Design Focus | Engineering Guidelines |
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Standard Interface Geometry | Apply ISO 2768 tolerances, DIN thread specs, and modular hole patterns to enable consistent fixture mounting and platform-level integration across vehicle systems. |
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High-Cycle Fatigue Design | Validate components for >10⁶ fatigue cycles using material S-N curves, notch factor reduction, and fatigue safety factors >1.3 in CAE simulations. |
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Thermal Stress Resistance | For powertrain components, select alloys like Inconel 718 or stainless 321 with verified creep resistance. Design thermal relief zones and use radiative surface finishes. |
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Crash Energy Management | Integrate crush zones using progressive deformation geometry. Validate via LS-DYNA or PAM-CRASH under ECE R94 and FMVSS 208 frontal impact conditions. |
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Dimensional Stack Control | Use true position GD&T and datum frameworks per ISO 1101 to control positional deviation within ±0.1 mm across assemblies. Apply tolerance analysis for multi-component stacks. |
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Corrosion Protection Strategy | Use Zn-Ni, hot-dip galvanizing, or e-coating for ferrous parts. Conduct salt spray tests (ASTM B117, ≥720 hrs) for body-in-white or suspension structures. |
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Lightweight Optimization | Apply topology optimization and CAE load path analysis to eliminate non-load-bearing mass. Use Al 7075, magnesium alloys, or composite reinforcements in non-critical zones. |
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Noise & Vibration Mitigation | Design isolation features using rubber-metal mounts or tuned mass dampers. Run harmonic response analysis to avoid resonance frequencies in 0–3 kHz range. |
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Process-Ready Geometry | Align features for casting, stamping, or CNC without undercuts. Use draft angles >2° for die-cast surfaces and R0.5–1.0 mm fillets for millable corners. |
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Ease of Assembly & Servicing | Implement keyed orientation, self-locating pins, and tool-friendly access for service parts. Avoid fasteners in blind zones; design for torque tools or robotic arms. |