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Development of aluminum brake & clutch pedal bracket for truck
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Abstracts / JSAE Review 18 (1997) 185-209
9637690 The Relationship between Car Size and Occupant Injury in Collisions Koji Mizuno, Tetsuhiro Umeda, Hideki Yonezawa (Traffic Safety and Nuisance Research Institute) The relationship between car size and occupant injury was examined using accident data in Japan. Based on approximation of occupant injury by delta-V, the injury rate is formulated by car mass in head-on collision. In addition to the size of the striking and struck car, the effect of using a seat belt on the occupant injury rate was examined in head-on and side collisions. The sensitivity analysis shows that the number of serious injuries or fatalities is larger as the dispersion of mass for the number of the cars increases. 9637708 Study on Fracture Surface Analysis of Gray Cast Iron Noriaki Katori (Hint Motors) The fracture surface provides significant information for the failure analysis of a fractured metallic object. However, an object made of gray cast iron can not show characteristic mode on fracture surface by microscopic observation. Therefore, to study the plastic zone size of dynamic and fatigue fracture surfaces of gray cast iron, fatigue and charpy impact tests were conducted. The plastic zone size beneath these fracture surfaces was evaluated using the X-ray diffraction parameters. Using this method, the failure of a fractured gray cast iron object can be analyzed. 9637717 Fatigue Behavior of ADI under roughly Ms Transformation Temperature Katsuyuki Sato (Oita University Graduate School), Shigem Doi, Yasunari Mimura (Oita University) One of the principal causes of fatigue strength is thermal environment. As an example of thermal environment, when vehicle gears meshing with each other rotate for a long time, fatigue strength will decrease due to a material change in the contacting face and the effect of thermal environment. In this study, rotating bending fatigue tests using austempered ductile cast iron (ADI) were carried out under roughly Ms transformation temperature, and the fatigue strength was compared with the data of another test under room temperature and the results discussed. The results of the experiment showed that fatigue strength decreased under this environment. 9637726 Bonding of Ferrous Sintered Alloys to Aluminum Alloy Junichi Inami, Shuhei Adachi (Yamaha Motor Co., Ltd.) A new bonding technology for dissimilar metals was developed aiming at an application for bonding ferrous valve seats to an aluminum cylinder head using resistance bonding technique. Several factors affecting the bonding strength were investigated and their mechanism was discussed. Good bonding could be achieved by the proper cross-sectional design of the contacting portion and the right choice of the surface-plating materials for the ferrous ring and of bonding parameters. Endurance tests on the optimized bonding condition showed that the bonding strength did not change after heating at 300°C, and no growth of intermetallic compounds was observed at the bonded interface. 9637735 Joint Strength of Extruded Aluminum Tubular Joint Components - - The Influence of Welding and Joining Improvement Yoshihaya Imamura, Kazuo Yonezawa, Tohru Hashimura (Kobe Steel, Ltd.) Extruded aluminum pipes were welded in configurations of T and L, and their stiffness and strength were investigated. The investigation results indicated that simple set-on joining tends to cause partial penetration and lowers strength, and improvement was made on the joining method. Properties were compared with those of welded steel pipes. Investigation was made on an aluminum joint with stiffness equivalent to that of a steel joint from the viewpoint of padding reinforcement and crossbar addition. Weight was also compared and it was shown that about 10-25% weight reduction is possible.
9637744 Development of Aluminum Brake & Clutch Pedal Bracket for Truck Yasuhiro Komiyama, Kaoru Umezawa, Seiichi Saitoh, Syuuichi hukal (Isuzu Motors Ltd.), Chikahiro Satoh (Furukawa Casting Co., Ltd.), Hisayosi Takei (Nissin Kogyo co., Ltd.) The need for weight reduction for trucks has increased since May 1994 when the regulations for over-load of trucks was tightened. A very effective method for weight reduction of trucks is to replace the material of steel parts with aluminum, but there are some engineering problems for introduction to a production model. We achieved an effective method not only for weight reduction but also for additional functions for absorption of collision energy of a B & C pedal bracket. The B & C pedal bracket is the first use of aluminum for truck parts in Japan. 9637753 Study on Vehicle Body Structure in Frontal Collision Part I: Strain Rate Sensitivity of Steel Sheets Kentaro Sato (NKK), Akira Oda (Isuzu), Hironori Tomizawa (Kanto Auto Works), Hisao Mikami (Daihatsu), Hiroshi Suganuma (Subaru Research Center), Akihito Norioka (Nissan Diesel), Masaaki Watanabe (Tokyo Univ. of Agric. and Tech.) In regard to mild steels and high strength steels, the relation between stress and strain under high strain rate was investigated by experimental analysis. Numerical simulations of axial crushing of a thin walled column with hat square cross section were carried out using FEM model that considered the effect of strain rate obtained by the experiment. In consequence, deformed mode and energy absorption showed good correlation to the experimental results. 9637762 Study on Vehicle Body Structure in Frontal Collision - Part II: Development of Body Structure Study Method with Genetic Algorithm Kenji Takada (Honda R & D), Kentaro Sato (NKK), Akihisa Maruyama (Nissan Motor), Kouyou Kawamura (Toyota Auto Body), Masahiro Awano (Mitsubishi Motors), Masaaki Watanabe (Tokyo Univ. of Agric. and Teck.) In this paper, the lumped-mass program for analyzing non-linear dynamic response using Impact - Acceleration Method was developed to simulate vehicle frontal collision. Vehicle body structure is modeled as non-linear springs and masses. The GA optimization method was applied to the lumped-mass program to obtain the spring characteristics which reduce both the occupant deceleration and the vehicle deformation. In addition, the optimum solution distributions using the GA optimization method were visualized. 9637771 Study on Vehicle Body Structure in Frontal Collision - Part III: Application of Body Structure Study Method with Genetic Algorithm Kouyou Kawamura (Toyota Auto Body), Akihisa Maruyama (Nissan Motor), Masahiro Awano (Mitsuhishi Motors), Kentaro Sato (NKK), Kenji Takada (Honda R & D), Masaaki Watanabe (Tokyo Univ. of Agric. and Tech.) Application results for actual vehicles and the effectiveness of the GA method, as reported in our 2nd report, were studied. Vehicle, passenger and restraint system were modeled as 4 masses and 7 springs, and the optimum spring characteristics were evaluated to simulate vehicle crash deformation and passenger chest deceleration. Comparison with conventional parametric study concluded that the GA method is more effective to obtain optimum results. 9637780 Study on Vehicle Body Structure in Frontal Collision Part IV: Effective structural design of Thin-wailed Curved Beams Hiroshi Suganuma (Subaru Research Center), Akira Oda (Isuzu), Hironori Tomizawa (Kanio Auto Works), Hisao Mikami (Daihatsu), Akihito Norioka (Nissan Diesel), Kentaro Sato (NKK), Masaaki Watanabe (Tokyo Univ. of Agric. and Tech.) This paper describes the effective structural design of Thin-walled Curved members with closed hat section under compression load.
Abstracts / JSAE Review 18 (1997) 185-209
9637690 The Relationship between Car Size and Occupant Injury in Collisions Koji Mizuno, Tetsuhiro Umeda, Hideki Yonezawa (Traffic Safety and Nuisance Research Institute) The relationship between car size and occupant injury was examined using accident data in Japan. Based on approximation of occupant injury by delta-V, the injury rate is formulated by car mass in head-on collision. In addition to the size of the striking and struck car, the effect of using a seat belt on the occupant injury rate was examined in head-on and side collisions. The sensitivity analysis shows that the number of serious injuries or fatalities is larger as the dispersion of mass for the number of the cars increases. 9637708 Study on Fracture Surface Analysis of Gray Cast Iron Noriaki Katori (Hint Motors) The fracture surface provides significant information for the failure analysis of a fractured metallic object. However, an object made of gray cast iron can not show characteristic mode on fracture surface by microscopic observation. Therefore, to study the plastic zone size of dynamic and fatigue fracture surfaces of gray cast iron, fatigue and charpy impact tests were conducted. The plastic zone size beneath these fracture surfaces was evaluated using the X-ray diffraction parameters. Using this method, the failure of a fractured gray cast iron object can be analyzed. 9637717 Fatigue Behavior of ADI under roughly Ms Transformation Temperature Katsuyuki Sato (Oita University Graduate School), Shigem Doi, Yasunari Mimura (Oita University) One of the principal causes of fatigue strength is thermal environment. As an example of thermal environment, when vehicle gears meshing with each other rotate for a long time, fatigue strength will decrease due to a material change in the contacting face and the effect of thermal environment. In this study, rotating bending fatigue tests using austempered ductile cast iron (ADI) were carried out under roughly Ms transformation temperature, and the fatigue strength was compared with the data of another test under room temperature and the results discussed. The results of the experiment showed that fatigue strength decreased under this environment. 9637726 Bonding of Ferrous Sintered Alloys to Aluminum Alloy Junichi Inami, Shuhei Adachi (Yamaha Motor Co., Ltd.) A new bonding technology for dissimilar metals was developed aiming at an application for bonding ferrous valve seats to an aluminum cylinder head using resistance bonding technique. Several factors affecting the bonding strength were investigated and their mechanism was discussed. Good bonding could be achieved by the proper cross-sectional design of the contacting portion and the right choice of the surface-plating materials for the ferrous ring and of bonding parameters. Endurance tests on the optimized bonding condition showed that the bonding strength did not change after heating at 300°C, and no growth of intermetallic compounds was observed at the bonded interface. 9637735 Joint Strength of Extruded Aluminum Tubular Joint Components - - The Influence of Welding and Joining Improvement Yoshihaya Imamura, Kazuo Yonezawa, Tohru Hashimura (Kobe Steel, Ltd.) Extruded aluminum pipes were welded in configurations of T and L, and their stiffness and strength were investigated. The investigation results indicated that simple set-on joining tends to cause partial penetration and lowers strength, and improvement was made on the joining method. Properties were compared with those of welded steel pipes. Investigation was made on an aluminum joint with stiffness equivalent to that of a steel joint from the viewpoint of padding reinforcement and crossbar addition. Weight was also compared and it was shown that about 10-25% weight reduction is possible.
9637744 Development of Aluminum Brake & Clutch Pedal Bracket for Truck Yasuhiro Komiyama, Kaoru Umezawa, Seiichi Saitoh, Syuuichi hukal (Isuzu Motors Ltd.), Chikahiro Satoh (Furukawa Casting Co., Ltd.), Hisayosi Takei (Nissin Kogyo co., Ltd.) The need for weight reduction for trucks has increased since May 1994 when the regulations for over-load of trucks was tightened. A very effective method for weight reduction of trucks is to replace the material of steel parts with aluminum, but there are some engineering problems for introduction to a production model. We achieved an effective method not only for weight reduction but also for additional functions for absorption of collision energy of a B & C pedal bracket. The B & C pedal bracket is the first use of aluminum for truck parts in Japan. 9637753 Study on Vehicle Body Structure in Frontal Collision Part I: Strain Rate Sensitivity of Steel Sheets Kentaro Sato (NKK), Akira Oda (Isuzu), Hironori Tomizawa (Kanto Auto Works), Hisao Mikami (Daihatsu), Hiroshi Suganuma (Subaru Research Center), Akihito Norioka (Nissan Diesel), Masaaki Watanabe (Tokyo Univ. of Agric. and Tech.) In regard to mild steels and high strength steels, the relation between stress and strain under high strain rate was investigated by experimental analysis. Numerical simulations of axial crushing of a thin walled column with hat square cross section were carried out using FEM model that considered the effect of strain rate obtained by the experiment. In consequence, deformed mode and energy absorption showed good correlation to the experimental results. 9637762 Study on Vehicle Body Structure in Frontal Collision - Part II: Development of Body Structure Study Method with Genetic Algorithm Kenji Takada (Honda R & D), Kentaro Sato (NKK), Akihisa Maruyama (Nissan Motor), Kouyou Kawamura (Toyota Auto Body), Masahiro Awano (Mitsubishi Motors), Masaaki Watanabe (Tokyo Univ. of Agric. and Teck.) In this paper, the lumped-mass program for analyzing non-linear dynamic response using Impact - Acceleration Method was developed to simulate vehicle frontal collision. Vehicle body structure is modeled as non-linear springs and masses. The GA optimization method was applied to the lumped-mass program to obtain the spring characteristics which reduce both the occupant deceleration and the vehicle deformation. In addition, the optimum solution distributions using the GA optimization method were visualized. 9637771 Study on Vehicle Body Structure in Frontal Collision - Part III: Application of Body Structure Study Method with Genetic Algorithm Kouyou Kawamura (Toyota Auto Body), Akihisa Maruyama (Nissan Motor), Masahiro Awano (Mitsuhishi Motors), Kentaro Sato (NKK), Kenji Takada (Honda R & D), Masaaki Watanabe (Tokyo Univ. of Agric. and Tech.) Application results for actual vehicles and the effectiveness of the GA method, as reported in our 2nd report, were studied. Vehicle, passenger and restraint system were modeled as 4 masses and 7 springs, and the optimum spring characteristics were evaluated to simulate vehicle crash deformation and passenger chest deceleration. Comparison with conventional parametric study concluded that the GA method is more effective to obtain optimum results. 9637780 Study on Vehicle Body Structure in Frontal Collision Part IV: Effective structural design of Thin-wailed Curved Beams Hiroshi Suganuma (Subaru Research Center), Akira Oda (Isuzu), Hironori Tomizawa (Kanio Auto Works), Hisao Mikami (Daihatsu), Akihito Norioka (Nissan Diesel), Kentaro Sato (NKK), Masaaki Watanabe (Tokyo Univ. of Agric. and Tech.) This paper describes the effective structural design of Thin-walled Curved members with closed hat section under compression load.