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Viewing 1 to 30 of 8357
2015-01-14
Technical Paper
2015-26-0061
Sanjay Nibandhe
The paper presents innovative approach for Automobile Assembly Process solution. The approach describes about production simulation for new products under development. This work leads towards the assembly process establishment for newly developed automobile vehicle and its control plan which compares to final production practices. In recent years Indian automotive business is expanding and with growing needs of fast new product development, the cycle time reduction becomes very crucial for environmental and economical reasons. Lean production assembly process and robust engineering process are optimized in this new approach. It’s an advance mechanism to identify process failures during final production setup. The experimentation has resulted to establish micro level study and the critical stages to be captured well in advances for better planning. This new approach takes care of all types of vehicles, product mix, end deliverables of vehicles in terms of quality.
2015-01-14
Technical Paper
2015-26-0060
Sujeet Kumar Sah
Nickel electroplating is commonly used with substrates including steel, aluminum, plastic and zinc die-cast parts because of its high resistance to temperature, corrosion and wear in harsh conditions. To further enhance its tribological and mechanical properties, research works are going on to produce nano reinforced composites of Ni with various ceramic and rare earth oxides like CeO2, ZrSiO4, SiC, TiO2, etc. The aim of present work is synthesis and characterization of Ni films and Ni based TiO2 nano-composite coating processed by pulse co-electrodeposition technique. Also, to investigate the various properties such as mechanical, wear and corrosion resistance & thermal stability of Ni-TiO2 nanocomposites electrodeposited on steel substrate, especially the effects of the amount of nanosized TiO2 particles in Ni-TiO2 nanocomposites.
2015-01-14
Technical Paper
2015-26-0074
Dhiyaneswar Rani, Saravanan A K, Mohammad Rafiq Agrewale, B Ashok
Material handling is a major section in all the industries especially for delicate and huge components. So here in TAFE Ltd, Chennai they are using pneumatics system to tilt the component so that operator will be able to do the further operation in the line. Pneumatic system needs electricity to operate. Due to frequent power shutdowns many industries are facing problem to run their manufacturing unit peacefully. As an alternate they are using generators which require fuel to generate power. This adds manufacturing cost and demand for fuel. So to avoid all this problem, dependability of energy resources has to be minimized. We planned to apply Karakuri kaizen a Japanese technology at machine shop of TAFE Ltd, Chennai with the help of my industry guide Mr. Saravanan A K and few of the industry officials. The system is completely fabricated and it is now running successfully in the industry without electricity.
2015-01-14
Technical Paper
2015-26-0187
Venu Ganti, Yogesh Dewangan, Saurabh Arvariya, Shyamsananth Madhavan
Scuffing is an instantaneous gear failure, where flanks are welded together under pressure and temperature at high speed conditions. This is one of the common failure modes in manual transmission. Fig: Picture of scuffing near the gear tip High contact pressures are often experienced in high density power transfer gears at the tip and the root regions. These higher pressures coupled with higher sliding velocities and frictional heat generation makes the tip and root regions in the gear susceptible to scuffing. Gear geometry, operating speed, gear material composition, surface roughness and lubricant properties influence scuffing. A balanced gear tooth design with lower sliding velocities is often chosen as an approach to avoid scuffing. However, in the current scenarios of transmissions with high power density requirements achieving a balanced gear tooth design is seldom. Lubricants with higher viscosity avoid scuffing but has adverse effects on the transmission efficiency.
2015-01-14
Technical Paper
2015-26-0019
Werner Bick, Cagri Cevik, Christoph Steffens
In order to minimize the development and production costs in the automotive industry, despite steadily increasing variety of models and applications offered by the OEMs, the pressure on standardization of components and production processes is increasing continuously. As a direct consequence, modular engine families are already established with high degrees of equal parts and kits as well as standardized interfaces for all vehicle platforms with most manufacturers these days. At the same time, the world adopted and announced massive legal demands concerning the reduction of CO2 emissions for the entire vehicle fleet. In addition to the optimization of the combustion process, the exhaust gas aftertreatment and thermal management, the use of improved and more resilient materials for higher reduction of mechanical friction leads to a significant amount of the realized lowering in fuel consumption resp. CO2 emissions.
2015-01-01
Journal Article
2014-01-9101
Susan Sawyer-Beaulieu, Edwin K.L. Tam
Abstract Life-cycle assessments (LCAs) conducted, to date, of the end-of-life phase of vehicles rely significantly on assumed values and extrapolations within models. The end phase of vehicles, however, has become all the more important as a consequence of increasing regulatory requirements on materials recovery, tightening disposal restrictions, and the rapid introduction of new materials and electronics, all potentially impacting a vehicle's efficacy for achieving greater levels of sustainability. This article presents and discusses selected research results of a comprehensive gate-to-gate life-cycle-inventory (LCI) of end-of-life vehicle (ELV) dismantling and shredding processes, constructed through a comprehensive and detailed case study, and argues that managing and implementing creative dismantling practices can improve significantly the recovery of both reusable and recyclable materials from end-of-life vehicles.
2014-10-13
Technical Paper
2014-01-2584
Krisada Wannatong, Sompach Kongviwattanakul, Thananchai Tepimonrat, Thanadech Priroon
Abstract End of line test (EOL) of Engine Control Units (ECU) is the process of ECU functions validation before releasing ECUs to the car assembly process. Examples of ECU function that need to be validated are idle control, air path control and faults manager function. To perform EOL, a vehicle and a chassis dynamometer are used to enable control functions validation inside the ECU. However, this poses high operating cost and long setup time. This paper presents the development of Hardware-in-the-Loop (HiL) system, which imitates real vehicle behavior on a chassis dynamometer. The diesel high pressure pump model was developed using an empirical dynamic modeling approach. The engine model was developed using AVL BOOST RT software, an engine cycle simulation modeling approach. The vehicle model was developed using AVL CRUISE software. In order to interface the engine and vehicle models with the ECU, HiL system was implemented.
2014-10-13
Technical Paper
2014-01-2805
Benjamin Kingsbury, Jonathan Stewart, Zhentao Wu, Roy Douglas, Kang Li
Abstract This study describes an innovative monolith structure designed for applications in automotive catalysis using an advanced manufacturing approach developed at Imperial College London. The production process combines extrusion with phase inversion of a ceramic-polymer-solvent mixture in order to design highly ordered substrate micro-structures that offer improvements in performance, including reduced PGM loading, reduced catalyst ageing and reduced backpressure. This study compares the performance of the novel substrate for CO oxidation against commercially available 400 cpsi and 900 cpsi catalysts using gas concentrations and a flow rate equivalent to those experienced by a full catalyst brick when attached to a vehicle. Due to the novel micro-structure, no washcoat was required for the initial testing and 13 g/ft3 of Pd was deposited directly throughout the substrate structure in the absence of a washcoat.
2014-10-01
Journal Article
2014-01-9028
Theodoros Kosmanis, Georgios Koretsis, Athanasios Manolas
Abstract The implementation of an electronic differential system in a delta-type, electrically assisted, three wheel Human Powered Vehicle is the subject of this paper. The electronic differential algorithm is based on the turning angle of the vehicle and its geometrical characteristics. The theoretical analysis is applied in a realistic human powered tricycle constructed in the premises of the Alexander Technological Educational Institute of Thessaloniki. The system's efficiency is validated through test measurements performed on the rear wheels during vehicle's operation in appropriately selected routes. The measurements are performed for both typical cornering and oversteering.
2014-10-01
Journal Article
2014-01-9027
Berna Balta, Onur Erk, H. Ali Solak, Numan Durakbasa
Rear underrun protection device is crucial for rear impact and rear under-running of the passenger vehicles to the heavy duty trucks. Rear underrun protection device design should obey the safety regulative rules and successfully pass several test conditions. The objective and scope of this paper is the constrained optimization of the design of a rear underrun protection device (RUPD) beam of heavy duty trucks for impact loading using correlated CAE and test methodologies. In order to minimize the design iteration phase of the heavy duty truck RUPD, an effective, real-life testing correlated, finite element model have been constructed via RADIOSS software. Later on, Pareto Optimization has been applied to the finite element model, by constructing designed experiments. The best solution has been selected in terms of cost, manufacturing and performance. Finally, real-life verification testing has been applied for the correlation of the optimum solution.
2014-09-30
Technical Paper
2014-01-2430
Rajendra Vivekananda Hosamath, Muralidhar Nagarkatte
Abstract All top ranking automobile companies in the world believe in single word “Quality” and maintaining quality standards is a philosophy, a belief in which we live, a task which cannot be put aside for another day. To achieve the world class quality standards Divgi-Warner meticulously follows a highly effective tool known as Quality System Basics (QSB).QSB helps Divgi-Warner to preserve integrity of commitment to achieve manufacturing excellence. This case study covers the Quality System Basics implementation experience of Divgi-Warner Pvt. Ltd. (DWPL) India, a BorgWarner's plants located at Pune and Sirsi in India.
2014-09-30
Journal Article
2014-01-2433
Abhishake Goyal, Nadeem Yamin, Naveen Kumar
Abstract Fuel cells are a promising energy source on account of their high efficiency and low emissions. Proton exchange membrane fuel cells (PEMFC) are clean and environmental-friendly power sources, which can become future energy solutions especially for transport vehicles. They exhibit good energy efficiency and high power density per volume. Working at low temperatures (<90°C), hydrogen fuelled proton exchange membrane fuel cells (PEMFCs) are identified as promising alternatives for powering autos, houses and electronics. At the middle of the proton exchange membrane (PEM) fuel cell is the membrane electrode assembly (MEA). The MEA consists of a proton exchange membrane, catalyst layers, and gas diffusion layers (GDL). However, most of the researchers have already mentioned that PEMFC are not competitive enough to rechargeable lithium ion battery with respect to price because of the rare metal used such as platinum in it.
2014-09-30
Technical Paper
2014-01-2428
Burcu Guleryuz, Cagkan Kocabas, Erkan Ozturk
Abstract Remanufacturing is a process in which used products are disassembled, and their components are repaired and used in the production of new products. This study investigates the impact of various remanufacturing decisions on Original Equipment Manufacturer (OEM) profitability and market cannibalization in an infinite-horizon production scenario for heavy duty vehicle (HDV) clutches. A discrete event simulation model is developed for benchmarking of different scenarios using various factors and their levels. There are two consumer segments as primary customer and grey customer in the market. Three different end of life (EOL) clutch quality conditions are defined, and three different percentages of clutch collect strategies are defined for all EOL products in the market.
2014-09-30
Technical Paper
2014-01-2434
Paul Salama, Adam Lubinsky, Bryan Roy, Ziga Ivanic, Paul Lipson, Luis Torres, Joseph Tario, Robert Ancar
Abstract The emergence of electric vehicle (EV) delivery trucks is resulting in health and environmental benefits, less noise, reduction of foreign energy dependency, and economic development opportunities. Green Loading Zones (GLZs) are dedicated curbside spaces for commercial delivery EVs meant to incentivize and accelerate market adoption. This study examined the impact and potential benefits of this strategy for New York City. Discussions with fleets revealed that while they are realizing operational savings and other benefits from the use of EVs, their incremental costs over diesel vehicles can take a very long time to recover, even with existing subsidy programs. Complementary incentives like GLZs can provide further justification for the investment in cleaner technology. Most fleets interviewed would place a high monetary value on guaranteed delivery locations and reduced parking violation expenses.
2014-09-30
Technical Paper
2014-01-2319
Iman Hazrati Ashtiani, Mehrnoosh Abedi
Abstract Road train vehicles have been applied as one of the common and efficient ways for transportation of goods, specifically hazardous liquid cargos, in different nations. These vehicles have a wide variety of lengths and towing systems such as the fifth wheel or the dolly draw-bar. Based upon specific regulations, they could be authorized to move on specific roads. In order to avoid hazard and danger in case of accidents, safety performance of a B-train vehicle as a specific type of road train vehicles is investigated in this paper. A Multi-Body Dynamic (MBD) model, which consists of a prime mover and two trailers coupled by fifth wheels, are simulated in the initial phase of the study. The developed dynamic model is capable of simulating required tests as well as the SAE lane change, along with a constant radius turn for the purpose of roll and yaw stability analysis and safety evaluation. The effects of variation of the fluid fill level are considered in this research.
2014-09-30
Technical Paper
2014-01-2335
Balakrishnan Natesan
Abstract Phosphorous is an important alloying element in powder metallurgy applications. It is used in Powder metal parts for effective Sintering, dimensional stability, improved machinability, corrosion resistance etc. However it does have some negative effects on properties of Powder metal parts. The purpose of the paper is to study the effect of phosphorous on Powder metal gear of Mix A and Mix B having identical composition differing only in phosphorous content. The samples were detailed on each stage, viz. sintering & Heat treatment. In addition two defective samples were studied to observe the extent to which phosphorous may deteriorate the Powder metal Gear.
2014-09-28
Technical Paper
2014-01-2503
Johannes Schneider
The brake discs and brake drums used on motor vehicles are, in 90% of applications, made from grey cast iron. Although other designs such as composite systems comprising of a grey iron braking band and a light weight mounting bell made from aluminum, Al-MMC or entire ceramic brake discs have been developed, cast iron will continue to play a major role as a work piece material for brakes. Cast iron offers advantages in material characteristics such as good thermal conductivity, high compressive strength and damping capacity. In addition it shows a superior casting behavior and also an unbeatable competitive price per part, when compared to other brake materials or designs. Ongoing research in material and casting science are leading to new types of alloyed CI materials, fulfilling the increasing demands in terms of performance but also increasing the demands for a reliable and economical production.
2014-09-16
Technical Paper
2014-01-2127
Karl Strauss
Abstract “Today's electronic components rely on principles of physics and science with no manufacturing precedence and little data on long term stability and reliability.” [1] Yet many are counting on their reliable performance years if not decades into the future, sometimes after being literally abandoned in barns or stored neatly in tightly sealed bags. What makes sense? To toss everything away, or use it as is and hope for the best? Surely there must be a middle ground! With an unprecedented number of missions in its future and an ever-tightening budget, NASA faces the daunting task of doing more with less. One proven way for a project to save money is to use already screened and qualified devices from the spares of its predecessors. But what is the risk in doing so? How can a project reliably count on the value of spare devices if the risk of using them is not, in itself, defined?
2014-09-16
Technical Paper
2014-01-2138
Ron Wang, Michelle Bash, Steven D. Pekarek
Abstract In this research, excitation strategies for a salient-pole wound rotor synchronous machine are explored using a magnetic equivalent circuit model that includes core loss. It is shown that the excitation obtained is considerably different than would be obtained using traditional qd-based models. However, through evaluation of the resulting ‘optimal’ excitation, a relatively straightforward field-oriented type control is developed that is consistent with a desire for efficiency yet control simplicity. Validation is achieved through hardware experiment. The usefulness/applicability of the simplified control to variable speed applications is then considered.
2014-09-16
Journal Article
2014-01-2230
Ruiqiang Lu
Abstract With the development of many new technologies in aircraft manufacturing area and the increasing competition of the global market, aircraft manufacturing enterprises have to reduce their production time and increase the cost-efficiency, with the consideration of high speed response to the changes inside enterprises or in the environment. Production scheduling is a significant process in manufacturing, especially for complicated part or component processing. This paper proposes an agent based multi-objective optimization approach for production scheduling based on Genetic Algorithms. It aims to minimize the total production cost and simultaneously reducing the emission released during production, and the delivery time and equipment constraints are satisfied as well. The new approach is tested in a virtual plant for turbine blade manufacturing.
2014-09-16
Journal Article
2014-01-2240
Joshua Norman, Cesar Moreno, Zhiyu Wang, James Mann, Christopher Saldana
Abstract The beneficial effects of contact disruption in modulation-assisted machining of aerospace alloys have been well documented, but sources for such improvements are not well understood. This study explores the underlying nature of differences that occur in energy dissipation during conventional and modulation-assisted machining by characterizing the relationship between controllable process parameters and their effects on chip formation. Simultaneous in situ force and tool position measurements are used to show that the forces in modulation-assisted machining can be described by empirical force models in conventional machining conditions. These models are found to accurately describe plastic dissipation over a range of modulation conditions and configurations, including in cases where energy expenditure decreases with the application of modulation.
2014-09-16
Technical Paper
2014-01-2238
Richard Kingston
Abstract Industrial robots are extremely good at repetitive tasks. They exhibit excellent repeatability, making them ideal candidates for many tasks. However, increasing use of CAD based offline programming highlights the fact that industrial robots are generally not accurate devices. Several approaches have been used to compensate for this deficiency. Robot calibration is well established and factory calibrated robots are available from most industrial robot manufacturers. This can improve the spatial accuracy of robots to figures better than 1mm which is adequate for most robot processes in use today. Improvements in accuracy beyond this point can be achieved if the working range of the robot is constrained in some way. For example, limiting a robot to working in a single plane or restricting the robot to a reduced work volume can contribute to significant improvements in accuracy.
2014-09-16
Journal Article
2014-01-2242
Samuel Baha II
Hybrid (bolted/bonded) joining is becoming one of the innovative joining processes for light weight structures in the transport industry, especially in the aerospace industry where weight reduction and high joining requirements are permanent challenges. Combining the adhesive bonding with the mechanical joining -riveting for instance- can lead to an enhancement of the properties of the joint compared to the wide established riveting, as a result of a synergistic load bearing interaction between the fastener and the adhesive bondline. The influence of the rivet installation process on a hybrid joint regarding the joint stress state, the change of the bondline thickness as well as its effects on the joint performance and load transfer are some of the factors that drive the users to a better understanding of the hybrid joining process.
2014-09-16
Journal Article
2014-01-2241
Jamie Skovron, Laine Mears, Durul Ulutan, Duane Detwiler, Daniel Paolini, Boris Baeumler, Laurence Claus
Abstract A state of the art proprietary method for aluminum-to-aluminum joining in the automotive industry is Resistance Spot Welding. However, with spot welding (1) structural performance of the joint may be degraded through heat-affected zones created by the high temperature thermal joining process, (2) achieving the double-sided access necessary for the spot welding electrodes may limit design flexibility, and (3) variability with welds leads to production inconsistencies. Self-piercing rivets have been used before; however they require different rivet/die combinations depending on the material being joined, which adds to process complexity. In recent years the introductions of screw products that combine the technologies of friction drilling and thread forming have entered the market. These types of screw products do not have these access limitations as through-part connections are formed by one-sided access using a thermo-mechanical flow screwdriving process with minimal heat.
2014-09-16
Journal Article
2014-01-2234
Nelson W. Sorbo, Jason J. Dionne
Abstract The use of composite materials and composite stackups (CO-Ti or CO-Al) in aerospace and automotive applications has been and will continue to grow at a very high rate due to the high strength and low weight of the materials. One key problem manufacturers have using this material is the ability to efficiently drill holes through the layers to install fasteners and other components. This is especially true in stackups of CFRP and titanium due to the desire of drilling dry for the CFRP layer and the need for cooling when drilling the high strength Ti layer. By using CO2 through tool cooling, it is possible to protect both layers. Through work supported by the National Science Foundation (NSF) and Department of Energy (DOE) it is shown that CO2 through tool cooling productivity can be significantly increased while maintaining required hole tolerances in both the composite and Ti layers.
2014-09-16
Journal Article
2014-01-2236
Julian Lonfier, Côme De Castelbajac
Abstract As aircraft programs currently ramp up, productivity of assembly processes needs to be improved while keeping quality, reliability and manufacturing cost requirements. Efficiency of the drilling process still remains an issue particularly in the case of CFRP/metal stacks: hot and long metallic chips are difficult to remove and often damage the surface of CFRP holes. Low frequency axial vibration drilling has been proposed to solve this issue. This innovative drilling process allows breaking up the metallic chips in such a way that jamming is avoided. This paper presents a case of CFRP/Ti6Al4V drilling on a CNC machine where productivity must be increased. A comparison is made between the current regular process and the MITIS drilling process. First the analysis and comparison method is presented. The current process is analyzed and its limits are highlighted. Then the vibration process is implemented and its performances are studied.
2014-09-16
Technical Paper
2014-01-2237
Rainer Mueller, Matthias Vette, Andreas Ginschel, Ortwin Mailahn
Abstract The global competition challenges aircraft manufacturers in high wage countries. The assembly of large components happens manually in fixed position assembly. Especially the completion of the inner fuselage structure is done 100% manually. The shells have to be joined with rivets and several hundred clips have to be assembled to connect the shell to the frames. The poise of the worker is not ergonomic so a lot of physical stress is added to the worker and minimizes the working ability. Aircraft manufacturers need a lot of different production resources and qualified persons for the production, which provokes higher costs. Due to these high costs there is a demand for automated reconfigurable assembly systems, which offer a high flexibility and lower manufacturing costs. The research project “IProGro” deals with this challenge and develops innovative production systems for large parts.
2014-09-16
Journal Article
2014-01-2252
Lucas Irving, Svetan Ratchev, Atanas Popov, Marcus Rafla
Abstract The replacement for the current single-aisle aircraft will need to be manufactured at a rate significantly higher that of current production. One way that production rate can be increased is by reducing the processing time for assembly operations. This paper presents research that was applied to the build philosophy of the leading edge of a laminar flow European wing demonstrator. The paper describes the implementation of determinate assembly for the rib to bracket assembly interface. By optimising the diametric and the positional tolerances of the holes on the two bracket types and ribs, determinate assembly was successfully implemented. The bracket to rib interface is now secured with no tooling or post processes other than inserting and tightening the fastener. This will reduce the tooling costs and eliminates the need for local drilling, de-burring and re-assembly of the bracket to rib interface, reducing the cycle time of the operation.
2014-09-16
Journal Article
2014-01-2253
Ralf Schomaker, Richard Pedwell, Björn Knickrehm
Abstract As a result of the increasing use of fibre reinforced plastic (FRP) components in a modern commercial aircraft, manufacturers are facing new challenges - especially with regards to the realisation of significant build rates. One challenge is the larger variation of the thickness of FRP components compared with metal parts that can normally be manufactured within a very narrow thickness tolerance bandwidth. The larger thickness variation of composite structures has an impact on the shape of the component and especially on the surfaces intended to be joined together with other components. As a result, gaps between the components to be assembled could be encountered. However, from a structural point of view, gaps can only be accepted to a certain extent in order to maintain the structural integrity of the joint. Today's state of the art technologies to close gaps between FRP structures comprise shimming methods using liquid and solid shims.
2014-09-16
Journal Article
2014-01-2256
Roger Holden, Paul Lightowler, Simon Andreou
Abstract The 30 month COMET project aims to overcome the challenges facing European manufacturing industries by developing innovative machining systems that are flexible, reliable and predictable with an average of 30% cost efficiency savings in comparison to machine tools. From a conceptual point of view, industrial robot technology could provide an excellent base for machining being both flexible and cost efficient. However, industrial robots lack absolute positioning accuracy, are unable to reject disturbances in terms of process forces and lack reliable programming and simulation tools to ensure right first time machining, once production commences. These three critical limitations currently prevent the use of robots in typical machining applications. The COMET project is co-funded by the European Commission as part of the European Economic Recovery Plan (EERP) adopted in 2008.
Viewing 1 to 30 of 8357