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2016-11-08
Technical Paper
2016-32-0064
Keiya Nishida, Takeru Matsuo, Kang Yang, Youichi Ogata, Daisuke Shimo
The injection amount per stage in the multiple injection strategy is smaller than the conventional single-stage injection. The research of the spray mixture formation and the combustion characteristics with a small injection amount is being meaningful. In this study, the effect of the injection amount (0.27mg, 0.89mg, 2.97mg) under 100MPa injection pressure and the effect of injection pressure (100MPa, 170MPa) under different injection amount (0.27mg, 2.97mg) on the spray and mixture formation characteristics were studied based on the vapor and liquid phase concentration distributions in the fuel spray by using the tracer LAS technique. In order to satisfy the requirements for the LAS test fuel, the tracer LAS technique was adopted. The spray was injected used a single-hole nozzle with a diameter 0.133mm into the high-pressure and high-temperature constant volume vessel.
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
2016-32-0025
Govardan Daggupati, Bapanna Dora Karedla, Chandan Bansilal Chavan, Gagandeep Singh Risam
In two wheelers the front suspension system is mounted on chassis by two steering bearings which are lubricated ball type angular contact bearings with significant radial force components. These bearings are designed to withstand maximum vehicle loads for target durability. Maximum load carrying capacity depends on the number and size of the balls, bearing size and material. For target durability with designed load carrying capacity, the ball contact pressure, bearing preload plays a major role as compared to other design parameters. Geometry parameters and maximum load defines contact pressure for given bearing design. But in two wheelers due to nature of usage and road conditions, the peak loads are dynamic and geometry based design calculations may not yield the most optimal bearing design. In this work the bearing ball race profile design is optimized by using dynamic bearing contact profiles by using nonlinear Finite Element Analysis.
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.
2016-10-17
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
One effective and easy way to improve fuel economy for automobiles is to decrease viscosity of lubricants, as it brings less churning loss. However, this option creates a higher potential for thinner oil film, which could damage the mechanical parts. This paper describes a new low-viscosity gear oil technology which was successfully developed to improve wear at tapered-roller bearings in differential gear units, whereas achieving higher fuel economy performance. As for tapered-roller bearings in differential gear units protected by gear oils, one major damage is supposed to cause wear at large end face of rollers and the counterpart, so-called bearing bottom wear. In order to understand the wear mechanism, wear at rolling contact surface of rollers and the counterparts, so-called bearing side wear was additionally observed to confirm the wear impact on tapered-roller bearing.
2016-10-17
Technical Paper
2016-01-2189
Bo Wang, Tawfik Badawy, Yanfei Li, Hongming Xu, Yizhou Jiang, Xinyu Zhang
Atomization of fuel sprays is a key factor in control of combustion quality in direct-injection engines. In this present work, effect of injection pressure and flash boiling levels of Ethanol (ETH) on near nozzle spray patterns was investigated using an ultra-high speed imaging technique. Ethanol was injected from a single-hole piezo injector into an optically accessible constant volume chamber at injection pressures of 30 MPa, 40 MPa and 50 MPa at different back pressure and temperature. High-speed imaging was performed using a long-distance microscope coupled with an ultra-high speed camera (Shimadzu HPV-2). The results revealed a clear mushroom-like structure at the start of injection at 30 MPa injection pressure and ambient condition whereas at higher injection pressure or higher flash boiling level this mushroom shaped injection tip was not observed. Micro cone angle experienced a sudden increase during the start of spray and then dropped.
2016-10-17
Technical Paper
2016-01-2202
Naoya Ochiai, Jun Ishimoto, Akira Arioka, Nobuhiko Yamaguchi, Yuzuru Sasaki, Nobuyuki Furukawa
The advanced development and optimization of fuel atomization in port and direct injection systems for automobile engine is desired for the improvement of fuel combustion performance and thermal efficiency of the engine. Computational prediction and design of injector nozzle spray flow is an effective method for that. However, a practical simulation method of the continuous primary, secondary spray breakups and the spraying behavior have not been developed yet. In this study, we have developed the integrated computational method of the total fuel atomization process of the injector nozzle. This new computational approach is taking into account the nozzle internal flow to form the primary breakup using Volume of Fluid (VOF) method in connection with the spray flow characteristics to the engine cylinder using Discrete Droplet Model (DDM).
2016-10-17
Technical Paper
2016-01-2345
Guoyu Feng, Wenku Shi, Henghai Zhang
To study the static and dynamic characteristics of thrust rod, based on multi-body dynamics and finite element method for static and dynamic characteristics of the thrust rod were analyzed. The establishment of a dynamic simulation model of vehicle and the road, in the extreme conditions of the thrust rod loads were calculated. Thrust rod finite element model is established, according to the calculation result of the load and test data of rubber, stiffness, strength and modal analysis, and verified by test, gained its deformation, stress distribution and low-order natural frequency and mode shape. The results provide a theoretical basis for the design and optimization of the thrust rod.
2016-10-17
Technical Paper
2016-01-2272
Carl Bennett, Jason Bell, Jeffrey Guevremont
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
2016-01-2079
Alexander Janssen, Thorsten Dillhoefer
The industry wide requirement of new highly flexible automated fastening systems in aircraft production has created the need for developing new fastening systems. This paper will focus on the development of the Frame Riveting Assembly Cell (FRAC) by BROETJE-Automation to meet this need. The new FRAC machine configuration is built for automated drilling and fastening of different aircraft type parts. It is highly flexible with a high speed positioning system mounted multifunction end effector. System travel is limited only by installed track length. The FRAC integrates well with conventional and reconfigurable automated fastening work holding tools.
2016-09-27
Journal Article
2016-01-2080
Carter L. Boad, Kevin Brandenstein
The newest generation of automated fastening machines require a feed system that is smaller, more flexible, and faster than any currently available. The feed system must be compact enough to fit on a robot base, yet have a capacity large enough to support unmanned production for hours. A large variety of fasteners must be supported and the entire system must be reloaded or reconfigured in minutes to match the next work piece being assembled by the machine. When requested by the part program, the correct fastener must be released directly and immediately into the feed tube to minimize cycle time. This paper describes a new “plate cartridge” feed system developed to meet these needs.
2016-09-27
Journal Article
2016-01-2081
Rodrigo Pinheiro, Robert Gurrola, Sead Dzebo
Abstract The installation of common threaded aerospace fasteners by the application of a torque to a nut or collar is made possible by an internal wrenching element or recess feature adapted to the threaded end of a pin, which accepts a mating anti-rotation key designed to partially balance the applied torque. In applications such as the mechanical joining of composite structures accomplished by wet clearance fit installations of permanent fasteners, high nut or collar seating torques not adequately opposed by frictional resistance at the contact surfaces of the fastener and joint members effectively shift a greater proportion of the torque reaction requirement onto the recess and mating anti-rotation key which in turn can experience high torsional stresses exceeding their design capability and result in frequent service failures.
2016-09-27
Technical Paper
2016-01-2083
Steven P. Smith
Abstract This paper traces the development of a temporary blind fastener in the aircraft industry. These are used with automated drilling machines as part of an integrated assembly process where one-way assembly is inappropriate. Traditional blind temporary fasteners have a high protrusion (stand-off) on the side they are installed from, effectively preventing automated drilling. No suitable fastener was available on the market and existing suppliers were uninterested in development at the time. A set of requirements were created out of the need to improve efficiency of A380 wing assembly. However focus changed as the A350XWB programme demanded such a fastener. Testing, development and Stress approval are described leading to full deployment. Finally the paper looks at the additional factors which are required to successfully introduce a new standard of temporary fastening process.
2016-09-27
Technical Paper
2016-01-2084
Curtis Hayes
Abstract Successfully riveting aerospace fatigue-rated structure (for instance, wing panels) requires achieving rivet interference between a minimum and a maximum value in a number of locations along the shank of the rivet. In unbalanced structure, where the skin is much thicker than the stringer, this can be particularly challenging, as achieving minimum interference at the exit of the skin (D2) can often be a problem without exceeding the maximum interference at the exit of the stringer (D4). Softer base materials and harder, higher-strength rivets can compound the problem, while standard manufacturing variations in hardness of part and rivet materials can cause repeatability issues in the process. This paper presents a solution that has been successfully implemented on a production commercial aircraft.
2016-09-27
Journal Article
2016-01-2085
Kyle Pritz, Brent Etzel, Zheng Wei
The automation cycle time of wing assembly can be shortened by the automated installation of single-sided temporary fasteners to provide temporary part clamping and doweling during panel drilling. Feeding these fasteners poses problems due to their complexity in design and overall heavy weight. In the past, Electroimpact has remotely fed these fasteners by blowing them through pneumatic tubing. This technique has resulted in occasional damage to fasteners during delivery and a complex feed system that requires frequent maintenance. Due to these issues, Electroimpact has developed a new fully automated single-sided temporary fastening system for installation of the LISI Clampberry fasteners in wing panels for the C919 wing factory in Yanliang, China. The feed system stores fasteners in gravity-fed cartridges on the end effector near the point of installation.
2016-09-27
Technical Paper
2016-01-2089
Jose Guerra cEng, Miguel Angel Castillo
Abstract Aernnova experience on automatic drilling operations started in 1,999. The company signed a new contract with Embraer, to design, manufacture and assembly several structures of the model 170. It was big news for the company. But after that minute of pride, manufacturing engineering people of the company started to think about the process to assemble those big panels of the Horizontal Stabilizer, Vertical Stabilizer and Rear Fuselages in the best Quality and Cost. There were a lot of rows of rivets to install. Some ideas arisen, but the final decision was to forget the available processes at that time and think about to automate the drilling, countersink and riveting of the stringers, doublers and window frames to the panels. There were a lot of doubts, figures to do and obstacles, but the company took the decision of going ahead with that process. That step changed the state of the art at that time in the company.
2016-09-27
Technical Paper
2016-01-2098
Christophe Vandaele, Didier Friot, Simon Marry, Etienne Gueydon
Abstract With more than 10 000 aircrafts in their order backlog Aircraft manufacturers focus on automated assembly is of critical importance for the future of efficient production assembly. Moreover to obtain maximum benefit from automation, it is necessary to achieve not only an automated assembly cell, but also a real breakthrough in fastener technology. The optimum solution, known as “One Side Assembly”, performs the whole assembly sequence from one side of the structure using an accurate robot arm equipped with a multifunction end effector and high performance fasteners. This configuration provides an efficient and flexible automated installation process, superior to current solutions which are typically, large scale, capital intensive systems, which still require operators to complete or control the fastener installation. The search for a technological breakthrough in this domain has been targeted for more than 15 years by many aircraft manufacturers.
2016-09-27
Technical Paper
2016-01-2128
Henry Guo, Farid Ahdad, DeDong Xie
Abstract In this work we have proposed an interesting clamping solution of V-band which has an important industrial impact by reducing the cost and assembly process as well compare to the traditional V-band. The design what we are focusing for is applied for all size of turbochargers which helps to connect the hot components such as manifold and turbine housing. The cost for V-band is mainly from T-bolt. It is made from special stainless steel which represents 50% of the total cost. In this work it is proposed a new V-band joint by changing bolt clamping status from tension to compression. From tension to compression we change the bolt material from high cost steel to low cost steel. The new total cost is reduced by 40%. The prototype is made and performed in static tests including anti-rotating torque test and salt spray test. The new joint meets the design requirements at static condition. Further work will focus on the dynamic qualification and at high temperature as well.
2016-09-27
Technical Paper
2016-01-2145
Ryan Haldimann
Abstract Inspection of fasteners prior to installation is critical to the quality of aerospace parts. Fasteners must be inspected for length/grip and diameter at a minimum. Inspecting the fasteners mechanically just prior to insertion can cause additional cycle time loss if inspection cannot be performed at the same time as other operations. To decrease fastener inspection times and to ensure fastener cartridges contain the expected fastener a system was devised to measure the fastener as it travels down the fastener feed tube. This process could be adapted to inspection of fasteners being fed to the process head of a running machine eliminating the mechanical inspection requirement and thus decreasing cycle time.
2016-09-27
Technical Paper
2016-01-8062
Jham Kunwar Tikoliya, Ram Krishna Kumar Singh, Ramesh Kumar, Suresh Kumar Kandreegula
Abstract The existing head cover is having external oil and blow by separation unit, which is not only costlier but also complex and leads to increase in overall height of engine which was difficult to integrate in new variants of vehicles. A new head cover has been designed with internal baffle type oil and blow by separation system to ensure efficient separation and proper packaging of the system in new variants. The new system has been finalized after 26 DOE’s of different wire mesh sizes and different baffle plate size and positions. The final system has two bowl shaped separation unit with wire mesh, two cup type oil separation passages and one baffle plate for separating blow by. The system works on condensation and gravity method. The blow by is guided through a well-defined passage integrated in aluminum cylinder head cover itself. The passage angle is maintained to ensure minimum oil flow with blow by.
2016-09-27
Journal Article
2016-01-8100
Jordan Kelleher, Nikhil Ajotikar
Abstract Piston cooling nozzles/jets play several crucial roles in the power cylinder of an internal combustion engine. Primarily, they help with the thermal management of the piston and provide lubrication to the cylinder liner and the piston’s wrist pin. In order to evaluate the oil jet characteristics from various piston cooling nozzle (PCN) designs, a quantitative and objective process was developed. The PCN characterization began with a computational fluid dynamics (CFD) turbulent model to analyze the mean oil velocity and flow distribution at the nozzle exit/tip. Subsequently, the PCN was tested on a rig for a given oil temperature and pressure. A high-speed camera captured images at 2500 frames per second to observe the evolution of the oil stream as a function of distance from the nozzle exit. An algorithm comprised of standard digital image processing techniques was created to calculate the oil jet width and density.
2016-09-26
WIP Standard
AS3411C
Scope is unavailable.
2016-09-26
WIP Standard
AS7460C
This procurement specification covers aircraft quality bolts and screws made of 6.0Al-4.0V titanium alloy and of 160 ksi tensile strength at room temperature.
2016-09-26
WIP Standard
MA3340C
SCOPE IS UNAVAILABLE.
CURRENT
2016-09-21
Standard
J583_201609
This SAE standard provides test procedures, performance requirements, design guidelines and installation guidelines for front fog lamps.
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