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The increased adoption of downsized engines along with higher electrical demand is generating a challenge to the Front-End Accessory Drive (FEAD) system functioning and validation. One alternative to speed up the validation of potential design solutions is the in-vehicle experimental tests approach. Nevertheless, experimental data collection during in-vehicle FEAD evaluation imposes some challenges due to, for instance, packaging space constraints and sample rate required to capture the dynamic events during vehicle operation, among others. In order to overcome this limitation, the objective of this research is focused in the development of a customized test rig that emulates FEAD layout of an actual automobile in a simulated operating condition.

Increasingly research has been conducted lately towards reduction of both fuel consumption and gases emission in automotive vehicles propelled by Internal Combustion Engines. Among many initiatives, downsizing of those engines has been broadly adopted, arising side effects as increased vibration levels along Front-End Accessory Drive (FEAD) system. The present study focuses on the potential improvement of transmission efficiency and of vibration levels along FEAD by considering different layouts for the system. Multiple combinations of alternator pulley technologies and tensioner types are evaluated either during in-vehicle tests or in customized test rig that emulates vehicle FEAD in operating conditions. Specific transducers spred over the vehicle and at test rig assure the relevant data are captured for every layout arrangement investigated.

In injection molds, the most common type of injection gate is the pinpoint gate. As many authors in the field of injection mold design diverge on the recommended dimensions for the pinpoint gate, the idea behind this study is to guide future mold projects for the better gate dimensions for each shape of the part to be made. Following previous studies about the pinpoint injection gate, this new study was conducted to broaden the applicability of the results. The first study was based on a flat, rectangular piece. Now, for different sets of results and to be able to apply them for a different shape of injected part, a rectangular box was used for the simulation. As with the first study, the objective is to analyze the results and to recommend the best gate dimensioning for the new shape, based on the performance of each dimension simulated.

On an injection mold, the runner system is divided in: main runner, secondary distribution runners and injection gates. As for the injection gates, one of the most widely used designs is the pinpoint gate, for being simple and leaving small marks on the injected part. In the literature, the authors diverge for the values for the optimization of the gate, recommending further studies for each application. On that note, the objective of this study is to analyze through CAE the values recommended for the pinpoint gate in order to obtain the optimized injection process, varying the material, shape and thickness of the product. At the end of the study, a reference chart will be presented with the gate dimensions that were the most efficient in the computer simulation for each type of part, to aid in the project of future injection molds.