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Viewing 1 to 30 of 14950
2016-12-21
Journal Article
2016-01-9082
Bradley Michael, Rani Sullivan, Dulip Samaratunga, Ratneshwar Jha
Abstract Polymer matrix composites are increasingly adopted in aerospace and automotive industries due to their many attributes, such as their high strength to weight ratio, tailorability, and high fatigue and durability performance. However, these materials also have complex damage and failure mechanisms, such as delaminations, which can severely degrade their strength and fatigue performance. To effectively and safely use composite materials in primary structures, it is essential to assess composite damage response for development of accurate predictive models. Therefore, this study focuses on determining the response of damaged and undamaged carbon epoxy beams subjected to vibration loadings at elevated temperatures. The Hilbert-Huang Transform (HHT) technique is used to analyze the beams’ modal response. The HHT shows potential in identifying the nonlinear damaged response of the beams.
2016-11-08
Technical Paper
2016-32-0021
Stephen Gurchinoff
Thermoplastic bearing materials are being used in automotive transmission architectures where higher pressures and velocities are driving innovation. The benefits thermoplastics offer are high PV capable materials suitable to reduce NVH, increase design freedom while reducing design space, thermal insulation, reduce coefficient of friction, and improve wear resistance when compared to needle bearings. Expanding on the success in automotive may allow for these types of materials to be evaluated in marine lower units, CVT’s, pumps, and other small engine applications
2016-11-08
Technical Paper
2016-32-0019
David Weiss
In the early 1980's, some promising research and development efforts focused on powder metallurgy revealed that aluminum alloys containing 4 wt% cerium exhibit high temperature mechanical properties exceeding those of the best commercial aluminum casting alloys currently in production. Cerium oxide is an abundant rare earth oxide that is often discarded during the refining of more valuable rare earths such as Nd and Dy. Therefore, the economics are compelling for cerium as an alloy additive. Aluminum-cerium alloy components prepared via hot pressing and forging exhibited tensile strengths of 43 ksi at 450°F. This compares to typical tensile strengths of 10-26 ksi for Al-Cu and Al-Mg-Zn systems at that temperature.
2016-11-08
Technical Paper
2016-32-0022
David Weiss, Simon Beno, Chris Jordan, Pradeep Rohatgi
Cylinder liners exert a major influence on engine performance, reliability, durability and maintenance. Various combinations of non-metallic reinforcements and coatings have been used to improve the tribological performance of sleeves or surfaces used in compressors and internal combustion engines in four stroke, two stroke and rotary configurations. In this paper we report the use of a hybrid composite containing silicon carbide and graphite in an aluminum alloy matrix to improve the performance of various small engines and compressors. Material properties of the base material, as well as comparative dynamometer testing, are presented.
2016-11-08
Technical Paper
2016-32-0020
Balasubramanian Thiruvallur Loganathan, Srivenkata Subramani Narasimhan, Lakshminarasimhan Varadha Iyengar, Ajith Kumar Sandur, Sudhagar Vediappan
Development of small air cooled motorcycles is ever challenging due to combination of customer expectation, regulatory requirements and cost factors. Achieving higher performance and emission standards means higher engine and parts operating temperature. Under these changes meeting durability targets at reasonable cost needs good understanding of material, surface treatment and tribological aspects. In this paper some of the surface and process improvements done to reduce wear in engine valves is discussed in detail. Design of engine valves shall ensure meeting thermal, mechanical strength requirements wear and durability targets. Surface treatments, coating, surface finish and also use of special materials in tip, valve stem, seat ensures higher durability; low wear in valve and interfacing parts. During new engine development process verification tests, wear observed in valve stem- valve guide, valve tip- screw interface.
2016-11-08
Journal Article
2016-32-0071
Koji Ueno, Hiroyuki Horimura, Akiko Iwasa, Yuji Kurasawa, Pascaline Tran, Ye Liu
Motorcycles are one of the major modes of transportation globally, and further expansion of motorcycle demand and usage is expected to continue because of population growth and individual income increase, in particular in emerging countries. At the same time, approach to critical environmental issues, such as escalation of air pollution, becomes more important challenge and this trend accelerates tightening of motorcycle emission regulation globally. In accordance with this, responding to social needs and minimizing the impact on air pollution while enhancing features of motorcycles, such as drive performance, convenience, and price attractiveness are our mission as a manufacture. Platinum group metals (PGMs) such as platinum, palladium and rhodium are commonly used for automotive and motorcycle catalysts. One of catalyst researchers’ dream is ultimately to develop catalyst without using such PGMs that are precious and costly resources.
2016-11-08
Journal Article
2016-32-0024
Daisuke Sugio, Shinpei Okazaki, Mitsuo Kaneko
Injection molding is a common molding method for plastic parts and is widely applied to outer parts of motorcycles. To make it stiff enough to hold a large load, glass fibers are usually mixed in it. However, when a plastic part contains glass fibers, the appearance of the outer surface becomes deteriorated after molding. It is because the glass fibers come out of the surfaces. Therefore, the surfaces of these parts are painted to conceal the exposed fibers. Moreover, in the case of glass fiber reinforced plastic made from polypropylene (PP-GF), glass fibers easily come out of the surface and painting is not easily applied. Accordingly, PP-GF hardly satisfies the requirements for outer appearances. In this development, a method that fulfills the appearance requirement and is applicable to mass production was established using rapid heat and cool molding (H&C molding) while eliminating painting process for cost reduction.
2016-11-08
Journal Article
2016-32-0023
Shinji Kasatori, Yuji Marui, Hideto Oyama, Kosuke Ono
One of the effective methods for weight reduction of valve systems in an engine is the application of titanium to the valve material. However, titanium exhaust valves that require high temperature resistance are basically expensive because they contain a lot of rare metals. Therefore, their application to a mass produced product has been very much limited. In this study, it was challenged to develop an alloy that contains only minimum required amount of rare metal elements which has a large impact to the cost, aiming at broadening the application of titanium exhaust valves. Generally speaking, heat-resisting titanium alloy has a high deformation resistance because of its superior strength at high temperature. Accordingly, its formability at high temperature is low and cracks and other defects may easily occur. In addition, when a titanium alloy is exposed with a high temperature atmosphere for a long time, oxidized scales that easily exfoliate are formed on its surface.
2016-10-17
Technical Paper
2016-01-2333
Akio Kawaguchi, Hiroki Iguma, Hideo Yamashita, Noriyuki Takada, Naoki Nishikawa, Chikanori Yamashita, Yoshifumi Wakisaka, Kenji Fukui
From the environmental and energy security point of view, drastic fuel efficiency improvement of engines is required. Cooling heat loss is one of the most dominant losses among the various engine losses to reduce. Since the 1980s, many attempts to reduce cooling heat loss by insulating the combustion chamber wall have been carried out, most of which have not been successful. Charge air heating by the constantly high temperature insulating wall is a significant issue of these attempts, because it deteriorates charging efficiency, fuel/air mixture in diesel engines, and the tendency of knock occurrence in gasoline engines. Toyota has developed a new concept heat insulation methodology, which can reduce cooling heat loss through the combustion chamber wall, without sacrificing any other engine performances. Surface temperature of insulation coat on combustion chamber wall changes rapidly, according with the fluctuating temperature of in-cylinder gas.
2016-10-17
Technical Paper
2016-01-2350
Zhien Liu, Jiangmi Chen, Sheng-hao Xiao
This paper combines fluid software STAR-CCM+ and finite element software ABAQUS to stimulate the internal field of this Gasoline engine exhaust manifold based on the theory of loose coupling. Through the simulation of car parking cooling - full load condition at full speed, we estimate thermal fatigue life of the exhaust manifold with the plastic strain increment as the evaluation parameters. Results shows that the manifold satisfies the target life performance. Here we also made a consideration about the how the bolt force affects the manifold elastic and plastic material behavior.
2016-10-17
Journal Article
2016-01-2351
Kotaro Tanaka, Kazuki Hiroki, Tomoki Kikuchi, Mitsuru Konno, Mitsuharu Oguma
Abstract Exhaust gas recirculation (EGR) is widely used in diesel engines to reduce nitrogen oxide (NOx) emissions. However, a lacquer is formed on the EGR valve or EGR cooler due to particulate matter and other components present in diesel exhaust, causing serious problems. In this study, the mechanism of lacquer deposition is investigated using attenuated total reflection Fourier transform infrared spectrometry (ATR-FTIR) and scanning electron microscopy (SEM). Deposition of temperature-dependent lacquers was evaluated by varying the temperature of a diamond prism between 80 and 120 °C in an ATR-FTIR spectrometer integrated into a custom-built sample line, which branched off from the exhaust pipe of a diesel engine. Lacquers were deposited on the diamond prism at 100 °C or less, while no lacquer was deposited at 120 °C. Time-dependent ATR-FTIR spectra were obtained for approximately 2 h from the beginning of the experiment.
2016-10-17
Technical Paper
2016-01-2238
Kazunari Kuwahara, Tadashi Matsuo, Yasuyuki Sakai, Yoshimitsu Kobashi, Tsukasa Hori, Eriko Matsumura, Jiro Senda
Abstract n-Tridecane is a low boiling point component of gas oil, and has been used as a single-component fuel for diesel spray and combustion experiments. However, no reduced chemical kinetic mechanisms for n-tridecane have been presented for three-dimensional modeling. A detailed mechanism developed by KUCRS (Knowledge-basing Utilities for Complex Reaction Systems), contains 1493 chemical species and 3641 reactions. Reaction paths during ignition process for n-tridecane in air computed using the detailed mechanism, were analyzed with the equivalence ratio of 0.75 and the initial temperatures of 650 K, 850 K, and 1100 K, which are located in the cool-flame dominant, negative-temperature coefficient, and blue-flame dominant regions, respectively.
2016-10-17
Technical Paper
2016-01-2161
Gangfeng Tan, Xuefeng Yang, Li Zhou, Kangping Ji, Mengying Yang
Abstract In this research, the Mg2Si1-xSnx thermoelectric material is used in the exhaust temperature difference power-generating system, and the material's heat transfer characteristic and power-generating characteristic were analyzed. Firstly, steady heat transfer model from vehicle exhaust to cooling water was established. Then the impact of Sn/Si ratio to the thermoelectric characteristic parameter was analyzed. Finally, considering the influence of varying thermal conductivity to the heat transfer process along the material's heat transfer direction, when the cold end temperature of thermoelectric materials was controlled by cooling water respectively boiling at 343K and 373K, the thermoelectric conversion efficiency and power output of Mg2Si1-xSnx thermoelectric materials with different x value were evaluated based on simulation calculation.
2016-10-17
Journal Article
2016-01-2204
Takafumi Mori, Masanori Suemitsu, Nobuharu Umamori, Takehisa Sato, Satoshi Ogano, Kenji Ueno, Oji Kuno, Kotaro Hiraga, Kazuhiko Yuasa, Shinichiro Shibata, Shinichiro Ishikawa
Abstract Torque loss reduction at differential gear unit is important to improve the fuel economy of automobiles. One effective way is to decrease the viscosity of lubricants as it results in less churning loss. However, this option creates a higher potential for thin oil films, which could damage the mechanical parts. At tapered roller bearings, in particular, wear at the large end face of rollers and its counterpart, known as bearing bottom wear is one of major failure modes. To understand the wear mechanism, wear at the rolling contact surface of rollers and its counterpart, known as bearing side wear, was also observed to confirm the wear impact on the tapered roller bearings. Because gear oils are also required to avoid seizure under extreme pressure, the combination of a phosphorus anti-wear agent and a sulfurous extreme pressure agent are formulated.
2016-10-17
Journal Article
2016-01-2205
Chris McFadden, Kevin Hughes, Lydia Raser, Timothy Newcomb
Abstract Hybrid drivetrain hardware combines an electric motor and a transmission, gear box, or hydraulic unit. With many hybrid electric vehicle (HEV) hardware designs the transmission fluid is in contact with the electric motor. Some OEMs and tier suppliers have concerns about the electrical properties of automatic transmission fluids (ATFs). Lubrizol has conducted a fundamental research project to better understand the electrical conductivity of ATFs. In this paper, we will present conductivity data as a function of temperature for a range of commercially available ATFs. All fluids had conductivities ranging from 0.9 to 8x10-9 S/cm at 100 °C and can be considered insulators with the ability to dissipate static charge. Next we will deconstruct one ATF to show the relative impact of the various classes of lubricant additives. We find that more polar additives have a larger effect on conductivity on a normalized (per weight %) basis.
2016-10-17
Technical Paper
2016-01-2214
Teuvo Maunula, Thomas Wolff
The latest emission regulations for mobile and stationary applications require the use of aftertreatment methods for NOx and diesel particulate filters (DPF) for particulate matter (PM). SCR catalysts were evaluated by laboratory experiments and the most promising SCR catalysts were also scaled up to full-size. Development with copper (Cu) and iron (Fe) on zeolitic materials (Beta, ZSM-5, SAPO, chabazite) has resulted in the new generation of thermally durable SCR (selective catalytic reduction) catalysts, which have also an improved sulfur tolerance and a low N2O formation tendency. Opposite to Cu on Beta and ZSM-5, Cu on chabazite and SAPO showed clearly lower N2O formation. Cu-SCR catalysts had a low dependency on NO2/NOx but Fe-SCR catalysts required a higher NO2/NOx ratio (>0.3) to keep a high NOx efficiency.
2016-10-17
Technical Paper
2016-01-2272
Carl Bennett, Jason Bell, Jeffrey Guevremont
Abstract Elastomer compatibility is an important property of lubricants. When seals degrade oil leakages may occur, which is a cause of concern for original equipment manufacturers (OEMs) because of warranty claims. Leakage is also a concern for environmental reasons. Most often, the mechanical properties and fitting of the oil seals is identified as the source of failure, but there are cases where the interaction between the lubricant and the seal material can be implicated. The performance of seal materials in tensile testing is a required method that must be passed in order to qualify lubricant additive packages. We conducted an extensive study of the interactions between these elastomeric materials and lubricant additive components, and their behavior over time. The physicochemical mechanisms that occur to cause seal failures will be discussed.
2016-09-27
Technical Paper
2016-01-2144
Galina M. Susova, Rostislav Sirotkin
FMEA methodology is widely used today for solution of practical analysis problems, quality (reliability, risks) evaluation and assurance etc., owing to a clear and simple algorithm and the absence of restrictions on a subject of analysis (i.e., systems, processes, products). However, the efficiency of applying FMEA methodology for problems solution is determined by the choice of elements of analysis, completeness of identification of potential non-conformities, their causes, frequencies and effects. Quality of manufacture is determined by deviations from requirements of design and manufacturing documentation including drawings. In this article a task of ensuring a steady reduction of deviations from these requirements during manufacture through implementation of preventive actions combined with control of time and costs for correction of non-conformances is considered.
2016-09-27
Technical Paper
2016-01-2143
Yury Zhuk
The EU REACH regulations set September 2017 as a “sunset date” for the use of toxic Hexavalent Chromium salts, and as this date is approaching the aerospace manufacturers are looking for alternative coatings to replace Hard Chrome plating (HCP). HCP is widely used in the aircraft industry to protect steel components against wear, corrosion and galling. Hardide-A CVD Tungsten/Tungsten Carbide coating has met the technical performance requirements as a potential alternative to HCP on some specific Airbus aircraft components. This newly-developed CVD coating is crystallized from the gas phase atom-by-atom, forming a uniform layer on both internal and external surfaces and complex shaped parts, which are impossible to coat by thermal spray coatings, considered to be the best available alternative to HCP. Hardide coating consists of Tungsten Carbide nano-particles dispersed in metal Tungsten matrix, combining hardness with toughness and crack-resistance.
2016-09-27
Journal Article
2016-01-2119
Gergis W. William, Samir N. Shoukry, Jacky C. Prucz, Mariana M. William
Abstract Air cargo containers are used to load freight on various types of aircrafts to expedite their handling. Fuel cost is the largest contributor to the total cost of ownership of an air cargo container. Therefore, a better fuel economy could be achieved by reducing the weight of such containers. This paper aims at developing innovative, lightweight design concepts for air cargo containers that would allow for weight reduction in the air cargo transportation industry. For this purpose, innovative design and assembly concepts of lightweight design configurations of air cargo containers have been developed through the applications of lightweight composites. A scaled model prototype of a typical air cargo container was built to assess the technical feasibility and economic viability of creating such a container from fiber-reinforced polymer (FRP) composite materials. The paper is the authoritative source for the abstract.
2016-09-27
Journal Article
2016-01-2118
Patrick Land, Luis De Sousa, Svetan Ratchev, David Branson, Harvey Brookes, Jon Wright
Abstract With increased demand for composite materials in the aerospace sector there is a requirement for the development of manufacturing processes that enable larger and more complex geometries, whilst ensuring that the functionality and specific properties of the component are maintained. To achieve this, methods such as thermal roll forming are being considered. This method is relatively new to composite forming in the aerospace field, and as such there are currently issues with the formation of part defects during manufacture. Previous work has shown that precise control of the force applied to the composite surface during forming has the potential to prevent the formation of wrinkle defects. In this paper the development of various control strategies that can robustly adapt to different complex geometries are presented and compared within simulated and small scale experimental environments, on varying surface profiles.
2016-09-27
Technical Paper
2016-01-2117
Rustam M. Baytimerov, Pavel Lykov, Sergei Sapozhnikov, Dmitry Zherebtsov, Konstantin Bromer
Abstract The development of Additive Technologies (SLS/SLM, EBM, DMD) suggests the increase of range expansion of materials used. One of the most promising directions is products manufacturing from composite materials. The technology of composite micro-powders production on the basis of heat-resistant nickel alloy EP648 and Al2O3 is proposed. The aim of this research is to develop a method of producing composite micropowders for additive technology application. This method is based on modification of the metal micropowders surface by the second phase in a planetary mixer (mechanochemical synthesis).The obtained composite micropowders are compared with powders which are recommended for selective laser melting usage (produced by MTT Technology). The equipment used in the research: planetary mixer, scanning electron microscopy (SEM), optical granulomorphometer Occio 500nano.
2016-09-27
Journal Article
2016-01-2116
Peter Mueller-Hummel
Abstract Drilling holes into metal with MQL (Minimal Quantity Lubrication) is a normal procedure, because the drill is designed for drilling metal and the malleable capability of the metal compensates for the insufficient cutting capability of a worn out drill. Drilling composite materials using the same drill (designed for drilling metal) is a different procedure, because composite fibers are not malleable like metal at all. Due to this fact the tools become very hot trying to forge composite fibers like metal. The elastic behavior of the composite and the delamination inside the hole makes the tool temporary smaller than the diameter of the drill. The hole in the metal part of the stack remains slightly larger due to the heat and the thermal expansion rate. This paper shows how to drill metal and composite with the same diameter, so that achieving H8 quality is no longer a dream.
2016-09-27
Technical Paper
2016-01-2114
Matthias Meyer
Carbon composites have been on an odyssey within the past 15 years. Starting on the highest expectations regarding the performance, reality was hitting a lot of programs hard. Carbon composites were introduced on a very high technical level and industry has shown of being capable to handle those processes in general. In particular, production never sleeps and processes undergo a continuous change. Within these changes costs remain the most critical driver. As products are improving during their lifetime, they usually increase the degree of complexity, too. According to the normal cost improvement, this has drastic consequences for production. When setting up the first generation of composite production, the part being produced has been in the centre of attention.
2016-09-27
Journal Article
2016-01-2112
Hilmar Apmann
Abstract As a new material FML, made by aluminum foils and Glasfiber-Prepreg, is a real alternative to common materials for fuselages of aircrafts like monolithic aluminum or CFRP. Since experiences within A380 this material has some really good advantages and develops to the status as alternative to aluminum and composite structures. To become FML as a real alternative to aluminum and carbon structures there are many things to improve: design, material, costs and process chain. So following one of the main goals for an industrial application for high production rates of aircrafts is the automation of production processes inside the process chain for FML-parts like skins and panels for fuselages. To reach this goal for high production rates first steps of automation inside this new process chain have been developed in the last two years. Main steps is the automated lay-up of metallic foils and Glasfiber-Prepreg.
2016-09-27
Technical Paper
2016-01-2113
Raphael Reinhold
Abstract Resin transfer molding (RTM) is gaining importance as a particularly economical manufacturing method for composites needed in the automotive and aerospace industries. With this method, the component is first shaped with dry fiber reinforcements in a so-called “preforming process” before the mold is placed in a RTM tool, injected with resin and cured. In recent years, Broetje-Automation has been developing innovative product solutions that are specially designed for these preforming processes and suitable for industrial use. For the first time ever, Broetje’s Composite Preforming Cell (CPC) makes large-quantity serial production of complex and near-net-shape preforms for composite components using this RTM process possible. With the additional integration of the patented 3D Composite Handling System Broetje impressively demonstrates its service and product portfolio in the area of innovative composite manufacturing technology and its know-how as a complete system integrator.
2016-09-27
Technical Paper
2016-01-2125
Henry Hameister
This paper presents an approach to how existing production systems can benefit from Industry 4.0 driven concepts. This attempt is based on a communication gateway and a cloud-based system, that hosts all algorithms and models to calculate a prediction of the tool wear. As an example we will show the Refill Friction Stir Spot Welding (RFSSW), a solid state joining technique, which is examined at the Institute of Production Engineering (LaFT) of the Helmut-Schmidt-University, University of the Federal Armed Forces Hamburg, for years. RFSSW is a sub-section of friction welding, where a rotating tool that consists out of three parts is used to heat up material to a dough-like state. Since Refill Friction Stir Spot Welding produces a selective dot-shaped connection of overlapping materials, the production requirements are similar to riveting or resistance spot welding.
2016-09-27
Journal Article
2016-01-2126
Ali Mohamed Abdelhafeez, Sein Leung Soo, David Aspinwall, Anthony Dowson, Dick Arnold
Abstract Despite the increasing use of carbon fibre reinforced plastic (CFRP) composites, titanium and aluminium alloys still constitute a significant proportion of modern civil aircraft structures, which are primarily assembled via mechanical joining techniques. Drilling of fastening holes is therefore a critical operation, which has to meet stringent geometric tolerance and integrity criteria. The paper details the development of a three-dimensional (3D) finite element (FE) model for drilling aerospace grade aluminium (AA7010-T7451 and AA2024-T351) and titanium (Ti-6Al-4V) alloys. The FE simulation employed a Coupled Eulerian Lagrangian (CEL) technique. The cutting tool was modelled according to a Lagrangian formulation in which the mesh follows the material displacement while the workpiece was represented by a non-translating and material deformation independent Eulerian mesh.
2016-09-27
Technical Paper
2016-01-2124
Sara Nilsson, Jonas Jensen, Mats Björkman, Erik Sundin
Abstract Carbon fiber-reinforced plastic (CFRP) is one of the most commonly used materials in the aerospace industry today. CFRP in pre-impregnated form is an anisotropic material whose properties can be controlled to a high level by the designer. Sometimes, these properties make the material hard to predict with regards to how the geometry affects manufacturing aspects. This paper describes eleven design rules originating from different guidelines that describe geometrical design choices and deals with manufacturability problems that are connected to them, why they are connected and how they can be minimized or avoided. Examples of design choices dealt with in the rules include double curvature shapes, assembly of uncured CFRP components and access for non-destructive testing (NDT). To verify the technical content and ensure practicability, the rules were developed by, inter alia, studying literature and performing case studies at SAAB Aerostructures.
2016-09-27
Technical Paper
2016-01-2123
Matthias Busch, Benedikt Faupel
Abstract The integration of omega stringers to panels made of carbon fiber reinforced plastic (CFRP) by adhesive bonding, which is achieved by baking in an autoclave, must be subject to high quality standards. Failures such as porosity, voids or inclusion must be detected safely to guaranty the functionality of the component. Therefore, an inspection system is required to verify these bonds and detect different kinds of defects. In this contribution, the advantages of a robotic inspection system, which will be achieved through continuous testing, will be introduced. The testing method is the active thermography. The active thermography has major advantages compared with other non-destructive testing methods. Compared to testing with ultrasonic there is no coupling medium necessary, thus testing will be significantly enhanced.
Viewing 1 to 30 of 14950