SAE PT-164-2014 Design of Automotive Composites (To Purchase Call 1-800-854-7179 USA Canada or 303-397-7956 Worldwide).pdf
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1、PROGRESS IN TECHNOLOGY SERIES Design of Automotive Composites Y. Charles Lu Srikanth Pilla AUTOMOTIVEDesign of Automotive CompositesOther SAE books of interest: Automotive Carbon Fiber Composites: From Evolution to Implementation By Jackie D. Rehkopf (Product Code: T-124) Engineered Tribological Com
2、posites: The Art of Friction Material Development By Roy L. Cox (Product Code: R-401) Dictionary of Materials and Testing, Second Edition By Joan Tomsic (Product Code: R-257) For more information or to order a book, contact: SAE INTERNATIONAL 400 Commonwealth Drive Warrendale, PA 15096 Phone: +1.877
3、.606.7323 (U.S. and Canada only) or +1.724.776.4970 (outside U.S. and Canada) Fax: +1.724.776.0790 Email: CustomerServicesae.org Website: books.sae.orgDesign of Automotive Composites Edited by Y . Charles Lu and Srikanth Pilla Warrendale, Pennsylvania, USA Copyright 2014 SAE International eISBN: 978
4、-0-7680-8138-1 Copyright 2014 SAE International. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, distributed, or transmitted, in any form or by any means without the prior written permission of SAE International. For permission and licensing requests
5、, contact SAE Permissions, 400 Commonwealth Drive, Warrendale, PA 15096-0001 USA; e-mail: copyrightsae.org; phone: +1-724-772-4028; fax: +1- 724-772-9765. Library of Congress Catalog Number 2014944059 SAE Order Number PT-164 DOI 10.4271/PT-164 Information contained in this work has been obtained by
6、SAE International from sources believed to be reliable. However, neither SAE International nor its authors guarantee the accuracy or completeness of any information published herein and neither SAE International nor its authors shall be responsible for any errors, omissions, or damages arising out o
7、f use of this information. This work is published with the understanding that SAE International and its authors are supplying information, but are not attempting to render engineering or other professional services. If such services are required, the assistance of an appropriate professional should
8、be sought. ISBN-Print 978-0-7680-8132-9 ISBN-PDF 978-0-7680-8138-1 ISBN-epub 978-0-7680-8140-4 ISBN-prc 978-0-7680-8139-8 To purchase bulk quantities, please contact SAE Customer Service e-mail: CustomerServicesae.org phone: +1.877.606.7323 (inside USA and Canada) +1.724.776.4970 (outside USA) fax:
9、+1.724.776.0790 Visit the SAE Bookstore at books.sae.org 400 Commonwealth Drive Warrendale, PA 15096 E-mail: CustomerServicesae.org Phone: +1.877.606.7323 (inside USA and Canada)+1.724.776.4970 (outside USA) Fax: +1.724.776.0790v Table of Contents Introduction . vii Body Structures 1 System Level De
10、sign Simulation to Predict Passive Safety Performance for CFRP Automotive Structures (2013-01-0663)3 Research of Multi-Axial Carbon Fiber Prepreg Material for Vehicle Body (2011-01-0216) 17 Glass-Reinforced Thermoplastic Composites for Front End Module Applications (2011-26-0053) 23 Powertrain Compo
11、nents . 29 Structural Analysis of Steering System Components Considering the Anisotropic Material Properties of Carbon Fiber Reinforced Plastic (2013-01-0019) .31 Development of Intercooler Plastic Tank Material Instead of Aluminum Die-Cast (2013-01-1175) 37 2013 SRT Viper Carbon Fiber X-Brace (2013
12、-01-1775)45 Wear of Glass Fiber Reinforced Polyamide Worm Gear According to the Direction of the Glass Fiber (2010-01-0917) .53 Suspension Components . 62 Design and Fatigue Life Comparison of Steel and Composite Leaf Spring (2012-01-0944) 65 Development of a Lightweight CFRP Coil Spring (2014-01-10
13、57) 71 Electric and Alternative Vehicle Components 77 Development of Polymer Composite Battery Pack Case for an Electric Vehicle (2013-01-1177) 79 Composite Gas Cylinders for Automotive Vehicles Current Status of Adoption of Technology and Way Forward (2013-26-0074) 87 About the Editors 99vii Introd
14、uction Structural materials are generally divided into four basic categories: metals, ceramics, polymers, and composites. This scheme is based primarily upon the microstructures and chemical makeups of the materials 1-1. Metals are combinations of metallic elements and contain nonlocalized electron
15、. Metals, including steels and nonferrous metals such as aluminum, are generally strong and yet deformable. Ceramics are compounds of metallic and nonmetallic elements. They are highly crystalline oxides, nitrides, or carbides, and therefore are very stiff and brittle. Polymers are composed of very
16、large molecular chains of carbon atoms that are side-bonded with various atoms or radicals. The long molecular chains are mostly bonded with weak van der Waals forces, which make polymers neither as strong nor as stiff as metals or ceramics. However, the long molecular structures provide polymers wi
17、th high flexibility. Composites are artificially produced materials that consist of two or more separate materials combined in a macroscopic structural unit. Unlike these traditional materials (metals, ceramics, and polymers) whose microstructures are relatively fixed, composites are highly tunable
18、from microstructure and mechanical properties points of view. As a result, composites can have a desirable combination of the best properties of the constituent phases, meaning they can be strong and ductile, stiff, and lightweight. Composites have been successfully used in aerospace and space indus
19、tries and are gaining momentum in the automotive industry. With a yield strength of more than ten times that of steel or aluminum, and a density of only about one-fifth that of steel and one-half that of aluminum, composites have become the top choice for producing lightweight vehicles 1-2. Accordin
20、g to the U.S. Department of Energy, the transportation sector accounts for 28% of total U.S. energy use, two-thirds of the nations petroleum consumption, and a third of the nations carbon emissions 1-3. Further, the transportation industry accounts for nearly 32% of U.S. greenhouse gas emissions 1-4
21、. It is known that the fuel consumption is directly related to the vehicle weight 1-5. Reductions in vehicle weight can be achieved by a combination of (1) vehicle downsizing, (2) vehicle redesign and contents reduction, and (3) material substitution 1-6. Among these three options, substituting heav
22、y metallic materials with strong and light composites seems to be the most viable choice. The benefits of composites go far beyond weight savings. Polymer matrix composites have great potential for part Materials Modulus of Elasticity (GPa) Ultimate Strength Density (g/cm3) (GPa) E-glass fiber 73 3.
23、4 2.5 S-glass fiber 86 4.5 2.4 PAN-based carbon fiber 230-595 1.9-6.2 1.8 Pitch-based carbon fiber 170-980 2.3-4.1 2.0 Aluminum 70 0.1 2.7 Steel 200 0.4 7.8 Table 1.1: Typical properties of reinforcement fibers and traditional materials 1-10 1-11 integration, which will result in lower manufacturing
24、 costs and faster time to market. The composite parts can have much smaller tooling costs as compared to metal ones. Composites also have much better corrosion resistance than metals and are more resistant to damage, such as dents and dings, than aluminums. Polymer composites possess superior viscoe
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