Sharif Digital Repository

In this paper we are to present a practical application of Axiomatic Design (AD) methodology, as a roadmap to lean production, in redesigning a car body assembly line. Axiomatic Design theory provides a framework to simplify the whole problem. According to the AD principles, a hierarchical structure has been developed. The developed structure originated in lean manufacturing principles and existing conditions of an assembly line, revealed that elimination of all kinds of waste is a prerequisite for other functional requirements. Several main sources of waste were recognized in the assembly line and some practical solutions are suggested to alleviate these problems. In the initial survey, it... 

Weight reduction is one of the most concerning issues of automotive and aircraft industries in reducing fuel consumption. Magnesium (Mg) alloys are the lightest alloys which can be used in the structure due to low density and high strength to weight ratio. Developing a reliable joining process of magnesium alloys is required due to limited ductility and low workability at room temperature. Friction stir welding (FSW) is a solid-state welding process that can be performed to produce sound joints in magnesium alloys. Researchers have performed investigations on the effect of rotation and travel speeds in FSW of AZ31B magnesium alloy. However, there is lack of study on the FSW parameters, i.e.... 

The effects of warm compaction on the green density and sintering behaviour of aluminium alloys were investigated. Particular attention is paid to prealloyed powders, i.e. eutectic and hypereutectic Al-Si alloys, regarding their potential applications in the automotive industry. The effects of chemical composition, alloying method, compacting temperature and the amount of powder lubricant were studied. The compaction behaviour was examined by an instrumented die enabling simultaneous measurement of density, die wall friction coefficient, the triaxial stresses acting on the powder during the course of compaction and ejection pressure. The sintering behaviour was studied via dilatometeric... 

Polypropylene matrix nanocomposites reinforced with organoclay are investigated and their ability to replace some polyamide automotive parts is evaluated. This is so interesting from industrial point of view because of cost saving and ease of processing and recycling. This work is focused on different nanocomposite systems which are PP/nanoclay, and PP/PA/nanoclay. Also the effect of compatibilizer is presented here. Structure of these systems are studied by using WAXD, TEM and SEM. Mechanical properties of specimens are studied using uniaxial tensile test. As it will be demonstrated, nanoclay sheets tend to disperse in PA particles. On the other hand, introducing nanoclay into PP/PA blends... 

This paper presents a neuro-predictive controller for temperature control of automotive air conditioning system. A numerical model for the automotive refrigeration cycle, which includes transient operating conditions, has been employed in simulations. In this model, which has been created from numerous laboratory tests on a typical passenger car, the vehicle is divided into two linked modules representing the air conditioning (A/C) system as well as the passenger compartment climate. Moreover, the thermal loads have been considered. This system demonstrates variable and large time delays, which is the case in reality. The simulation results show good performance of the proposed controller. ©... 

This study provides a comprehensive literature review to summarize all contributing factors and the logit-based models that were used to predict the severity of crashes. Using the General Estimates Systems (GES) dataset, as a subset and a branch of the National Automotive Sampling System in the US, a Generalized Ordered Logit (GLM) model is developed to predict the crash severity. The developed severity model detects the most important parameters based on characteristics of the driver, the environment, the vehicle, the road, and the type of crash. This study aims to take a more in-depth look into the distraction-related factors as one of the most important groups of contributing factors to... 

Assembly line is the most well-known mass production system which was first used by Henry Ford in automobile industries. Malfunction of a station will have an impact on the whole assembly line. Having a great impact on the performance of the whole assembly line, Interaction of the stations on each other should be considered precisely. In this paper we will use discrete event simulation to improve performance of a station and the whole assembly line by smoothing the exit rate, which is the entrance rate to the next station. At the end of this article, the results for a case problem are illustrated and several conclusions are driven. © 2007 IEEE  

Dynamic and stability analysis of non-uniform Timoshenko beam under axial loads is carried out. In the first case of study, the axial force is assumed to be perpendicular to the shear force, while for the second case the axial force is tangent to the axis of the beam column. For each case, a pair of differential equations coupled in terms of the flexural displacement and the angle of rotation due to bending was obtained. The parameters of the frequency equation were determined for various boundary conditions. Several illustrative examples of uniform and non-uniform beams with different boundary conditions such as clamped supported, elastically supported, and free end mass have been... 

Ultrasonic Testing (UT) is one of the most common types of nondestructive methods that is being used in various industries, especially in the automotive industry. In this paper, qualitative and quantitative control of resistance spot welds on three-sheet joints was studied. Initially, mathematical model of ultrasonic waves was extracted for triple sheet joints. Then, acoustic simulation of ultrasonic testing on spot welds was performed using Finite Element Method (FEM). Afterwards, A Multilayer Perceptron (MLP) neural network was used to classify spot welds based on their diameter. There was a mean error of 20.9 % between peak amplitudes of numerical and theoretical models which the most... 

To assess a car under the Euro New Car Assessment Program (Euro-NCAP), Adult Occupant Protection is one out of three parameters which need to be calculated with a weight factor of 50% while the other parameters, Child Occupant Protection and Pedestrian Occupant Protection, have a weight factor of 20%. The Pole Side Impact Test, beside two other tests, Side and Front Impact, is also required to calculate the Adult Occupant Protection. It shows how important the Pole Side Impact Test is and what an effective role it has in the car rating assessment. In this paper, the objective is to evaluate the effect of thickness on the energy absorbed by the side doors and the B pillar and its... 

Hybridization of conventional vehicles is considered an important step to achieve high fuel economy and low emissions. In this study, principle considerations involved in a hybridizing process are discussed and consequently, a sequential approach for designing hybrid components for both series and parallel configurations has been introduced. The so called approach has then been applied to one of the productions of Iran-Khodro Company called SAMAND. Having designed the hybrid components, the conventional SAMAND and its series and parallel hybrid configurations were defined and evaluated using the ADvanced VehIcle SimulatOR (ADVISOR) software. It is observed that compared to the conventional... 

Charge-discharge rate capability is one of the most important properties of cathode materials for lithium batteries, in particular when envisaging high power density applications such as automotive applications. Efforts to modify rate have been carried out by carbon coating and decreasing particle size in order to modify electronic and ionic conductivity. However, this approach cannot justify all experimental data reported in the literature. Here, we investigated the rate capability of cathode materials by considering their density of states (DOS) calculated by several density functional theory (DFT) methods, in both the lithiated and the delithiated case. We suggested that these structures... 

In this paper the objective is to study the effect of the material and thickness of the side doors and B pillar on crashworthiness and the energy absorbed in order to select a proper material and an optimized thickness to approach a five star car concept based on the Euro New Car Assessment Program (Euro-NCAP) testing Pole Side Impact. In this matter, four materials and five thicknesses have been chosen for the vehicle model and a total of twenty simulations have been conducted. The results showed that the best selected materials and thicknesses were high strength Steel 204M with a thickness of 1.2mm for side doors and 0.65mm for the B pillar, however, it is important to note that this... 

Pole Side Impact Tes is one out of three crash tests described by Euro NCAP standard for star rating of a vehicle and is required for assessing the Adult Occupant Protection. In this paper the goal is to determine the crashworthiness of side doors and B pillar in a Pole Side Impact Test based on Euro New Car Assessment Program (Euro-NCAP) using computer and simulation method. In this matter, a vehicle model has been prepared and meshed using Hypermesh and CATIA. The velocity of 29 km/h has been assigned to the vehicle which was on top of a cart while the pole has been assigned as a rigid static object based on Euro NCAP requirements specifically. Results show that different amounts of energy... 

Reduction of cold start hydrocarbon (HC) emission requires a proper compromise between low engine-out HC emission and fast light-off of the three way catalytic converter (TWC). In this paper a model based approach is used to design and optimize a hybrid switching system for reducing HC emission of a mid-sized passenger car during the cold start phase of FTP-75. This hybrid system takes the benefit of increasing TWC temperature during the early stages of the driving cycle by switching between different operational modes. The switching times are optimized to reduce the cumulative tailpipe HC emission of an experimentally validated automotive emission model. It is shown that the new hybrid...