Research Projects

Plastic Mirror Development

The aim of this project is to develop a cost effective plastic mirror to replace the traditional components of glass, backing plate and screen printed resistive heater pads on automotive exterior mirrors utilising technologies that include injection compression moulding, vacuum metallisation and resin based hard coatings.  The proto-type product at present has several limitations, including optical quality and coating performance.

Lightweight Wheel

As part of mass reduction for fuel consumption reduction, this project looks at new ways of designing wheels.  Current design techniques are based on long established emperical SAE methods.  While producing a good sound wheel they often tend to be overdesigned.  The ultimate goal is to develop and apply new methodologies for wheel design that produce the lightest possible part while safely sustaining the actual loadings encountered.  Lightweight wheels not only directly contribute to vehicle mass reduction but give lower suspension loads allowing savings in the vehicle structure for a compounding benefit.

VPAC
GM Holden

Tool Wear Prediction

The increased usage of Advanced High Strength Steels (AHSS) in stamping has led to higher press forces, tooling loads and consequently an increase in tool wear problems.  Expensive die steel inserts, complex tool coatings and heat treatments can be used to combat these problems but can significantly increase tooling cost and potentially increasing tooling development time. Ultimately this project will develop a tool to predict the likelihood of tool wear problems for a new tool design and facilitate solutions to those problems.

Advanced Weld Modelling

Fuel economy has become increasingly important in this day and age due to environmental and economical pressures.  Decreasing vehicle weight using Aluminium, Magnesium and HSS is one way to facilitate this.  Increased use of these metals in the automotive industry has in turn brought about the need to further develop associated joining technologies.  This project looks at modeling welding processes to optimise manufacturing processes.

Development of the Next Generation Conventional Powerfold

The project aims to develop a new powerfold product with improved vibration performance, quieter operation, superior torque capability with higher mass ratings and other value adds to cater better to the needs of a growing automotive powerfold customer base.   It is anticipated that the outcomes of this project will directly enhance the global competitiveness of this technology and the sustainability of this industry sector through smarter actuator design and improved manufacturing flexibility and efficiency.

Automobile Supplier Excellence Australia

The Automotive Supplier Excellence Australia (ASEA) Program is intended to assist the Australian automotive supply base in achieving international competitiveness and sustainability.  Through the creation of an independent, best-in-class benchmarking process and targeted supplier assistance initiatives, ASEA aims to assist automotive suppliers in achieving world-class capability and competency levels.
Website: www.asea.net.au

Diamond Like Carbon and Hard Coatings

CSIRO Industrial Physics and Holden Innovation are researching the application of low friction diamond-like carbon (DLC) to components in the engine valve train.  New technology is being employed to deposit DLC onto valves, valve followers and eventually camshafts using Plasma Activated Chemical Vapour Deposition.  This process technology holds the promise of large scale coating of components for production engines to improove fuel efficiency.

Low Cost Composites Feasibility Study

Low Cost Composites Feasibility Study This project is being lead by Dr Niall Finn of CSIRO TFT with the objective to study the capability and feasibility of producing 3D knitted composite preforms utilising a specialised knitting machine. Alternative knit patterns, fibre materials, binder materials, impregnation, forming techniques and curing methods shall be explored. The mechanical properties of simple 3D tube structures will be tested with the above variables prior to moving on to more complex branched structures to investigate the design flexibility of the concept process. 

Rapid Tooling Development

With the development of new virtual design capabilities and shorter concept-to-production-times the Rapid Tooling Development project will ensure new tooling development does not create production bottlenecks. A scoping study will identify areas for major improvement. A series of sub-projects will identify new die-making technologies, reduce proving-time for new dies, and investigate design requirements for high-strength steels.

Alternative Seat Adjuster Mechanism

The development of a novel, possibly integrated, design of an automotive seat adjuster system for worldwide application. The main objective is a manufactured and tested proof of concept model and a full assessment of its possible commercial application.

HVAC & Refrigerant Noise Standards

HVAC noise (heating, ventilation & air conditioning) is a major noise source for some fan operating conditions. The project will develop a design handbook for refrigerant systems and a design hand book for HVAC air noise to assist engineers develop strategies for noise minimisation at design.

Low Global Warming Potential Refrigerant

Design and build, instrument and test, under Australian conditions, a car air-conditioning system that uses an improved working fluid with a low global warming potential. This project is to keep Australia abreast of developing European technology and legislation to utilise more environmentally friendly refrigerant gas than the current R134a (gas).