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Formability is a continuing quest for sheet metal manufacturing processes. This paper intends to study formability of a sheet metal oil pan using AKDQ (Aluminum Killed Draw Quality) steel and to perform finite element modal analysis on the formed part. Forming a sheet metal oil pan requires a blank, a die having the geometry of the desired oil pan and a punch that replicates the die geometry. For parts with quite complex geometry or with deep cavities or intricacies, a blank holder or binder is required to hold the blank with the die. This is to feed the blank inside the cavity in a controlled manner. The hold-down pressure or the pressure with which the blank is held with the die can be properly controlled as a function of time in order to get the desired part with minimum strain concentration zones. On successful forming, the formed part is subjected to modal analysis to visualize and understand the motions occurring when the part vibrates.

Aerodynamics of trucks and other high sided vehicles is of significant interest in reducing road side accidents due to wind loading and in improving fuel economy. Recognizing the limitations of conventional wind tunnel testing, considerable efforts have been invested in the last decade to study vehicle aerodynamics computationally. In this paper, a three-dimensional near field flow analysis has been performed for axial and cross wind loading to understand the airflow characteristics surrounding a truck-like bluff body. Results provide associated drag for the truck geometry including the exterior rearview mirror. Modifying truck geometry can reduce drag, improving fuel economy.

A comprehensive finite element methodology is developed to predict the compressible flow performance of a non-symmetric 7-blade axial flow fan, and to quantify the source strength and sound pressure levels at any location in the system. The acoustic and flow performances of the fan are predicted simultaneously using a computational aero-acoustic technique combining transient flow analysis and noise propagation. The calculated sound power levels compare favorably with the measured sound power data per AMCA 300-96 code.