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Among various efforts pursued to produce fuel efficient vehicles, light weight engineering (i.e. the use of low‐density structurally‐efficient materials, the application of advanced manufacturing and joining technologies and the design of highly‐integrated, multi‐functional components/sub‐assemblies) plays a prominent role. In the present work, a multi‐disciplinary design optimization methodology has been presented and subsequently applied to the development of a light composite vehicle door (more specifically, to an inner door panel). The door design has been optimized with respect to its weight while meeting the requirements /constraints pertaining to the structural and NVH performances, crashworthiness, durability and manufacturability. In the optimization procedure, the number and orientation of the composite plies, the local laminate thickness and the shape of different door panel segments (each characterized by a given composite‐lay‐up architecture and uniform ply thicknesses) are used as design variables. The methodology developed in the present work is subsequently used to carry out weight optimization of the front door on Ford Taurus, model year 2001. The emphasis in the present work is placed on highlighting the scientific and engineering issues accompanying multidisciplinary design optimization and less on the outcome of the optimization analysis and the computational resources/architecture needed to support such activity.

The purpose of this paper is to use PAM-CRASH, a finite element analysis solver, to assess the performance of a mass production vehicle cross car beam (CCB) under an overlap frontal crash scenario (crashworthiness). Simulation results were reviewed according to what is plausible to register regarding some critical points displacements and, moreover, to identify its stress concentrations zones. Furthermore, it was also computed the CCB modal analysis (noise, vibration and harshness (NVH) assessment) in order to examine if its natural modes are within with the original equipment manufacturer (OEM) design targets.

The available data at the beginning of the present study consisted of the structure CAD file and performance requirements stated by the OEM for NVH. No technical information was available concerning crashworthiness. Taking into account these limitations, it was decided to adapt the requirements for other mass production cars of the same category, as regards dynamic loading. A dynamic explicit code finite element analysis was performed throughout the CCB structure simulating the 120e−3 s crash event. For the modal analysis, there were some necessary modifications to the explicit finite element model in order to perform the analysis in implicit code. In addition, the car body in white stiffness was assigned at the boundaries. These stiffness values are withdrawn from the points where the CCB is attached to the car body’s sheet metal components.

Although the unavailability of published results for this particular CCB model prevents a comparison of the present results, the trends and order of magnitude of the crash simulation results are within the expectations for this type of product. Concerning modal analysis, the steering column first natural frequency has a percent deviation from the design lower bound value of 5.09 percent when local body stiffness is considered and of 1.94 percent with fixed boundary conditions. The other requirement of the NVH assessment regarding a 5 Hz minimum interval between first vehicle CCB mode and the first mode of the steering column was indeed achieved with both boundary configurations.

This study is a further confirmation of the interest of numerical modeling as a first step before actual experimental testing, saving time and money in an automotive industry that has seen an enormous increase of the demand for new car models in the last decade.

In the past several years, there has been increased market place awareness of noise, vibration, and harshness performance in automobiles. The differentiation between the quality and reliability levels of automobiles has become less pronounced and, as a result, manufacturers have had to demonstrate superiority by focusing on NVH concerns. The automotive industry is currently spending millions of dollars on NVH work to develop new materials and damping techniques so that the damping treatments are lighter, cheaper and more effective. Some of the methods used to control noise, vibration and harshness includes the use of different carpeting treatments, the addition of rubber or asphalt material to car panels, gap sealant, and the injection of expandable foam into body panels. The aim of this study is to explore the feasibility of smart damping materials such as magnetorheological elastomers (MRE), piezoelectric materials, with its basic properties, for augmenting and improving the performance benefits of damping materials. This study also evaluates the noise and vibration benefits of smart damping materials as compared to conventional damping treatments.

In the past several years, there has been increased market place awareness of noise, vibration, and harshness performance in automobiles. The differentiation between the quality and reliability levels of automobiles has become less pronounced and, as a result, manufacturers have had to demonstrate superiority by focusing on NVH concerns. The automotive industry is currently spending millions of dollars on NVH work to develop new materials and damping techniques so that the damping treatments are lighter, cheaper, and more effective. Some of the methods used to control noise, vibration, and harshness includes the use of different carpeting treatments, the addition of rubber or asphalt material to car panels, gap sealant, and the injection of expandable foam into body panels. The aim of this study is to explore the feasibility of smart damping materials such as magnet orheological elastomers (MRE), piezoelectric materials, with its basic properties, for augmenting and improving the performance benefits of damping materials. This study also evaluates the noise and vibration benefits of smart damping materials as compared to conventional damping treatments.

This research aims to investigate the influence of building design on the thermal comfort of occupants of naturally ventilated hospital (NVH) wards to identify the aspects with the most significant influence on the thermal comfort of hospital buildings during the hot-dry season in the hot-humid tropics of Southeast Nigeria.

Field measurements, physical observations and a questionnaire survey of 60 occupants of the wards of the Joint Presbyterian Hospital, Uburu in Ebonyi State, Nigeria were undertaken. The data were analysed using Humphreys' neutral temperature formula, descriptive statistics and multiple regression analysis.

The results revealed that the neutral temperature for the wards ranges from 26.2 °C to 29.9 °C, the thermal condition in the wards was not comfortable because it failed to meet the ASHRAE Standard 55 as only 65% of the occupants said the thermal condition was acceptable. The number and sizes of windows, building orientation, the presence of high-level windows and higher headroom significantly influenced the occupants' thermal comfort vote.

This research is valuable in estimating comfort temperature and identifying aspects that require attention in enhancing the capacity of NVH wards to effectively meet the thermal comfort needs of occupants in the hot-humid tropics of Southeast Nigeria and other regions that share similar climatic conditions.

To the best of the authors’ knowledge, this is the first study of this nature that provides valuable feedback for building design professionals on the performance of existing hospital buildings in meeting users' thermal comfort needs in the hot-dry season of the hot-humid tropics in Southeast Nigeria.

Snap fits are crucial in automotive applications for rapid assembly and disassembly of mating components, eliminating the need for fasteners. This study aims to focus on designing and analyzing serviceable cantilever fit snap connections used in automobile plastic components. Snap fits are classified into permanent and semi-permanent fittings, with permanent fittings having a snap clipping angle between 0° and 5° and semi-permanent fittings having a clipping angle between 15° and 45°. Polypropylene random copolymer is chosen for its exceptional fatigue resistance and elasticity.

The design process includes determining dimensions, computing assembly, disassembly pressures and creating three-dimensional computer-aided design models. Finite element analysis (FEA) is used to evaluate the snap-fit mechanism’s stress, deformation and general functionality in operational scenarios.

The study develops a modified snap-fit mechanism with decreased bending stress and enhanced mating force optimization. The maximum bending stress during assembly is 16.80 MPa, requiring a mating force of 7.58 N, while during disassembly, it is 37.3 MPa, requiring a mating force of 16.85 N. The optimized parameters significantly improve the performance and dependability of the snap-fit mechanism. The results emphasize the need of taking into account both the assembly and disassembly processes in snap-fit design, because the research demonstrates greater forces during disassembly. The approach developed integrates FEA and design for assembly (DFA) concepts to provide a solution for improving the efficiency and reliability of snap-fit connectors in automotive applications.

The research paper’s distinctiveness comes from the fact that it presents a thorough and realistic viewpoint on snap-fit design, emphasizes material selection, incorporates DFA principles and emphasizes the specific requirements of both assembly and disassembly operations. These discoveries may enhance the efficiency, reliability and sustainability of snap-fit connections in plastic automobile parts and beyond. In conclusion, the idea that disassembly needs to be done with a lot more force than installation in a snap-fit design can have a good effect on buzz, squeak and rattle and noise, vibration and harshness characteristics in automobiles.

The purpose of this study is to evaluate the 3D printability of a multimaterial, fully self-supporting auxetic structure. This will contribute to expanding the application of additive manufacturing (AM) to new products, such as automotive suspensions.

An experimental approach for sample fabrication on a multiextruder 3D printer and characterization by compression testing was conducted along with numerical simulations, which were used to support the design of different auxetic configurations for the jounce bumper.

The effect of stacking different auxetic cell modules was discussed, and the findings demonstrated that a one-piece printed structure has a better performance than one composed of multiple single modules stacked on top of each other.

The quality of the 3D printing process affected the performance of the final components and reproducibility of the results. Therefore, researchers are encouraged to further study component fabrication optimization to achieve a more reliable process.

This research work can help improve the manufacturing and functionality of a critical element of automotive suspension systems, such as the jounce bumper, which can efficiently reduce noise, vibration and harshness by absorbing impact energy.

In previous research, auxetic structures for the application of jounce bumpers have already been suggested. However, to the best of the authors’ knowledge, in this work, an AM approach was used for the first time to fabricate multimaterial auxetic structures, not only by co-printing a flexible thermoplastic polymer with a stiffer one but also by continuously extruding multilevel structures of auxetic cell modules.

Dimensional quality of sheet metal assemblies is an important factor for the final product. However, the part tolerance is not easily controlled because of the spring back deformation during the stamping process. Selective assembly is a means to decrease assembly tolerance of the assembly from low-precision components. Therefore, the purpose of this paper is to propose a fully efficient method of selective assembly optimization based on an improved genetic algorithm for optimization toolbox (IGAOT) in MATLAB.

The method of influence coefficient is first applied to calculate the assembly variation of sheet metal components since the traditional rigid assembly variation model cannot be used due to welding deformation. Afterwards, the IGAOT is proposed to generate optimal selective groups, which consists of advantages of genetic algorithm for optimization toolbox (GAOT) and simulated annealing.

The cases of two simple planes and the tail lamp bracket assembly are used to illustrate the flowchart of optimizing combinations of selective groups. These cases prove that the proposed IGAOT has better precision than that of GAOT with the same parameters for selective assembly.

The research objective of this paper is to evaluate the changes from rigid bodies to sheet metal parts which are very complex for selective assembly. The method of IGAOT was proposed to the selected groups which has better precision than that of current optimization algorithms.