Production Of Automotive Parts Research Articles

Application of methods for ecological optimization of crank shaft forging process

The manufacturing process of forged parts is usually conducted by different subsequent process steps. According to various technological as well as economical and ecological requirements, different and often opposing objectives have to be fulfilled. A representative example for this conflicting situation is the requirement of high product qualities on the one hand and low processing costs on the other hand. A third important factor influencing the process in addition to quality and cost-efficiency is the ecological aspect that is focused more and more in recent years. Material shortage, high energy costs and increasing intensification of statutory regulations lead to the necessity of ecologically optimized processes. Nevertheless, an economic-based evaluation of forging processes is not easy to carry out due to a versatile process chain from raw material to final product. Within the framework of the joint research project “Holistic process chain optimization for forging production of automotive parts in terms of manufacturing efficiency and saving operation energy” an entire evaluation and optimization with special regard to ecologic aspects will be conducted on the example of a crank shaft forging process (Denkena et al. in ZWF 4:224–228, 2013; Int J Precis Eng Manuf 14(7), 2013).

시뮬레이션과 네트워크 분석법을 이용한 자동차 부품 가공시스템의 다목적 최적운영설계

본 연구에서는 시뮬레이션과 네트워크 분석법을 이용하여 다품종 소량생산 체제로 운영되는 자동차 부품 가공시스템의 최적 운영방안을 제시하였다. 이를 위해 먼저, 생산현장의 복잡하고 다양한 운영 요소들을 반영하여 시뮬레이션 모델링 한 후 반응표면법으로 메타모델을 설계하였다. 그 후 의사결정권자들로부터 주요 평가 요소들과 그 요소들 간의 중요도를 수집하여, 네트워크 분석법으로 그 가중치를 설계한 후 다목적 유전자알고리즘을 사용하여 그 최적운영방안을 제시하고 그 결과를 분석하였다. 그와 더불어 계층화분석법으로 설계한 가중치를 반영한 운영방안과의 비교를 통해, 본 연구에서 제시한 방법이 평가 요소간의 내 외부 종속성과 상호연관성을 반영하여 더 정밀하고 우수한 운영방안임을 입증하였다. 본 연구를 활용하면 자동차 부품산업과 같은 다품종 소량생산 시스템의 운영방안 설계시 의사결정권자에게 보다 효과적이고 정밀한 정보를 제공해 줄 수 있을 것이다. This paper suggested the optimal operating design method using simulation and ANP(Analytic Network Process) for mass-customization in the automotive component manufacturing industry. For this, first of all, we built the simulation model including various and complex factors in the field, and estimated the meta-model by RSM(Response Surface Method). Secondly using ANP, we calculated the weight of relative importance of evaluation factors gathered from decision makers. And then, we proposed the optimal operation designs by MOGA(Multi-Objective Genetic Algorithm), analyzed results of them. Moreover, by comparing the results with the consequences using AHP(Analytic Hierarchy Process), we showed its superiority of suggested method to the manner using AHP, because it reflects inner, outer dependency, and inter-relation among judgement factors. In conclusion, through this process, we can present the better way to serve mover effective, precise, and accurate information to decision makers when they build operation design for mass-customization system as automotive parts production system.

Optimizing Humidity Level and Illuminance to Enhance Worker Performance in an Automotive Industry

The objective of this study is to determine the optimum values of environmental factors such as relative humidity (%) and illuminance (lux), on the operators’ productivity at Malaysian automotive industry. Production of automotive parts is among the largest contributor to economic earnings in Malaysia. The dominant work involve in producing automotive part were manual assembly process. Where it is definitely used a manpower capability. Thus, the quality of the product heavily depends on worker’s comfort in the working condition. Humidity and illuminance level can give significant effect on the worker performance. Humidity level, illuminance level and productivity rate were observed in automotive factory. An automotive manufacturing firm was chosen to observe the relative humidity level, illuminance level and worker’s productivity rate. The data were analyzed using Artificial Neural Network's (ANN) analysis. Artificial Neural Network's (ANN) analysis technique is usual analysis method used to form the best linear relationship from the collected data. It is apparent from the linear relationship, that is the optimum value of production (value?1) is attained when relative humidity is 54.86% RH and lighting value is 146.386 lux. Optimum value production rate (value?1) for one manual production line in that particular company is successfully achieved. Through ANN's system, optimum environmental factor manage to be predicted.

Optimization of Temperature Level to Enhance Worker Performance in Automotive Industry

Problem statement: Production of automotive parts is among the largest contributor to economic earnings in Malaysia. The dominant work involve in producing automotive part were manual assembly process. Where it is definitely used a manpower capability. Thus the quality of the product heavily depends on worker's comfort in the working condition. Temperature is one of the environmental factors that give significant effect on the worker performance. Approach: Temperature level and productivity rate were observed in automotive factory. An automotive manufacturing firm was chosen to observe the temperature level and worker's productivity rate. The data were analyzed using Artificial Neural Network's analysis (ANN). ANN analysis technique is usual analysis method used to form the best linear relationship from the collected data. Results: It is apparent from the linear relationship, that the optimum value of production (value≈1) attained when temperature value (WBGT) is 24.5°C. Conclusion: Optimum value production rate (value≈1) for one manual production line in that particular company is successfully achieved. Through ANN method, the optimum temperature level for the optimum manual workers' performance manage to be predicted.

Taiwanese Automotive Parts Suppliers in China

Bilateral policies and rising labour costs have driven the relocation of automotive parts production from Taiwan to China. Using a company-level survey of 72 Taiwanese automobile parts suppliers in 2004–05, this contribution identified significant levels of technology transfer from Taiwanese automobile parts suppliers to Chinese firms in China. The technical division of labour among Taiwanese supplier-linked Chinese automotive assemblers is that key advanced technology is drawn from Japan which is then fused with Taiwanese conventional body parts technology to meet Chinese and Taiwanese joint-venture assembly demands.

The Effect of Isothermal Heat Treatment on the Rolling Contact Fatigue of Carburized Low Carbon Microalloyed Steel

In case of the low carbon chromium steel that have widely been used for the carburized gears or rolling bearings, the austenite grain coarsening may be occasionally occurred during carburizing. To restrain this phenomenon, most of hot forged parts have been given to an isothermal heat treatment or normalizing immediately after hot forging and/or prior to carburizing. Therefore, their production cost includes unexpected additional expenses caused by such a non-value added process. To confirm the possibility of an energy saving, as well as attaining a superior fatigue life, in the production of automotive parts to be carburized, the austenite grain coarsening with the manufacturing process of the microalloyed steel, containing Nb and B as a grain refining elements, was investigated. The heat treatment characteristics and rolling contact fatigue behavior of the carburized specimens with the isothermal heat treatment were also investigated. In spite of omitting the isothermal heat treatment after hot forging, the abnormally coarse austenite grains were not found out in the carburized specimens. However, the rolling contact fatigue life of the carburized specimens, in which the isothermal heat treatment was omitted, was shorter than that of isothermally heat-treated specimens.

Investigation of deviations of the lock-position of dies due to unsteady thermal conditions

Abstract Common manufacturing technologies for mass production of automotive parts include forging presses. Eccentric presses are used in order to achieve short cycle times and high output rates. During the start-up phase of these path-bound forging presses high scrap rates occur due to the unsteady thermal conditions of the forging press. This leads to a reduced operational availability of these capital-intensive production lines and higher costs against the background of decreasing batch sizes. Similar parts were forged with differently sized raw part dimensions for the examination of the thermal influence. The impact to the lock-position was investigated by measuring the thickness of the parts. These results are used to derive a correlation from temperature and lock-position in order to predict the shift in lock-position. Thereby, the production of parts within tolerances from the start of production is possible.

Series Production of Thixoformed Steel Parts

In recent years several attempts were made to transfer the thixoforming technology of steel parts into industrial applicable processes. This paper gives an overview about the progress of a European consortium that established a fully automated thixoforming process for the series production of automotive steel parts. Due to the multi-faceted nature of this technology, problems concerning the development of suitable steel grades and tool materials as well as the development and application of an inductive heating system, a handling unit and of a complex forming tool had to be solved. Besides the development of adapted steel grades and the inductive heating, the handling of the semi solid billets plays a special role because during the manipulation of the parts from the heating station into the tool a loss of heat is unavoidable. Furthermore, scaling of the parts must be prevented. By means of a fully automated process line existing constraints were reduced and the forming process is kept reproducible. Improved silicon nitride composites have been developed as a tool material, which show good mechanical properties in combination with an acceptable chemical stability at the occurring process temperatures as well as in contact with semi solid steel. Basing on the practical experience a comparison of the thixoforming technology to existing processes and an outlook for the future are given.

Forming Technology for Cold Forging Processes of Ball Stud Using Non-Heat-Treated Cold Forging Materials

A microalloyed (MA) forging steel is non-heat-treated materials that have been replacing for conventional quenched and tempered (Q/T) structural steels since the MA forging steels are very cost-effective compared with Q/T steels for the production of automotive parts. However, due to a high strength and low elongation, it has been difficult to apply the MA cold forging steel to the ball stud for automobile. In this study, finite element analyses were carried out to investigate the forming loads, the stress and strain distributions of the workpiece in the cold forging processes of the ball stud using the MA cold forging steel. Compression test at room temperature and fatigue test were also performed to obtain the flow stress and fatigue life, respectively. From these results, it was found that the fatigue life was greatly affected by the strength in the neck region of the ball stud and the cold forging processes should be designed to improve the fatigue life of the ball stud used the MA cold forging steel.

An Empirical Study of QS 9000 in the Automobile and Related Industries in Taiwan

QS 9000 was established by three famous automotive manufacturers—Ford, GM & Chrysler—who integrated different quality systems among the automotive manufacturers and developed this common quality system standard. QS 9000 achieves its objectives, which are continually to improve the production of automotive parts and related services, and to strengthen the international competition for the automotive industry and its suppliers. By applying this quality system standard, automotive manufacturers could offer superior products and good services to customers. Two sections are included in this research. The first section comes with the statistical results of surveys of automotive companies in Taiwan that have failed and succeeded in QS 9000. Furthermore, the performances after executing QS 9000 were evaluated by internal management and the PZB model. The second section provides a systematic procedure for QS 9000 and internal quality audits that help an automotive industry company to qualify for QS 9000 registration. The study tends to provide a reference guide for the automotive industry in pursuing QS 9000 and procuring maximum benefit from the results.

Titanium in Automotive Production

AbstractAlthough titanium has meanwhile made its way into serial production of automotive parts, its use has been widely limited to niche applications and was not driven by weighing the technical and economic aspects. Cost of semi‐finished titanium products is still limiting; indeed, new and cheaper processes for production of Ti itself are urgently needed. However, if one extrapolates the current status of Ti technology based on the historic development of the knowledge bases on other automotive metals (steel, Al, and Mg), the future of titanium use in cars looks quite bright.

Production of automotive parts using an environmentally friendly P/M (powder metallurgy) process.

Production of automotive parts using an environmentally friendly P/M (powder metallurgy) process.

Process economics and technological advances in PM automotive part production: D.Whittaker. (T&N Composites and Camshafts Group, Halesowen, UK.) Int. J. Powder Metall., Vol 34, No 4, 1998, 53–62

Process economics and technological advances in PM automotive part production: D.Whittaker. (T&N Composites and Camshafts Group, Halesowen, UK.) Int. J. Powder Metall., Vol 34, No 4, 1998, 53–62

The development of a cellular manufacturing system for automotive parts

The similarity of coefficient method, simulation modeling, and computer-aided layout design are employed to develop, implement, and evaluate a cellular manufacturing system for the production of automotive parts for car seats.

Leading Edge Technology

TWI has been investigating the potential of high power CO2 lasers for production of automotive parts using new and coated materials. Lasers are ideal for mass production of consumer goods.

Development and application of aluminum extrusion for automotive parts, mainly bumper reinforcement

Whilst there is an advancing tendency toward lighter vehicles, the application of aluminum extrusion to the production of automotive parts has been quite rare due to cost, strength and corrosion problems. In this report, it is explained how new materials, product design and processing have been developed to match the automotive parts to which is aimed the adoption of the aluminum extrusion technique. Also activity to solve the problems in applying this technique, and the endeavor to widen the application of aluminum extrusion are reported.

Information Control in Manufacture

Production has a very high priority in our national economic development plan and information control by computer aided devices plays a vital role in furthering manufacture by adaptive control of machine tools. We are using powerful and growing multi-access computer systems and relatively slender numbers of staff with modern bands with communication links to other computer systems in various parts of the state of Uttar Pradesh and elsewhere in our country. This ensures planning and decision making in order to produce information to ensure correct manufacture and construction. A whole series of basic tools are shaped, consolidated and improved as experience grows of industry by interaction with research. The widest possible exploitation of results was obtained by making suitable arrangements for marketing and the provision of service by other organisations. The constant feedback of the computer system provided a powerful control in the direction of computer system development, thus ensuring that the total system evolved on the right lines. We were very much concerned with command processing. When using the tektromix terminal device, the input was largely keyboard oriented. Fortran, Algol, MAD, BASIC were used and new manufacturing devices and new materials have given rise to less expensive and more powerful computing equipment. Vertical circular indexing was used where the work was circle indexed automatically in a vertical plane. The work pieces were automatically clamped in the interlocked trunion fixture and were indexed through the various operations of spot drilling, drilling spot facing reaming, and counter-boring. An automatic time delay mechanism was arranged in the machine when the tools reverse. An automatic coolant system for cooling the tools and automatic lubrication to the drill heads and machine ways were provided. Automated broaching operations were recommended where a large volume of identical pieces was used with a number of independent machine units through them aided by specially designed handling equipment. A typical inline indexing transfer machine for high production of automotive parts was designed. The parts produced on this machine were torque converter adaptor plates. The complete machine was arranged as a group of single production units with all necessary controls in a central position, enabling the operator to manipulate from the main console. Other individual remote push buttons were also strategically located in various positions, assuring additional instant control and safety.Typically electronic phase-sensitive demodulators were also designed. The tubes acted as gating devices or switches that permitted the input signal to reach the output only during certain intervals. Both tubes were supplied with the same plate voltage which caused the anode potentials of both tubes to be positive with respect to cathode during a portion of each cycle and negative for the remainder of each.(1)

シェルモールド法による自動車部品の量産方式

シェルモールド法による自動車部品の量産方式