Research Projects
Materials & Sustainable Manufacturing
CO2 Mobile Air Conditioning Development
This project will design, build, instrument and test under Australian conditions, a car air conditiong system that uses carbon dioxide as the working fluid. Australian participants of the project will thus keep abreast of the developing CO2 air conditioning technology that is being demanded by some European vehicle OEM's and to whom Australian designed air conditiong systems may be sold in the future.
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Lightweight Wheel
As part of mass reduction for fuel consumption reduction, this project looks at new ways of designing wheels. Current design techniques are based on long established emperical SAE methods. While producing a good sound wheel they often tend to be overdesigned. The ultimate goal is to develop and apply new methodologies for wheel design that produce the lightest possible part while safely sustaining the actual loadings encountered. Lightweight wheels not only directly contribute to vehicle mass reduction but give lower suspension loads allowing savings in the vehicle structure for a compounding benefit.
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Advanced Riveting System
Fuel economy has become increasingly important in this day and age due to environmental and economical pressures. Decreasing vehicle weight by using HSS, Aluminium and Magnesium alloys, are options to facilitate this. Increased use of these metals in the Automotive industry has caused the need to further develop joining technologies. This project aims to futher develop, validate, and demonstrate the effective, efficient application of GM patented rivet technology.
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Tool Wear Prediction
The increased usage of Advanced High Strength Steels (AHSS) in stamping has led to higher press forces, tooling loads and consequently an increase in tool wear problems. Expensive die steel inserts, complex tool coatings and heat treatments can be used to combat these problems but can significantly increase tooling cost and potentially increasing tooling development time. Ultimately this project will develop a tool to predict the likelihood of tool wear problems for a new tool design and facilitate solutions to those problems.
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Advanced Weld Modeling
Fuel economy has become increasingly important in this day and age due to environmental and economical pressures. Decreasing vehicle weight using Aluminium, Magnesium and HSS is one way to facilitate this. Increased use of these metals in the automotive industry has in turn brought about the need to further develop associated joining technologies. This project looks at modeling welding processes to optimise manufacturing processes.
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Development of the Next Generation Conventional Powerfold
The project aims to develop a new powerfold product with improved vibration performance, quieter operation, superior torque capability with higher mass ratings and other value adds to cater better to the needs of a growing automotive powerfold customer base. It is anticipated that the outcomes of this project will directly enhance the global competitiveness of this technology and the sustainability of this industry sector through smarter actuator design and improved manufacturing flexibility and efficiency.
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Advanced Paints and Pigments
GM Holden in collaboration with R&D and educational facilities investigating the development of innovative coatings through surface modifications, nano-technology and chromogenic materials to enhance performance and design aesthetics for automotive applications.
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Automobile Supplier Excellence Australia
The Automotive Supplier Excellence Australia (ASEA) Program is intended to assist the Australian automotive supply base in achieving international competitiveness and sustainability. Through the creation of an independent, best-in-class benchmarking process and targeted supplier assistance initiatives, ASEA aims to assist automotive suppliers in achieving world-class capability and competency levels.
Website: www.asea.net.au
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Diamond Like Carbon and Hard Coatings
CSIRO Industrial Physics and Holden Innovation are researching the application of low friction diamond-like carbon (DLC) to components in the engine valve train. New technology is being employed to deposit DLC onto valves, valve followers and eventually camshafts using Plasma Activated Chemical Vapour Deposition. This process technology holds the promise of large scale coating of components for production engines to improove fuel efficiency.
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Carpet Acoustics
This project under the leadership of Dr Xu Wang of RMIT, School of Aerospace, Manufacturing and Mechanical Engineering and in collaboration with Dr Stuart Lucas of CSIRO TFT, will explore methods of evaluating and assessing a number of alternative materials and constructions for light weight, recyclable automotive carpet systems. The objective is to establish a sophisticated portable method of optimising acoustic performance of carpet and interiors systems of future vehicles given different body in white and cost targets.
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Low Cost Composites Feasibility Study
Low Cost Composites Feasibility Study This project is being lead by Dr Niall Finn of CSIRO TFT with the objective to study the capability and feasibility of producing 3D knitted composite preforms utilising a specialised knitting machine. Alternative knit patterns, fibre materials, binder materials, impregnation, forming techniques and curing methods shall be explored. The mechanical properties of simple 3D tube structures will be tested with the above variables prior to moving on to more complex branched structures to investigate the design flexibility of the concept process.
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Rapid Tooling Development
With the development of new virtual design capabilities and shorter concept-to-production-times the Rapid Tooling Development project will ensure new tooling development does not create production bottlenecks. A scoping study will identify areas for major improvement. A series of sub-projects will identify new die-making technologies, reduce proving-time for new dies, and investigate design requirements for high-strength steels.
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Advanced Seating Solutions for PU Foam
The development of materials for the manufacture of automotive seating, with enhanced properties for recycling, reduced mass and reduced cost. The project will yield environmental advantages whilst maintaining the safety and comfort required from superior automotive seating technology.
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Alternative Seat Adjuster Mechanism
The development of a novel, possibly integrated, design of an automotive seat adjuster system for worldwide application. The main objective is a manufactured and tested proof of concept model and a full assessment of its possible commercial application.
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HVAC & Refrigerant Noise Standards
HVAC noise (heating, ventilation & air conditioning) is a major noise source for some fan operating conditions. The project will develop a design handbook for refrigerant systems and a design hand book for HVAC air noise to assist engineers develop strategies for noise minimisation at design.
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Low Global Warming Potential Refrigerant
Design and build, instrument and test, under Australian conditions, a car air-conditioning system that uses an improved working fluid with a low global warming potential. This project is to keep Australia abreast of developing European technology and legislation to utilise more environmentally friendly refrigerant gas than the current R134a (gas).
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