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Viewing 1 to 30 of 19780
2015-03-30
Technical Paper
2015-01-0105
Perakit Viriyarattanasak
Farm trucks, otherwise known as a light truck, is a vehicle used to transport agricultural products from farmers in the farm fields. Originally, farm trucks are assembled by local truck workshops using used parts of cars scrapped from abroad. It causes a serious problem in terms of quality and safety, since conventional truck garages are lack of correct engineering principles in the assembly and there has a potential risk of accidents that may occur during use. This study is focused on enhancement of life quality and safety of farm truck users from different regions in Thailand. One problem encountered in the operation is that a clutch case to cover the flywheel-clutch-module, consisting of the engine flywheel and the clutch, is mostly fabricated without applying engineering understanding. This leads to time-consuming trial and errors manufacturing process and overweight parts.
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
2015-26-0204
Satyajeet Kulkarni, Abhijit Kumbhar, Jagannath M Paranjpe, Nagesh Voderahobli Karanth
To achieve first time right in any new part development process requires number of trials,skilled manpower, huge cost and massive time. In case of forging process,to develop new component lot of physical trialsrequired to be conducted due to process variations.Need of hour is shorter development time with highest quality.All these requirements can be achieved with the help of reliable computer simulation. With computer simulation, process can be optimized, crack analysis can be carried out, Additionally use of computer simulation in forging process reduces no. of trials, ultimately saves time, energy and product cost. The paper deals with forging process optimization by effective use of computer simulation. Existing forging process and modified forging process wassimulated. Forging process was able to simulate crack generation due to improper metal flow as observed in existing forging simulation process, and good co-relation was established.
2015-01-14
Technical Paper
2015-26-0165
Sivaprasad Koralla, Ganesh Bhagwant Gadekar, V Ramana Pavan Nadella, Susanta Dey
Spot welding is the primary joining method used in automobiles. Spot-weld plays a major role to maintain vehicle structural integrity during impact tests. Robust spot weld failure definitions is critical for accurate predictions of structure performance in safety simulations. Spot welds have a complex metallurgical structure, mainly consisting of fusion and heat affected zones. For accurate material property definitions in simulation models, huge no of inputs from test data is required. Multiple tests, using different spot weld joinery configurations, have to be conducted. In order to accurately represent the spot-weld behavior in CAE, detailed modeling is required using fine mesh. The current challenge in spot-weld failure assessment is developing a methodology having a better trade-off between prediction accuracy, testing efforts and computation time. In view of the above, cohesive zone models have been found to be very effective and accurate.
2015-01-14
Technical Paper
2015-26-0019
Werner Bick, Cagri Cevik, Christoph Steffens
Abstract 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 common parts and kits as well as standardized interfaces for all vehicle platforms by 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 respective CO2 emissions.
2015-01-14
Technical Paper
2015-26-0187
Venu Ganti, Yogesh Dewangan, Saurabh Arvariya, Shyamsananth Madhavan
Abstract Scuffing is an instantaneous failure which occurs when the meshed gear flanks undergo adhesive wear under extreme operating temperatures at medium- or high-speed conditions. It is one of the common failures in transmission gears, which tend to operate under long-duty cycle hours. The tip and the root regions often experience higher contact pressures because of the loading and surface curvature. These higher pressures, coupled with higher sliding velocities and heat generation, make the tip and root regions in the gear susceptible to scuffing. Gear geometry, material composition 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 rare. Lubricants with higher viscosity avoid scuffing, but have adverse effects on the transmission efficiency.
2015-01-14
Technical Paper
2015-26-0115
MV Rajasekhar, J Perumal, Samir Rawte, Nabin Nepal
Abstract In current scenario importance of fuel efficient vehicles, lesser emissions & energy efficiency are the major considerations for any vehicle manufacturer. To meet these expectations vehicle manufacturer are exploring alternate powertrains to reduce emissions and produce better fuel efficient vehicles. For any vehicle manufacturer component cost, weight and package volume are the major driving factors for success. This is even true for latest upcoming hybrid and electric vehicles as well. To gain advantage and introduce products faster, OEMs are inclined to electrify their existing platforms to compete with other manufacturers. To convert existing vehicles into hybrid vehicles, all the major components like e machine, High voltage battery, power electronics etc. needs to be carefully packaged along with existing components in the same package space.
2015-01-14
Technical Paper
2015-26-0175
Sajeev Silvester, Alex Lakic, Michael Buckley
Abstract Dimensional distortion, cosmetic distortion issues can arise during heating and cooling in the paint shop processing of car bodies. A car body can be in perfect cosmetic condition as it leaves the BIW facility, yet develop distortion defects during painting. Traditionally such issues have only been detectable on new car body designs by building and painting prototypes of a new design. The timing of such activities, by their very nature, mean that precious little time is available to address these issues by design changes in today's condensed new vehicle programmes. The result is often a vehicle entering production with partial resolution of an issue, accompanied by on-going product rework and rectification activities throughout the lifecycle of the product. This created the need for developing a CAE simulation tool which could predict these issues very early during the virtual CAE build phases of a vehicle program itself.
2015-01-14
Technical Paper
2015-26-0183
Aditya Malladi, Sridhar lingan Sr, Hari Sudhan
Abstract Crush box in an automotive passenger car has become an integral part of structural design performing various functions like optimizing energy absorption in high speed impacts, replaceable part during low speed impacts etc. Design of crush box for high speed impacts is very important as it is the first major energy absorbing component in the load path and its deformation significantly affects the overall vehicle crash behavior. The present paper explains development of a hydro-formed crush box in the front end of a sports utility vehicle. Hydro-formed components have residual plastic strains and non - uniform thickness variation throughout their length which is difficult to measure from a physical test coupon. It is critical to add hydro-forming effects onto crash FE models as it significantly affects the deformation under high speed impact. But detailed forming simulations need mature design and material data which is not available during early phases of product development.
2015-01-14
Technical Paper
2015-26-0239
Azeez Ahmed, Gopalakrishna Deshpande, Varghese Manu Varghese, Ramakrishnan Rangaswamy, Prakash Prashanth Ravi
Abstract The engine research and development has a significant contribution to meet the stringent emission norms and the changing global market demands. Leveraging the available virtual engineering methods to improve performance, velocity, quality and diminish the lead time is the key for any global brand to stay in the competition. It is the key element to reduce the research and development costs substantially by virtually developing the idea as it is conceived. Engine development test cells consist of expensive test and measurement systems which demand skilled labor and advanced equipment. Effective utilization of the test cells is essential to meet the scheduled project deadlines and cost targets. Engine Design process and tools when used effectively can increase the efficiency and lower the test cell operation costs substantially. This paper discusses the examples for this application in the area of engine installation, sensitive instrumentation/assembly.
2015-01-14
Technical Paper
2015-26-0074
Dhiyaneswar Rani, A K Saravanan, Mohammad Rafiq Agrewale, B Ashok
Abstract Material handling is a major section in all the industries especially for delicate and huge components. Here in this industry they are using pneumatics system to tilt the component for certain angle so that operator will be able to do the further operation in the line. Pneumatic system needs compressed air for running the system, which in turn requires electricity to compress the air using an air compressor. 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 excess cost for manufacturing the products and demand for fuel is also increasing day by day. So to avoid all this problem with a one step solution, dependability of energy resources has to be minimized. For avoiding the usage of energy resources the usage of pneumatics and compressed air has to be reduced.
2015-01-14
Technical Paper
2015-26-0191
Pablo Cruz, Jose Antonio Muñoz, Jordi Viñas
Abstract Robust and reliable FE-model spotweld characterization has been a challenge since spotweld technology was incorporated extensively into the automotive industry. The innovation required leads to constant enhancement of product performance; reduced time-tomarket, cost and weight. The need for quality requires robust development tools, consistency of design decisions, andrepeatability of the development process. Proper spotweld characterization has a clear impact on the above-mentioned needs and carmakers invest in efforts to increase the efficiency of the development process. Furthermore, the continuoususage of new steel grades increases the complexity of the topic. This paper presents an in-depth spotweld study that involves three different spotweld specimens: KSII; lap shear and peeling, for automotive steel grades and usual part thicknesses for each steel grade.
2015-01-07
Book
This is the electronic format of the Journal.
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.
2015-01-01
Journal Article
2014-01-9104
Salah A. Elmoselhy
The lean production system has been successful in the cost-based winning order criterion markets. However, the automotive market has been volatile and the new criterion of winning orders has been availability, which has called for an agile system. The present paper argues that because of fierce competition the current automotive market winning order criterion is now a blend of cost and availability. It shows how a hybrid lean-agile system can strategically meet such a challenging criterion. The study presents the drivers, attributes and providers in lean manufacturing, agile manufacturing, and hybrid lean-agile manufacturing systems. It investigates how the strategic facet of the proposed hybrid lean-agile manufacturing system addresses the six manufacturing competitive dimensions. It presents as well the hybrid lean-agile manufacturing key performance indicators.
2015-01-01
Journal Article
2014-01-9105
Akram Faqeeh, Ahmed Sherif El-Gizawy
The present paper aims at optimization of multiple quality characteristics (dimensional accuracy and surface roughness) in dry drilling Ti-6Al-4V using TiAlN-coated carbide tool while the controllable factors are spindle speed and feed rate. To do so, desirability methodology is used to explore optimum conditions for concurrent optimization of the addressed quality characteristics. Central composite design (CCD) is used for experimentation. In order to create reliable models describing the process behavior, response surface methodology (RSM) is used.
2014-12-17
Article
At any one time, up to 80 new steel grades are under development at ArcelorMittal. The person responsible for these advanced-development activities is Greg Ludkovsky, Vice President of Global R&D. Ludkovsky spoke with Automotive Engineering this fall at the AM/NS Calvert plant in Alabama, which the company touts as “the world’s most advanced steel finishing facility.”
2014-12-17
WIP Standard
AMS5622/H1025
This specification covers a corrosion-resistant steel product in the solution and precipitation heat treated (H1025) condition.
2014-12-16
Article
Interest in automated guided vehicles to convey product from one station to another on the plant floor assembly line continues to grow as manufacturers look for greater flexibility, scalability, and sustainability in their operations, says RedViking.
2014-12-12
Article
Al-Fe Heat Treating adds glycol quenching to its aluminum heat treat services.
2014-12-12
Standard
AS755F
This SAE Aerospace Standard (AS) provides a performance station designation system for aircraft propulsion systems and their derivatives. The station numbering conventions presented herein are for use in all communications concerning propulsion system performance such as computer programs, data reduction, design activities, and published documents. They are intended to facilitate calculations by the program user without unduly restricting the method of calculation used by the program supplier. The contents of this document were previously a subset of AS755E. Due to the growing complexity of station numbering schemes and an industry desire to expand nomenclature descriptions, a decision was made to separate the “station numbering” and “nomenclature” contents of AS755 into two separate documents. AS755 will continue to maintain standards for station numbering. SAE Aerospace Standard AS6502 will maintain standards for classical nomenclature moving forward.
2014-12-11
Standard
AMS4783G
This specification covers a cobalt alloy in the form of wire, rod, strip, foil, and powder and a viscous mixture (paste) of powder in a suitable binder. This filler metal has been used typically for joining cobalt alloys requiring corrosion and oxidation resistant joints with good strength at elevated temperatures, but usage is not limited to such applications.
2014-12-11
Standard
AMS4111E
This specification covers an aluminum alloy in the form of die forgings, hand forgings, and forging stock.
2014-12-11
Standard
AMS4140K
This specification covers an aluminum alloy in the form of die forgings and forging stock.
2014-12-11
Standard
AMS5544K
This specification covers a corrosion and heat-resistant nickel alloy in the form of sheet, strip, and plate.
2014-12-11
Standard
AMS5629/H1000
This specification covers a corrosion-resistant steel in the form of bars, wire, forgings, flash welded rings, and extrusions in the solution and precipitation heat treated (H1000) condition. These products have been used typically for parts requiring corrosion resistance, stress-corrosion resistance, high strength up to 600 °F (316 °C), and good ductility and strength in the transverse direction in large section sizes, but usage is not limited to such applications.
2014-12-11
Standard
AMS5675H
This specification covers a corrosion and heat resistant nickel alloy in the form of welding wire.
Viewing 1 to 30 of 19780

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