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The basic raw material used in manufacture of fiberboard is cellulose fiber which is obtained from trees and/or reclaimed (waste) paper. Cellulose fibers are obtained from trees by the “pulping” operation which involves debarking, chipping, and cooking with chemicals to separate the cellulose from other wood components. Cellulose fibers are obtained from reclaimed paper by mechanical repulping in water. Cellulose fibers, once pulped, go through the stock preparation phase where they are cleaned and sent through a refining stage. The conditioned fibers are sent to the paper machine in a water slurry for conversion to paperboard. The paper machine is a large controlled water removal system having four distinctive manufacturing steps: mat formation, pressing, drying, and calendering. The paperboard from the paper machine is sheeted or wound in rolls. It may be sold in this condition or undergo further processing such as laminating or coating before it is sent to the automotive fabricator.

From efforts to utilize waste wood fiber more fully from the lumber industry has come a substrate now widely used for interior trim parts in automobiles. Hardboard results from the separation of wood fibers, formation of the fiber into a mat, and subsequent consolidation with heated presses. Humidification of the pressed board followed by trimming and edging complete the manufacturing process of hardboard. Environmental improvement is a continuous program in the hardboard industry and has resulted in the development of a number of salable byproducts from mill residue.

The paper describes many of the methods of fabricating and finishing fiberboard parts for the automotive industry. Fabricating methods include die-cutting, crease bending, forming, fastening, and adhesive bonding. Finishing methods discussed are paint roll coating, spray painting, printing, and embossing. The equipment and tooling required are also described.

A Procedure for Optimizing Elastomeric Mountings (POEM) is described which provides a systematic investigation of vehicle ride performance as a function of both the spring rate and damping of a selected mounting. POEM assumes the mounting design and its placement on the vehicle have been established. Then nine mounts satisfying a three-level factorial experiment in spring rate and damping are evaluated. Evaluations can be subjective or objective and can employ laboratory simulators or road tests. Dynamic properties of the mounts are measured at simulated on-car conditions. Computer, step-wise regressions of the data are performed to define any performance/property relationships. Final regression equations are contourized by computer, displaying performance versus dynamic properties. Results enable easy and quantitative optimization of dynamic properties. Examples of POEM analyses are given.

This paper presents a brief description of each of the main types of fiberboard used in the automobile. It covers typical applications for fiberboards with detailed information only on the interior trim parts. Applications where fiberboard and plastics compete are discussed. Also included are the advantages and disadvantages of fiberboards. The effect of humidity changes on fiberboard resulting in dimensional changes and warping tendencies in the fiberboard are explained with illustrations which emphasis the need for proper fastening of fiberboard and a method of measuring war-page. Test methods, performance testing, and possible future applications are discussed.

This paper describes a constant natural frequency spherical elastomeric spring element. The concept of constant natural frequency and its advantage in providing consistent ride quality with varying vehicle weight is reviewed. Performance data on the spherical spring for both laboratory and field tests is presented and evaluated.

This paper discusses the sources of noise pollution in the civilized human environment and reviews the numerous criteria which have evolved for their assessment and description. It is stressed that criteria should be established in simple basic units and dBA values are recommended. By far the most common single source of annoyance is that of road transportation noise and this aspect has been covered in specific detail. Methods of predicting vehicle noise from the engine design and operating parameters are shown and some measures for noise reduction are discussed.

This paper describes the development of a process that will mold a urethane resin in the form of a laminate. The urethane resin is a most unusual material: it can be formulated to produce thermosetting foam of almost any density, and the formulation can also be made to produce either a flexible or rigid foam. It has excellent adhesive properties, which we have used to make the laminate. The process produces a laminate of two skins, which are combined with a film of urethane resin in its liquid form. This combination, when placed in a heated mold, causes the resin to expand until both skins reach the confine of the mold. This then cures to the shape of the mold and the texture of its surface, making it possible to mold sculptured and formed shapes or panels, which can be used for interior trim for automobiles.

An automotive tune-up clinic for the purpose of reducing undesirable exhaust emissions was held March 14, 1970, as part of an environmental teach-in. The event was sponsored by the student branch of SAE at the University of Michigan. The results of this event clearly show that improper automotive maintenance can be a major factor in atmospheric pollution. It was found that idle hydrocarbon emissions were reduced by an average of 55% with a tune-up in which the idle mixture ratio and speed were adjusted for minimum carbon monoxide emissions. Our conclusion is that the individual motorist must begin to develop an attitude of responsibility toward the maintenance of his automobile to ensure low emissions.

Maintenance programs indicate that exhaust emission controlled cars with hydrocarbon (HC) emissions above 400 ppm or carbon monoxide (CO) above 2.25% will have emissions reduced by proper maintenance. Distribution curves of recent surveillance data show that one-third of the 1966-1969 cars have emissions above these assured reduction levels. Calculations show that maintenance based on reducing high emitters of HC and CO should reduce total HC by 19%, CO by 30%, but increase oxides of nitrogen (NOx) by 9%. Further calculations show that maintenance based on reducing high emitters of HC, CO, and NOx should reduce total HC by 20%, CO by 25%, and NOx by 6%. The inclusion of NOx testing along with HC and CO in the idle inspection test method is nearly as effective in identifying high emitters of HC, CO, and NOx as the longer seven-mode test method.

Lap-shoulder belts, although infrequently used by vehicle occupants, are demonstrating a remarkably high reduction of injury in collisions where they were used. A search was made for all collisions in the GM files where at least one occupant was wearing the lap-shoulder belt combination restraint. Of the 160 cases found for this study, 60% of the vehicles had heavy damage of the type often associated with occupant injury: however, 99% of the lap-shoulder belt users either had no-injury or only minor injury. The only two fatalities found in the study involved accidents occurring under unusual circumstances. This paper describes 18 of the most severe damage and/or injury cases by means of photographs and collision descriptions. Some grouping of body injuries is also listed. These data illustrate that the use of different occupant restraint configurations (unrestrained, lap belt, and lap-shoulder belt) affect the severity of injuries to various body areas.

Increased emphasis on high speed vehicle rolling smoothness may be attributed to the growing network of Interstate highways. Tire/wheel vibration inputs which disturb highway rolling smoothness are measurable in terms of force variation of the tires, and runout variation of the wheels. New techniques are available to screen and correct for excessive tire and wheel variations. These techniques apply to the tires or wheels individually; or to the tire/wheel assembly. Tire/wheel assembly screening and tire honing correction is a unique method which has been implemented at Cadillac Motor Car Division. This improvement was adopted to enhance the luxury ride of the Fleetwood Eldorado vehicle during the 1970 model run.

This paper introduces the development of a new idea in traction prime movers, to be known as the Differential Compound Engine. The DCE contains in addition to the compressor, an exhaust driven turbine geared into the output shaft, which leads to improved power and efficiency. It also enables the engine to operate at unchanged speed and power, regardless of output shaft speed. This concept was designed to provide an integrated engine transmission of high output and with stepless single pedal control.

Tire uniformity grading machines have become an indispensable tool used by all original equipment tire producers for screening tires to acceptable levels for automobile manufacturers. However,so many machines and procedures have been used by tire manufacturers in the past that correlating tire uniformity levels from various sources and determining the effect of variations on the ride quality of passenger vehicles have been been difficult. Logical follow-up ride evaluations of vehicles have been conducted in comprehensive programs to further investigate the correlation of the various nonuniformity parameters and their individual and compound effects upon ride quality. Investigations are also being conducted to determine correlations of high-speed tire uniformity to low speed and vehicle ride. These and other efforts are directed toward an eventual development of a mathematical description of tire-vehicle behavior.

A new process has been developed for the manufacture of passenger car wheels to reduce the effect of the wheel on vehicle shake. The process is now in production and the resulting improvements in uniformity are detailed here.

This paper describes a program conducted on a 1971 Continental Mark III to derive profiles of engine compartment temperatures for analysis of severe environment conditions to which primary wire would be subjected. Also covered are solutions to provide primary wire material selection, routing, and protective devices for specific problem areas.

Machining techniques that reduce the amplitude of low-speed radial uniformity measurements and their effects on smooth-road vehicle vibrations were investigated. The methods ranged from simple concentric and eccentric truing suited for service work to a servo-controlled tire-wheel assembly measuring and corrective machine installed at an auto assembly plant. These methods produce significant reduction of the measured low-speed radial uniformity. Corresponding vehicle evaluation showed significant reduction of smooth-road shake-a 1 per wheel revolution vibration-but little change of higher order vibrations. The simplicity of eccentric truing, combined with its predictable reduction of shake, provides a service fix for smooth-road shake.

Several new features have been developed for light-duty cranking motors which reduce costs, improve manufacturing productivity, and improve reliability. These include a face type commutator which combines the function of current collection and connection to the armature windings, fully insulated plastic molded brushgear, a single field coil to replace the four coils of a conventional four pole field system, a five roller extruded roller clutch, and a solenoid with a two part sintered iron body.

Irradiation of polymers by electrons or gamma rays effects cross-linking and increases high-temperature capabilities. Cross-linking does not, however, increase resistance to chemical degradation of a polymer. Changes in formulation can inhibit high-temperature oxidative degradation. The results of tests on the high-temperature stability of a series of polyvinylchloride formulations is presented, showing that changes in formulation accompanied by radiation cross-linking improve the ability of an insulation to function in high-temperature environments.

This paper introduces a design method, suitable for use on a computer, which predicts the performance of a cranking motor from the geometry of the machine and the material characteristics. The versatility of this method is illustrated by describing its use to produce optimum motor designs, to determine the effect of manufacturing and material specification tolerances, and to investigate marginal variations of component parameters in cranking systems.