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Viewing 1 to 30 of 6148
2017-10-08
Technical Paper
2017-01-2328
Yuanxu Li, Karthik Nithyanandan, Zhi Ning, Chia-Fon Lee, Han Wu
Abstract Bio-butanol has been widely investigated as a promising alternative fuel. However, the main issues preventing the industrial-scale production of butanol is its relatively low production efficiency and high cost of production. Acetone-butanol-ethanol (ABE), the intermediate product in the ABE fermentation process for producing bio-butanol, has attracted a lot of interest as an alternative fuel because it not only preserves the advantages of oxygenated fuels, but also lowers the cost of fuel recovery for individual component during fermentation. If ABE could be directly used for clean combustion, the separation costs would be eliminated which save an enormous amount of time and money in the production chain of bio-butanol.
2017-10-08
Technical Paper
2017-01-2428
Peilin Dai, Ying Huang, Donghao Hao, Ting Zhang
Abstract The vehicle driveline suffers low frequency torsional vibration due to the abrupt change of input torque and torque fluctuation under variable frequency. This problem can be solved by model based control, so building a control oriented driveline model is extremely important. In this paper, an on-line recursive identification method is proposed for control oriented model and validated based on an electric car. First of all, the control oriented driveline model is simplified into a six-parameter model with double inertia. Secondly, based on stability analysis, motor torque and motor speed are chosen as input signal for on-line model identification. A recursive identification algorithm is designed and implemented based on Simulink. Meanwhile a detail model of the vehicle which considering driveline parameter variation is built based on ADAMS. Thirdly, on-line identification is conducted by using co-simulation of ADAMS and Simulink.
2017-10-08
Technical Paper
2017-01-2357
Mark Devlin, Jeffrey Guevremont, Chip Hewette, Marc Ingram, Grant Pollard, William Wyatt
Abstract Different mechanical components in a vehicle can be made from different steel alloys with various surface treatments or coatings. Lubricant technology is needed to prevent wear and control friction on all of these different surfaces. Phosphorus compounds are the key additives that are used to control wear and they do this by forming tribofilms on surfaces. It has been shown that different operating conditions (pressures and sliding conditions) can influence the formation of tribofilms formed by different anti-wear additives. The effect of surface metallurgy and morphology on tribofilm formation is described in this paper. Our results show that additive technology can form proper tribofilms on various surfaces and the right combination of additives can be found for current and future surfaces.
2017-09-23
Technical Paper
2017-01-1987
Renjie Li, Shengbo Li, Hongbo Gao, Keqiang Li, Bo Cheng, Deyi Li
Abstract Vehicle automation is a fundamental approach to reduce traffic accidents and driver workload. However, there is a notable risk of pushing human drivers out of the control loop before automation technology fully matures. Cooperative driving (or vehicle co-piloting) is a novel paradigm which is defined as the vehicle being jointly navigated by a human driver and an automatic controller through shared control technology. Indirect shared control is an emerging shared control method, which is able to realize cooperative driving through input complementation instead of haptic guidance. In this paper we first establish an indirect shared control method, in which the driver’s commanded input and the controller’s desired input are balanced with a weighted summation. Thereafter, we propose a predictive model to capture driver adaptation and trust in indirect shared control.
2017-09-22
Technical Paper
2017-01-5009
Li Fang, Henry Hu, Xueyuan Nie, Jimi Tjong, Xuezhi Zhang
In the present study, a design of experiment (DOE) technique, the Taguchi method, was used to develop as-cast high strength aluminum alloys with element additions of Si, Cu, Ni and Sr. The Taguchi method uses a special design of orthogonal arrays to study all the designed factors with a minimum of experiments at a relatively low cost. The element factors chosen for this study were Si, Cu, Ni and Sr content in the designed aluminum-based alloys. For each factor, three different levels of weight percentages were selected (Si: 6, 9, 12%, Cu: 3, 5, 7%, Ni: 0.5, 1, 1.5% and Sr: 0.01, 0.02, 0.03%). Tensile properties such as ultimate tensile strength, yield strength and elongation at fracture were selected as three individual responses to evaluate the engineering performance of the designed alloys. The results of the factor response analysis were used to derive the optimal level combinations. The contribution of each factor was determined by an analysis of variance.
2017-09-17
Technical Paper
2017-01-2504
Scott Lambert
Abstract As the brake industry moves completely into globalization, a standardized method to define and validate the dimensions of backing plates, in a way that is both clear and feasible, is of critical importance for manufacturers at all tiers. The plate drawing not only defines the component as it fits into a brake assembly; it is also what the plate supplier relies on to define the plate for manufacture. If a drawing does not define every dimensional aspect of the product with perfect clarity, in ways that are easily measured, loss of time and resources will result from questions and/or mistakes. This paper proposes an SAE standard for defining the dimensional requirements of backing plates on the drawings themselves, and defining the measuring procedures used to validate those dimensions.
2017-09-17
Technical Paper
2017-01-2507
Matthias Hoch, Michal Kaczmarek, Markus Ahr
Abstract The demand for zinc-nickel coatings continuously increases in the automotive industry due to their high corrosion protection as well as superior wear and heat resistance compared to pure zinc platings. The state-of-the-art plating systems in the brake caliper industry are acid zinc-nickel electrolytes, as only they allow for direct plating on cast iron. Cast iron is the most common base material for the production of automotive brake components due to excellent mechanical and thermal properties. Well suited coatings will preserve the functional properties and provide additional advantages like improved corrosion protection and homogeneous and long lasting appearance. Consistently increasing quality demands, extended warranty periods and cost pressure lead to further developments and force the industry to look for new solutions.
2017-08-25
Technical Paper
2017-01-5007
Jinlun Wang, Zhengwei Ma
Abstract Flanging U-shaped piece is the typical auto-body part, such as tailor-welded front rail inner panel, whereas, large springback amount is a critical challenge in sheet metal forming process, which size and shape accuracy affect the quality of the following assembly process. Firstly, a new form of variable blank holder force (BHF) was proposed in this paper, the springback problem was analyzed by numerical method based on the constant BHF of 90 t, and the contours of Von-Mises stress and springback amount were calculated by the dieless method. Secondly, variable BHF with changes in position and punch stroke was designed and used to control springback. Finally, orthogonal experimental and range analysis method were used to optimize the variable BHF parameters. In addition, the springback angles of sidewall and flange under 16 different combinations were calculated.
2017-08-01
Journal Article
2017-01-9682
Mohsen Rahmani, Kamran Behdinan
Abstract Widely used in automotive industry, lightweight metallic structures are a key contributor to fuel efficiency and reduced emissions of vehicles. Lightweight structures are traditionally designed through employing the material distribution techniques sequentially. This approach often leads to non-optimal designs due to constricting the design space in each step of the design procedure. The current study presents a novel Multidisciplinary Design Optimization (MDO) framework developed to address this issue. Topology, topography, and gauge optimization techniques are employed in the development of design modules and Particle Swarm Optimization (PSO) algorithm is linked to the MDO framework to ensure efficient searching in large design spaces often encountered in automotive applications. The developed framework is then further tailored to the design of an automotive Cross-Car Beam (CCB) assembly.
2017-07-10
Technical Paper
2017-28-1938
Shyam Sunder Manivannan, Gopkumar Kuttikrishnan, Rajesh Siva, Janarthanan C, G A Ramadass
Abstract The hybrid robot will be a battery operated four wheel drive vehicle with a rigid chassis for all terrain operation. The vehicle will be suited for various payloads based on applications with geological, atmospheric sensors and buried object identification at a depth of 8 to 100 m., etc. The vehicle will be remotely controlled through a RF signal, allows it to maneuver up to 5 km. The novelty of the design, is its capability for all terrain and ease of trafficability based on skid steering, self-alignment of sensors and vehicle traction in spite of possible inverted conditions and the vehicle can travel from land, snow, water and vice versa. The vehicle could be deployed for surveying coastline of water bodies, borderlines and also be extensively used in polar region for studying glacier aging and as advance vehicle for the convoys and polar mapping.
2017-07-10
Technical Paper
2017-28-1964
Rajaganesh Ramamoorthy, T. Venkatesan, R. Rajendran
Abstract Machining of materials has received significant consideration due to the increasing use of machining processes in various industrial applications. In machining, the heat generated in the cutting zone during machining is critical in deciding the work piece quality. Lubricants are widely used to reduce the heat generation. Their usage poses threat to environment and health hazards. Hence, there is a need to identify eco-friendly and user-friendly alternatives to conventional cutting fluids. Modern tribology has facilitated the use of solid lubricants such as graphite, calcium fluoride, molybdenum disulphide, and boric acid as an alternative to cutting fluids in machining. Solid lubricant assisted machining is an environmental friendly clean technology for improving the surface quality of the machined work piece.
2017-07-10
Technical Paper
2017-28-1966
Praveen Kumar, Nareen Kinthala, Sri Viknesh Mohan, Harshad Bornare
Abstract 3D Printing is a revolutionizing technology extensively used in automotive and aerospace industries. It is an additive layer manufacturing process by which a scale model is quickly fabricated from CAD data in just a matter of hours. In Automotive trims, 3D Printing technology is a boon. It is used: To simulate the ‘tooled up/production part’ in terms of assembly, defined function, limited CMF and fit & finish. To evaluate and capture early feedback from top management with respect to aesthetic, design, etc. For early prediction and plan of action towards improvement for craftsmanship. To reduce design iterations, interface concerns, product lifecycle time and cost. In this paper, we will discuss on the technical aspects of how the trims 3D printed models have been effectively put to use. We have covered case studies under door trims, floor console, tail gate trim, glove box latch, molded spare wheel cover, Instrumental panel duct and bumper mask-painting template.
2017-07-10
Technical Paper
2017-28-1965
Ganesan Selvam, Surya Prakash Vaidhyanathan, Prince Arockia Doss Sebastian, Mohamed Zaheer Abdulla, Vedantham Baskaran
Abstract Lean approaches are being implemented in various manufacturing facilities across the globe. The application of lean approaches are extended to Body proto build shop to maximize the efficiency of the shop with lesser floor space and optimized equipment. Weld fixture, Weld equipment and assembly tools are the major tools required essentially for proto BIW assembly. This paper explains how the Weld equipment planning was carried out with lean approaches and implemented effectively in proto body assembly shop. The implemented lean concepts are compared with Italy and Japanese proto body build makers to validate the frugal planning of the facility for the said intent. The implemented facility is capable of producing more than a model at a time. Weld parameter selection for weld gun, gun movement to the fixture with minimized change over time and movable weld gun gantry are the lean approaches implemented.
2017-07-10
Technical Paper
2017-28-1962
Pervaz Ahmed Mouda, H Siddhi Jailani
Abstract Cryogenic treatment is an ultra low temperature treatment technique. Effect of cryogenic treatment on properties of ferrous materials and alloys is well understood. Due to which, cryogenic treated materials are being used in various applications. One among them is Electro-Discharge Machining (EDM). In EDM, the replica of electrode is obtained on the work piece, during the process tool also worn out to certain extent. In order to reduce the tool wear rate cryogenic treatment can be applied to the tool material. In this paper, the effect of cryogenic treatment on electrode wear rate of electro-discharge machining for varied pulse ON time (EDM) was studied. The cryogenic treatment was applied to the copper electrode and the microstructure analysis was carried out using optical microscope. EDM experiment was conducted using untreated and cryogenic treated copper as electrode and High Speed Steel (HSS) as work piece. Electrical resistivity was also measured.
2017-07-10
Technical Paper
2017-28-1985
Hemasunder Banka, Radhika Muluka, Vikram Reddy
Abstract Conventional materials like steel, brass, aluminum etc will fail without any indication, cracks initiation, propagation, will takes place with a short span. Now-a-days to overcome these problem, conventional materials are replaced by hybrid composite material. Not only have this conventional material failed to meet the requirement of high technology applications, like space applications and marine applications and structural applications in order to meet the above requirements new materials are being searched. Hybrid composites materials found to the best alternative with its unique capacity of designing the materials to give required properties and light weight. This paper aims to preparing hybrid composite using artificial fibers. Epoxy as resin and glass fiber as fiber for artificial hybrid composite to make a laminate for preparing leaf spring.
2017-07-10
Technical Paper
2017-28-1983
J Ronald Aseer, P Baskara Sethupathi, J. Chandradass, Renold Elsen
Abstract The utilization of unconventional machining methods such as electron beam machining, electrical discharge machinating, etc., have been increased in the manufacturing industry to create holes on the materials. In this paper, twist drill was used for drilling of Bahunia racemosa (BR)/ glass fiber composites and then the measurement of hole diameter error was analysed. The main objective was to establish a correlation between feed rate, cutting speed and drill tool with the induced hole diameter error in a composites. The drilling process was performed under various cutting speed, feed rates and different drilling tools with a point angle of 118°. A Coordinate measuring machine was used to examine the hole diameter error of drilling hole. Taguchi L9 (33) orthogonal array was used to determine the optimum levels of the parameters and analyze the effect of drilling parameters on hole diameter error.
2017-07-10
Technical Paper
2017-28-1987
Vigneshwaran K, Palanivendhan Murugadoss, K Gokul
Abstract The main objective is to Extraction of cellulose fibers using mechanical ball milling process and chemical treatment methods. The fibers are incorporated with an epoxy matrix to make composite plates. Mechanical properties such as tensile strength, flexural strength, and impact energy are evaluated. Ball milling is the mechanical extraction method of producing nano size powder. The increase in milling process results in the chance of occurring nanofibers. The ball milling process is carried out without any chemical treatment process. In chemical treatment methods, three different kinds of treatment are performed namely sodium hypochlorite, sulphuric acid and acetic acid. Using hand layup methods these fibers are incorporated into the epoxy matrix to fabricate composite plates. In my study nanosized fiber is not obtained, only 28 micron fibers are converted into 3-4 microns.
2017-07-10
Technical Paper
2017-28-1977
M Malathi, J Herbert Mabel, R. Rajendran, N Gowrishankar
Abstract Piston rings are used to seal the cavity formed between the piston and the cylinder in order to allow the engine to operate efficiently. The piston rings wear out due to constant rubbing action with cylinder wall and also have to withstand high temperature. This has lead to the development of new piston ring coatings with good wear properties under increasingly challenging running conditions. To improve the wear resistance of the piston rings several coating techniques are employed. One such technique is Ni-P composite coating which is widely used in the automotive industry. Reinforcement of ceramic particles enhances the tribological and mechanical properties of the coating. The base material of the piston ring used in this study is hardened carbon steel. The main objective is to develop an optimum Ni-P composite coating on piston ring to improve wear and friction resistance.
2017-06-28
Journal Article
2017-01-9180
Johannes Wurm, Eetu Hurtig, Esa Väisänen, Joonas Mähönen, Christoph Hochenauer
Abstract The presented paper focuses on the computation of heat transfer related to continuously variable transmissions (CVTs). High temperatures are critical for the highly loaded rubber belts and reduce their lifetime significantly. Hence, a sufficient cooling system is inevitable. A numerical tool which is capable of predicting surface heat transfer and maximum temperatures is of high importance for concept design studies. Computational Fluid Dynamics (CFD) is a suitable method to carry out this task. In this work, a time efficient and accurate simulation strategy is developed to model the complexity of a CVT. The validity of the technique used is underlined by field measurements. Tests have been carried out on a snowmobile CVT, where component temperatures, air temperatures in the CVT vicinity and engine data have been monitored. A corresponding CAD model has been created and the boundary conditions were set according to the testing conditions.
2017-06-05
Technical Paper
2017-01-1815
Pranab Saha, Satyajeet P. Deshpande
Abstract This paper discusses the importance of a dissipative sound package system in the automotive industry and how it works. Although this is not a new technique at this stage, it is still a challenge to meet the subsystem target levels that were originally developed for parts based on the barrier decoupler concept. This paper reviews the typical construction of a dissipative system and then emphasizes the importance of different layers of materials that are used in the construction, including what they can do and cannot do. The paper also discusses the importance of the proper manufacturing of a part.
2017-06-05
Technical Paper
2017-01-1817
Steven M. Gasworth, Vasudev Nilajkar, Matteo Terragni
Abstract Polycarbonate (PC) glazing as a one-for-one glass replacement offers a 50% weight reduction, but exhibits several dB lower sound transmission loss (STL) in the low frequency range where tire and engine noise are dominant. In the high frequency range where wind noise is dominant, PC glazing offers an STL at least comparable to its glass counterpart, and an STL exceeding glass when this frequency range encompasses the glass coincidence frequency. However, a key value proposition of PC glazing is the opportunity for feature integration afforded by the injection molding process generally used for forming such glazing. Two-component (2K) molding fuses a second shot of plastic material behind, and along the perimeter of, the transparent PC first shot. This second shot can incorporate features and implement functions that require additional components attached or peripheral to a glass version.
2017-06-05
Technical Paper
2017-01-1809
Dhanesh Purekar
Abstract Engine noise is one of the significant aspects of product quality for light and medium duty diesel engine market applications. Gear whine is one of those noise issues, which is considered objectionable and impacts the customer’s perception of the product quality. Gear whine could result due to defects in the gear manufacturing process and/or due to inaccurate design of the gear macro and micro geometry. The focus of this technical paper is to discuss gear whine considerations from the production plant perspective. This includes quick overview of the measurement process, test cell environment, noise acceptance criteria considerations. A gear whine case study is presented based on the data collected in the test cell at the engine plant. Gear whine data acquired on current product and next generation of prototype engines is analyzed and presented. This paper concludes by highlighting the lessons learned from the case study.
2017-05-10
Technical Paper
2017-01-1926
Tobias Winter, Simon Thierfelder
Hatz is a medium sized engine manufacturer with a production volume of currently ~58000 engines per year and a rather diversified product portfolio. To be cost and time efficient in new and further developments of our engines a deep system knowledge is indispensable. In order to achieve this we use a strongly simulation based developing approach in combination with component and specially suited engine testing. This combines to a state-of-the art R&D process which helps us to overcome an increasingly cost challenging competition.
2017-03-28
Technical Paper
2017-01-1704
D.J. Branagan, A.E. Frerichs, B.E. Meacham, S. Cheng, A.V. Sergueeva
Abstract Automotive OEMs are compelled by increasingly stringent global emissions standards to find economic solutions for building higher efficiency vehicles without compromising safety and ride quality. This challenge requires new advanced high strength steels (AHSS) that will significantly reduce vehicle weight and improve fuel economy. In addition to providing higher strength, these automotive sheet steels must have exceptional formability to produce reduced gauge parts with increasingly complex geometries. Formability is comprised of two components, global and local. Global formability represents the ability of a sheet material to be deformed under various stress conditions and to be formed into a part without failure. It can be estimated using forming-limit diagrams or ductility measurements from conventional uniaxial tensile tests. However, these tests cannot reliably assess the local formability at the edges or at the internal holes of the blanks during stamping.
2017-03-28
Technical Paper
2017-01-1703
Ryan A. Howell, Richard Gerth
Abstract Fe-Mn-Al-C steel alloys have been previously studied for their potential as an alternative steel alloy for Rolled Homogeneous Armor (RHA). Prior examination of the material system has shown promise in this capacity due to the high strength and reduced density of Mn steels as compared to RHA. The prior tested materials were both wrought and cast versions but were all less than an inch in thickness. The alloy is once again being examined, but this time in thicker wrought plate. The aim of the current body of work is to develop a Military Specification (MIL-SPEC) for this new class of ballistically capable material. For industry and communities interested in such material development, the purpose of this paper, then, is to provide a summary of the processing parameters, the prior ballistic and dynamic material testing, cutting and welding approaches, and the extent of progress on industrial sized thick plate development.
2017-03-28
Technical Paper
2017-01-1700
Rebekah L. Houser, Willett Kempton, Rodney McGee, Fouad Kiamilev, Nick Waite
Abstract Electric vehicles (EVs) hold the potential to greatly shape the way the electric power grid functions. As a load, EVs can be managed to prevent overloads on the electric power system. EVs with bidirectional power flow (V2G) can provide a wide range of services, including load balancing, and can be used to increase integration of renewable resources into electric power markets. Realizing the potential of EVs requires more advanced communication than the technology that is in wide use. Common charging standards do not include a means for an EV to send key vehicle characteristics such as maximum charge rate or battery capacity to a charging station and thus to the grid.
2017-03-28
Technical Paper
2017-01-1726
Sameer Shah, Aayoush Sharma, Raghav Angra, Nitin Singh, Khalique Ahmed
Abstract In an unavoidable event of a suspect being chased by police, there is high probability for the criminal to evade the police while driving his vehicle. At many instances, criminal escapes without leaving a trail behind and becomes untraceable. A new concept of Vigilance Assistance System Network (VASN) has been developed, which is spread across the city and helps in catching the escaping criminals. At every junction, the traffic-signals are installed with a microcontroller chip and these connected traffic signals form a network with distinct city areas demarcated on the map. The vehicle is installed with GPS and a RFID module on their ECU when it approaches any intersection or junction; they receive wireless signals from traffic-signals and transmit another registering signal to the traffic-light wirelessly through RFID.
2017-03-28
Technical Paper
2017-01-1708
Saeid Nasheralahkami, Sergey Golovashchenko, Collin Malek, Erika Rugh, Daniel Kowalsky, Weitian Zhou
Abstract In recent years, dual phase (DP) Advanced High Strength Steels (AHSS) and Ultra High Strength Steels (UHSS) are considered as prominent materials in the automotive industry due to superior structural performance and vehicle weight reduction capabilities. However, these materials are often sensitive to trimmed edge cracking if stretching along sheared edge occurs in such processes as stretch flanging. Another major issue in the trimming of UHSS is tool wear because of higher contact pressures at the interface between cutting tools and sheet metal blank caused by UHSS’s higher flow stresses and the presence of a hard martensitic phase in the microstructure. The objective of the current paper is to study the influence of trimming conditions and tool wear on quality and stretchability of trimmed edge of DP980 steel sheet. For this purpose, mechanically trimmed edges were characterized for DP980 steel and compared with other steels such as HSLA 350 and BH210.
2017-03-28
Technical Paper
2017-01-1706
Sandeep Bhattacharya, Daniel Green, Raj Sohmshetty, Ahmet Alpas
Abstract Automobile body panels made from advanced high strength steel (AHSS) provide high strength-to-mass ratio and thus AHSS are important for automotive light-weighting strategy. However, in order to increase their use, the significant wear damage that AHSS sheets cause to the trim dies should be reduced. The wear of dies has undesirable consequences including deterioration of trimmed parts' edges. In this research, die wear measurement techniques that consisted of white-light optical interferometry methods supported by large depth-of-field optical microscopy were developed. 1.4 mm-thick DP980-type AHSS sheets were trimmed using dies made from AISI D2 steel. A clearance of 10% of the thickness of the sheets was maintained between the upper and lower dies. The wear of the upper and lower dies was evaluated and material abrasion and chipping were identified as the main damage features at the trim edges.
2017-03-28
Technical Paper
2017-01-1732
Payodh Dwivedi
Abstract The conventional hybrid engine faces one major problem i.e. high cost of production. Although hybrid engines, in many sense proved to be highly efficient and environmental friendly, but high cost of production makes them less feasible and limits their applications. This problem is overcome by a new design in which instead of having Internal Combustion(IC) engine and electric motor separately, these two are incorporated under same housing. This involves a different working mechanism of electric motor which is as described below- This mechanism is applied to a normal engine which has two or more than two cylinders in any configuration or orientation. Taking example of In-line four cylinder engines as it is most widely used. In this the two cylinders work on conventional internal combustion mechanism, but the other two cylinders are electric cylinder and works on electricity.
Viewing 1 to 30 of 6148