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Electrically powered hydraulic steering systems (EPHS) are in mass production for about 6 years. They have been and still are very successful in the market as they follow the trend of supplying fully assembled and tested steering modules and the increasing demand for engine independent electrically powered systems. This paper illustrates the latest results of research and development in this sector leading to a new EPHS generation.

An Electric Power Steering (EPS) System will be considered in this report. The modeling of this dynamic system will be achieved with both simplicity and usability taken into account. As such, a Reduced Order Model that reveals the important dynamic distinctions of the system will be developed from a more complex one. This model will be used to analyze various closed loop effects such as torque performance, disturbance rejection, noise rejection, road feel, and stability. These fundamental effects (compromises) are used toward the design of a desired control system. This modeling philosophy together with a comprehensive understanding of system compromises is essential to an optimized EPS system.

Finite Element Method (FEM) simulation of the powder metal forging process can be a useful tool in new product or process development because the simulation provides tooling load estimates, press size requirements, preform design feasibility and allows accurate and inexpensive parametric studies of forging process variables. Several examples of simulations using ALPID-P code are presented. Axisymmetric and plane strain simulations at several cross sections of an automotive P/M connecting rod forging indicate that die wall friction has a large effect on the densification process. Also, simulations indicate a significant die wall velocity effect on densification.