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Technical Paper
2014-11-11
Alessandro Franceschini, Emanuele Pellegrini, Raffaele Squarcini
Nowadays the challenge in design auxiliary device for automotive small engine is focused on the packaging reduction and on the increase of the performances. This 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. A calculation procedure has been set up in order to consider all the necessary loads applied on the joint.
Technical Paper
2014-11-11
T Manikandan, S Sarmadh Ameer, A Sivakumar, Samaraj Dhinagar
The proposed paper is on electrical energy conservation in a two wheeler. Electrical energy generation adds a maximum of 10% excess load torque on an engine and hence saving electrical energy would ultimately reduce the consumption of fuel. Load Control Module is a single intelligent device which is placed in between electrical energy generation and consumption. The Module controls and distributes energy to the corresponding loads depending on parameters like battery voltage, engine RPM, overhead light illumination levels and load usage time. The Module prioritizes battery charging for maintaining the life of the battery. The Module has a microcontroller and it is programmed with algorithm for prioritization and energy distribution with respect to input conditions. A vehicle fitted with the Load Control Module was tested in city driving cycle (CDC) condition as per ARAI (Automotive Research Association of India) standard and it was found that the electrical loading decreased to about 30% when compared to vehicle with uncontrolled loading.
Technical Paper
2014-11-11
T Manikandan, S Sarmadh Ameer, A Sivakumar, Davinder Kumar, R Venkatesan, VenkataKalyana Kumar
The proposed paper is on advanced vehicle information panel which shall display instant mileage zone in which the user is operating with inputs from engine crank sensor and vehicle speed sensor alone. And moreover, gear assistance and throttle assistance through visuals is provided. Mileage data for different engine loading at different Speeds is pre-calculated at standard conditions and fed into a micro-controller. In real time, the engine loading, by means of intelligent software, is sensed by engine crank sensor and based on the pre-fed value, the mileage zone of the vehicle at that particular instant is to be displayed using an information panel. Based on the relation between speed sensor and engine crank sensor when the vehicle is running, the gear in which the vehicle is running is to be calculated. For a vehicle running in a certain gear and in certain speed, the ideal engine loading and mileage zone is predefined. So when the user is riding in a certain gear with certain engine load, the micro controller compares that with the programmed data which is the ideal condition data, and assists the user, in case the rider is not riding the vehicle as per the ideal data, by gear up/down prompt or throttle up/down prompt by means of the said information panel.
Technical Paper
2014-09-30
Matt Zwick
Abstract The base design of commercial vehicle wheel end systems has changed very little over the past 50 years. Current bearings for R-drive and trailer wheel end systems were designed between the 1920's and the 1960's and designs have essentially remained the same. Over the same period of time, considerable gains have been made in bearing design, manufacturing capabilities and materials science. These gains allow for the opportunity to significantly increase bearing load capacity and improve efficiency. Government emissions regulations and the need for fuel efficiency improvements in truck fleets are driving the opportunity for redesigned wheel end systems. The EPA and NHTSA standard requires up to 23% reduction in emissions and fuel consumption by 2017 relative to the 2010 baseline for heavy-duty tractor combinations. This paper summarizes the history of current wheel end bearing designs and the opportunity for change to lighter-weight, cooler-running and more fuel-efficient wheel bearing designs to help meet the new industry standards.
Technical Paper
2014-09-30
Meng-Huang Lu, Figen Lacin, Daniel McAninch, Frank Yang
Abstract Diesel exhaust aftertreatment solutions using injection, such as urea-based SCR and lean NOx trap systems, effectively reduce the emission NOx level in various light vehicles, commercial vehicles, and industrial applications. The performance of the injector plays an important role in successfully utilizing this type of technology, and the CFD tool provides not only a time and cost-saving, but also a reliable solution for extensively design iterations for optimizing the injector internal nozzle flow design. Inspired by this fact, a virtual test methodology on injector dosing rate utilizing CFD was proposed for the design process of injector internal nozzle flows. For a low-pressure (less than 6 bar) injector application, the characteristic Reynolds number based on the diameter and mass flow rate of the inlet, return flow outlet, and nozzle exit of the injector might range from 2000 to 20000, therefore, employing a flow-physics based viscous model for building up a virtual test methodology is critical to properly capture the fluid dynamics of injector internal nozzle flow.
Technical Paper
2014-09-28
Sukumar T, Murugan Subramanian
Abstract This paper presents a systematic procedure for design and evaluation of snap fit for Quadruple System Protection Valve (QSPV) piston assembly. The QSPV piston is assembled with housing by means of snap joint. Snap joints are a very simple, economical and rapid way of joining two different components. All types of snap joints have in common the principle that a protruding part of one component, e.g., a hook, stud or bead is deflected briefly during the joining operation and catches in a depression (undercut) in the mating component. After the joining operation, the snap-fit features should return to a stress-free condition. The joint may be separable or inseparable depending on the shape of the undercut; the force required to separate the components varies greatly according to the design. It is particularly important to bear the following factors in mind when designing snap joints: Mechanical load during the assembly operation and force required for assembly.
Standard
2014-09-16
This Aerospace Standard establishes the details of the maximum and minimum thread profile and tolerance classes for the metric 60° screw threads recommended for use in the aerospace industry for metric module bolts and nuts.
Technical Paper
2014-09-16
Pietro Ladisa, Gabriele Santonico
Abstract The marman interface is widely used in space applications to fit the spacecrafts to the launch vehicle and it is the same interface that allows the integration, test and transport of the satellites (AIT). It is usually designed for launch loads with related flight design safety factors and margins, but this is not always compatible with the handling and transport environment. In particular some criticalities are evidenced during the transport of satellites, where they are mounted in the container in horizontal position therefore subjected to bending loads due to gravity and transport dynamic loads. The study deals with a finite element analysis approach in the calculation and verification of marman clamp bands used for spacecraft AIT operations. The paper describes the details of modeling of the clamp band parts, the involved spacecraft launch vehicle interface ring and the MGSE interface. All these parts are in contact and this configuration has been modeled adopting the most recent non linear contact analysis techniques.
Technical Paper
2014-09-16
Jamie Skovron, Laine Mears, Durul Ulutan, Duane Detwiler, Daniel Paolini, Boris Baeumler, Laurence Claus
Abstract A state of the art proprietary method for aluminum-to-aluminum joining in the automotive industry is Resistance Spot Welding. However, with spot welding (1) structural performance of the joint may be degraded through heat-affected zones created by the high temperature thermal joining process, (2) achieving the double-sided access necessary for the spot welding electrodes may limit design flexibility, and (3) variability with welds leads to production inconsistencies. Self-piercing rivets have been used before; however they require different rivet/die combinations depending on the material being joined, which adds to process complexity. In recent years the introductions of screw products that combine the technologies of friction drilling and thread forming have entered the market. These types of screw products do not have these access limitations as through-part connections are formed by one-sided access using a thermo-mechanical flow screwdriving process with minimal heat. The friction drilling, thread forming process, hereto referred to as “FDS” is an automated continuous process that allows multi-material joining by utilizing a screw as both the tool and the fastener.
Technical Paper
2014-09-16
Samuel Baha II
Hybrid (bolted/bonded) joining is becoming one of the innovative joining processes for light weight structures in the transport industry, especially in the aerospace industry where weight reduction and high joining requirements are permanent challenges. Combining the adhesive bonding with the mechanical joining -riveting for instance- can lead to an enhancement of the properties of the joint compared to the wide established riveting, as a result of a synergistic load bearing interaction between the fastener and the adhesive bondline. The influence of the rivet installation process on a hybrid joint regarding the joint stress state, the change of the bondline thickness as well as its effects on the joint performance and load transfer are some of the factors that drive the users to a better understanding of the hybrid joining process. This paper deals therefore on one hand with the numerical simulation of the rivet installation process in an adhesively bonded joint to understand the phenomena occurring during the installation process and on the other hand with the investigation of the load transfer depending on the joint parameters.
WIP Standard
2014-09-12
This document covers the performance requirements for solid dry film lubricants, air dried, or heat cured for use in aerospace applications. These lubricants are intended to prevent galling, and may be capable of remaining effective for extended periods of time after exposure to extreme environmental conditions.
WIP Standard
2014-09-09
This SAE Standard covers the dimensional and general specifications, including performance requirements, for carbon steel self-drilling tapping screws suitable for use in general applications. It is the objective of this document to insure that carbon steel self-drilling tapping screws, by meeting the mechanical and performance requirements specified, shall drill a hole and form or cut mating threads in materials into which they are driven without deforming their own thread and without breaking during assembly. Appendix A is included to provide a recommended technique for measuring the case depth on the screws.
Standard
2014-09-05
This standard provides a method of applying surface roughness, waviness and lay control. The data included herein also covers the method of applying surface roughness symbols and related designations to drawings and specifications of parts when applicable. This standard is based on the Arithmetical Average (AA) method of instrumentation. Data compiled are based on current manufacturing practices. It also includes a summary of data published in the latest issue of the American Standards Association publication ASA B46.1.
Standard
2014-09-05
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Standard
2014-09-05
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Standard
2014-09-05
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