Door Panel Research Articles

Valorization of Plastic Waste through Incorporation into Construction Materials

The growing plastic pollution has prompted the quest to reduce plastic waste sustainably and control the mismanaged plastic stream. The valorization of plastic waste through reusing and recycling has received much attention as a sustainable solution to the global plastic problem, and the construction sector provides an important avenue for such an endeavor. This review aims to present the latest advances in the valorization of plastic waste as construction and building materials through the review of 60 relevant scholarly papers and a content analysis of the papers. In the construction sector, plastic waste can be valorized as additives or raw materials for brick production. As additives, plastic waste is added at different proportions (1%–70%) with other materials, including non-plastic waste, followed by curing to acquire the desired properties. Plastic waste is used as a raw material to contain strength-imparting materials. The former has been reported to have good strengths (5.15-55.91 MPa), chemical, and thermal resistance, whereas the latter may impart lower strengths (0.67-15.25 MPa). Plastic waste is also used as additives for road pavement, primarily as substitutes for concrete-making materials, and was observed to produce desirable strengths (0.95–35 MPa) at appropriate proportions (0.5–25%), indicating the importance of optimizing the plastic contents in the concrete. Plastic waste has been recycled as plastic lumber, plastic-based door panels and gates, as well as insulation materials. Plastic-based construction materials are generally lightweight, resistant to chemicals and heat, and have good sound insulation, but they may pose a fire safety concern.

Mechanical Response of Fiber-Filled Automotive Body Panels Manufactured with the Ku-FizzTM Microcellular Injection Molding Process.

To maximize the driving range and minimize the associated energy needs and, thus, the number of batteries of electric vehicles, OEMs have adopted lightweight materials, such as long fiber-reinforced thermoplastics, and new processes, such as microcellular injection molding. These components must withstand specific loading conditions that occur during normal operation. Their mechanical response depends on the fiber and foam microstructures, which in turn are defined by the fabrication process. In this work, long fiber thermoplastic door panels were manufactured using the Ku-FizzTM microcellular injection molding process and were tested for their impact resistance, dynamic properties, and vibration response. Material constants were compared to the properties of unfoamed door panels. The changes in mechanical behavior were explained through the underlying differences in their respective microstructures. The specific storage modulus and specific elastic modulus of foamed components were within 10% of their unfoamed counterparts, while specific absorbed energy was 33% higher for the foamed panel by maintaining the panel's mass/weight.

Evaluation of a coach door under a frontal impact

PurposeThe vehicle´s body front pillar should absorb most of the striker kinetic energy, while only a fraction of that is absorbed by the door structure. This study aims to discuss the aforementioned issue. In this test the striker is a virtual entity. Six uniaxial strain gauges are installed throughout the door. Additionally, contactless 3D digital image correlation (DIC) allows to assess the major door panel’s continuous deformation and strain fields.Design/methodology/approachA coach is a large and heavy long-distance passenger transport vehicle. Their structural certification, classifies coaches as M3 Class III vehicles. New coach structures’ designs need analyses of each sub-system for critical pre-validation of the entire structure, aiming driver and passenger carrier safety. Also, a thorough examination due to increased travel speed is needed.FindingsExperimental pseudo-dynamic (PSD) results were compared and validated using finite element method (FEM) with two pieces of distinct FEM software (Abaqus® and PamCrash®). The time dependent solution was carried out by explicit techniques. Results by FEM and PSD test showed good agreement, evidencing the reliability of the tools selected. Results by PamCrash® were closer to the experimental data.Practical implicationsR-29 is truck-only regulation, however can be adapted to coaches in case of a frontal collision. The present work focuses on the impact behavior of the passenger front door subsystem.Originality/valueAs a first validation the entire structure, the behavior of a vehicle door, under in-plane impacts was studied. The corresponding deformation energy absorbed by the frontal passenger coach door under virtual impacts of a swinging striker was assessed using a PSD approach.

Influence of Various Surface Treatments on Mechanical, Thermal, Morphological, and Water Absorption Properties of Rattan (Calamus beccarii) Fiber

ABSTRACT The goal of this study is to thoroughly comprehend the advantages of rattan (Calamus beccarii) as potential reinforcement in polymeric composites. The influence of various chemical treatments on thermal, morphological, mechanical and water absorption characteristics of natural rattan (RA) stem fiber were investigated. In this research, RA fiber surface was modified through different chemical treatments such as alkalization, bleaching, and benzoylation. The presence of voids and rough surfaces was investigated on SEM micrographs which are due to removal of lignin, wax, and oils from the fiber surface to a large extent. The results obtained from Fourier transform infrared may indicate the presence of cellulose, hemicellulose, and lignin compounds in the case of untreated and treated RA fiber. The increase in tensile strength and Young’s modulus confirms improvement in the mechanical properties of the RA fiber after chemical treatment. It was observed that alkali-treated RA fibers exhibit highest mechanical properties (295.28 MPa tensile strength, 8.23 GPa Young’s modulus). Also, X-ray diffraction analysis gives a higher crystallinity index (62.50%) for treated RA fiber. Thermogravimetric analysis confirms that there was an increase in the thermal stability of the fiber after chemical treatment. Overall results confirm that the RA fiber is appropriate for use as a reinforcing phase in composite materials for prospective engineering semi-structural applications such as roofing sheets, bricks, door panels, furniture panels, interior paneling, storage tanks, and pipelines.

Analysis of polypropylene material and hybrid bio mixtures for automotive applications

The car door is typically made of steel, with an internal and external panel that also serves as a mounting plate for the various connections. However, doors are among the most appealing vehicle parts for light weighting: the ability to reduce absolute weight with two or four entrances is critical. The objective of this work is to reduce the weight of car doors by using Natural Fibers (NF) such as Kenaf fiber (KF), Prosopis juliflora bark (PJb) and Jute fiber (JF) fortified polyester mixtures for modelling and simulation. These models are compared with existing polypropylene material. In this study, the car door has modelled through Solid works. Afterward, the various impact attributes of automobile car door panel for mixture material and polypropylene material at different speeds are performed using Ansys Explicit Dynamic Analysis. The analysis results of NF reveal the enhanced total deformation and equivalent strain by about 20.14%, 27.78%, 85.9%, and 68.9% respectively for the velocities of 60 and 72kmph compared with polypropylene material. The NF composite helps to absorb more stress and strain, preventing damage to the vehicle body as well as the passengers.

Fatigue behavior of hybrid eco-composites: A review

Multifunctionality of composites has gained popularity, primarily through the hybridization of polymer composites for augmented performance. In this case, hybridization is ensured by adding fibrous reinforcement of different materials. There are a multitude of characteristics which can be enhanced due to hybridization. The synthetic reinforcements respond to uncontrolled carbon footprints, so we cannot claim them as sustainable. Hence, scientists have been discovering new solutions in sustainable eco-composites (with natural reinforcements) to tackle the environmental challenge. It is reported that albeit the natural fibres are eco-friendly, but they often lack in desired properties and hence find difficulty to enter the market. To achieve desired properties, several limitations of natural fibre, such as hydrophilic qualities, can be addressed by different surface alterations and chemical treatment procedures. Post the fourth industrial revolution, the rising concern about environmental issues has led an increased interest in natural fibre hybrid composites (also called as hybrid eco-composites). Such composites are composed of eco-friendly fibres or a combination of synthetic and natural fibres as a reinforcing material which makes it capable for multifunctional applications. Natural fiber reinforced composites have a great potential of cost per unit weight reduction and renewability over applications such as door panel, seat backs, dashboard, noise insulation panel, railing, bridge, and roof tiles. The prior art reveals that these composites have low fatigue strength which limits itself in structural application in comparison to its competitors, the synthetic composites. This means hybridization could result in synergy of advantages of each of the constituents leading to high fatigue strength, better load carrying, eco-friendly, and a low-cost structure. This review provides an overall insight on various hybrid eco-composites including their mechanical properties, fatigue behavior and its applications.

Further study on strain hardening of a steel panel in the hemming process

ABSTRACTAn experimental study on steel panel bending is conducted to clarify the mechanism of strain hardening of the panel during flanging, pre-hemming and hemming processes in the production of automotive door panels and other types of panels. A planar straight-edge-shaped hot-dip-galvanised steel sheet panel is set and pressed in prototype equipment. The experimental process consists of the first flanging to 90°, the second pre-hemming to each angle of 15°, 30°, 45°, 60° and 75°, and the final hemming. Time-lapse images captured from a video of the processes, the geometry of the pre-hemmed and hemmed flanges, and the microVickers hardness distribution of the lateral surface of the panel are measured. A detailed examination of the obtained results clearly indicates new findings that each flange pre-hemmed to different angle of 15° and 75° gave excellent geometry with small creepage and quality of the final hemmed flanges, owing to remarkable strain-hardening of each flange corner. On the other hand, a pre-hemming to each angle of 30°, 45° and 60° gave a geometry with large creepage due to loose flange corner bending.

A digital twin for 3D path planning of large-span curved-arm gantry robot

Gantry robots enjoy important applications in unmanned factories and intelligent manufacturing tasks. Aiming at the automated production of customized wooden furniture, this paper proposes a digital twin for three-dimensional (3D) path planning of a large-span curved-arm gantry robot. First, a digital twin platform is built to show the door panel loading and unloading process of the gantry robot. Then the 3D path planning problem and method are proposed based on the built platform. The core of the algorithm consists of a bilateral control method, a 3D mesh construction strategy, and multi-objective 3D path planning using assembly line scheduling. The bilateral control method is used to achieve the perception and control of the gantry robot in the physical space. The mesh construction strategy entails static point set construction, obstacle avoidance analysis, point set construction for leap obstacles, and convex plane construction analysis. Multi-objective 3D path planning is primarily based on the NavMesh algorithm, which leverages an assembly line scheduling model to complete the wooden door processing task. Experimental results show that the proposed method can ensure safety, improved production efficiency, and satisfactory real-time performance in controlling the real gantry robot.

Vibration Analysis of Composite Internal Door Panel of a Car

Abstract: The main objective behind this paper is to develop a suitable model of internal door panel for cars, to conduct a static structural analysis of internal door panel by finite element method and to compare the performance of glass fiber material with previously recommended materials of internal door panel. This paper deals with the mechanical behavior and vibration analysis of glass fiber-based polymer composite beam structures. Glass fiber has been widely used for many applications due to its high strength, flexibility, stiffness and resistance to chemical this extended work the inactive basic Limited Component Investigation of inside entryway board of a vehicle by considering glass fiber composite materials was conducted. The entryway board of the vehicle was utilized to create the geometric show of the inward entryway board by CATIA V5 R20 modeling program. This 3-D geometric demonstration was imported to utilize ANSYS Workbench 19.0. Model analysis of the internal door panel has been done using ANSYS software.

Analysis of chest response characters for drivers in lateral and oblique automotive impact

Chest injury frequently occurs in oblique and side impacts. Apart from the loading of airbags and seatbelts, secondary impacts with door panels and armrests also cause severe chest injuries. This study aims to investigate the characteristics of the chest injury of occupants in the oblique and lateral impact. It focuses on the secondary impact between occupants and vehicle side structure. A model comprising GHBMC and components of Toyota Camry is established with acceleration curves. Combined with typical impact directions in NCAP tests, four sets of simulations are carried out. Results indicate that the maximum deflection occurs in oblique far-side impact, reaching 53 mm. Additionally, the maximum stress occurs in lateral near-side impact, reaching 259 MPa. In contrast, the stresses of far-side lateral and oblique impacts are only 2% and 3% smaller than the maximum one. Therefore, the occupant injury is serious in the far-side impact. Due to the lower lateral acceleration and the better seatbelt protection, the minimum deflection and stress are found in the near-side oblique impact. In conclusion, when the seatbelt can restrain the movement of the occupant during oblique and lateral impact, the injury level will be reduced. In addition, in the oblique and lateral impact simulations, the lowest rib stress exceeds the tolerance, while the highest chest deflection is still lower than the tolerance. This study provides a reference for the subsequent improvement of the restraint system.

Study of injection molding process simulation and mold design of automotive back door panel

Numerical simulation of the injection molding process of the outer panel of the automotive plastic rear door and mold design is presented here. Computer aided three-dimensional interactive application (CATIA) is employed to design the original automotive steel structure, and the modal and thermodynamic properties of the plastic back door outer panel are changed by changing the different injection materials of the back door outer panel. In order to efficiently design the panels, finite element analysis is used to verify whether the designed parts meet the mechanical properties requirements such as light weight, low fuel consumption, short production cycle, strong modeling design, high corrosion resistance and good recovery, the above main parameters have been evaluated, and the above main parameters are carried out evaluate. To simulate the injection molding process, computer aided engineering (CAE) software such as ANSYS and HyperWorks are used to analyze the back door of the selected material. After the numerical analysis, suitable material is selected, so that the modal and thermodynamic properties of the product could be satisfied as well as improved. Unigraphics NX (UG) is employed to design the convex and concave mold for the injection molding of the automobile’s plastic back door panel. Combined with the characteristics of the parts and the design requirements of the injection mold, the multi-scheme design of the pouring and cooling system is carried out. By comparing the effects of different gating and cooling systems on injection molding, the best gating and cooling system is selected. The artificial fish swarm algorithm is used to optimize the process parameters of the injection molding process, and the best combination of the injection molding process parameters of the outer panel of the rear door of the automobile is obtained.

Influence of water ageing on the mechanical properties of flax/PLA non-woven composites

Flax fibres are widely used in the automotive sector to reinforce polyolefins, such as for dashboard and interior door panels. A promising option is poly-(lactid) (PLA), as it leads to higher mechanical properties and offers an additional end-of-life scenario following recycling: industrial composting. However, like other composite systems such as flax/polyolefin, flax/PLA composites are also sensitive to water. Here, a non-woven flax/PLA composite is aged under several conditions (50% RH/75% RH/98% RH/Immersion) until saturation. After ageing, all samples are reconditioned at 50% RH, and their residual properties are assessed. The presence of a critical relative humidity between 75 and 98% is highlighted, above which, increases in moisture content irreversibly decrease the composite's mechanical properties. After ageing at 98% RH and in immersion, tangent modulus was reduced by 23.0 and 33.8% and ultimate strength by 26.7 and 37.4%, respectively, compared to reference materials. This decrease is mainly due to microstructure evolution in the form of increasing porosity. This microstructure evolution is induced by the swelling of flax fibres, which generates high local stresses, above what PLA can withstand. As a result, micro-cracks appear in the matrix, responsible for reduction in mechanical properties.

Influence of Freeze-Thaw Aging on the Impact Performance of Damped Carbon Fiber Reinforced Plastics for Automotive Applications

The increasing use of composite materials in the automotive field requires more attention with regards to the appearance of noise, vibration and harshness (NVH) study in cars construction. However, in car door panels production, impact characteristics need to be evaluated in sandwich laminates. Furthermore, it is important to consider the effect of prolonged environmental aging on crashworthiness properties. The innovative content of the work is the hygrothermal effects evaluation on impact performance for two damped CFRP sandwich laminates. In this paper, two damping materials, Kraibon HHZ9578/99 and SUT9609/24, were used as core between two skins of CFRP for sandwich composite production. Freeze-Thaw aging treatment according to IEC 60068, specific for Automotive, was performed to investigate environmental effects on components. Up to 750 h, it was demonstrated that water absorption is regulated by Fick’s Law. The low-velocity impact behavior of the damped sandwiches has been studied according to ASTM D7136 throughout drop dart test equipment. Both main peak forces and energy absorption characteristics are negatively affected by aging condition. The introduction of damping core inside the composite structure of vehicle components can satisfy NVH constrictions. By contrast, at least same operating conditions must be assured in relation to not-damped components.

Sealing state monitoring of watertight door using fiber Bragg grating sensor with arc-shaped structure

The sealing state of the watertight door (SSWD) is important information for the safe operation of a ship. A monitoring method for the SSWD based on fiber Bragg grating (FBG) sensor is designed, which can monitor the opening and closing state of the watertight door in real-time. A highly sensitive and temperature-independent sensor is installed under the rubber of the watertight door, the relationship between the displacement of the door panel and the wavelength shift of FBG is linearly fitted with the sensitivity of about 314.511 pm / mm, and the error percentage with the finite element analysis is 6.22%. The watertight door is opened and closed many times, the results show that the sensor has good stability and reliability, and the opening state, closing state, and the degree of opening and closing can be accurately judged by the wavelength shift of FBG. At the same time, the sensor can also identify the foreign body within a certain range on the rubber surface.

USULAN EFISIENSI WASTE PROSES PRODUKSI BED SHEET DI PT. ABC MENGGUNAKAN METODE VALUE STREAM MAPPING

Smooth production is very important to achieve the targets to be achieved by producers efficiently. This is also done at PT. ABC which produces various products in the form of bed linen. In the production process PT. ABC still has many production processes that consume a lot of production time (waste), starting from the beginning of the work to the time of product delivery to the customer, especially the high process that experiences lead times, equipment and machines that do not meet production capacity. The purpose of this study is to provide suggestions for improvement in reducing waste that occurs at PT. ABC This research method is a value stream mapping (VSM) which will map the value of each activity in each production process that occurs. It aims to determine which activities provide added value (value added) and which do not provide added value (non-value added) and can provide suggestions. improvements to the future state map to reduce time waste that occurs in the production process activity of the door panel box 7. The results of the approach using the value stream mapping tool and applying the proposed improvements, where the analysis compares the analysis of the current state map with the future state map. The results of this study get the results of the current state map analysis for value added activities of 499.8 seconds and non-value-added activities of 801.27 seconds

Low-Cost Magnesium Alloy Sheet Component Development and Demonstration Project

<div class="section abstract"><div class="htmlview paragraph">Most of the applications of magnesium in lightweighting commercial cars and trucks are die castings rather than sheet metal, and automotive applications of magnesium sheet have typically been experimental or low-volume serial production. The overarching objective of this collaborative research project organized by the United States Automotive Materials Partnership (USAMP) was to develop new low-cost magnesium alloys, and demonstrate warm-stamping of magnesium sheet inner and outer door panels for a 2013 MY Ford Fusion at a fully accounted integrated component cost increase over conventional steel stamped components of no more than $2.50/lb. saved ($5.50/kg saved). The project demonstrated the computational design of new magnesium (Mg) alloys from atomistic levels, cast new experimental alloy ingots and explored thermomechanical rolling processes to produce thin Mg sheet of desired textures. A new commercial Mg alloy sheet material was sourced and pretreated with protective coil coatings, and its properties fully characterized. The Mg sheet was successfully warm-formed using novel lubricants into intermediate size benchmark parts and full-size automotive door inner and outer panels. The project also explored conventional welding processes for joining of Mg sheet, developed novel corrosion treatments for multi-metal assembly coatings, performed computer simulations of door panel forming using two new material cards based on crystal plasticity theory, and concluded with a door static and dynamic performance analysis. An overall cost driver and sensitivity assessment task compared the final cost penalty depending on the cost of the primary magnesium sheet.</div></div>

Optimal design of sealing structure of vehicular radar case door

The quality of antenna array environment control technology directly affects the reliability and service life of vehicular radar. The structure design of case door sealing is an important part of the environmental control technology of vehicular radar. The stress distribution analysis of case door sealing structure of vehicular radar antenna is carried out in this paper. Maximum stress of double-peaked sealing ring and stress distribution and deformation of case door panel are investigated through finite element analysis based on ABAQUS. In order to increase the reliability of sealing structure, the section size of double-peaked sealing ring and the spacing length of fasteners are optimized by the way of co-simulation optimal design method using ISIGHT. Through radial basis function neural network surrogate model, which is built based on Latin hypercube sample algorithm, the sensitivity of each optimization variable is analyzed. Meanwhile the optimal section size of double-peaked sealing ring and spacing length are obtained through non-dominated sorting genetic algorithm.

A Critical Review on Wood-Based Polymer Composites: Processing, Properties, and Prospects.

Waste recycling is one of the key aspects in current day studies to boost the country’s circular economy. Recycling wood from construction and demolished structures and combining it with plastics forms wood-polymer composites (WPC) which have a very wide scope of usage. Such recycled composites have very low environmental impact in terms of abiotic potential, global warming potential, and greenhouse potential. Processing of WPCs can be easily done with predetermined strength values that correspond to its end application. Yet, the usage of conventional polymer composite manufacturing techniques such as injection molding and extrusion has very limited scope. Many rheological characterization techniques are being followed to evaluate the influence of formulation and process parameters over the quality of final WPCs. It will be very much interesting to carry out a review on the material formulation of WPCs and additives used. Manufacturing of wood composites can also be made by using bio-based adhesives such as lignin, tannin, and so on. Nuances in complete replacement of synthetic adhesives as bio-based adhesives are also discussed by various researchers which can be done only by complete understanding of formulating factors of bio-based adhesives. Wood composites play a significant role in many non-structural and structural applications such as construction, floorings, windows, and door panels. The current review focuses on the processing of WPCs along with additives such as wood flour and various properties of WPCs such as mechanical, structural, and morphological properties. Applications of wood-based composites in various sectors such as automotive, marine, defense, and structural applications are also highlighted in this review.

Microstructure modeling of microfiber sound absorbers and investigation of improvement of sound absorption coefficient

In the automotive industry, various studies have been conducted to reduce cabin noise. Currently, it is common to use sound-absorbing materials in door panels and front panels to reduce low-frequency noise such as road noise and wind noise. Porous materials such as glass wool and urethane foam are used as sound-absorbing materials, but they currently have problems such as low sound absorption performance at low frequencies. Therefore, this study focused on fiber-based sound-absorbing materials consisting of multiple diameters. A microstructural model was created based on data obtained from microstructural observations of this fiber material. Using this model, flow resistance and sound absorption coefficient were calculated by the homogenization method. The results of the calculations using the model with bundled fibers showed that the effect of changes in the flow path area was significant.

Recycling plastic waste materials for building and construction Materials: A minireview

The production of plastic wastes is a growing environmental problem in the era of industrialization and economic growth due to the varied applications of polymeric materials. The wastes, which are mainly landfilled pollute land and waste resources due to the toxic and resistant to biodegradation nature of their components. Therefore, innovative approaches to channel plastic wastes away from landfills are imperative. In this mini-review, recycling of plastic wastes to materials useful in the building and construction sector as a viable solution to their environmental accumulation was focused on. Using pre-existent empirical studies, it was established that plastics can be used alone or in combination with other materials at varied percentage compositions to make various building and construction materials. These include bricks, blocks, tiles, asphalt, bitumen, geosynthetics, door panels, insulation materials and cementitious composites. These applications are enhancers to environmental sustainability as they reduce the mining and transport of conventional building and construction materials, which result to atmospheric pollution. It was noted that there was need to commercialize the applications by advancing to better plastic harvesting technologies and cost-effective recycling approaches for wastes with a variety of plastics. Assessing the lifecycle of recycling plastic materials for building and construction in addition to devising regulations to standardize the processes involved was recommended to validate the ability of the advances to enhance sustainability.