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The resin, part design, moulding process, preplate process and electroplate structure, have an interrelationship that determine part durability of electroplated plastics in the exterior automotive environments. Explanation of these interrelationships is given to assist in proper application of electroplated plastics for this use.

With the onset of newer plastics for the weight reduction program in automobiles, the finishing process becomes more complex. The organic coating must adhere to the substrate without destroying the desirable properties of the plastic. Factors, such as, cure temperature of the coating must be less than the heat distortion temperature of the plastic, crazing,embrittlement and adhesion must be considered. With the new EPA regulations, the desired coatings will tend to be high solids or water.

Some special features of the turbocharged gasoline engine are discussed in comparison with the turbocharged Diesel engine. The influence of compression-ratio, temperature of the charge air, air/fuel-ratio and ignition-timing on combustion, fuel economy and power output is shown. A combined compressor- and engine air-flow-map of the turbocharged gasoline-engine is developed and the features of a compressor matching the special requirements of a TC gasoline engine are deduced from this map. The position of the throttle in the intake-system, which has great influence on governing-qualities and load-change-responce of a turbocharged gasoline engine is discussed and the problems and disadvantages of a waste-gate governed turbocharger especially in connection with a gasoline engine are figured out.

In an effort to make the diesel engine vehicle as convenient to drive, as is a spark ignitioned vehicle, Oldsmobile designed a fast warm-up glow plug control system. The new system attains glow plug operating temperature in about 6.5 seconds, compared to 60 seconds for the system it replaces. This paper details the system design which is based on feedback control of a model of the glow plugs.

An economical and proven new process for manufacturing large automotive parts in high volume is exciting Detroit. The Bailey Division of USM Corporation, an Emhart Subsidiary, has demonstrated commercially that large automotive parts can be injection molded using glass-fiber reinforced thermoset polyester polymers. More particularly, the process lends itself to the manufacture of parts with Class A surfaces without sink marks from ribs and bosses showing. There are advantages for the design engineer, the parts manufacturer and the assembly plant. Dimensionally stable, light weight Class A surface parts that can be painted on the body assembly paint line can now be made using readily available raw materials.

Emphasis is placed on formability and weldability of higher-strength cold-rolled AK rephosphorized steel body panels. Production forming trials were conducted to determine the feasibility of producing higher-strength cold-rolled AK rephosphorized body panels with production low-strength tooling and if press modifications were necessary to produce acceptable higher-strength parts. In addition, laboratory spot-welding characteristics of higher-strength AK rephosphorized steels were examined to compare weldability to weldability data generated for lower-strength AK steel. Case studies described indicate that higher-strength AK rephosphorized steels can be substituted for lower-strength steels with minimal sacrifice in formability and spot weldability.

Motorcyclists' visual behavior was examined and compared with that of drivers' by an eye-marker method. The background of this research is as follows. From the accident statistics of Osaka prefecture, characteristics of motorcycle accidents and those of ordinary passenger cars were analysed and compared and it was revealed that collisions on turning right (in the United States, collisions on turning left) are most remarkable. In this case, collisions between motorcycles running straight ahead and automobiles turning right are most typical. The automobile drivers expected that the motorcyclists would give way. But, almost without braking, the motorcycles crashed into the automobiles turning right. Here, one of the problems is motorcyclists' unawareness of existence of automobiles turning right. We focused upon this. Three males participated as subjects in these experiments with an eye-marker. Independent variables were type of vehicel and speed.

Analytical results describing moped lateral-directional response properties are presented. Design characteristics of four example mopeds related to directional handling are presented and compared with sample motorcycle properties. Resultant moped dynamics are quantified and compared. Using a nominal moped example, the sensitivity of the vehicle dynamics to operational and design variables, such as speed, loading and tire properties, is shown. Implications for rider/moped handling are reviewed.

Dynamic properties of motorcycles are, to a great extent, governed by motorcycle tire properties. In this study, the influences of various factors such as, internal pressure, load, tire make, width, etc., on tire dynamic properties are clarified through the experiments carried out on laboratory testing machines. It was found that tire dynamic properties are significantly influenced by these factors, and the experiments yielded some beneficial data for the improvement of motorcycle dynamic properties as well as tire dynamic properties.

A new system has been proposed for the recuperation of waste heat energy in steel mill soaking pit furnaces. The new system offers efficiency increases from 130% to 360% above conventional recuperation systems. This is possible through the combination of a low leakage, compact ceramic recuperator and a highly efficient, low cost metallic unit. Included in the advanced design is a newly developed ultra high temperature preheated air multi-fuel burner and an improved system for air/fuel ratio and temperature control.

This paper presents the results of a program investigating the potential of unconventional motorcycle configurations for improved accident avoidance performance. Stability and obstacle avoidance characteristics were investigated analytically using mathematical models of both the uncontrolled and rider-controlled motorcycle. An analysis was also performed of the sensitivity of the optimum front-rear brake proportioning to road surface conditions and lateral acceleration. The results indicate that a low center of gravity, long wheelbase configuration has advantages in the moderate-to-high speed regime in terms of the margin of safety in performing an obstacle avoidance maneuver, and rider skill level required in braking. These advantages accrue at the expense of low speed maneuverability and controllability, and weight and overall complexity of the machine.

Procedures, materials and results are reported for the materials selection process performed in conjunction with efforts to develop, test, and evaluate High Temperature Range Recuperator designs for an industrial glass furnace. Potential materials were evaluated on material properties, fabrication capability, and relative performance in the flue environment of a day tank glass furnace. Polycrystalline alumina (Vistal), reaction sintered silicon carbide (KT and NC 430), chemically vapor deposited silicon carbide (CVD) and Sintered Alpha silicon carbide proved most satisfactory in the material temperature range of 2300°F to 2800°F. Relatively pure alumina (AD 998 and AD 94), mullite and cordierite were most satisfactory in the material temperature range of 1700°F to 2300°F. Thermo-mechanical stress for each material was calculated under expected operating conditions for the optimized design.

The minimum practicable levels of diesel combustion noise and mechanical noise, which might be achieved by control at source, are estimated for direct injection engines of 1 litre per cylinder capacity, as used in trucks and tractors of European manufacture. These levels are compared with targets derived from proposals for more stringent noise legislation for such vehicles. The targets might be achieved by a combination of control of combustion and mechanical noise at source and reduction of the engine structure response to these sources.

This paper presents the background and development of the reradiant concept for the radiant stack type recuperator. It also presents the results of an ongoing demonstration program of this concept. IGT developed the concept of the reradiant recuperator which increases the effectiveness of conventional radiant recuperators by 5 - 15% depending on unit size. This paper discusses the mathematical model developed by IGT which optimized the application of a metal leaf type insert within the hot gases passing through a conventional radiant recuperator. The metal leaf insert is designed to maximize radiation to the annulus wall. This increase in heat transfer is not due to increased convective heat exchange, as when a “core buster” insert is used, but strictly due to radiation from the leaf insert. Data on a prototype unit operated by IGT to verify the mathematical model will be presented and explained.

From measured overall I. C. engine noise levels and corresponding measured combustion (cylinder pressure) levels the paper illustrates the major influence that the combustion system has on the engine radiated noise. The basic ‘noisiness’ of normally aspirated and turbocharged two- and four-stroke D.I. systems, normally aspirated I.D.I. (swirl chamber) diesel and gasoline systems are compared by a normalised frequency spectrum method. Using a simple linear model for calculating the direct combustion noise level of each combustion system the relative levels of noise are calculated. The results show good agreement with measured noise levels for normally aspirated two-stroke and four-stroke D.I. engines and indicate that combustion noise is low in turbocharged diesels, I.D.I. diesels and particularly gasoline engines.

The different impacts on Diesel knock were investigated. The main parameters were fuel quality, ambient and engine temperature, quantity of fuel injected, compression ratio, and injection timing. One of the most reasonable methods to decrease cold knock is exhaust gas recirculation (EGR). The mechanism of the EGR effect was explained and the limitations of Diesel application of EGR was estimated.

An acceleration mode in measuring vehicle pass-by noise was simulated on an engine test bed in an anechoic room. The accelerated running noise of various types of diesel engines was measured and compared with the steady running noise. The measurement results show that naturally aspirated DI engines become noisier at acceleration, while IDI engines change only slightly. In turbocharged DI engines, the response lag of the turbo charger causes an especially big noise level difference immediately after acceleration start. This paper deals also with the mechanisms of higher level of accelerated running noise in DI engines.

Analytical and experimental studies of the transient and oscillatory behavior of motorcycles are reported. Three example vehicles were used. The effects of adding load, changing operating conditions, and modifying the vehicle configuration are shown. The phenomenon known as cornering weave is illustrated and interpreted.

Previously indirect test methods were used to investigate Diesel engine combustion noise. Now digital signal analysis gives the possibility of determining it and its narrow band spectra directly. Such a method for direct evaluation of the combustion noise is described and the possibilities offered by it are shown. A single-cylinder direct-injection Diesel serves as a test engine. Steady-state as well as transient conditions of the engine are evaluated by the procedure.

A study of the lateral motion of motorcycles has been conducted through experiments on four large motorcycles of Japanese manufacture. A total of five experimental procedures were applied to straight or nearly straight running conditions and curve running conditions, and the results of each experiment were arranged by frequency response function in terms of input and output. Consideration is given to steer torque and rider lean angle as independent control inputs, and both single-input and dual-input analysis were conducted. This analysis revealed that the major determining input force is steer torque, and that the rider lean angle by itself has almost no influence on output.