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Viewing 1 to 30 of 14369
2015-01-14
Technical Paper
2015-26-0070
Amit Gawande, Virendra Bheda, Dinesh D. Welukar
Light weighting is the Current trends in automotive to achieve better fuel economy which helps for meeting fuel economy standards & to offset the higher fuel prices. Thus there is a need to develop composite running board which is light weight & structurally sound enough to meet the performance. The present paper provides a composite running board assembly for an automobile. The running board assembly includes a board, an insert body and a plurality of brackets. Upon stepping of a passenger on the board, the board transfers load on the insert body which subsequently transfers the load to the plurality of brackets thus facilitating even distribution of the load on the automobile body. This paper also put lights on the use of improved TRIZ application - an approach to inventive problem solving for designing highly affordable & light weight running board.
2015-01-14
Technical Paper
2015-26-0170
Chaitanya Pendurthi, Sourabh Tiwari, Sujit Chalipat, Ganesh Bhagwant Gadekar
Tyre plays a pivotal role in frontal impact, as it acts as a load path to transfer loads from barrier to side sill or rocker panels. Conventionally, tyres are represented with less modelling detail which can potentially effect CAE prediction. Aim of this study is to improve CAE prediction through more realistic way of representing tyre for crash event. This involves detailed study ranging from coupon level tests to full tyre model. Different tyre components like steel-belts, body plies, steel-beads, tread and sidewall, which influence tyre characterization have been considered for this study. This paper explains in detail about various experimental test and their CAE predictions to arrive at acceptable level of performance. The approach in this study is to have systematic process of rubber tyre characterization which includes quasi-static tensile coupon tests, static compression test on tyre assembly and dynamic impact test with moving trolley.
2015-01-14
Technical Paper
2015-26-0062
Pankaj Kumar Verma, Shashi Bhushan Singh, Kalyan Vedula
The Armoured fighting vehicle designers are continuously fighting for ways to reduce vehicle weight, increase fuel efficiency, improve reliability, and reduce cost. Customized engineering design, and materials are becoming more widespread on all fronts. Also, vehicle emission norms are getting stringent day by day and there is increasing pressure to reduce fuel consumption. One important method of achieving the fuel economy and improve vehicle performance is to reduce vehicle weight. In view of the above advanced materials like Carbon Fiber Reinforced Polymer (CFRP) composites are promising to be the material to look for when it comes to reduce weight of structural elements due to its high strength to weight and high stiffness to weight ratios and hence was used for the development of Bogie Wheel of a light tracked vehicle. This paper illustrates the developmental methodology of Carbon Fiber Reinforced Polymer (CFRP) Road wheel for 20 ton class of tracked vehicle.
2015-01-14
Technical Paper
2015-26-0065
Muzaffar Ali Quazi, Shalabh Parashar
The performance of internal combustion engines should be improved depending on some technological requirements and rapid increase in the fuel expenses. On the other hand, the improvements in engine materials are forced by using alternative fuels and environmental requirements. Therefore, the performances of engine materials become increasingly important. Experimental research of insulated diesel engine incorporating thermal barrier coating (TBC) has produced controversial result. Some publication report that engine efficiency increases with insulation, while other argue that efficiency decreases. There are report also presenting a mixed picture. This Paper presents comparative analysis of heat release in base line and insulated(Piston crown with plasma sprayed zirconia coating) diesel engine. The coating system effects on the fuel consumption, the power and the combustion efficiency, pollution contents and the fatigue lifetime of engine components.
2015-01-14
Technical Paper
2015-26-0169
Simhachalam Bade, Lakshmanarao C
There is a growing need for improved conceptual vehicle designs along with alternative materials to reduce the damage to the passengers and structures in aerospace and automotive industries. The energy absorption characteristics of materials play a major role in designing a safe vehicle for transport. In this paper, compression behavior and energy absorption of aluminum alloy AA6061 and AA7005 tubes in T4 and T6 conditions are investigated by experimental and numerical methods. The AA7005 and AA6061 tubes are solution heat treated and then aged to achieve the final strength in T6 condition. Experimental compression test results have shown improved energy absorption of tubes in T6 condition compared to tubes in T4 condition. There is less variation of energy among the tested samples. The mean load is compared with the results obtained from analytical formulas. Tensile properties have been obtained from tensile tests using UTM for both AA6061 and AA7005 tubes.
2015-01-14
Technical Paper
2015-26-0168
Dinesh Munjurulimana, Manish Chaturvedi
With a significant increase in awareness of safety and sustainability among the automobile original equipment manufacturers and end users, every car manufacturer is looking for lightweight, safe and cost-effective solutions for every unit present in their vehicle. The latter gets much more focus in developing countries, where the automobile market is extremely cost sensitive. Further, with implementation of the proposed global technical regulations on pedestrian safety in the near future and low-speed vehicle damageability requirements, demand for a low-cost, lighter and safer bumper system is ever increasing. This paper focuses on development of a unique thermoplastic energy-absorbing device for vehicle bumpers. Conventionally, major energy absorbing members of these bumper systems consist of three separate pieces: energy absorber, bumper beam and crash cans. A hybrid approach based on logical reasoning and topology optimization is used to conceive the design.
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
2015-26-0226
Bhaskarjyoti Saikia, Piyush Ranjan, Remesan Chirakkal, Vasundhara V Arde
The application of virtual simulation of Engine components has become an integral part of design and development process. Virtual simulation offers opportunities to reduce number of physical testsduring design verification and validation and thereby helps in achieving considerable reduction in development time and cost. This paper explains a case study that was essential for assessment of strength & fatigue analysis of diesel engine connecting rod as part of an engine development program for power upgrade through Turbo charging. The methodology adopted simulates major loading conditions for Compressive& Tensile stress &fatigue life of connecting rod. Finite element analysis was done to calculate static displacement, strain and stresses under maximum compressive and tensile loading which were then used for critical point evaluation.
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
2015-26-0189
Aniket Basu, Nitin Gokhale, Kedar Kanase, Yogesh Aghav, M N Kumar
Valve trains are highly burdened powertrain subsystem which has to undergo high fatigue cycles during its service lifespan. Wear enhances valve lash thus depreciating the performance drastically. Analytical advances have helped engineers to predict parameters such as wear, contact stresses, lubrication etc. to uphold the durability of valve train components. Most of the genset and industrial engines running at medium speed use type 5 valve train. In this paper, our study involves about crack induced “wear” due to Hertzian stress on rocker toe and the process followed to resolve the problem for a medium speed diesel engine We experienced the problem of rocker toe crack resulting in toe wear in field and on test bed. Our investigations led us to evaluate the life of a rocker toe by specifically developing a test cycle to reproduce the wear due to induced cracks as well as to assess the durability.
2015-01-14
Technical Paper
2015-26-0068
Muthuraj Ramasamy, Vignesh E, Sundararajan Thiyagarajan
Speaking of industrial design in automotive engineering, safety, aesthetics (user driven aspects), ergonomics (technology driven aspects) and product economics play a key role in the success and sustenance of any auto component or product in service. One such auto component in a vehicle which necessitates equal attention from all the above said aspects is a “WHEEL”. A conventional tube type wheel for commercial vehicles is made of steel with steel side rings (multi-piece construction). In course as headway in wheel design the single piece wheels were developed which used the tubeless tires. These wheels were made available in both steel and aluminium versions. Wherein the aluminium wheels were lighter in weight than steel, aesthetically more appealing and had other significant advantages. Despite the advantages of these tubeless tire wheels, the end user had to invest for both wheels and tubeless tires to replace conventional tube type steel wheels.
2015-01-14
Technical Paper
2015-26-0066
Aravind Vadiraj, Shashank Tiwari, Ashutosh Dasare
Mechanical and wear properties of Al alloyed gray cast iron (0.5% and 1.0%) was compared with that of Mo (1.0%) and Cu (0.77%) alloyed gray cast iron in this investigation. All the alloys showed pearlitic microstructure. The graphite morphology varied due to varying chemistry. The fracture surface showed “cabbage” life dimpled morphology indicating the predominant ductile fracture. It was found that the Mo containing cast iron show 25 to 30% higher strength and 6 to 7 times better wear resistance compared to Al containing cast irons. The worn surface showed oxide formation during sliding.
2015-01-14
Technical Paper
2015-26-0035
Krishnan Sadagopan, Somasundaram Suresh Kumar, Arulsivan T, Senthilnathan Karunakaran
In the recent Past the automobile Industry have been focusing on Cost reduction and Quality Improvement. Ashok Leyland DOST- Engine has been designed with the motto of developing engine of Japanese Quality at Indian Cost. An Aluminum Alloy Cylinder Head has been designed & developed for this application through an Innovative and Efficient approach for the Cost Centric & Quality Conscious Indian Market. This is a first Aluminum 3-Cylinder Head developed for LCV application in India. Robust design process has helped us in achieving industry benchmark of BS4 emission with 2-Valve per Cylinder arrangement itself. In order to keep the tooling Cost minimum, the Cylinder Head has been manufactured using "Tilting GDC" Process. The selected material combined with apt Heat Treatment has eliminated the need of Bearing for the Single Overhead Camshaft. An Innovative approach for Compactness has been achieved by Mounting the Fuel Pump Housing , Tensioner and Common rail on the Cylinder Head.
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
2015-26-0233
Marc Pinilla, Pau Kuipers
Abstract Asphalt specifications for a Wet Handling Track (WHT) are very stringent regarding coefficient of adherence and homogeneity of this coefficient over time. Currently, asphalt mixture pavements used in wet conditions have a very limited useful life and continue degrading following different patterns depending on the asphalt mixtures used. This is due to many reasons, but mainly as a consequence of supporting big strains and the extreme conditions during its useful life. During its lifetime, the asphalt is constantly immersed in water and submitted to adverse weather conditions. Moreover, Wet Handling pavements should provide very specific and stable adherence values for vehicle testing during the asphalt aging evolution. Consequently, the study, execution and testing of the new asphalt concrete mixture for the pavements and the materials used for WHT is necessary to reach durable, homogenous in time and cost effective pavements with very low adherence parameters.
2014-12-01
Journal Article
2014-01-9004
Mohammad Danish Khan
Abstract Effectiveness of current electromagnetic shielding techniques in composite aircraft has been called into question several times before and is a subject of interest and research in the aerospace industry. We present an analytical approach to understand the issues in detail. It was found using first order approximations that a panel with Aluminum expanded metallic foil (ExMF) along with carbon fiber plies used on composite aircraft provides fair albeit lower electromagnetic shielding from source frequencies of a few KHz until well into MHz range when compared to an aluminum panel used on metallic aircraft. This was primarily attributed to relatively large skin depth value at low frequencies which was due to: a) low electrical conductivity of aluminum ExMF when compared to bulk aluminum; b) low electrical conductivity of resin impregnated carbon fiber layers and; c) very thin layer of aluminum ExMF used.
2014-11-11
Technical Paper
2014-32-0117
Matthew Smeeth
Abstract Rolling contact fatigue is a particular type of fatigue that occurs in heavily loaded, non-conformal contacts, such as gears and rolling element bearings. It is primarily a failure mode associated with repeated cyclic loading that generates high local Hertzian pressures, leading to local plastic deformation and substantial surface or sub surface stress. This in turn leads to crack formation and propagation. In some instances this results in sudden and often critical mechanical failure of contacting parts. This failure mode can, to a certain degree, be controlled by the appropriate choice of lubricant; in terms of both the physical and chemical properties of the films formed at the surface. A three contact disc machine has been used to examine the rolling contact fatigue of motorcycle lubricants in such heavily loaded contacts. Three counterface test rings of equal diameter (54mm) are mounted 120° apart with a smaller (12mm diameter) test roller in the centre.
2014-11-11
Technical Paper
2014-32-0034
Saager Paliwal, Alex S. Bare, Katherine J. Lawrence, Marc Anderson, Glenn Bower
Abstract This study looks at the application of a titanium dioxide (TiO2) catalytic nanoparticle suspension to the surface of the combustion chamber as a coating, as well as the addition of hydrogen gas to a four-stroke spark-ignited carbureted engine as a possible technique for lowering engine-out emissions. The experiments were conducted on two identical Generac gasoline powered generators using two, four and six halogen work lamps to load the engine. One generator was used as a control and the second had key components of the combustion chamber coated with the catalytic suspension. In addition to the coating, both engines were fed a hydrogen and oxygen gas mixture and tested at low, medium and high loads. Using an unmodified engine as a control set, the following three conditions were tested and compared: addition of hydrogen only, addition of coating only, and addition of hydrogen to the coated engine.
2014-11-11
Technical Paper
2014-32-0042
Bernard Alsteens
Abstract Composite materials can bring significant weight saving in the design of a new component. These materials are one of the solutions offered to designers to achieve new fuel efficiency regulation. New challenge arises in term of design optimization and manufacturing. Shifting from a metal to composite paradigm requires a dedicated tool for composite design in order to take into account the specific composite behavior. Material performance varies widely over the entire part mainly due to the manufacturing process and the corresponding microstructure. Classical design tools are not able to describe accurately the local composite material behavior, leading to the introduction of safety factors and lack of confidence in the design. Accurate modelling of composites require the use of a multi-scale approach. The composite is not seen as a homogeneous material anymore but as a heterogeneous material made of several constituents.
2014-11-11
Technical Paper
2014-32-0026
Alessandro Franceschini, Emanuele Pellegrini, Raffaele Squarcini
Abstract Nowadays the challenge in design of auxiliary devices for automotive small engines is focused on packaging reduction and on the increase of the performance. These requirements are in contrast to each other and in order to fulfil the project specifications, new and more refined design tools and procedures need to be developed. This paper presents a calculation loop developed by Pierburg Pump Technology Italy S.p.A. (PPT). It supports the design of a variable displacement oil pump component for engine applications. The work is focused on the fatigue life evaluation of a joint, which transmits the drive torque from the engine to the oil pump. The aim of the procedure is to calculate the onset of the surface fatigue phenomenon in the hexagonal joint which drives the oil pump, taking into account the axes misalignment and the flat-to-flat clearance. The study has involved several matters, experimental measures, CFD, MBA and FEM analyses.
2014-11-11
Journal Article
2014-32-0045
Akiko Tanaka, Ikue Sato
Abstract Currently, there is a growing demand for application of plastic coverings for motorcycles in the market. Accordingly, decorative features for plastic coverings are increasingly important to enhance the attractiveness of exterior designs of those motorcycles. Under these circumstances, the magnetically formed decorative painting had been adopted to a mass-production model sold in Thailand in 2008. Magnetically formed decorative painting is a method in which the design patterns are formed by painting a material that contains flakes movable along with magnetic fields, while applying magnetic sheets in the ornamenting design shapes underneath the part being painted. It offers a three-dimensional appearance even though its surface has no protrusions or indentations. The degree of three-dimensionality on the paint surface appearance was defined as “plasticity” [1] (a term used in pictorial arts).
2014-11-11
Journal Article
2014-32-0044
Simone Vezzù, Carlo Cavallini, Silvano Rech, Enrico Vedelago, Alessandro Giorgetti
Abstract The deposition of thick, pore-free, high-performance copper alloy matrix composite coatings is a topic of interest for several industrial applications, including friction materials, high-strength electrical contacts, and welding electrodes, among others. This study investigates the use of cold spray to deposit CuCrZr/Al2O3 cermet coatings on aluminum alloy 6060. The objective is to integrate copper-based materials with aluminum-based materials, ensuring a high degree of mechanical and thermal contact, using a low temperature process that does not adversely affect the properties of the base materials. This technique can be used to produce integral coolers and aluminum-based bearings for automotive and motorcycle applications. Fused and crushed alumina and gas-atomized CuCrZr powder blends have been used as initial feedstocks, with compositional weight ratios of 65/35 and 80/20 (ceramic/metal).
2014-10-13
Technical Paper
2014-01-2866
Zhi-yong Chen, Ning Sun, Wenku Shi
Abstract In order to improve structure and performance of magneto-rheological dual mass flywheel (MRF-DMF), some parameters effects on dynamic characteristics are acquired by parameters analysis. The dynamic stiffness and loss angle in different current and different frequency are gained through dynamic characteristic test. The fluid-structure interaction finite element model of MRF-DMF is built and the accuracy is verified by comparison between test and simulation. Based on the model, the parameters analysis is done and the law of MRF viscosity, arc spring stiffness, working clearance, rotor radius and axial width effect on dynamic characteristics are gained, it will prove some guidance for the structure and performance improvement.
2014-10-13
Technical Paper
2014-01-2865
Anandan Sivakumar, V. Saishanker, Raghvendra Gopal
Abstract Success of the vehicle in cold countries depends on performance of the vehicle under cold climatic conditions. In automobiles, structural elastomer components have strong influence on vehicle performance including NVH, ride comfort & durability. Elastomers are sensitive in nature to these climatic conditions due to its temperature dependent visco-elastic behavior. Thus, it is very important to understand structural elastomer component's performance at sub zero temperatures. In a vehicle, Engine mount is used to hold engine firmly and isolate vibrations away from chassis. Vibration isolation of a mount at low temperature is generally affected by the rubber composition. Major ingredients of the rubber composition influencing the low temperature characteristics are Elastomer type, filler type, plasticizer and curing system. Rubber composition plays key role in achieving engine mount properties like static stiffness, dynamic stiffness, permanent set and durability.
2014-10-13
Technical Paper
2014-01-2867
Zhiyong Chen, Zhiyuan Chen, Yang Mao, Wenku Shi, Guihui Zhang
Abstract To research the torsional vibration damping characteristic of magneto-rheological fluid dual mass flywheel (MRF-DMF) and the control system in power train, the multi-degree power train torsional vibration model which contains MRF-DMF and semi-active fuzzy control model are built, then the damping characteristic of MRF-DMF in several conditions are gained and compared with MRF-DMF when no control system. The result indicates: the damping characteristic of MRF-DMF effect on power train when using control is better than without control in idle, speed up, slow down, ignition and stalling, while the damping characteristic is less obvious in constant speed because the simulation condition and damping moment relatively stable.
2014-10-13
Technical Paper
2014-01-2859
Oliver P. Taylor, Richard Pearson, Richard Stone, Phil Carden, Helen Ballard
Abstract Most major regional automotive markets have stringent legislative targets for vehicle greenhouse gas emissions or fuel economy enforced by fiscal penalties. Large improvements in vehicle efficiency on mandated test cycles have already taken place in some markets through the widespread adoption of technologies such as downsizing or dieselization. There is now increased focus on approaches which give smaller but significant incremental efficiency benefits such as reducing parasitic losses due to engine friction. Fuel economy improvements which achieve this through the development of advanced engine lubricants are very attractive to vehicle manufacturers due to their favorable cost-benefit ratio. For an engine with components which operate predominantly in the hydrodynamic lubrication regime, the most significant lubricant parameter which can be changed to improve the tribological performance of the system is the lubricant viscosity.
2014-10-13
Technical Paper
2014-01-2765
Simona Silvia Merola, Cinzia Tornatore, Luca Marchitto, Gerardo Valentino, Adrian Irimescu
Abstract Liquids with stable suspensions of nanoscale materials are defined as nanofluids. As reported in recent scientific literature, a very small amount of suspended nanostructures has the potential to enhance the thermo physical, transport and radiative properties of the base fluid. One of the main applications of this technology is in the field of combustion and fuels. In fact, adding nanomaterials (such as metals, oxides, carbides, nitrides, or carbon-based nanostructures) to liquid fuels is able to enhance ignition and combustion. The focus of this research is to gain a fundamental understanding of the characteristics of a nanofluid fuel prepared using carbon nanoparticles (CNPs) and multi-walled carbon nanotubes (MWCNTs) dispersed in butanol. This study starts with the investigation of the optical properties of the mixtures. The transmission spectra of the nanofluids are measured in a wide wavelength range from UV (250 nm) to near IR (800 nm).
2014-10-13
Technical Paper
2014-01-2818
Mohammad Reza Hamedi, Athanasios Tsolakis, Jose Martin Herreros
Abstract Recent developments in diesel engines lead to increased fuel efficiency and reduced exhaust gas temperature. Therefore more energy efficient aftertreatment systems are required to comply with tight emission regulations. In this study, a computational fluid dynamics package was used to investigate the thermal behaviour of a diesel aftertreatment system. A parametric study was carried out to identify the most influential pipework material and insulation characteristics in terms of thermal performance. In the case of the aftertreatment pipework and canning material effect, an array of different potential materials was selected and their effects on the emission conversion efficiency of a Diesel Oxidation Catalyst (DOC) were numerically investigated over a driving cycle. Results indicate that although the pipework material's volumetric heat capacity was decreased by a factor of four, the total emission reduction was only considerable during the cold start.
2014-10-13
Technical Paper
2014-01-2849
Wei Guo, Henry Guo, Xiaowei Du, Daniel Wang
Turbochargers are widely used to boost internal combustion engines for both on and off high way applications to meet emission and performance requirements. Due to the high operating temperature, turbochargers are subjected to hostile environment. Low vibration level is one of the key requirements while designing turbo for every application. An engine bracket is employed to support turbine housing to reduce total vibration level. Turbine housing in the turbocharger is commonly equipped with boss to accommodate the engine bracket supporting which eventually includes additional constraints in the turbocharger system. Additional constraints in the turbine housing can lead to adverse impact in the Thermo-Mechanical Fatigue (TMF) life of the housing component. Boss generally has critical influence to thermal stress distribution of the turbine housing.
2014-10-13
Technical Paper
2014-01-2790
Sakthinathan Ganapathy Pandian
Nanolubricants are suspensions of nanoparticles in base fluids, a new challenge for thermal sciences provided by nanotechnology. The objective of this work is to analyze the thermal and tribological properties of yttria stabilized zirconia (YSZ) nanolubricants. Nanosized YSZ particles were prepared by milling YSZ (10μm) in a planetary ball mill equipped with vials using tungsten carbide balls. After 40 hrs, milled YSZ nanoparticles of sizes ranging from 70-90nm were obtained. The nanoparticles were characterized by Energy Dispersive X-ray analysis (EDXA), Scanning Electron microscope (SEM), Transmission Electron Microscope, Thermo Gravimetric-Differential Scanning Calorimeter and non contact 3D surface profilometer and the images of the same were obtained.
Viewing 1 to 30 of 14369