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2014-04-28
Technical Paper
2014-28-0006
Rohitt Ravi, Sivasubramanian, Bade Simhachalam, Dhanooj Balakrishnan, Krishna Srinivas
Abstract Tubular stabilizer bar for commercial vehicle is developed using advanced high strength steel material. Tubular section is proposed to replace the existing solid section. The tubular design is validated by component simulation using ANSYS Software. The tubes are then manufactured of the required size. The bend tool is designed to suit the size of the profile stabilizer bar and the prototypes are made using the tube bending machine. The strength of the tubular stabilizer is increased by using robotic induction hardening system. The tubular stabilizer bar is tested for fatigue load using Instron actuators. Higher weight reduction is achieved by replacing the existing solid stabilizer bar with the tubular stabilizer bar.
2014-04-28
Technical Paper
2014-28-0038
Y. S. Thipse
Abstract Hyperelastic material simulations are commonly performed in commercial FE codes due to availability of sophisticated algorithms facilitating virtual characterization of such materials in FEA easily. However, the solution time required is longer in FEA. Especially when excitation frequencies do not interfere with structural modes, flexible multibody simulation offers a lucrative and computationally inexpensive alternative. However, it is difficult to directly characterize hyperelastic materials in commercial MBS simulation codes, so the reduced solution time comes at the cost of decreased simulation accuracy, especially if the designer is provided with crude stress - strain test data. Hence, the need is to overcome the drawbacks in FEA and multibody codes, as well as to leverage best of both these codes simultaneously. A methodology is presented where non-linear stiffness properties of the hyperelastic materials are expressed as an analytical function in terms of constants of hyperelastic constitutive material models.
2014-04-28
Technical Paper
2014-28-0016
Ashok KK, Bade Simhachalam, Dhanooj Balakrishnan, Krishna Srinivas
Abstract In this paper, the application of tube Extrusion for the development of stepped tubular components is discussed. Thickness increase with respect to cold reduction of diameter is predicted with reasonable accuracy. Thickness increase, length increase and strain hardening coefficient for a given cold reduction of diameter of tube are obtained using LS-DYNA Software. True stress-plastic strain curves from the tensile test are used in the forming simulation using LS-DYNA. A special purpose machine is developed for the production of steering shaft components. Considerable reduction in weight is achieved by using stepped tubular components.
2014-04-21
WIP Standard
J1705
This SAE Recommended Practice was prepared by the Motor Vehicle Brake Fluids Subcommittee of the SAE Hydraulic Brake Systems Actuating Committee to provide engineers, designers, and manufacturers of motor vehicles with a set of minimum performance standards in order to assess the suitability of silicone and other low water tolerant type brake fluids (LWTF) for use in motor vehicle brake systems. These fluids are designed for use in braking systems fitted with rubber cups and seals made from natural rubber (NR), styrene-butadiene rubber (SBR), or a terpolymer of ethylene, propylene, and a diene (EPDM). In the development of the recommended requirements and test procedures contained herein, it is concluded that the LWTFs must be functionally compatible with existing motor vehicle brake fluids conforming to SAE J1703 and with braking systems designed for such fluids. To utilize LWTFs to the fullest advantage, they should not be mixed with other brake fluids. Inadvertent mixtures of LWTFs with fluids meeting SAE J 1703 are not known to have any adverse effects on performance, but all combinations have not been tested.
2014-04-16
Standard
J2246_201404
This SAE Information provides information applicable to production Original Equipment Manufacturer antilock braking systems found on some past and current passenger cars and light trucks. It is intended for readers with a technical background. It does not include information about aftermarket devices or future antilock brake systems. Information in this document reflects that which was available to the committee at the time of publication.
2014-04-11
Book
Today’s designers seek to integrate sensor technology, electronic and mechatronic systems in progressively introducing Electric Power Steering (EPS) systems. However, from a customer perspective on the one hand steering is one of the most visible or tangible aspects of vehicle quality in driving when quality is compromised (through NVH issues), while on the other hand, when executed well, a steering system is all but transparent to the driver. To a number of commentators and OEMs ‘steering feel’ has become termed as contributing to the essential ‘DNA” of the vehicle, and it is therefore an essential aspect of competitive advantage or position. This report examines steering feel and the increasing effect of vehicle electrification, and looks at steering and chassis performance. It also considers the key drivers including fuel efficiency and CO2 emissions, steering design, materials considerations and the packaging dilemma. Furthermore the report looks at the latest steering system trends, in particular electrically power assisted steering (EPAS), electro-hydraulic power steering (EHPS), electric power steering (EPS), active front steering (AFS), four-wheel steering, steer-by-wire, automated parking and NVH reduction.
2014-04-10
WIP Standard
J1987
This SAE Recommended Practice describes the determination of passenger car and light truck tire force and moment properties on a belt-type flat surface test machine. It is suitable for accurately determining five tire forces and moments in steady-state under free-rolling conditions as a function of slip angle and normal force which are incrementally changed in a given sequence. Heavy-duty tires are not considered in this document, because the measuring system would have force and moment ranges too large to meet sensitivity requirements for passenger and light truck tire force and moment measurements. A standard for heavy-duty truck tires would have many of the same features as this document, but the measuring system, would have to be extensively altered. Inclination angle combined with slip angle, pull forces, and any combination with spindle torque are not considered in this document. Standards needed for these topics will be considered separately. The test method described in this document is suitable for comparative evaluations of tires for research and development purposes.
2014-04-10
WIP Standard
J1633
This SAE Recommended Practice provides a method for testing the speed performance of light truck tires under controlled conditions in the laboratory on a test wheel.
2014-04-10
WIP Standard
J1561
This SAE Recommended Practice provides a method for testing the speed performance of passenger car tires under controlled conditions in the laboratory on a test wheel. This procedure applies to "standard load," "extra load," and "T-type high-pressure temporary-use spare" passenger tires.
2014-04-10
WIP Standard
J1988
This Recommended Practice describes the determination of tire pull force properties for an uninclined tire (SAE J670e) on a laboratory flat surface tire force and moment machine. It is suitable for accurately determining pull forces and residual aligning moments for passenger and light-truck tires. These properties are important determinants of vehicle trim. They describe steady-state, free-rolling pull effects ascribable to tires. The test method described in this document is suitable for comparative evaluation of tires for research and development purposes. The method is also suitable for modeling when followed carefully.
2014-04-10
WIP Standard
J2530
This SAE Recommended Practice provides performance and sampling requirements, test procedures, and marking requirements for aftermarket wheels intended for normal highway use on passenger cars, light trucks, and multipurpose passenger vehicles. For aftermarket wheels on trailers drawn by passenger cars, light trucks or multipurpose vehicles, see SAE J1204. These performance requirements apply only to wheels made of materials included in Table 1 and Table 2. New nomenclature and terms are added to clarify wheel constructions typically not used in OEM applications. The testing procedures and requirements are based on SAE standards listed in the references.
2014-04-07
WIP Standard
J1605
This SAE Standard covers performance requirements and methods of test for master cylinder reservoir diaphragm gaskets that will provide a functional seal and protection from outside dirt and water.
2014-04-01
Collection
This technical paper collection focuses on new theory, formulation and modeling of amplitude-, frequency- and temperature-dependent nonlinear components/systems such as rubber and hydraulic mounts or bushings, shock absorbers, and any joint friction/damping; dynamic characterization through lab and field testing; Linearization methodology; Model validation, application, and sensitivity analysis in vehicle system/subsystem simulations; Nonlinear system identification, modeling, and application in testing accuracy improvement, etc.
2014-04-01
Collection
This technical paper collection presents papers on steering and suspension related topics as it applies to ground vehicles. Papers for this session address new approaches as well as advances in application of steering, suspension related technologies.
2014-04-01
Collection
This technical paper collection is focused on vehicle dynamics and controls using modeling and simulation, and experimental analysis of passenger cars, heavy trucks, and wheeled military vehicles. The papers address active and passive safety systems to mitigate rollover, yaw instability and braking issues; driving simulators and hardware-in-the-loop systems; suspension kinematics and compliance, steering dynamics, advanced active suspension technologies; and tire force and moment mechanics.
2014-04-01
WIP Standard
J2204
This SAE Standard applies to the usage of tires of the same nominal size and tread type, but with different outside diameter for articulated front-end loaders. Articulated four-wheel-drive front-end loader performance and component life can be affected by excessive differences in the tire outside circumference and/or diameter. The purpose is to provide specific guidelines for the usage of tires with different outside circumference and/or diameter on articulated front-end loaders.
2014-04-01
Technical Paper
2014-01-1009
Yoon Cheol Kim, Seong Jin Kim, Jaeyoung Lee, Jeongkyu Kim, SooHyuk Lee, Kyoungdon Yi, KiJeong Kim
Abstract Reducing unsprung mass of the car is a representative method to enhance the ride & handling performance and fuel efficiency. In this study, brake disc weight is reduced 15∼20% using a hybrid type material. The basis for this study is the separation of the friction surface and HAT(mounting part). Aluminum material is applied in the HAT for a light weight effect. Gray iron is applied in the friction surface section to maintain braking performance. Two types of joining between aluminum and cast iron are developed. One is the aluminum casting method utilizing a gray iron insert and the other is a bolted assembly method. Detailed structure, process and material are optimized using try-out & dynamometer experiments. The Reliability of this development is proved through durability (dynamometer and vehicle) testing.
2014-04-01
Technical Paper
2014-01-0945
Romeo Sephyrin Fono-Tamo
Abstract The development of a non-asbestos automotive brake pad using palm kernel shell (PKS) as friction filler material is presented. This was with a view to exploiting the characteristics of PKS, which are otherwise largely deposited as waste from palm oil production, to make substitution for asbestos which has been found to be carcinogenic. Two sets of brake pads with identical ingredients but using either PKS or asbestos as base material were produced, following standard procedures employed by a commercial brake pad manufacturer. The physical, thermal, mechanical and the wear characteristics of the PKS-based brake pads were evaluated, compared with the values for the asbestos-based brake pads, and weighted against established recommendations for friction materials for road vehicle brake pads. The PKS based brake pad was characterized by 32.34 Brinell hardness number; 0.62%, swell and growth; 3375 N/s, bonding to back plate, and phase change at 689.5°C. The coefficient of friction of the experimental brake pad on cast iron was 0.43; whilst, wear rate was 9.17 E-5 g/min and exhibiting a third order polynomial with run-in time.
2014-04-01
Technical Paper
2014-01-0944
Ovun Isın, Ilyas Istif, Deniz Uzunsoy, Feray Guleryuz
Abstract The brake friction materials in an automotive brake system play an important role in the overall braking performance of a vehicle. Metal Matrix Composites (MMCs) have been widely investigated and applied due to their advantages of improved strength, stiffness and increased wear resistance over the monolithic alloys in automobile industries. In this paper, Al/B4CP and Mg/B4CP composites were compared to find a suitable candidate material for automotive disk brake application, in terms of wear behavior results of the materials. In addition, the experimental data was also used to model this behavior by identification. The measured tangential force was considered as the input parameter, whereas the weight loss as the output parameter. Preliminary results of this work showed that B4CP addition improved wear resistance of both aluminum and magnesium matrix composites. Additionally, the study pointed out that identified models provide a reliable and cost effective tool for wear prediction.
2014-04-01
Technical Paper
2014-01-0929
Changxin Wang, Wenku Shi, Qinghua Zu
Abstract Aiming at the difficulty of sovling the stiffness calculation of taper-leaf spring with variable stiffness, a combined method was proposed, which combine superposition method and finite difference method. Then the calculation results of different differential segments were compared with experimental results. The compared results show that the proposed method is effective and simple. So it has some practical significance in designing the taper-leaf spring. In addition, based on the stiffness test of the taper-leaf spring, the proper adjustments to the correction factor of the single parabolic leaf spring stiffness formula was recommended(ξ =0.92-0.96).
2014-04-01
Technical Paper
2014-01-0928
Daryl R. Poirier, Ravindra Patil, Robert Geisler, Joseph Schudt
Abstract The automotive industry is under great pressure to reduce vehicle mass for both cost and fuel economy gains. A significant contributor to body and suspension structure mass is peak vertical loads, primarily entering the body structure through the jounce bumper to body interface. This paper focuses on the successful development of “Loads Management Striker Caps” for the 2013 Cadillac ATS front and rear suspension. Component design and development of the striker caps was executed using explicit finite element analysis tools. Multi-body dynamics vehicle models were used to set component requirements and confirm striker cap performance for the vehicle during peak vertical events. The “Loads Management Striker Caps” ultimately reduced peak strut/shock tower loads by 40% in the front suspension and 25% in the rear suspension. This resulted in significant body and chassis mass savings, contributing to the Cadillac ATS's class leading curb weight.
2014-04-01
Technical Paper
2014-01-0974
Deepak Tiwari, Anand Bhope, Akshay Hegde
Abstract Hardened steel is the majorly used raw material for automotive components. In spite of its abundance, its application is limited due to low fatigue life in dynamic loading. Shot peening is one of the identified processes to improve the fatigue life of the ductile steel by inducing the work hardening & surface improvement. The process of shot peening involves the bombardment of shots on the component surface. As the process & technique, the shot size selection plays very important role in the fatigue life improvement as it alters the results substantially. Also during the process, shot size decreases due to the normal wear of the shots after hitting the component surface. As a result, there is always a ratio of various sizes of the shots involved in the process. Therefore it becomes imperative to control the shot size ratio for obtaining the required work hardening & possible fatigue life improvement. This paper explains the effects of shot size ratio on the durability life of a component & the process of shot size ratio selection.
2014-04-01
Technical Paper
2014-01-0874
Edoardo Sabbioni, Federico Cheli, Matteo Riva, Andrea Zorzutti
Abstract For passenger cars, individual tyre model parameters, used in vehicle models able to simulate vehicle handling behavior, are traditionally derived from expensive component indoor laboratory tests as a result of an identification procedure minimizing the error with respect to force and slip measurements. Indoor experiments on agricultural tyres are instead more challenging and thus generally not performed due to tyre size and applied forces. However, the knowledge of their handling characteristics is becoming more and more important since in the next few years, all agricultural vehicles are expected to run on ordinary asphalt roads at a speed of 80km/h. The present paper presents a methodology to identify agricultural tyres' handling characteristics based only on the measurements carried out on board vehicle (vehicle sideslip angle, yaw rate, lateral acceleration, speed and steer angle) during standard handling maneuvers (step-steers, J-turns, etc.), instead than during indoor tests.
2014-04-01
Technical Paper
2014-01-0876
Barys Shyrokau, Dzmitry Savitski, Danwei Wang
Abstract Nowadays there is a tendency to implement various active vehicle subsystems in a modern vehicle to improve its stability of motion, handling, comfort and other operation characteristics. Since each vehicle subsystem has own limits to generate supporting demand, their potential impact on vehicle dynamics should be analyzed for steady-state and transient vehicle behavior. Moreover, the additional research issue is the assessment of total energy consumption and energy losses, because a stand-alone operation of each vehicle subsystem will provide different impact on vehicle dynamics and they have own energy demands. The vehicle configuration includes (i) friction brake system, (ii) individual-wheel drive electric motors, (iii) wheel steer actuators, (iv) camber angle actuators, (v) dynamic tire pressure system and (vi) actuators generating additional normal forces through external spring, damping and stabilizer forces. A passenger car is investigated using commercial software. The actuator models are defined using experimental test results and technical literature information.
2014-04-01
Technical Paper
2014-01-0878
Adam C. Reid, David Philipps, Fredrik Oijer, Inge Johansson, Moustafa EL-Gindy
Abstract The rigid-ring tire model is a simplified tire model that describes a tire's behaviour under known conditions through various in-plane and out-of-plane parameters. The complex structure of the tire model is simplified into a spring-mass-damper system and can have its behaviour parameterized using principles of mechanical vibrations. By designing non-linear simulations of the tire model in specific situations, these parameters can be determined. They include, but are not limited to, the cornering stiffness, vertical damping constants, self-aligning torque stiffness and relaxation length. In addition, off-road parameters can be determined using similar methods to parameterize the tire model's behaviour in soft soils. By using Finite Element Analysis (FEA) modeling methods, validated soil models are introduced to the simulations to find additional soft soil parameters. By determining the full FEA tire model's characteristics, a simplified rigid-ring model can replace the complex model in full vehicle model simulations to reduce computation time and effort.
2014-04-01
Technical Paper
2014-01-0883
Wenku Shi, Changxin Wang
Abstract In order to reasonably match the variable stiffness suspension and optimize the ride comfort and stability of a light bus, a virtual prototype model of the light bus was established in Adams-Car. Before the optimization, the tyre mechanical characteristics were tested by using a plate-type tyre tester, then the magic formula model of the tyre (Pac2002) was obtained by means of the global parameter identification method. The vertical vibration of the virtual model was simulated with the simulated B-class road profile, and its handling stability performance was also studied by simulation of the pylon course slalom test and steady static circular test. After that, an optimal method of the variable stiffness suspension was put forward. In the proposed method, the two-level stiffness (k1, k2) and the damping of the rear suspension and the torsional stiffness of the pre and post stabilizer bars were taken as the optimal variables. The Z-direction acceleration RMS of the bus frame, the yaw rate and the roll angle of the bus body were selected as the optimal target.
2014-04-01
Technical Paper
2014-01-0885
Mustafa Ali Arat, Saied Taheri
Abstract A vehicle's response is predominately defined by the tire characteristics as they constitute the only contact between the vehicle and the road; and the surface friction condition is the primary attribute that determines these characteristics. The friction coefficient is not directly measurable through any sensor attachments in production-line vehicles. Therefore, current chassis control systems make use of various estimation methods to approximate a value. However a significant challenge is that these schemes require a certain level of perturbation (i.e. excitation by means of braking or traction) from the initial conditions to converge to the expected values; which might not be the case all the time during a regular drive. This study proposes an observer scheme that utilizes an instrumented tire (i.e. smart tire) as an additional sensor input and develops a sliding-mode observer based on tire force feedback to provide the estimated friction coefficient irrespective of the available excitation.
2014-04-01
Technical Paper
2014-01-0847
Andrew Hall, John McPhee
Abstract Physical rig testing of a vehicle is often undertaken to obtain experimental data that can be used to ensure a mathematical model is an accurate representation of the vehicle under study. Kinematics and Compliance (K&C) testing is often used for this purpose. The relationship between the hard point locations and compliance parameters, and K&C characteristics of a suspension system is complex, and so automating the process to correlate the model to the test data can make the exercise easier, faster and more accurate than hand tuning the model. In this work, such a process is developed. First, the model parameters are adjusted, next a simulation is run, before the results are read and post processed. This automation processed is used in conjunction with an optimization procedure to carry out the K&C correlation. MATLAB scripts are created to modify the model parameters, run simulations and read the results so that MATLAB optimization algorithms can be used to identify the most appropriate suspension parameter values.
2014-04-01
Technical Paper
2014-01-0848
Dongmei Wu, Haitao Ding, Konghui Guo, Zhiqiang Wang
Abstract Pressure following control is the basic function of Electro-Hydraulic Braking system (EHB), which is also the key technology of stability control system and regenerative braking system for hybrid and electric vehicles. Experimental research is an important method for the control and application of EHB. This paper describes a method to test and control the EHB system through experiment on the Hardware-in-the-loop (HIL) test bench and wheel motor electric vehicle. First, the HIL test bench was established, in which the EHB was tested, including the characteristics of solenoid valves and motor. Then the wheel cylinder pressure was controlled to follow the specific signal input and the master cylinder pressure. Based on this, EHB and the pressure following control method were applied to the wheel motor electric vehicle. The results show that the braking pressure can follow the driver's braking intention to realize the conventional braking function of electric vehicles. This is the basis of stability control system and regenerative braking system for hybrid and electric vehicles.
2014-04-01
Technical Paper
2014-01-0849
Xinxin Shao
Abstract In this paper, a passive anti-pitch anti-roll hydraulically interconnected suspension is proposed for compromising the control between the pitch and roll mode of the sprung mass. It has the advantage in improving the directional stability and handling quality of vehicles during steering and braking manoeuvres. Frequency domain analysis of a 7-DOF full-car model with the proposed system is presented. The modeling of mechanical subsystem is established based on the Newton's second law. Then the mechanical-hydraulic system boundary conditions are developed by incorporating the hydraulic strut forces into the mechanical subsystem as externally applied forces. The hydraulic subsystem is modelled by using the impedance method, and each circuit are determined by the transfer matrix method. And then the modal analysis method is employed to perform the vibration analysis between the vehicle with the conventional suspension and the proposed HIS. Comparison analysis focuses on natural frequencies and modal shapes with identified eigenvalues and eigenvectors.
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