: The purpose of the paper is to redefine the levels of structure of corporate, business and functional strategies that were established over the past several decades, to a conceptual model, consisting of corporate, business and operations strategies, that are reinforced by functional strategies. We will propose a conceptual framework of different perspectives in the role of strategic operations as a separate strategic place and reposition the remaining functional strategies as supporting tools, existing at all three levels. The proposed model is called ‘the strategic engine’, since the mutual relationships of its ingredients are identical with main elements and working principle of the internal combustion engine. Based on theoretical essence, related to every strategic level, we will prove that the strategic engine model is useful for managers seeking to safeguard the competitive advantage of their companies. Each strategy level is researched through its basic elements. At the corporate level we examine the scope of firm’s product, the vertical and geographical coverage. At the business level, the point of interest is limited to the SWOT analysis’ basic elements. While at operations level, the key research issue relates to the scope of the following performance indicators: cost, quality, speed, flexibility and dependability. In this relationship, the paper provides a different view for the role of operations strategy within the overall strategy concept. We will prove that the theoretical essence of operations goes far beyond the scope of traditionally accepted business functions. Exploring the applications of Resource-based theory and Market-based theory within the strategic levels framework, we will prove that there is a logical consequence of the theoretical impact in corporate, business and operations strategy – at every strategic level, the validity of one theory is substituted to the level of the other. Practical application of the conceptual model is tested in automotive industry. Actually, the proposed theoretical concept is inspired by a leading global automotive group – Inchcape PLC, listed on the London Stock Exchange, and constituent of the FTSE 250 Index.
Abstract: Power transmitted from the engine to the final drive where useful work is applied through a system consisting of a gearbox, clutch, drive shaft and a differential in the rear-wheel-drive automobiles. It is well-known that the steel drive shaft is usually manufactured in two pieces to increase the fundamental bending natural frequency to ensure safe operation conditions. In this work, hybrid one-piece propeller shafts composed of carbon/epoxy and glass/epoxy composites have been designed for a rear wheel drive automobile satisfying three design specifications, such as static torque transmission capability, torsional buckling and the fundamental natural bending frequency. Hybridization of carbon and glass fibers is being studied to optimize the cost/performance requirements. Composites shaft materials with various fiber orientation angles and stacking sequences are being fabricated and analyzed using finite element analysis (FEA).
Abstract: Any industrial company needs to determine the amount of variation that exists within its measurement process and guarantee the reliability of their data, studying the performance of their measurement system, in terms of linearity, bias, repeatability and reproducibility and stability. This issue is critical for automotive industry suppliers, who are required to be certified by the 16949:2016 standard (replaces the ISO/TS 16949) of International Automotive Task Force, defining the requirements of a quality management system for companies in the automotive industry. Measurement System Analysis (MSA) is one of the mandatory tools. Frequently, the measurement system in companies is not connected to the equipment and do not incorporate the methods proposed by the Automotive Industry Action Group (AIAG). To address these constraints, an R&D project is in progress, whose objective is to develop a web and cloud-based MSA tool. This MSA tool incorporates Industry 4.0 concepts, such as, Internet of Things (IoT) protocols to assure the connection with the measuring equipment, cloud computing, artificial intelligence, statistical tools, and advanced mathematical algorithms. This paper presents the preliminary findings of the project. The web and cloud-based MSA tool is innovative because it implements all statistical tests proposed in the MSA-4 reference manual from AIAG as well as other emerging methods and techniques. As it is integrated with the measuring devices, it reduces the manual input of data and therefore the errors. The tool ensures traceability of all performed tests and can be used in quality laboratories and in the production lines. Besides, it monitors MSAs over time, allowing both the analysis of deviations from the variation of the measurements performed and the management of measurement equipment and calibrations. To develop the MSA tool a ten-step approach was implemented. Firstly, it was performed a benchmarking analysis of the current competitors and commercial solutions linked to MSA, concerning Industry 4.0 paradigm. Next, an analysis of the size of the target market for the MSA tool was done. Afterwards, data flow and traceability requirements were analysed in order to implement an IoT data network that interconnects with the equipment, preferably via wireless. The MSA web solution was designed under UI/UX principles and an API in python language was developed to perform the algorithms and the statistical analysis. Continuous validation of the tool by companies is being performed to assure real time management of the ‘big data’. The main results of this R&D project are: MSA Tool, web and cloud-based; Python API; New Algorithms to the market; and Style Guide of UI/UX of the tool. The MSA tool proposed adds value to the state of the art as it ensures an effective response to the new challenges of measurement systems, which are increasingly critical in production processes. Although the automotive industry has triggered the development of this innovative MSA tool, other industries would also benefit from it. Currently, companies from molds and plastics, chemical and food industry are already validating it.
Abstract: Due to the constant development of measurement systems and the aim for computerization, unavoidable improvements are made for the main disadvantages of air gauges. With the appearance of the air-electronic measuring devices, some of their disadvantages are solved. The output electrical signal allows them to be included in the modern systems for measuring information processing and process management. Producer efforts are aimed at reducing the influence of supply pressure and measurement system setup errors. Increased accuracy requirements and preventive error measures are due to the main uses of air electronic systems - measurement of geometric dimensions in the automotive industry where they are applied as modules in measuring systems to measure geometric parameters, form, orientation and location of the elements.
Abstract: The relationship of the automotive industry with raw material supply is a major challenge and presents obstacles. Automobiles are ones of the most complex products using a large variety of materials. Safety, eco-friendliness and comfort requirements, physical, chemical and economic limitations set the framework in which this industry continuously optimizes the efficient and responsible use of resources. The concept of circular economy covers the issues of waste generation, resource scarcity and economic advantages. However, circularity is already known for the automobile industry – several efforts are done to foster material reuse, product remanufacturing and recycling. The aim of this study is to give an overview on how the producers comply with the growing demands on one hand, and gain efficiency and increase profitability on the other hand from circular economy.
Abstract: Friction stir welding is a modern and an environmentally friendly solid state joining process used to joint relatively lighter family of materials. Recently, friction stir spot welding has been used instead of resistance spot welding which has received considerable attention from the automotive industry. It is environmentally friendly process that eliminated heat and pollution. In this research, friction stir spot welding has been used to study the possibility to weld AA1100 aluminum alloy sheet with 3 mm thickness by overlapping the edges of sheet as lap joint. The process was done using a drilling machine instead of milling machine. Different tool rotational speeds of 760, 1065, 1445, and 2000 RPM have been applied with manual and automatic compression to study their effect on the quality of welded joints. Heat generation, pressure applied, and depth of tool penetration have been measured during the welding process. The result shows that there is a possibility to weld AA1100 sheets; however, there is some surface defect that happened due to insufficient condition of welding. Moreover, the relationship between rotational speed, pressure, heat generation and tool depth penetration was created.
Abstract: The demand for an increasing diversification of the product spectrum associated with the current huge customization desire and subsequently the decreasing unit quantities of each production lot is gaining more and more importance within a great variety of industrial branches, e.g. automotive industry. Nevertheless, traditional product development and production processes (molding, extrusion) are already reaching their limits or fail to address these trends of a flexible and digitized production in view of a product variability up to lot size one. Thus, upcoming innovative production concepts like the additive manufacturing technology basically create new opportunities with regard to extensive potentials in product development (constructive optimization) and manufacturing (economic individualization), but mostly suffer from insufficient strength regarding structural components. Therefore, this contribution presents an innovative technological and procedural conception of a hybrid additive manufacturing process (fiber-reinforced sandwich structures based on selective laser sintering technology) to overcome these current structural weaknesses, and consequently support the design of complex lightweight components.
Abstract: The growing speed of innovation in related industries requires the automotive industry to adapt and increase release frequencies of new vehicle derivatives which implies a significant reduction of investments per vehicle and ramp-up times. Emerging markets in various parts of the world augment the currently dominating established main automotive markets. Local content requirements such as import tariffs on final products impede the accessibility of these micro markets, which is why in the future market exploitation will not be driven by pure sales activities anymore but rather by setting up local assembly units. The aim of this paper is to provide an overview of the concept of decentralized assembly and to discuss and critically assess some currently researched and crucial approaches in production technology. In order to determine the scope in which complementary mobile assembly can be profitable for manufacturers, a general cost model is set up and each cost driver is assessed with respect to varying levels of decentralization. One main result of the paper is that the presented approaches offer huge cost-saving potentials and are thus critical for future production strategies. Nevertheless, they still need to be further exploited in order for decentralized assembly to be profitable for companies. The optimal level of decentralization must, however, be specifically determined in each case and cannot be defined in general.
Abstract: This article presents the beginning of a wider study that intends to demonstrate how within organizations of the automotive industry from the city of Querétaro. Knowledge management and technological management are required, as well as people’s initiative and the interaction embedded at the interior of it, with the appropriate environment that facilitates information conversion with wide information technologies management (ITM) range. A company was identified for the pilot study of this research, where descriptive and inferential research information was obtained. The results of the pilot suggest that some respondents did noted entity the knowledge management topic, even if staffs have access to information technology (IT) that serve to enhance access to knowledge (through internet, email, databases, external and internal company personnel, suppliers, customers and competitors) data, this implicates that there are Knowledge Management (KM) problems. The data shows that academically well-prepared organizations normally do not recognize the importance of knowledge in the business, nor in the implementation of it, which at the end is a great influence on how to manage it, so that it should guide the company to greater in sight towards a competitive strategy search, given that the company has an excellent technological infrastructure and KM was not exploited. Cultural diversity is another factor that was observed by the staff.
Abstract: The simulation in wind tunnel is used thoroughly to model real situations of drainages of air. Besides the automotive industry, a great number of applications can be numbered: dispersion of pollutant, studies of pedestrians’ comfort, and dispersion of particles. This work had the objective of visualizing the characteristics aerodynamics of two automobiles in different ways. To accomplish that drainage of air a fan that generated a speed exists (measured with anemometer of hot thread) of 4,1m/s and 4,95m/s. To visualize the path of the air through the cars, in the wind tunnel, smoke was used, obtained with it burns of vegetable oil. For “to do smoke” vegetable oil was used, that was burned for a tension of 20V generated by a thread of 2,5mm. The cars were placed inside of the wind tunnel with the drainage of “air-smoke” and photographed, registering like this the path lines around them, in the 3 different speeds.
Abstract: Nanotechnology in pristine sense refers to building of
structures at atomic and molecular scale. Meticulously
nanotechnology encompasses the nanomaterials with at least one
dimension size ranging from 1 to 100 nanometres. Unlike the literal
meaning of its name, nanotechnology is a massive concept beyond
imagination. This paper predominantly deals with relevance of
nanotechnology in automotive industries. New generation of
automotives looks at nanotechnology as an emerging trend of
manufacturing revolution. Intricate shapes can be made out of fairly
inexpensive raw materials instead of conventional fabrication
process. Though the current era have enough technology to face
competition, nanotechnology can give futuristic implications to pick
up the modern pace. Nanotechnology intends to bridge the gap
between automotives with superior technical performance and their
cost fluctuation. Preliminarily, it is an area of great scientific interest
and a major shaper of many new technologies. Nanotechnology can
be an ideal building block for automotive industries, under constant
evolution offering a very wide scope of activity. It possesses huge
potential and is still in the embryonic form of research and
development.
Abstract: This research was conducted in an automotive company in Indonesia to overcome the problem of high logistics cost. The problem causes high of additional truck delivery. From the breakdown of the problem, chosen one route, which has the highest gap value, namely for RE-04. Research methodology will be started from calculating the ideal condition, making simulation, calculating the ideal logistic cost, and proposing an improvement. From the calculation of the ideal condition, box arrangement was done on the truck has efficiency with three trucks delivery per day. Route simulation making uses Tecnomatix Plant Simulation software as a visualization for the company about how the system is occurred on route RE-04 in ideal condition. The last step is proposing improvements on the area of route RE-04. The route arrangement is done by Saving Method and sequence of each supplier with the Nearest Neighbor. The results of the proposed improvements are three new route groups, where was expected to decrease logistics cost and increase the average of the truck efficiency per day.
Abstract: The end of the line controls of the finished products in
the automotive industry is important. The control that has been
conducted with the manual methods for the sliding doors tracks is not
sufficient and faulty products cannot be identified. As a result, the
customer has the faulty products. In the scope of this study, the
design criteria of the PLC integrated modular end of line control unit
has been examined, designed and manufactured to make the control
of the 10 different track profile to 2 different vehicles with an
objective to minimize the salvage costs by obtaining more sensitive,
certain and accurate measurement results. In the study that started
with literature and patent review, the design inputs have been
specified, the technical concept has been developed, computer
supported mechanic design, control system and automation design,
design review and design improvement have been made. Laser
analog sensors at high sensitivity, probes and modular blocks have
been used in the unit. The measurement has been conducted in the
system and it is observed that measurement results are more sensitive
than the previous methods that we use.
Abstract: A sliding door system is used in commercial vehicles
and passenger cars to allow a larger unobstructed access to the
interior for loading and unloading. The movement of a sliding door
on vehicle body is ensured by mechanisms and tracks having special
cross-section which is manufactured by roll forming and stretch
bending process. There are three tracks and three mechanisms which
are called upper, central and lower on a sliding door system. There
are static requirements as strength on different directions, rigidity for
mechanisms, door drop off, door sag; dynamic requirements as high
energy slam opening-closing and durability requirement to validate
these products. In addition, there is a kinematic requirement to find
out force values from door handle during manual operating. In this
study, finite element analysis and physical test results which are
realized for sliding door systems will be shared comparatively.
Abstract: In Automotive Industry, sliding door systems that are
also used as body closures are safety members. Extreme product tests
are realized to prevent failures in design process, but these tests
realized experimentally result in high costs. Finite element analysis is
an effective tool used for design process. These analyses are used
before production of prototype for validation of design according to
customer requirement. In result of this, substantial amount of time
and cost is saved. Finite element model is created for geometries that are designed in
3D CAD programs. Different element types as bar, shell and solid,
can be used for creating mesh model. Cheaper model can be created
by selection of element type, but combination of element type that
was used in model, number and geometry of element and degrees of
freedom affects the analysis result. Sliding door system is a good
example which used these methods for this study. Structural analysis
was realized for sliding door mechanism by using FE models. As
well, physical tests that have same boundary conditions with FE
models were realized. Comparison study for these element types,
were done regarding test and analyses results then optimum
combination was achieved.
Abstract: Elastomeric polymer foam has been used widely in
the automotive industry, especially for isolating unwanted vibrations.
Such material is able to absorb unwanted vibration due to its
combination of elastic and viscous properties. However, the ‘creep
effect’, poor stress distribution and susceptibility to high
temperatures are the main disadvantages of such a system.
In this study, improvements in the performance of elastomeric
foam as a vibration isolator were investigated using the concept of
Foam Filled Fluid (FFFluid). In FFFluid devices, the foam takes the
form of capsule shapes, and is mixed with viscous fluid, while the
mixture is contained in a closed vessel. When the FFFluid isolator is
affected by vibrations, energy is absorbed, due to the elastic strain of
the foam. As the foam is compressed, there is also movement of the
fluid, which contributes to further energy absorption as the fluid
shears. Also, and dependent on the design adopted, the packaging
could also attenuate vibration through energy absorption via friction
and/or elastic strain.
The present study focuses on the advantages of the FFFluid
concept over the dry polymeric foam in the role of vibration isolation.
This comparative study between the performance of dry foam and the
FFFluid was made according to experimental procedures. The paper
concludes by evaluating the performance of the FFFluid isolator in
the suspension system of a light vehicle. One outcome of this
research is that the FFFluid may preferable over elastomer isolators
in certain applications, as it enables a reduction in the effects of high
temperatures and of ‘creep effects’, thereby increasing the reliability
and load distribution. The stiffness coefficient of the system has
increased about 60% by using an FFFluid sample. The technology
represented by the FFFluid is therefore considered by this research
suitable for application in the suspension system of a light vehicle.
Abstract: In this paper we propose a computer-aided solution
with Genetic Algorithms in order to reduce the drafting of reports:
FMEA analysis and Control Plan required in the manufacture of the
product launch and improved knowledge development teams for
future projects. The solution allows to the design team to introduce
data entry required to FMEA. The actual analysis is performed using
Genetic Algorithms to find optimum between RPN risk factor and
cost of production. A feature of Genetic Algorithms is that they are
used as a means of finding solutions for multi criteria optimization
problems. In our case, along with three specific FMEA risk factors is
considered and reduce production cost. Analysis tool will generate
final reports for all FMEA processes. The data obtained in FMEA
reports are automatically integrated with other entered parameters in
Control Plan. Implementation of the solution is in the form of an
application running in an intranet on two servers: one containing
analysis and plan generation engine and the other containing the
database where the initial parameters and results are stored. The
results can then be used as starting solutions in the synthesis of other
projects. The solution was applied to welding processes, laser cutting
and bending to manufacture chassis for buses. Advantages of the
solution are efficient elaboration of documents in the current project
by automatically generating reports FMEA and Control Plan using
multiple criteria optimization of production and build a solid
knowledge base for future projects. The solution which we propose is
a cheap alternative to other solutions on the market using Open
Source tools in implementation.
Abstract: The popularity of quality management system models
continues to grow despite the transitional crisis in 2008. Their
development is associated with demands of the new requirements for
entrepreneurs, such as risk analysis projects and more emphasis on
supervision of outsourced processes. In parallel, it is appropriate to
focus attention on the selection of companies aspiring to a quality
management system. This is particularly important in the automotive
supplier industry, where requirements transferred to the levels in the
supply chain should be clear, transparent and fairly satisfied. The
author has carried out a series of researches aimed at finding the
factors that allow for the effective implementation of the quality
management system in automotive companies. The research was
focused on four groups of companies: 1) manufacturing (parts and
assemblies for the purpose of sale or for vehicle manufacturers), 2)
service (repair and maintenance of the car) 3) services for the
transport of goods or people, 4) commercial (auto parts and vehicles).
The identified determinants were divided into two types of criteria:
internal and external, as well as hard and soft. The article presents the
hard – technical factors that an automotive company must meet in
order to achieve the goal of the quality management system
implementation.
Abstract: Micro-alloyed steel components are used in
automotive industry for the necessity to make the manufacturing
process cycles shorter when compared to conventional steel by
eliminating heat treatment cycles, so an important saving of costs and
energy can be reached by reducing the number of operations. Microalloying
elements like vanadium, niobium or titanium have been
added to medium carbon steels to achieve grain refinement with or
without precipitation strengthening along with uniform
microstructure throughout the matrix. Present study reports the
applicability of medium carbon vanadium micro-alloyed steel in hot
forging. Forgeability has been determined with respect to different
cooling rates, after forging in a hydraulic press at 50% diameter
reduction in temperature range of 900-11000C. Final microstructures,
hardness, tensile strength, and impact strength have been evaluated.
The friction coefficients of different lubricating conditions, viz.,
graphite in hydraulic oil, graphite in furnace oil, DF 150 (Graphite,
Water-Based) die lubricant and dry or without any lubrication were
obtained from the ring compression test for the above micro-alloyed
steel. Results of ring compression tests indicate that graphite in
hydraulic oil lubricant is preferred for free forging and dry lubricant
is preferred for die forging operation. Exceptionally good forgeability
and high resistance to fracture, especially for faster cooling rate has
been observed for fine equiaxed ferrite-pearlite grains, some amount
of bainite and fine precipitates of vanadium carbides and
carbonitrides. The results indicated that the cooling rate has a
remarkable effect on the microstructure and mechanical properties at
room temperature.