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Filled-rubber is widely used in automotive applications for noise and vibration isolation. The inherent material characteristics of filled-rubber make it suitable for these applications, but its complicated nonlinear behavior under both static and dynamic loading can make material modeling a challenge. This paper presents a two-element overlay technique to capture the nonlinear vibration amplitude dependency of a carbon-filled rubber material commonly referred to as the “Payne Effect.” This overlay technique is practically applied to predict the nonlinear dynamic stiffness and damping loss characteristics of a carbon-filled rubber body cab mount component from a body-on-frame vehicle calculated as a function of large static pre-strain, dynamic excitation frequency, and small dynamic strain amplitude in a single analysis.

A system approach is taken for the design of catalytic converters. An axisymmetric stuffing method is considered as a module for canning procedure in this investigation. The major aspects considered in this paper entail; three dimensional parametric modeling, parametric studies on the stuffing procedure, thermo-coupled stress analysis, modal analysis, thermal flow analysis, fatigue analysis for the steel parts, and parametric studies for optimizing the design of the total converter system. Popular commercial software are utilized to form the core of analysis modules. Developed in-house codes provide smooth interfaces between analysis modules by setting detailed analysis techniques and input decks. The system approach integrates established analysis procedures and parametric modeling.