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It is important to reduce the viscosity of automatic transmission fluid (ATF) in order to improve fuel economy. However, in general, low viscosity fluid can cause metal fatigue, wear, and seizure. It is necessary to increase the viscosity of the fluid at higher temperatures to maintain the durability of the automatic transmission (AT). The key point is the selection of the base oil and the viscosity index improver (VII) with both a high viscosity index (VI) and excellent shear stability. On the basis of this concept, a new generation high performance ATF named WS was developed. WS can achieve the highest level of fuel economy, while maintaining the durability of the AT.

This study examined the evolution of the surface topography of imperfections in response to painting. Critically-sized imperfections on industrially produced coated sheet steel surfaces were sampled, and carefully characterized. Changes in the surface topography were measured after painting simulations, and visibility after painting was assessed. Three-dimensional optical profilometry was demonstrated to be a powerful technique for assessing imperfection topographies and their evolution during painting; several imperfections that were completely invisible through human inspection after painting were still measurable by 3-D topography. Two primer surfacer systems were used, to compare a conventional liquid system with a high-build anti-chip powder system.

The oven shock test is an accelerated test which is often used to quantify the thermal durability of both coated and uncoated ceramic substrates. The test calls for heating the substrate for 30 minutes in an oven, which is preheated to specified temperature, and then cooling it in ambient environment for 30 minutes. Such a cycle induces axial and tangential stresses, during cooling, in the skin region whose magnitude depends on physical properties, oven temperature, radial temperature gradient and the aspect ratio of substrate. In addition, these stresses vary with time; their maximum values occur as soon as the substrate is taken out of the oven. This paper evaluates the severity of thermal stresses as function of above factors and estimates the probability and mode of failure during cooling using thermocouple data. Methods to reduce these stresses are discussed.

The effects of Injector deposits, Combustion Chamber Deposits (CCD), and Intake Valve Deposits (IVD) on exhaust emissions, fuel economy and vehicle performances have long been recognized in engine and fuel/detergent design. Because important elements of engine design such as injector position, exhaust gas recirculation (EGR) ratio, and air fuel ratio (AFR) differ from those of port fuel injection (PFI) engines, current existing test methods are not applicable. Therefore, the demand has been increasing year by year for specific evaluation methods for vehicles with direct injection spark ignition (DISI) engines which have spread rapidly worldwide. Oil and Auto Cooperation for International Standards (OACIS) of Japan selected the Mitsubishi DISI engine (4G93-1.8L) [1] and conducted engine bench tests to investigate the effects of deposits on operating conditions at 40km/h, 70km/h, 140km/h and WOT.

The biomechanical behavior of 4-point seat belt systems was investigated through MADYMO modeling, dummy tests and post mortem human subject tests. This study was conducted to assess the effect of 4-point seat belts on the risk of thoracic injury in frontal impacts, to evaluate the ability to prevent submarining under the lap belt using 4-point seat belts, and to examine whether 4-point belts may induce injuries not typically observed with 3-point seat belts. The performance of two types of 4-point seat belts was compared with that of a pretensioned, load-limited, 3-point seat belt. A 3-point belt with an extra shoulder belt that “crisscrossed” the chest (X4) appeared to add constraint to the torso and increased chest deflection and injury risk. Harness style shoulder belts (V4) loaded the body in a different biomechanical manner than 3-point and X4 belts.

Pedestrian accidents are one of the main causes of traffic fatalities and injuries worldwide. New pedestrian safety regulations are being proposed in Europe and Japan to improve the protection afforded to pedestrians. Numerical simulations with biofidelic pedestrian models can be used to efficiently assess the risk to injury in pedestrian-vehicle impacts and to optimize the pedestrian protection in the early stages of the vehicle design process at relatively low costs. The goal of this study was to develop and validate a scaleable mid-size male pedestrian model. The model parameters were derived from published data and a large range of impactor tests. The biofidelity of the model has been verified using a range of full pedestrian-vehicle impact tests with a large range in body sizes (16 male, 2 female, height 160-192 cm, weight 53.5-90 kg). The simulation results were objectively correlated to the experimental data. Overall, the model predicted the measured response well.

In this study, we first present a comparison between pelvis/upper leg injuries observed in real-world accidents as recorded in the database of the Medical University of Hanover, and the EEVC test results of corresponding cars as published by EuroNCAP. The fact that modern cars with rounded hood edges cause very few pelvis/upper leg injuries is discussed against the findings of the EEVC tests, where these cars do not perform significantly better than their older counterparts with sharper hood leading edges. This discrepancy could be due to the fact that the radius of the hood edge is not accounted for in the current version of the test protocol. In a second step, various impacts against several different simplified hood shapes were simulated using a detailed finite element model of a 50th percentile male pedestrian. The finite element model (THUMS) has been extensively validated against PMHS experiments in previous studies.

The European Enhanced Vehicle-Safety Committee (EEVC) has proposed a test procedure to assess the protection vehicles provide to the lower extremity of pedestrians during a collision. This procedure utilizes a legform impactor developed by the Transport Research Laboratory (TRL). However, the TRL Pedestrian Legform Impactor (TRL-PLI) is composed of rigid long bones (cannot simulate the bone flexibility of the human) and rather stiff knee joint. The differences lead to a lack of biofidelity of the TRL-PLI, i.e., unnaturally stiff responses are observed. This study develops a biofidelic Flexible Pedestrian Legform Impactor (Flex-PLI) that can simulate human bone flexibility and human knee joint stiffness properly. The Flex-PLI can also measure many of the injury parameters, long bone strains at multiple locations, knee ligament elongations, and the compression forces between the femoral condyles and tibial plateau in comparison to the TRL-PLI.

The objective of our study was to investigate the properties of the BioRID II and RID2 dummies regarding repeatability and reproducibility as well as their suitability to identify the protection potential of different car seats. For repeatability and reproducibility tests, three BioRID II and three RID 2 dummies at current build levels were seated on a rigid bench seat equipped with a head restraint, and mounted on a HyGe-type sled. The test velocity was prescribed by the proposed ISO-Pulse. For testing the interaction of the dummies with varying car seat geometries and mechanical properties and their ability to assess the protection potential of the seats, three seat types with passive and one seat with an active head restraint system from different car manufacturers were used. The seats were chosen due to their injury protection potential, indicated by accident field data and results of seat evaluation tests.

In this study, three dummies were evaluated on the component level and as a whole. Their responses were compared with available volunteer and embalmed Post Mortem Human Subject (PMHS) data obtained under similar test conditions to evaluate their biofidelity The volunteer and PMHS data, used as comparators in this study, were used previously to establish some of the biofidelity requirements of the Hybrid III. The BioRID II, the Hybrid III, and the RID2 were all subjected to rear impact HYGE sled tests with ΔVs of 17 and 28 km/hr to determine their biofidelity in these conditions. A static pull test, where a load was manually applied to the head of each dummy, was used to evaluate the static strength of their necks in flexion and extension. Finally, pendulum tests were conducted with the Hybrid III and RID2 to evaluate the dynamic characteristics of their necks in flexion and extension.

Six European laboratories have evaluated the biomechanical response of the new advanced frontal impact dummy THOR-alpha with respect to the European impact response requirements. The results indicated that for many of the body regions (e.g., shoulder, spine, thorax, femur/knee) the THOR-alpha response was close to the human response. In addition, the durability, repeatability and sensitivity for some dummy regions have been evaluated. Based on the tests performed, it was found that the THOR-alpha is not durable enough. The lack in robustness of the THOR-alpha caused a problem in completing the full test program and in evaluating the repeatability of the dummy. The results have demonstrated that the assessment of frontal impact protection can be greatly improved with a more advanced frontal impact dummy. Regarding biofidelity and injury assessment capabilities, the THOR-alpha is a good candidate however it needs to be brought up to standard in other areas.

This paper describes the design and development of a small female crash test dummy, results of biofidelity tests, and preliminary results from full-scale, 3-point belt and airbag type sled tests. The small female THOR was designed using the anthropometric data developed by Robbins for the 5th percentile female and biomechanical requirements derived from scaling the responses of the 50th percentile male. While many of the mechanical components of the NHTSA THOR 50th percentile male dummy were scaled according to the appropriate anthropometric data, a number of improved design features have been introduced in the new female THOR. These include; improved neck design, new designs for the head and neck skins: and new designs for the upper and lower abdomen. The lower leg, ankle and foot, known as THOR-FLx, were developed in an earlier effort and have been included as a standard part of the new female dummy.

Both frontal and side air bags can inflict injuries to the upper extremities in cases where the limb is close to the air bag module at the time of impact. Current dummy limbs show qualitatively correct kinematics under air bag loading, but they lack biofidelity in long bone bending and fracture. Thus, an effective research tool is needed to investigate the injury mechanisms involved in air bag loading and to judge the improvements of new air bag designs. The objective of this study is to create an efficient numerical model that exhibits both correct global kinematics as well as localized tissue deformation and initiation of fracture under various impact conditions. The development of the model includes the creation of a sufficiently accurate finite element mesh, the adaptation of material properties from literature into constitutive models and the definition of kinematic constraints at articular joint locations.

… The pattern of left- and right-side hip injuries to front-seat occupants involved in offset and angled frontal crashes suggests that hip posture (i.e., the orientation of the femur relative to the pelvis) affects the fracture/dislocation tolerance of the hip joint to forces transmitted along the femur during knee-to-knee-bolster loading in frontal impacts. To investigate this hypothesis, dynamic hip tolerance tests were conducted on the left and right hips of 22 unembalmed cadavers. In these tests, the knee was dynamically loaded in the direction of the long axis of the femur and the pelvis was fixed to minimize inertial effects. Thirty-five successful hip tolerance tests were conducted. Twenty-five of these tests were performed with the hip oriented in a typical posture for a seated driver, or neutral posture, to provide a baseline measure of hip tolerance. The effects of hip posture on hip tolerance were quantified using a paired-comparison experimental design.

While the number of deaths from vehicle accidents is declining, probably because of mandatory seat belt laws and air bags, a high frequency of lower extremity injuries from frontal crashes still occurs. For the years 1979-1995 the National Accident Sampling System (NASS) indicates that knee injuries (AIS 1-4) occur in approximately 10% of cases. Patella and femur fractures are the most frequent knee injuries. Current literature suggests that knee fractures occur in seated cadavers for knee impact forces of 7.3 to 21.0 kN. Experimental data shown in a study by Melvin et al. (1975) further suggests that fracture tolerance of the knee may be reduced for an impact directed obliquely to the axis of the femur. The current study hypothesized that the patella is more vulnerable to fracture from an oblique versus an axial impact (directed along the femoral axis), and that the fracture pattern would vary with impact direction.

Unlike other modes of loading, the tolerance of the human neck in tension depends heavily on the load bearing capabilities of the muscles of the neck. Because of limitations in animal models, human cadaver, and volunteer studies, computational modeling of the cervical spine is the best way to understand the influence of muscle on whole neck tolerance to tension. Muscle forces are a function of the muscle's geometry, constitutive properties, and state of activation. To generate biofidelic responses for muscle, we obtained accurate three-dimensional muscle geometry for 23 pairs of cervical muscles from a combination of human cadaver dissection and 50th percentile male human volunteer magnetic resonance imaging and incorporated those muscles into a computational model of the ligamentous spine that has been previously validated against human cadaver studies.

The SIMon (Simulated Injury Monitor) software package is being developed to advance the interpretation of injury mechanisms based on kinematic and kinetic data measured in the advanced anthropomorphic test dummy (AATD) and applying the measured dummy response to the human mathematical models imbedded in SIMon. The human finite element head model (FEHM) within the SIMon environment is presented in this paper. Three-dimensional head kinematic data in the form of either a nine accelerometer array or three linear CG head accelerations combined with three angular velocities serves as an input to the model. Three injury metrics are calculated: Cumulative strain damage measure (CSDM) – a correlate for diffuse axonal injury (DAI); Dilatational damage measure (DDM) – to estimate the potential for contusions; and Relative motion damage measure (RMDM) – a correlate for acute subdural hematoma (ASDH).

Traumatic brain injury (TBI) is caused by brain deformations resulting in the pathophysiological activation of cellular cascades which produce delayed cell damage and death. Understanding the consequences of mechanical injuries on living brain tissue continues to be a significant challenge. We have developed a reproducible tissue culture model of TBI which employs organotypic brain slice cultures to study the relationship between mechanical stimuli and the resultant biological response of living brain tissue. The device allows for the independent control of tissue strain (up to 100%) and strain rate (up to 150 s-1) so that tolerance criteria at the tissue level can be developed for the interpretation of computational simulations. The application of texture correlation image analysis algorithms to high speed video of the dynamic deformation allows for the direct calculation of substrate strain and strain rate which was found to be equi-biaxial and independent of radial position.

This paper presents the results of dynamic material tests and computational modelling that elucidate the effects of regional rib mechanical properties on thoracic fracture patterns. First, a total of 80 experiments were performed using small cortical bone samples from 23 separate locations on the rib cages of four cadavers (2 male, 2 female). Each specimen was subjected to dynamic three-point bending resulting in an average strain rate of 5 ± 1.5 strain/s. Test coupon modelling was used to verify the test setup. Regional variation was defined by location as anterior, lateral, or posterior as well as by rib level 1 through 12. The specimen stiffness and ultimate stress and strain were analyzed by location and rib level. Second, these material properties were incorporated into a human body computational model. The rib cage was partitioned into anterior, lateral, and posterior segments and the material properties were varied by location using an elastic-plastic material model.

Linear shear properties of human and bovine brain tissue were determined from transient stress-relaxation experiments and their material functions were compared. Quasi-linear viscoelastic theory was then utilized to determine material constants for bovine brain tissue subjected to large deformations. The range of applicability for linear and quasi-linear constitutive models of brain tissue was determined. A nonlinear Green-Rivlin constitutive model was subsequently applied to characterize temporal nonlinearity of bovine brain tissue in shear. Overall, 10 brain specimens from 5 fresh human cadavers and 156 brain specimens from 26 fresh bovine cadaver brains were used to quantify and compare shear brain responses under various loading conditions. The assumptions of homogeneity, isotropy, and incompressibility of brain material were made in order to reduce the required number of experiments.