Experimental investigation on the bending behaviour of hybrid and steel thin walled box beams—The role of adhesive joints

In the automotive design, nowadays there are two fundamental drivers. On one hand there are the environmental problems, on the other hand there are the safety matters. Within this contest, the weight reduction has become a key driver in the design of vehicles and it is necessary to consider and to study the use of nonconventional materials taking advantage from their high potential of weight reduction and energy absorption capability. In this perspective, the aim of this work is the study of the structural behaviour of box beams by means of a series of three points bending tests. The examined cross sections are those typically used in automotive construction. Different type of materials (steel, composite) and joining technologies (adhesive, spot weld) have been examined, considering different configurations. The work put in evidence the advantages coming from the use of adhesive, which allows structures with important weight reduction and better mechanical properties than traditional joining solution

Dynamic additional loads influencing the fatigue life of gears in an electric vehicle transmission

In recent years the implementation of the electric engine in the automotive industries has been increasingly marked. The speed of the electric motors is much higher than the combustion engine ones, bringing transmission gears to be subjected to high dynamic loads. For this reason the dynamic effects on fatigue life of these components have be taken into account in a more careful way respect to what is done with the usual gears. In the present work the overload effects due to both speed and meshing in a gear couple of an electric vehicle transmission have been analyzed. The electric vehicle is designed for urban people mobility and presents all the requirements to be certified as M1 vehicle (a weight less than 600 kg and a maximum speed more than 90 Km/h). To investigate the overload effects of teeth in contact, the reference gear design Standards (ISO 6336) introduce a specific multiplicative factor to the applied load called Internal Dynamic Factor (K v ). Aim of this work is to evaluate how dynamic overloads may influence the fatigue life of the above quoted gears in term of durability. To this goal, Kv values have been calculated by means of the analytical equations (ISO 6336 Methods B and C) and then they have been compared with the results coming from multibody simulations, involving full rigid and rigid-flexible models

Thermosetting and thermoplastic impact attenuator under axial loading

High-performance composites are generally fabricated with continuous fibre and fabric reinforcements embedded in a thermosetting resin. Using thermoplastic matrices, there are substantial reductions in forming time and labour. More recently, the availability of all-polypropylene composites, achieved using the same thermoplastic polymer for both the fibre and the matrix phase, is also increasing because of their recyclability. In this perspective, the work aims to study the mechanical behaviour of a new fully thermoplastic composite, first showing the results of an experimental campaign for the mechanical characterization of the material properties, then examining the behaviour of structures made of such material under axial loading to evaluate their energy absorption capability. The second part of this work is divided into two steps. In the first step, crush tests on simple tubes were performed. In the second step, the behaviour of a specific impact attenuator for a Formula SAE racing car was analysed. Using the same geometry, different material solutions were tested. Beside traditional thermosetting composite structure, a new fully thermoplastic composite and a hybrid solution were used taking into account various feasibility problems in the manufacturing phases. Even if the thermoplastic attenuator does not exhibit the same absorption capability of the thermosetting solutions, an interesting crushing mechanism was noticed: no more brittle failure with formation of debris, but a ductile progression with a load distribution very close to an ideal absorber

Rapid assessment of the fuel economy capability of parallel and series-parallel hybrid electric vehicles

Efficiently solving the off-line control problem represents a crucial step to predict the fuel economy capability of hybrid electric vehicles (HEVs). Optimal HEV control approaches implemented in literature usually prove to be either computationally inefficient or sub-optimal. Moreover, they often neglect drivability and comfort associated to the generated control actions over time. This paper therefore aims at introducing a rapid near-optimal approach to solve the off-line control problem for parallel and series-parallel HEV powertrains while accounting for drivability criteria such as the frequency of gear shifts and the number of activations of the thermal engine. The performance of the introduced slope-weighted energy-based rapid control analysis (SERCA) algorithm is compared with the global optimal benchmark provided by dynamic programming (DP) for both the parallel and the series-parallel HEV layouts over different driving missions. Results demonstrate how the SERCA algorithm can produce comparable control results with respect to DP by limiting the increase in the estimated fuel consumption within 2.2%. The corresponding computational time can be simultaneously reduced by around 99.5% while ensuring a limited number of gear shifts and engine activations over time. Engineers could therefore potentially implement the proposed SERCA algorithm in design and calibration procedures of parallel and series-parallel HEVs to accelerate the overall vehicle development process

Investigation of creep phenomenon on composite material for bolt connections

One of the main target in the automotive design is the weight reduction. This reduction leads to the reduction of the gas emissions. The designers tend to use innovative materials for the automotive field such as plastics and composites. To use the right material for the right application, multi material solutions are increasingly adopted. To join dissimilar materials, solutions like adhesive, bolt and nuts, riveting are necessary. It is necessary to know the behaviour of the materials to be joined, under different loading conditions to ensure the joint. In this work, a bolt connection between composite and aluminium plates has been considered. The behaviour of a carbon fibre reinforced material under compression load, taking into account creep is studied. A specific experimental equipment has been design and built. A series of experimental compressive tests, in the laminate thickness direction, have been done on carbon fibre reinforced material specimens. Different set-up in terms of temperature, compression load and surface roughness have been investigated. The obtained results are presented and discussed. A mathematical model will be proposed for interpolation of the obtained results. Finally, a possible strategy for reducing the tight loss in the initial phase of the joint life is propose

Investigation of influence of tab types on tensile strength of E-glass/epoxy fiber reinforced composite materials

Abstract Mechanical response of E-glass/epoxy fiber reinforced composite was investigated in tensile loading. Different types of tabs were considered in order to evaluate their effects on the tensile strength of material. Specifically, two types of molded tabs and five types of bonded tabs were considered in the study. The influence of different amount of gripping pressures on failure mode and on tensile strength of specimens was also considered in the analysis. The experimental results showed that the tabs configuration affected the tensile strength of the specimens. Starting from the experimental results, an appropriate testing methodology is proposed for E-glass/epoxy fiber reinforced composite specimens in order to reduce problems that may arise during the test and to optimize procedures for preparation of specimens

Design and Manufacturing Issues in the Development of Lightweight Solution for a Vehicle Frontal Bumper

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Dynamic behaviour of polyolefin thermoplastic hot melt adhesive under impact loading conditions

Dynamic behavior of polyolefin thermoplastic hot melt adhesive under impact loading conditions R. Ciardiello1, A. Tridello1, G. Belingardi1, L. Goglio1. 1 Politecnico di Torino, Department of Mechanical and Aerospace Engineering, Torino, 10129, IT. The mechanical behaviour of adhesive joints under impact loadings is an active area of research due to significant industrial interests. Furthermore, the absence of a unique adopted standard for the study of bonded joints under impact loading increases the academic interests for this topic [1]. In this work, the static and the dynamic response of adhesive joints, bonded with a polyolefin hot-melt adhesive (HMA), were investigated by means of Single Lap Joint (SLJ) tests. The adhesive studied in this work is used in automotive application for bonding plastic internal and external plastic components [2], such as plastic bumpers that can be subjected to impacts during its life. The mechanical and thermal properties of this adhesive are presented in [3]. The main aim of this study is to test standard specimens, SLJ, under dynamic impacts with the use of a modified Charpy pendulum in order to compare the differences between static and dynamic behaviour. The substrate used in this activity are made of a polypropylene copolymer with 10% in weight of talc. Figure 1 shows the testing machine with the clamping system of the specimen. These special fixtures were designed by Goglio et al. [4] with the aim to apply a dynamic load on the tested SLJ. The specimen is fixed to the hammer at the front end, as shown in the right part of Figure 1; the back end is connected to a transverse tail, which hits the two stoppers fixed on the pendulum base, shown in the red circle of Figure 1. The fixtures hold the specimen during the fall of the hammer and transmit the load. A tail in aluminium alloy with T cross section was used, in order to guarantee a high stiffness during the impact, without adding excessive inertia to the system. The system is able to perform dynamic tests for SLJ specimens up to 3.75 m/s. Figure 1: Charpy pendulum used for the experimental tests. Mechanical tests show that there is a clear influence of the load rate on force-displacement diagram and on the maximum force for the tested adhesive. Figure 2 illustrates the differences between a representative curve of quasi-static test and dynamic tests with two different velocities. Figure 2: Force vs linear displacement: comparison between quasi-static and dynamic tests. Figure 3 shows the average values of the peak force and absorbed energies. This Figure illustrates that the velocity increase leads to an increase of the maximum force while the adsorbed energy significantly decreases by comparing quasi-static and dynamic tests. Figure 3: Peak loads and absorbed energy of the quasi-static and dynamic tests. Finally, the fracture surfaces of the SLJ specimens were assessed by means of visual inspection. This analysis showed that the joint separation in the quasi-static tests is mostly cohesive, whereas it becomes completely adhesive in dynamic tests. [1] J.J.M. Machado, E.A.S. Marques and L.F.M. da Silva, J. Adhes., (2017). https://doi.org/10.1080/00218464.2017.1282349. [2] G. Belingardi, V. Brunella, B. Martorana and R. Ciardiello, in Adhesives applications and properties, Cap.13, p.341, A. Rudawska Ed. (INTECH, Rijeca, 2016). [3] E. Koricho, E. Verna, G. Belingardi, B. Martorana, and V. Brunella, Int. J. Adhes. Adhes. 68, 169–181 (2016). [4] L. Goglio and M. Rossetto, in Proceedings of ESDA2006 8th Biennial ASME Conference on Engineering Systems Design and Analysis, 637-643 (2006)