An investigation of industry-wide emarketplaces in the Australian automotive industry

Covisint, a global, industry-wide eMarketplace in the automotive industry, has received considerable literature attention since its inception some four years ago. Despite predictions that it would transform the industry, it has made little impact on automotive markets in countries where its progress has been documented. A lack of literature concerning Covisint use in Australia makes understanding the Australian situation quite difficult.
This study addresses this deficiency by investigating several Australian automotive organizations and their application of Covisint in conducting supply chain trading with their business partners. The research found that the application of Covisint is significantly less than its potential.

Sheet forming simulation for AHSS components in the automotive industry

The trend in the automotive industry towards new advanced high strength steels (AHSS), combined with the ongoing reduction in program lead times have increased the need to get tool designs right, first time. Despite the fact that the technology used by sheet metal stamping companies to design and manufacture tooling is advancing steadily, finding optimal process parameters and tool geometries remains a challenge. Consequently, there has been a transition from designs based largely on trial and error techniques and the experience of the stamping engineer, to the increased use of virtual manufacturing and finite element (FE) simulation predictions as an indispensable tool in the design process. This work investigates the accuracy of FE techniques in predicting the forming behavior of AHSS grades, such as TRIP and dual phase, as compared to more commonly used conventional steel grades. Three different methods of simulation, one-step, implicit and explicit techniques, were used to model the forming process for an automotive part. Results were correlated with experimental strain and thickness measurements of manufactured components from the production line.

Impact of electronic data interchange in the Australian automotive industry

Information technology continues to play an increasingly significant role in the development of firms competing in the vast array of markets from those classified as global markets, such as the automotive industry, to the smaller nationally-based markets such as retailing. An objective of electronic commerce is to assist organisations to remain competitive and gain entry to markets which were previously unattainable. This study focuses on the organisational impact of one form of electronic commerce (electronic data interchange) on the component sector of the Australian automotive industry and examines the extent to which trading partner relationships have been affected. The research investigates the extent to which the integration of electronic data interchange (EDI) with an organisation’s internal application system may facilitate specific net benefits. The automotive industry became the first Australian industry to cooperatively adopt EDI. Research to date has not adequately examined the organisational impact of the nature and extent of net benefits gained from EDI adoption. To achieve the objective of assessing EDI net benefits, a conceptual model was developed. The model proposed that the level of EDI net benefits expected is influenced by the size of the organisation and the concentration of trade achieved within the industry via intervening links through (a) the level of senior management commitment and (b) the extent of system integration. Nine empirically testable research propositions are derived from the model, each testing the relationship between model constructs. Data was collected from 114 component suppliers to Ford Australia in 1992 and 1994 using a repeated cross-sectional longitudinal design. Structural equation modelling using partial least squares was adopted in the analysis of the data. A pure longitudinal model together with 12 case studies of selected component manufacturers supplemented the research design. The results of the research showed that the proposed conceptual model is a good description of the data. In particular, net benefits obtained from EDI adoption are directly determined by the size of the organisation, and the extent to which firms integrate EDI into their internal application systems. The level of net benefits is only indirectly influenced by the level of senior management commitment to the EDI project through (a) management commitment’s direct effect on integration, and (b) the direct effect the volume of trade a supplier achieves with the automotive industry on senior management commitment and system integration. The major benefits organisations experienced from EDI were enhanced productivity, clerical staff savings, improved data accuracy, enhanced customer service and reduced administration costs. The research showed that few suppliers gained inventory savings from EDI, a frequently claimed benefit from EDI adoption. Evidence of small improvements in product quality emerged from the results. In summary, this research attempts to make two primary contributions to knowledge, first in providing a method by which net benefits from electronic commerce can be measured within an industry adopting electronic trading, and second, by providing organisations with the knowledge of the specific net benefits organisations could expect from EDI adoption, together with the four major factors affecting these benefits. The research concludes with possible directions for future research, in particular an assessment of the impact of incorporating financial EDI into electronic trading.

Effect of bake-hardening on the structure-property relationship of multiphase steels for the automotive industry

The effect of a bake-hardening (BH) treatment on the microstructure and mechanical properties has been studied in C-Mn-Si TRansformation Induced Plasticity (TRIP) and Dual Phase (DP) steels after: (i) thermomechanical processing (TMP) and (ii) intercritical annealing (IA). The steels were characterized using X-ray diffraction, transmission electron microscopy (TEM) and three-dimensional atom probe tomography (APT). All steels showed high BH response. however, the DP and trip steels after IA/BH showed the appearance of upper and lower yield points, while the stress-strain behavior of the trip steel after TMP/BH was still continuous. This was due to the higher volume fraction of bainite and more stable retained austenite in the TMP/BH steel, the formation of plastic deformation zones with high dislocation density around the "as-quenched” martensite and “TRIP” martensite in the IA/BH DP steel and IA/BH TRIP steel, respectively.

Design of experiments and springback prediction for AHSS automotive components with complex geometry

With the drive towards implementing Advanced High Strength Steels (AHSS) in the automotive industry; stamping engineers need to quickly answer questions about forming these strong materials into elaborate shapes.
Commercially available codes have been successfully used to accurately predict formability, thickness and strains in complex parts. However, springback and twisting are still challenging subjects in numerical simulations of AHSS components. Design of Experiments (DOE) has been used in this paper to study the sensitivity of the implicit and explicit numerical results with respect to certain arrays ofuser input parameters in the forming ofan AHSS component. Numerical results were compared to experimental measurements of the parts stamped in an industrial production line. The forming predictions of the implicit and explicit codes were in good agreement with the experimental measurements for the conventional steel grade, while lower accuracies were observed for the springback predictions. The forming
predictions of the complex component with an AHSS material were also in good correlation with the respective experimental measurements. However, much lower accuracies were observed in its springback predictions. The number of integration points through the thickness and tool offset were found to be of significant importance, while coefficient of friction and Young's modulus (modeling input parameters) have no significant effect on the accuracy of the predictions for the complex geometry.

Effect of manufacturing process on the final properties of advanced high strength steels for automotive applications

The performance of multiphase steels with high strength and improved toughness or ductility, such as intercritically annealed dual-phase (DP) and transformation-induced plasticity (TRIP) steels, is of key importance to the automotive industry. In this work we have considered the entire manufacturing process and the effects of this on the final product performance. These steels are formed to produce the required final shape and then the car is paint baked. In this work we also consider the effect of cold working and bake hardening on the fatigue life of the components.

Glass/carbon fibre hybrid composite laminates for structural applications in automotive vehicles

Light-weight structure is one of the keys to improve the fuel efficiency and reduce the environmental buden of transport vehicles (automotive and rail). While fibreglass composites have been increasingly used to replace steel in automotive industry, the adoption rate for carbon fibre composites which are much lighter, stronger and stiffere than glass fibre composites, remains low. The main reason is the high cost of carbon fibres. To further reduce vehicle weight without excessive cost increase, one technique is to incorporate carbon fibre reinforcement into glass fibre composites and innovative design by selectively reinforcing along the main load path. Glass/carbon woven fabrics with epoxy resin matrix were utilised for preparing hybrid composite laminates. The in-plane mechanical properties such as tensile and three-point-bending flexural properties were investigated for laminates with different carbon fibre volume and lay-up scheme. It is shown that hybrid composite laminates with 50% carbon fibre reinforcement provide the best flexural properties when the carbon layers are at the exterior, while the alternating carbon/glass lay-up provides the highest compressive strength.

The correlation between stacking fault energy and the work hardening behaviour of high-mn twinning induced plasticity steel tested at various temperatures

High-Mn Twinning Induced Plasticity (TWIP) steels have superior mechanical properties, which make them promising materials in automotive industry to improve the passenger safety and the fuel consumption. The TWIP steels are characterized by high work hardening rates due to continuous mechanical twin formation during the deformation. Mechanical twinning is a unique deformation mode, which is highly governed by the stacking fault energy (SFE). The composition of steel alloy was Fe-18Mn-0.6C-1Al (wt.%) with SFE of about 25-30 mJ/m2 at room temperature. The SFE ensures the mechanical twinning to be the main deformation mechanism at room temperature. The microstructure, mechanical properties, work hardening behaviour and SFE of the steel was studied at the temperature range of ambient ≤T[°C]≤ 400°C. The mechanical properties were determined using Instron tensile testing machine with 30kN load cell and strain rate of 10-3s-1 and the work hardening behaviour curves were generated using true stress and true strain data. The microstructure after deformation at different temperatures was examined using Zeiss Supra 55VP SEM. It was found that an increase in the deformation temperature raised the SFE resulting in the deterioration of the mechanical twinning that led to decrease not only in the strength but also in the total strain of the steel. A correlation between the temperature, the SFE, the mechanical twinning, the mechanical properties and the work hardening rate was also found. © (2014) Trans Tech Publications, Switzerland.

Properties and automotive applications of advanced high-strength steels (AHSS)

Advanced high-strength steels (AHSS) are a class of steel used primarily in sheet form for automotive structures. The microstructures of the types of steel in this classification were initially multiphase, with ferrite as the dominant phase; however, grades introduced more recently have been fully martensitic or based on austenite. This chapter initially introduces the requirements of an automotive body structure, then the different classes of AHSS that have been used in the automotive industry and their typical characteristic tensile properties. The specific properties that are required for steel used in automotive body structures are subsequently described, including formability and crash behaviour. Finally, some of the current and future trends in the development of new steel grades are discussed.