Automotive Trim Research Articles

A study on classifying BSR noise in automotive door trim using a deep learning method

In this paper, we demonstrated a deep learning model that can automatically classifies BSR(Buzz, Squeak, Rattle) noise in automotive door trim using convolutional neural networks. In the preprocessing process, sound features of door trim noises are extracted by using STFT(Short-time Fourier Transform) algorithm to obtain spectrogram images for each noises we obtained from experiment. To classify various noises of door trim, those image data are labeled with its root cause, then it is trained with deep convolutional neural network. Furthermore, t-SNE (t-Stochastic Neighbor Embedding) algorithm was used to visualize the effect of deep convolutional neural network we demonstrated. The classifier of the demonstrated method achieved with the accuracy of 96%.

A review on the environment friendly electroplating of Cr (III) & Cr (VI)

Chromium plating process is the most effective way of protecting the base material against hostile environment or improving surface properties of base material. There are several problems with traditional chrome plating. Traditional process uses toxic acid baths and may cause various health conditions. The baths employed contain chromic acid in which the chromium is in the hexavalent state. Hexavalent chromium has been proved to have toxic, mutagenic and cancerogenic effects for human health. As a result, In Europe, the implementation of the reach initiative will increase fees on companies still using Cr (VI) in 2017 and will require action plans to phase out Cr (VI) in the future. This has left the plating industry in a very delicate position with dark future prospects unless new solutions that are both effective and environmentally friendly are discovered. Superchrome Physical Vapor Deposition coating ahead of looming industry regulatory actions that will drive towards the removal of hazardous hexavalent chromium compounds. These new sputtered chromium coatings do not require a protective paint top coat to pass exterior automotive trim specifications. Visually the chromium coatings match those of electroplated decorative chromium in color and appearance.

Influence of Surface Geometry on Palm and Fist Contact Pressure Distribution During Strikes With the Hand in Automotive Assembly.

The increase in repetitive strain injuries to the hand underscores the need for assessing and preventing musculoskeletal overuse associated with hand-intensive tasks. This study investigates the risk of overload injuries in soft tissue structures of the hand by analyzing the pressure distribution and location of peak pressure in the hand during snap-fit connection assembly in the automotive industry. The influence of the surface geometry of automotive trim components the pressure distribution and force imparted during strikes with the palm and the fist are investigated in a cohort of 30 subjects with extensive experience installing trim parts with snap-fit connections. Using the palm or fist (ulnar hand side) of the dominant hand, the subjects struck a simulation device with a flat, rounded, or edged surface geometry. The average peak force applied was 600N (±122N), nearly 3 times the force required to overcome the technical resistance of the snap-fit connector (220N). Fist strikes exerted a 40% higher mean peak pressure and 18% higher mean pressure than did palm strikes. The pressure distribution in the region of the thenar eminence and soft tissue of the ulnar side of the hand did not differ between fist strikes on flat and edged surfaces. Considering the delicate anatomy of the hand, especially the hypothenar muscles on the ulnar side, assembling connection claps using the fist instead of the palm may prevent repetitive blunt trauma to the sensitive blood vessels and nerves in the palm.

Plastic design and strength on automotive hard trims doghouse

Trims are the plastic parts installed on the inside and outside of a car. Interior trims are typically used to give the interior of a vehicle an aesthetic appearance.There are various types of trims used in automobiles. The door's inner mechanisms and the vehicle's interior are connected by the door panel, as are the passengers inside the car and the door. They must adhere to a number of design requirements in terms of functionality, appearance, and safety. They should also maintain the dashboard's material theme while hiding complex electrical and mechanical parts that control the vehicle's locks, windows, and other features. From a straightforward latch and winding mechanism in two parts, the door panel has developed into a more complex enclosure. Currently, doors have an inner full-width panel with speakers, electronic windows, and a central locking system. These panels typically have a foamed core that is covered in either plastic or textiles. Trim manufacturing requires a lot of essential plastic material properties, such as restraining the passengers from the sharp edges and corner points of the BIW parts and underlying components.

Carbon fibre-reinforced polydicyclopentadiene composites for automobile applications

In this study, two types of carbon fibre (CF)-reinforced polydicyclopentadiene (PDCPD) composites were prepared using CF powder and cloth. The effects of the CF content and curing temperature on the mechanical properties of PDCPD were investigated, and the reinforcement mechanisms were explored from a microstructural perspective. CF cloth-reinforced PDCPD achieved a tensile strength of 405 MPa and bending strength of 213 MPa, which were higher than those of CF powder-reinforced PDCPD. Based on the results, PDCPD composites reinforced with CF powder can be used in automotive exterior trims, whereas PDCPD composites prepared using CF cloth can be used in load-bearing parts of automobiles.

Flexible Machining Capabilities

Hemlock Engineering benefits from automation; Son-x GmbH ensures high precision; MJ Engineering Ltd ups capacity and capabilities; Automotive Trim Developments invests to fulfil major new contract; SWM cuts cutting times; plus, products in brief

Design of Self-Healing EPDM/Ionomer Thermoplastic Vulcanizates by Ionic Cross-Links for Automotive Application.

The development of smart elastomeric materials with inherent self-repairing abilities after mechanical damage has important technological and scientific implications, particularly in regard to the durability and life cycle of rubber products. The interest in self-healing materials for automotive applications is rapidly growing along with the increasing importance of vehicle scratch quality and quantity. The creation of a reversible network by noncovalent ionic cross-linking in elastomer/rubber blends is an effective approach to generate the self-healing phenomenon, with reprocessing and recycling properties. In this work, thermoplastic vulcanizates (TPVs) were prepared using ethylene–propylene–diene (EPDM) polymers and high-acid-containing thermoplastic ionomers. Along with the general EPDM, maleic anhydride grafted EPDM (EPDM-g-MAH) was also used for the preparation of the TPVs. The strategy was based on a simple ionic crosslinking reaction between the carboxyl groups present in the ionomer and zinc oxide (ZnO), where the formation of reversible Zn2+ salt bondings exhibits the self-healing behavior. The heterogeneous blending of EPDM and ionomers was also used to investigate the thermal and mechanical properties of the TPVs. The experimental findings were further supported by the surface morphology of the fracture surfaces viewed using microscopy. The self-healing behavior of the TPVs has been identified by scratch resistance testing, where the EPDM-g-MAH TPVs showed excellent healing efficiency of the scratch surface. Therefore, this work provides an efficient approach to fabricate new ionically cross-linked thermoplastic vulcanizates with excellent mechanical and self-repairing properties for the skins of automotive interior door trims and instrument panel applications.

Method for Segmentation and Hybrid Joining of Additive Manufactured Segments in Prototyping Using the Example of Trim Parts

Rapid prototyping has become increasingly popular over the past years. However, its application is heavily confined to a part size that fits the small build volume of additive machines. This paper presents a universal design method to overcome this limitation while preserving the economic advantages of rapid prototyping over conventional processes. It segments large, thin-walled parts and joins the segments. The method aims to produce an assembly with minimal loss to the performance and characteristics of a solid part. Based on a set of requirements, a universal segmentation approach and a novel hybrid joint design combining adhesive bonding and press fitting are developed. This design allows for the force transmission, positioning, and assembly of the segments adaptive to their individual geometry. The method is tailored to fused deposition modeling (FDM) by minimizing the need for support structures and actively compensating for manufacturing tolerances. While a universal application cannot be guaranteed, the adaptive design was proven for a variety of complex geometries. Using automotive trim parts as an example, the usability, benefits, and novelty of the design method is presented. The method itself shows a high potential to overcome the build volume limitation for thin-walled parts in an economic manner.

UV-resistant transparent lignin-based polyurethane elastomer with repeatable processing performance

Lignin, as a green and environmentally sustainable natural material, is indispensable to be reasonably developed and utilized. Herein, lignin macromolecules are used as raw materials of polyhydroxyl structure to synthesize polyurethane macromolecules. It is found that the optimal mass ratio of lignin to isocyanate group in the synthesis of polyurethane is 95/5. The lignin-based polyurethane putted the lignin as a fulcrum to form a hydrogen bond with the polyurethane macromolecular chain to form a hydrogen bond network structure, so that its elastic recovery rate attains 94.7%. Meanwhile, its tensile strength and breaking elongation rate reach 16.2 MPa and 1049.5% respectively. Furthermore, the lignin-based polyurethane synthesized in this work still maintain excellent mechanical properties after thermal reprocessing. Moreover, the lignin-based polyurethanes prepared by this approach also possess excellent transparency and UV resistance, and the average ultraviolet protection factor (UPF)value of the lignin-based polyurethane hot-pressed fabrics obtained by hot pressing is greater than 50. This work provides an innovative and sustainable strategy for the further application of lignin, a pure natural material, as a bio-based multifunctional additive to packaging, textiles, automotive trim and other fields.

Evaluation of UV post-curing depth for homogenous cross-linking of stereolithography parts

Purpose During post-processing of stereolithography photopolymers, the limited penetration depth of ultraviolet (UV) light can lead to inhomogeneous cross-linking. This is a major problem in part design for industrial applications as this creates uncertainty regarding the mechanical load capacity. Therefore, this paper aims to present an experimental method to measure the post-curing depth in stereolithography photopolymers. Design/methodology/approach Printed specimens made from urethane acrylate photopolymers are placed in a protective housing and are exposed on one side to UV light during post-processing. A depth profile of the hardness according to ASTM D2240 Shore D is determined alongside the specimens. UVA,-B and -C spectra are investigated and the dependence on exposure dose and pigmentation is studied. The results are directly linked to the mechanical properties via tensile tests and validated on an automotive trim part. Findings Exposure with a 405 nm light-emitting diode provides the deepest homogenous post-curing depth of 10.5 mm, which depends on the overall exposure dose and pigmentation. If the initially transparent photopolymer is colored with black pigments, post-curing depth is significantly reduced and no homogenous post-curing can be achieved. To obtain comparable mechanical properties by tensile tests, complete cross-linking of the specimen cross-section has to be ensured. Research limitations/implications The spatial resolution of the presented measurement method depends on the indenter size and sample hardness. As a result, the resolution of the used setup is limited in the area close to the edges of the specimen. Originality/value This paper shows that the spatially resolved hardness measurement provides more information on the post-curing influence than the evaluation of global mechanical properties. The presented method can be used to ensure homogenous cross-linking of stereolithography parts.

Effect of Machining On Stainless Steel: A Review

Machining takes place when a part of undesirable material ranging from metals, polymer, and wood to ceramic or even composite is removed from a part to give a better shape and design. The parts that are machined are called workpiece and undesirable materials are called the chips. The machining process is in three forms which are the conventional (traditional) process, abrasive process and non-traditional processes. This review paper focused on the various forms of machining in stainless steel, based on the machine able family. Stainless found the way into various applications resulting in their wide usage which include equipment in the industries, equipment’s in beverage and food, automotive trim and cookware. This paper aims at opening more light on the importance of stainless steel during machining operations.

Optimization of Machining Parameters for Turning of Aluminium Alloy-2011 using Taguchi Method

Aluminium composites are among the most normally used lightweight metallic materials as they offer different various fascinating mechanical and warm properties. They are reasonably easy to shape metals, especially in material ejection structures, for instance, machining. Aluminium composites have physical properties for good machinability, as far as (cutting apparatus life-more prominent efficiency - low explicit cutting powers.) they have high solidarity to weight proportion. Subsequently, the aluminium composite 2011 is utilized in assembling of Appliance parts and automotive trim, Fasteners and fittings cylinders and funnels. Machining activity on Al alloy 2011 are performed and cutting parameters for example feed rate, depth of cut and shaft speed have been improved for metal removal rate (MRR) and surface roughness by utilizing Taguchi method. CNC lathe machine is utilized for turning activity so as to decide metal removal rate (MRR). The primary target of the present research is to explore the impact of procedure parameters on the presentation of by and large machining procedure and on surface unpleasantness in turning activity utilizing CNC machining of Aluminium composite [Al compound 2011].

Cellular structure and mechanical strength of straw fiber/polypropylene plastics under chemical foam molding

Plant fiber-reinforced polypropylene composites are low-cost, good-performance and resource-saving, so has wide application prospect in automotive components. While the density of composites increases with the increase in the plant fiber content, the chemical foaming injection process was used to prepare straw fiber/PP foamed composites with exothermic foaming agent azodicarbonamide, in order to reduce the density of composite products and meet the requirements for lightweight automotive trim parts. The effects of temperature and fiber content on the mechanical properties and microstructures of the composites were investigated. Research results show that the microporous straw fiber/PP composites have close bond with the core layer fibers, the matrix, and the cells. The cells evenly distributed around the fibers to form a ‘sea island’ phase structure of the fiber microporous matrix, and the toughness of microporous sample is better than solid composites. Within a certain range, the cell density and the impact resistance of the microporous composites increases first and then decreases as the molding temperature increases, and maximize at 185 °C. Straw fiber plays a role of nucleation and toughening in the microporous straw fiber/PP composite system. And as its content increases, the cell density increases, similarly the toughness of the composites increases.

Experimental analysis of the forming behavior of ash wood veneer with nonwoven backings

In the present study, the forming behavior of veneer with nonwoven backings was analyzed. The paper contributes to the lack of data on numerical predictions of the formability of veneers for the manufacturing of automotive trim parts. Tensile and shear tests were carried out at normal climate conditions and after water immersion to obtain material parameters for a transverse isotropic material description. The Tsai Wu failure criterion was applied to the estimation of strength under different stress combinations. Analysis of the directional deep drawing capacity of the veneer laminate was done by the Nakajima test. Stress states from biaxial to uniaxial were induced into the material depending on the geometry of the sample. Strains were evaluated locally until material failure using the digital image correlation method. Major strain was defined in the direction perpendicular to the grain. Increasing major strain was found from biaxial to uniaxial stress states. Highest strain limits were found for wet veneers tested with heated forming tools. Cracks occurred in the early wood zone for all geometries and propagated in the direction parallel to the grain. Generally, the Nakajima test is suitable for the evaluation of the formability of veneer laminate sheets. The presented data and, in general, the suggested experimental program can be used for the development and validation of veneer laminate material models for forming simulations.

AK STEEL TYPES 430, 434, 435 MOD, 436

Abstract AK Steel Types 430, 434, 435 Mod, and 436 are ferritic stainless steels that provide a combination of corrosion resistance, functionality, and beauty that make them suitable for many roll-formed and stamped automotive trim applications. This datasheet provides information on composition, physical properties, hardness, elasticity, and tensile properties. It also includes information on corrosion resistance as well as forming and joining. Filing Code: SS-1314. Producer or source: AK Steel Corporation.

Synergetic effect of graphene oxide-carbon nanotube on nanomechanical properties of acrylonitrile butadiene styrene nanocomposites

Herein, multiwall carbon nanotubes (MWCNTs), reduced graphene oxide (rGO), graphene oxide-carbon nanotubes (GCNTs) hybrid reinforced acrylonitrile butadiene styrene (ABS) nanocomposites have been prepared by micro twin screw extruder with back flow channel and the effect of different type of fillers on the nanomechanical properties are studied. The combination of both graphene oxide and CNT has enhanced the dispersion in polymer matrix and lower the probability of CNTs aggregation. GCNTs hybrid have been synthesized via novel chemical route and well characterized using Raman spectroscopic technique. The nanoindentation hardness and elastic modulus of GCNTs-ABS hybrid nanocomposites were improved from 211.3 MPa and 4.12 GPa of neat ABS to 298.9 MPa and 6.02 GPa, respectively at 5wt% GCNTs loading. In addition to hardness and elastic modulus, other mechanical properties i.e. plastic index parameter, elastic recovery, ratio of residual displacement after load removal and displacement at the maximum load and plastic deformation energy have also been investigated. These results were correlated with Raman and X-ray photoelectron spectroscopic (XPS) techniques and microstructural characterizations (scanning electron microscopy). Our demonstration would provide guidelines for the fabrication of hard and scratches nanocomposite materials for potential use in, automotive trim components and bumper bars, carrying cases and electronic industries and electromagnetic interference shielding.

Physical Properties of Eco-friendly Kenaf Fiber Imbedded Nonwoven for Automotive Pillar Trim

This study investigated the physical properties including the sound absorption property of Kenaf natural fiber imbedded nonwoven for automotive pillar trim. Seven kinds of Kenaf imbedded nonwoven specimens mixed with polypropylene and low melting PET fibers were prepared through needle punching nonwoven process. Physical properties such as air permeability, water absorption, sound absorption coefficient, and porosity were measured and compared with different processing factors of needle punching nonwoven. High blend percentage of low melt PET fibers made pore size lower and smaller, which resulted in low air permeability and water absorption. Sound absorption coefficient of nonwoven specimen was highly dependent upon weight and thickness of the nonwoven and correlation coefficient was above 0.83, respectively. It was also affected by pore diameter, i.e. low pore sized nonwoven showed high sound absorption coefficient, which was caused by the high needle depth and high blend ratio of low melt PET.

Loosening analysis for fastening screw of automotive door trim parts

While a screw is a fastening element that can tighten the two parts at low cost, the loosening of the screw is generated due to external forces such as repetitive load, vibration, and thermal stress. This phenomenon decreases the initial clamping force, and this can be a serious problem to the safety of the product. However, while fastening parts are handled through experiment and experience, there is a lack of research on the screw loosening of plastic fastening parts. For example, vehicles have various fastening parts. Among the fastening elements, screws are typically used for tightening parts of the vehicle door trim. Vehicle interior materials are mainly composed of plastic parts. Especially, the temperature of the vehicle interior changes from a sub-zero temperature to 100 degrees (°C) due to solar radiation. Unlike metals, plastic materials are commonly susceptible to the environment. In this study, the fastening screw of automotive door trim parts is selected. First, a screw loosening mechanism is implemented through Computer Aided Engineering (CAE) analysis and the influences of degradation are then analyzed. Secondly, the selecting method of clamping force is suggested through the analysis result of reduction according to the tightening torque.

Influence of processing parameters on warpage according to the Taguchi experiment

An automotive triangle trim was chosen as a research model, and the influence of processing parameters was determined with the Taguchi experimental method. An L27 (313) orthogonal array was constructed to investigate the significance of each factor (mold temperature, melt temperature, injection time, V/P switchover, packing pressure, and packing time). The computer-aided engineering software Moldflow was employed to determine the extent of warpage. The influence of processing parameters was analyzed by obtaining the signal- to-noise ratio and by conducting a range analysis. Furthermore, the processing parameters for minimizing warpage were optimized. Subsequently, the optimization packing condition for warpage minimization based on the filling conditions.

Hybrid biocomposites with enhanced thermal and mechanical properties for structural applications

ABSTRACTThe current work focuses on enhancing the mechanical and thermal properties of sisal fiber reinforced composites that were previously used in developing interior automotive trims. In order to extend their use in other structural applications, two hybrid biocomposites with the combination of sisal (SF) and glass fiber (GF)‐SF20/GF10 and SF10/GF20 were blended with polypropylene via extrusion and injection molding process. Critical material properties such as density, fogging, acoustic, mechanical, thermal, and rheological properties were evaluated and results were analyzed using ANOVA. Hybridization of SF and GF enhanced flexural strength and thermal properties of the biocomposites by 33 and 19%, respectively, while no significant change in acoustic, impact and rheological properties were observed. The properties of the hybrid biocomposites were compared with the material specification of a battery tray and it was found that these hybrid biocomposites could be better alternative materials in structural applications. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015, 132, 42452.