OptiFlow is investing in the development of a data collection system to track labor hours. However, in order to enhance their understanding of labor costs and develop real-time tracking
capabilities they would need help with data aggregation, preparation and visualization.
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The scope of this phase of the VOC SMM Analytical Profiling, was the creation and validation of the profiling model. This report identifies a repeatable approach and opportunities for a widespread application of such analyses.
Trenton Corp. is a small manufacturer (SMM) that produces anticorrosion products for use in the pipeline industry custom parts and assemblies. Trenton required assistance in developing a dashboard app for demand forecasting which could then be used to optimize their production schedules.
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The Lightweight Automotive Materials Program, or LAMP, is a partnership between NCMS and a host of technology innovators across the country. Funded in part by the U.S .Department of Energy, LAMP is a suite of R&D programs that will drive innovation in advanced lightweight materials development for the automotive industry. New or improved lightweight materials such as composites or titanium alloys have great potential to drastically improve vehicle fuel economy without sacrificing automotive safety.
||The LAMP objective is to establish the successful development and validation of cost-effective, high-strength materials and technologies that could significantly reduce vehicle weight without compromising cost, performance, safety, or recyclability. The target is to have the automotive industry adopt technology, inserting lightweight materials into production vehicles. The program focuses on improved manufacturability, lowered costs for the deployment of new lightweight materials, and introducing sustainability considerations into the design process.
||NCMS was awarded management of this program by the Department of Energy, Office of Energy Efficiency and Renewable Energy and by the National Energy Technology Laboratory due to its expertise in collaborative R&D program management and industry capability.
Several R&D projects are currently operating under LAMP. All are digital manufacturing initiatives, making use of tools such as high performance computing’s Modeling & Simulation (M&S) capability to support the selection and optimization of lightweight materials for their products during the product design phase. The tools developed in this NCMS program allow companies of all sizes to access and apply cutting edge digital manufacturing techniques in an affordable, revolutionary way.
Thermal Processing of Aluminum Alloys
Partners: Deformation Control Technology, Inc., General Motors Powertrain, and Case Western Reserve University
Background: The primary goal of this project was to develop new predictive software capability that can be used to address the issue of residual stresses and distortions of aluminum alloy components. This project will utilize materials processing, advanced characterization techniques and process simulation and modeling (S&M) to develop and design methodologies for reducing residual stresses and minimizing/eliminating distortions that occur during thermal processes; and to predict the final microstructure and anticipated strength for aluminum alloys. View Executive Report
Ultra-Lightweight Sandwich Composite Constructions for Autobody Applications
Partners: Wayne State University, MAG-IAS, LLC, and Nimbis Services
Project Background: This project modeled revolutionary ultra-lightweight sandwich composite structure technologies for significant weight reduction in platforms such as electric and hybrid vehicles. These structures achieve strength targets and accomplish weight reductions far beyond those feasible using present stamped steel/aluminum welded car body construction methods. View Executive Report
Automotive Component Manufacture in Titanium
Partners: CU ICAR, BMW MC, OKUMA America Corporation, Dassault Systemes Simulia Corp., and SimaFore, LLC.
Project Background: The purpose of this project was to explore the use of titanium as an automotive component material in order to reduce vehicle weight and energy consumption. The benefits are identification of validated titanium grades for automotive use, and creation of a template for identifying and justifying automotive component design in titanium, thereby cost-effectively reducing vehicle weight, and subsequently reducing energy consumption. View Executive Report
Low Cost Resin System for Lightweight PMC Components
Partners: GE Global Research, Plasan Carbon Composite, SimaFore LLC, and Dassault Systemes Simulia Corp.
Project Background: The introduction of polymer matrix composite (PMC) components is highly desirable due to PMC offering excellent weight and property benefits without sacrificing strength.This project was initiated to find a solution to reduce process cycle time and other related costs of PMC components. View Executive Report
Lightweight Material Usage Optimization for Multi-Mode Safety, NVH, & Durability Performance Using HPC
Partners: L&L Products, Altair Engineering, R Systems NA, Inc., and Nimbis Services
Project Background: The project’s goal was to develop new methods to allow automotive Tier 1 and 2 suppliers to effectively access modeling and simulation tools to assist them in developing new lightweight component designs that are capable of meeting OEM performance and safety requirements at a reasonable cost. View Executive Report
Ultra-Fine Grained/Nano Aluminum Material for Connecting Rods
Partners:MAHLE Industries, Incorporated, Engineered Performance Materials (EPM), Department of Energy (DOE)
Project Background: A high strength yet lightweight connecting rod allows for complete powertrain optimization by integrating sophisticated components that contribute to better fuel economy and reduced exhaust emissions. The target of this project was to develop and validate a cost-effective, high-strength, ultra-fine grained/nano-aluminum material for connecting rods and focus on processing steps for con-rod volume production and advanced fracture split technology. View Executive Report
Simplified CFD Analysis of Tow Vehicle & Trailer Bodies
CFD Analysis is commonly used by the major automotive and truck manufacturers, suppliers in smaller niche markets such as trailers and after-market devices don’t. The low level of usage is due to a combination of lack of expertise as well as a scarcity of in-house computational infrastructure needed. Typically, high barriers to entry exist in undertaking any aerodynamic development program, either in designing and building scale models, utilizing full-scale wind tunnels, or starting a CFD program. View Executive Report
Lightweight Fiber Composite Structures with Embedded Communications
This initiative targeted the materials development activities for production and characterization studies of lab-scale composite panels that include embedded fiber optics as a “proof of concept.” The proposed composite structures investigated were continuous-fiber, thermoset pre-preg, multi-laminate fabrications made from unidirectional or woven-fabric glass and hybrid glass/carbon fiber combinations. View Executive Report
Ultra-Lightweight Sandwich Composition: A Predictive Simulation Approach
Studies have shown that a reduction in vehicle weight by only 25% would save the US 750,000 barrels of oil each day reducing domestic fuel consumption by 13% per year and prevent 101 million tons of CO2 from being emitted into our atmosphere. The original goal was a 40% reduction vehicle weight, but further investigations showed that a 60% reduction in vehicle weight was possible with the advent of Ultra-lightweight Composite Constructions. View Executive Report