SD 3-26-99

DEV 22452 samples for EAR 15728 completed 3-26-99

Delphi Interiors. Steering column compressive energy absorber.
Compression / Recovery test

Customer specifications: (SS mesh cylinder)

dimensions: OD = 4.0 in, ID = 1.5 in, Height = 4.0 in
performance: 50% reduction in height before spike in stiffness occurs. From supplied graph,
the "spike" appears to be when the force reaches 1,000 to 1,500 lb.
function: compressive energy absorption in an automotive steering column.

compression force (lb) force (lb) compression force (lb) force (lb)
(in) compression recovery (in) compression recovery
0.1 15 0 1.4 415 0
0.2 35 0 1.5 450 0
0.3 55 0 1.6 490 0
0.4 80 0 1.7 525 0
0.5 105 0 1.8 560 10
0.6 130 0 1.9 600 20
0.7 160 0 2.0 630 35
0.8 185 0 2.1 675 50
0.9 215 0 2.2 720 75
1.0 250 0 2.3 770 110
1.1 290 0 2.4 830 160
1.2 340 0 2.5 905 280
1.3 375 0 2.6 1000 1,000
NOTES:
1) EAR 15728 samples are very preliminary parts, intended to allow the customer to perform
their own testing in order to get an idea of the general characteristics of knitted wire mesh.
Factors such as housing dimensions and compression speed will affect performance.
The non-linear compression / recovery characteristics of wire mesh is expected to be suitable for
their application.
2) Compression tests performed using a test fixture (similar to a hollow round die) with a 4.0 in ID
barrel and a 1.5 in OD pin. Crosshead speed = 1.0 in/min.
3) Samples for EAR 15728 were made using 4 pieces of crimped mesh (crimped length =13.75 in each)
from 56-0510-0990 / Honda 25176001. This mesh is 4.5 in wide after crimping.
The mesh pieces were wound on a 1.5 in diameter mandrel (end to end as if they were 1
continuous piece of mesh), and the outside 3 layers (wraps) of mesh were welded in 2 places.
These samples were not pressed, only wound and welded.
(Samples were fabricated from production mesh, which Metex had in stock.)
4) EAR 15728 samples (quantity = 2): OD: snug fit into a 4.0 in ID housing.
DEV 22452

ID: snug fit onto a 1.5 in OD pin.

HT = 4.5 in Wgt = 11.782, 12.160 oz
5) To meet the customer HT specification mesh width must be reduced to approximately 4.5
inches, in order to achieve a 4.0 in width after crimping. (use crimper from 56-0510-0990)
6) To reduce cost while still providing more than adequate corrosion resistance, the wire may
be changed from 316A to 304A. The effect on compression / recovery must be determined.
7) Future samples should be made with 1 continuous piece of mesh.
8) Contact: Rale Wolf, Delphi Interiors, 250 Northwood Blvd, Vandalia, OH 45377-5057
mail code110. 937-356-2248, fax 937-356-2303