The Experts below are selected from a list of 111 Experts worldwide ranked by ideXlab platform
Joche Holzleitne - One of the best experts on this subject based on the ideXlab platform.
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suitability analysis of a polymer metal hybrid technology based on high strength steels and direct polymer to metal adhesion for use in load bearing automotive Body in White applications
Journal of Materials Processing Technology, 2009Co-Authors: Mica Grujicic, Guruprasad Arakere, V Sellappa, Marc Erdma, S Kotrika, Andreas Obieglo, Joche HolzleitneAbstract:Abstract A comprehensive set of computational engineering analyses is carried out in order to assess the suitability of a “direct adhesion” polymer–metal hybrid (PMH) technology for use in load-bearing automotive Body-in-White (BIW) components. Within the direct adhesion PMH technology, load transfer between stamped sheet-metal and injection-molded rib-like plastic subcomponents is accomplished through a variety of nanometer-to-micron scale chemical and mechanical phenomena which enable direct adhesion between the two materials. The resultant adhesion strength in a 5–10 MPa range has been assessed. in the present work it has been investigated if such level of adhesion strength is sufficient to restore the component's stiffness in the cases when stiffness has been compromised by substituting a twin-shell large-thickness drawing-quality-steel design of a prototypical BIW component with a single-shell lower-thickness high-strength-steel and polymer-hybridized design of the same component. The results obtained suggest that meeting the bending stiffness requirements is the most challenging task and if such requirements do not control the overall component design, weight savings in a 2.0–2.5% range can be obtained.
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computational analysis of injection molding residual stress development in direct adhesion polymer to metal hybrid Body in White components
Journal of Materials Processing Technology, 2008Co-Authors: Mica Grujicic, V Sellappa, A Vahidi, Norbe Sey, Marc Erdma, Joche HolzleitneAbstract:To overcome some of the main limitations of the current polymer metal hybrid (PMH) technologies, a new approach, the so-called “direct-adhesion” PMH process, has been recently proposed [Grujicic, M., Sellappan, V., Arakere, G., Seyr, N., Erdmann, M., in press. Computational feasibility analysis of direct-adhesion polymer-to-metal hybrid technology for load-bearing Body-in-White structural components, J. Mater. Process. Technol.]. Within this approach, the necessary level of polymer-to-metal mechanical interconnectivity is attained through the use of polymer-to-metal adhesion promoters. Such promoters are applied to the metal stamping prior to their placement into the injection mold for plastic-subcomponent injection molding. The resulting enhanced polymer-to-metal adhesion affects the way injected plastic develops residual stresses while it is cooled from the plastic-melt temperature down to room temperature. in the present work, injection-molding mold-filling and material-packing analyses are combined with a structural analysis involving polymer/metal adhesion analysis to assess the extent of residual stresses and warping in a prototypical direct-adhesion PMH component. The magnitude and the distribution of such stresses and distortions are critical for the component assembly, performance and durability. The results obtained show that adhesion at the metal-stamping/plastics-subcomponent interfaces, whose presence is the bases for the direct-adhesion PMH technology, has a profound effect on the distribution and magnitude of residual stresses/distortions in the PMH component and that it must be taken into account when the component and its manufacturing processes are being designed.
Mica Grujicic - One of the best experts on this subject based on the ideXlab platform.
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suitability analysis of a polymer metal hybrid technology based on high strength steels and direct polymer to metal adhesion for use in load bearing automotive Body in White applications
Journal of Materials Processing Technology, 2009Co-Authors: Mica Grujicic, Guruprasad Arakere, V Sellappa, Marc Erdma, S Kotrika, Andreas Obieglo, Joche HolzleitneAbstract:Abstract A comprehensive set of computational engineering analyses is carried out in order to assess the suitability of a “direct adhesion” polymer–metal hybrid (PMH) technology for use in load-bearing automotive Body-in-White (BIW) components. Within the direct adhesion PMH technology, load transfer between stamped sheet-metal and injection-molded rib-like plastic subcomponents is accomplished through a variety of nanometer-to-micron scale chemical and mechanical phenomena which enable direct adhesion between the two materials. The resultant adhesion strength in a 5–10 MPa range has been assessed. in the present work it has been investigated if such level of adhesion strength is sufficient to restore the component's stiffness in the cases when stiffness has been compromised by substituting a twin-shell large-thickness drawing-quality-steel design of a prototypical BIW component with a single-shell lower-thickness high-strength-steel and polymer-hybridized design of the same component. The results obtained suggest that meeting the bending stiffness requirements is the most challenging task and if such requirements do not control the overall component design, weight savings in a 2.0–2.5% range can be obtained.
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computational analysis of injection molding residual stress development in direct adhesion polymer to metal hybrid Body in White components
Journal of Materials Processing Technology, 2008Co-Authors: Mica Grujicic, V Sellappa, A Vahidi, Norbe Sey, Marc Erdma, Joche HolzleitneAbstract:To overcome some of the main limitations of the current polymer metal hybrid (PMH) technologies, a new approach, the so-called “direct-adhesion” PMH process, has been recently proposed [Grujicic, M., Sellappan, V., Arakere, G., Seyr, N., Erdmann, M., in press. Computational feasibility analysis of direct-adhesion polymer-to-metal hybrid technology for load-bearing Body-in-White structural components, J. Mater. Process. Technol.]. Within this approach, the necessary level of polymer-to-metal mechanical interconnectivity is attained through the use of polymer-to-metal adhesion promoters. Such promoters are applied to the metal stamping prior to their placement into the injection mold for plastic-subcomponent injection molding. The resulting enhanced polymer-to-metal adhesion affects the way injected plastic develops residual stresses while it is cooled from the plastic-melt temperature down to room temperature. in the present work, injection-molding mold-filling and material-packing analyses are combined with a structural analysis involving polymer/metal adhesion analysis to assess the extent of residual stresses and warping in a prototypical direct-adhesion PMH component. The magnitude and the distribution of such stresses and distortions are critical for the component assembly, performance and durability. The results obtained show that adhesion at the metal-stamping/plastics-subcomponent interfaces, whose presence is the bases for the direct-adhesion PMH technology, has a profound effect on the distribution and magnitude of residual stresses/distortions in the PMH component and that it must be taken into account when the component and its manufacturing processes are being designed.
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computational feasibility analysis of direct adhesion polymer to metal hybrid technology for load bearing Body in White structural components
Journal of Materials Processing Technology, 2008Co-Authors: Mica Grujicic, Velmurugan Sellappan, Guruprasad Arakere, Norbert Seyr, Marc ErdmannAbstract:Abstract The potential of direct-adhesion polymer metal hybrid (PMH) technology for use in load-bearing structural automotive components is explored computationally. Multi-disciplinary computations are carried out ranging from computational fluid mechanics of injection-mold filling and packing processes, flow-induced fiber orientation analysis, visco-elastic analysis of in-cavity residual stress developments and structural-mechanics computation of injection-molded part warping (under the effect of residual stresses) and deflection under simulated thermal loading encountered in the paint shop and under mechanical in-service loading. The results obtained helped identify the minimum level of polymer-to-metal adhesive strength and an optimal PMH-component architecture which are required in order for the direct-adhesion PMH technology to be considered a viable (weight-saving, parts-consolidation, manufacturing process-chain compatible) alternative to the currently used PMH technologies.
A Mayyas - One of the best experts on this subject based on the ideXlab platform.
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life cycle assessment based selection for a sustainable lightweight Body in White design
Energy, 2012Co-Authors: A Mayyas, Ala Qattawi, Abdel Raouf Mayyas, Mohammed OmaAbstract:Nowadays life cycle tools namely; Life Cycle Assessment (LCA), Life Cycle Costing (LCC), and Life Cycle Optimization (LCO) are being used to assess new vehicular structures from sustainability and design for the environment perspectives. This manuscript implements a Life Cycle Assessment (LCA) based design approach to assess the performance of vehicular Body-in-White’s (BIW) through its complete life cycle. The proposed LCA model will aid in the early design stages (i.e. conceptual design stage) serving as an eco-design decision-making support tool. This study provides a complete life cycle assessment covering the extraction and the processing of virgin materials, the manufacturing, the use and maintenance stage, the end-of-life stage, in addition to the fuel extraction and production stages. Traditional LCA studies do not usually consider the latter stages which accounts for a significant portion of the energy consumed and the generated CO2 emissions. This study results show that the material selection for vehicular applications is a sensitive process not only to the vehicle lifetime (as expressed in traveled miles), but also to the environmental burdens from the extraction stage and recyclability efforts. Additionally, the proposed study shows the effect of the different materials choices on the vehicle structure functionality.
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using quality function deployment and analytical hierarchy process for material selection of Body in White
Materials & Design, 2011Co-Authors: A Mayyas, Qin Shen, Mahmoud Abdelhamid, Dongri Shan, Ala Qattawi, Mohammed OmarAbstract:Abstract Presented manuscript discusses the usage of multi-attribute decision making tools to assist in the material selection for vehicular structures; mainly the automotive Body-in-White (BiW) panels at the conceptual design stage using Quality Function Deployment (QFD) and Analytical Hierarchy Process (AHP). The main advantage of using QFD and AHP is their abilities to rank choices in the order of their effectiveness in meeting the functional objective. AHP discriminates between competing options where interrelated objectives need to be met; AHP is based on straightforward mathematical formulations. QFD on the other side is a customer focused method that usually starts by collecting customer needs and tries to integrate these needs into the product. in this study, following classes of engineering materials are analyzed; forming grade Bake Harden-able steel (BH), Dual Phase steel (DP), High Strength Low Alloy Steel (HSLA), Martenistic steel, Aluminum 5xxx, 6xxx sheets, Magnesium sheets, Titanium sheets, Carbon Fiber Reinforced Plastic (CFRP) and High Density Polyethylene (HDPE). The presented study showed that the different grades of steel gained the first ranks in the selection process for almost most of the BiW panels; however other alternatives could work in trade-off with cost and manufacturability.
Guruprasad Arakere - One of the best experts on this subject based on the ideXlab platform.
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suitability analysis of a polymer metal hybrid technology based on high strength steels and direct polymer to metal adhesion for use in load bearing automotive Body in White applications
Journal of Materials Processing Technology, 2009Co-Authors: Mica Grujicic, Guruprasad Arakere, V Sellappa, Marc Erdma, S Kotrika, Andreas Obieglo, Joche HolzleitneAbstract:Abstract A comprehensive set of computational engineering analyses is carried out in order to assess the suitability of a “direct adhesion” polymer–metal hybrid (PMH) technology for use in load-bearing automotive Body-in-White (BIW) components. Within the direct adhesion PMH technology, load transfer between stamped sheet-metal and injection-molded rib-like plastic subcomponents is accomplished through a variety of nanometer-to-micron scale chemical and mechanical phenomena which enable direct adhesion between the two materials. The resultant adhesion strength in a 5–10 MPa range has been assessed. in the present work it has been investigated if such level of adhesion strength is sufficient to restore the component's stiffness in the cases when stiffness has been compromised by substituting a twin-shell large-thickness drawing-quality-steel design of a prototypical BIW component with a single-shell lower-thickness high-strength-steel and polymer-hybridized design of the same component. The results obtained suggest that meeting the bending stiffness requirements is the most challenging task and if such requirements do not control the overall component design, weight savings in a 2.0–2.5% range can be obtained.
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computational feasibility analysis of direct adhesion polymer to metal hybrid technology for load bearing Body in White structural components
Journal of Materials Processing Technology, 2008Co-Authors: Mica Grujicic, Velmurugan Sellappan, Guruprasad Arakere, Norbert Seyr, Marc ErdmannAbstract:Abstract The potential of direct-adhesion polymer metal hybrid (PMH) technology for use in load-bearing structural automotive components is explored computationally. Multi-disciplinary computations are carried out ranging from computational fluid mechanics of injection-mold filling and packing processes, flow-induced fiber orientation analysis, visco-elastic analysis of in-cavity residual stress developments and structural-mechanics computation of injection-molded part warping (under the effect of residual stresses) and deflection under simulated thermal loading encountered in the paint shop and under mechanical in-service loading. The results obtained helped identify the minimum level of polymer-to-metal adhesive strength and an optimal PMH-component architecture which are required in order for the direct-adhesion PMH technology to be considered a viable (weight-saving, parts-consolidation, manufacturing process-chain compatible) alternative to the currently used PMH technologies.
V Sellappa - One of the best experts on this subject based on the ideXlab platform.
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suitability analysis of a polymer metal hybrid technology based on high strength steels and direct polymer to metal adhesion for use in load bearing automotive Body in White applications
Journal of Materials Processing Technology, 2009Co-Authors: Mica Grujicic, Guruprasad Arakere, V Sellappa, Marc Erdma, S Kotrika, Andreas Obieglo, Joche HolzleitneAbstract:Abstract A comprehensive set of computational engineering analyses is carried out in order to assess the suitability of a “direct adhesion” polymer–metal hybrid (PMH) technology for use in load-bearing automotive Body-in-White (BIW) components. Within the direct adhesion PMH technology, load transfer between stamped sheet-metal and injection-molded rib-like plastic subcomponents is accomplished through a variety of nanometer-to-micron scale chemical and mechanical phenomena which enable direct adhesion between the two materials. The resultant adhesion strength in a 5–10 MPa range has been assessed. in the present work it has been investigated if such level of adhesion strength is sufficient to restore the component's stiffness in the cases when stiffness has been compromised by substituting a twin-shell large-thickness drawing-quality-steel design of a prototypical BIW component with a single-shell lower-thickness high-strength-steel and polymer-hybridized design of the same component. The results obtained suggest that meeting the bending stiffness requirements is the most challenging task and if such requirements do not control the overall component design, weight savings in a 2.0–2.5% range can be obtained.
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computational analysis of injection molding residual stress development in direct adhesion polymer to metal hybrid Body in White components
Journal of Materials Processing Technology, 2008Co-Authors: Mica Grujicic, V Sellappa, A Vahidi, Norbe Sey, Marc Erdma, Joche HolzleitneAbstract:To overcome some of the main limitations of the current polymer metal hybrid (PMH) technologies, a new approach, the so-called “direct-adhesion” PMH process, has been recently proposed [Grujicic, M., Sellappan, V., Arakere, G., Seyr, N., Erdmann, M., in press. Computational feasibility analysis of direct-adhesion polymer-to-metal hybrid technology for load-bearing Body-in-White structural components, J. Mater. Process. Technol.]. Within this approach, the necessary level of polymer-to-metal mechanical interconnectivity is attained through the use of polymer-to-metal adhesion promoters. Such promoters are applied to the metal stamping prior to their placement into the injection mold for plastic-subcomponent injection molding. The resulting enhanced polymer-to-metal adhesion affects the way injected plastic develops residual stresses while it is cooled from the plastic-melt temperature down to room temperature. in the present work, injection-molding mold-filling and material-packing analyses are combined with a structural analysis involving polymer/metal adhesion analysis to assess the extent of residual stresses and warping in a prototypical direct-adhesion PMH component. The magnitude and the distribution of such stresses and distortions are critical for the component assembly, performance and durability. The results obtained show that adhesion at the metal-stamping/plastics-subcomponent interfaces, whose presence is the bases for the direct-adhesion PMH technology, has a profound effect on the distribution and magnitude of residual stresses/distortions in the PMH component and that it must be taken into account when the component and its manufacturing processes are being designed.