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Viewing 1 to 30 of 1187
2015-04-14
Technical Paper
2015-01-1490
Tony R. Laituri, Scott Henry, Kaye Sullivan
A study of belted driver injury in various types of frontal impacts in the US field data was conducted. Specifically, subject to the Frontal Impact Taxonomy of Sullivan et al. (2008), injury potential of belted drivers in non-rollover, frontal impacts in the National Automotive Sampling System (NASS) was assessed. The field data pertained to 1985 - 2013 model-year light passenger vehicles in 1995 - 2012 calendar years of NASS. Two levels of injury were considered: AIS2+ and AIS3+. For ease of presentation, we grouped the injury data into lower- or upper-body regions. Frontal impacts were binned into eight taxonomic groups: Full-engagement, Offset, Narrow, Oblique, Side-swipe corner, High/low vert (i.e., over- and under-ride crashes), DZY-No rail (i.e., distributed crashes, but with negligible frame rail involvement), and Other. The results of the survey yielded insights into the distribution of belted-driver injury in NASS.
2015-04-14
Technical Paper
2015-01-1413
Louis Tijerina
Objective: Investigate statistical effects of repeated measures design in FCW (warning vs. no-warning ) evaluation Background: Repeated measures designs are often used in FCW testing despite concerns that 1st exposure creates expectancy effects which may dilute or bias outcomes Method: 32 participants were divided into groups of 8 for an AA, BB, AB, BA design (A= no warning; B=FCW). They drove in a high-fidelity, motion-base simulator with a visual distraction task. After some 25 minutes of driving a simulated nighttime rural highway, a high-intensity forward collision threat arose during the distraction task. Response time was analyzed. Results: There was evidence of differential carryover and significant Period 1 vs. 2 effects which dilute the magnitude of difference between FCW and no warning relative to 1st exposure only. Also there was a trend toward slower response with no-warning after FCW exposure as first exposure than after no-warning as first exposure.
2015-04-14
Technical Paper
2015-01-0257
Jianbo Lu, Dimitar Filev, Sanghyun Hong
This paper proposed a method to characterize a driver’s handling behavior through the measured and computed signals used for various vehicle electronic control systems. It uses the vehicle responses under the influence of both the driver and its electronic control systems. It characterizes the driving behavior into different categories based on the driver’s control action. The estimated driver behavior can be used to personalize vehicle control functions or warn the driver. The approach is validated by testing on various vehicles during different driving conditions.
2015-04-14
Technical Paper
2015-01-0297
Jianbo Lu, Dimitar Filev, Finn Tseng
This paper studies the problem of characterizing the driving behavior during steady-state and transient car-following. An approach utilizing the online learning of an evolving Takagi-Sugeno fuzzy model that is combined with a Markov model is used to characterize the multi-model and evolving nature of the driving behavior. Such an approach is targeted for real-time implementation instead of the traditional off-line approach to driver characterization. The approach is validated by testing on a test vehicle during different driving conditions.
2015-04-14
Technical Paper
2015-01-0525
Constantin Chiriac, Ming F. Shi
Automotive structural parts made out of Advanced High Strength Steel (AHSS) are often produced in a multistage forming process using progressive dies or transfer dies. During each forming stage the steel is subjected to work hardening, which affects the formability of the steel in the subsequent forming operation. Edge flanging and in-plane edge stretching operations are forming modes that are typically employed in the last stage of the multistage forming processes. In this study, the multistage forming process was simulated by pre-straining a DP980 steel in a biaxial strain path with various strain levels followed by edge flanging and in-plane edge stretching. The biaxial prestrains were obtained using the Marciniak stretch test and edge flanging and in-plane edge stretching were accomplished by the hole expansion test using a flat punch and a conical punch, respectively.
2015-04-14
Technical Paper
2015-01-1242
Hao Yuan, Tien Mun Foong, Zhongyuan Chen, Yi Yang, Michael Brear, Thomas Leone, James E. Anderson
Ethanol has demonstrated strong, anti-knock performance in spark ignition (SI) engines, and this is one important reason for its increasing use around the world. Ethanol’s high octane rating is attributed to both its low autoignition reactivity and high charge cooling capability. Further, whilst detailed chemical kinetic mechanisms have been developed for gasoline surrogates and ethanol, little work has been done to investigate whether autoignition in modern, SI engines with ethanol/gasoline blends can be reproduced by these mechanisms, in particular for cases with direct fuel injection. This paper therefore presents a numerical study of the trace knocking of ethanol/gasoline blends in a modern, single cylinder SI engine. Results of these numerical simulations are compared to experimental results obtained in a prior, published work [1]. The engine is modeled using GT-Power and a two-zone combustion model.
2015-04-14
Technical Paper
2015-01-1281
Ahsanul Karim, Anthony Morelli, Keith Miazgowicz, Brian Lizotte, Robert Wade
The use of Swirl-Vanes or Inlet Guide Vanes (IGV) in gas engines is well-known and has demonstrated their ability to improve compressor surge margin at low flow rates. But, the use of swirl-vanes is not too common in large diesel engine turbo-chargers where compressor housing inlet has some form of Casing–Treatment (CT). Recently, Ford engineers used swirl-vanes in a diesel engine turbocharger where the compressor inlet had a casing-treatment and the experimental data showed no improvement in surge margin. To investigate reasons for not improving surge margin after introducing swirl-vanes at the compressor inlet, CFD analyses were performed. The CFD results showed strong interactions between swirling flow at the compressor inlet and flow stream coming out of the compressor inlet casing-treatment.
2015-04-14
Technical Paper
2015-01-0510
Joy Hines Forsmark, Zachary Dowling, Kelsey Gibson, Caroline Mueller, Larry Godlewski, Jacob Zindel, James Boileau
Magnesium die-cast alloys are known to have a layered microstructure composed of: (1) An outer skin layer characterized by a refined microstructure that is relatively defect-free; and (2) A “core” (interior) layer with a coarser microstructure having a higher concentration of features such as porosity and externally solidified grains (ESGs). Because of the difference in microstructural features, it has been long suggested that removal of the surface layer by machining could result in reduced mechanical properties in tested tensile samples. To examine the influence of the skin layer on the mechanical properties, a series of round tensile bars of varying diameters were die-cast in a specially-designed mold using the AM60 Mg alloy. A select number of the samples were machined to different final diameters. Subsequently, all of the samples (as-cast as well as machined) were tested in tension.
2015-04-14
Technical Paper
2015-01-0470
Joanna Rakowska, Shawn Morgans, Michael Lee, Jeffrey Laya, Amir Chator, Gregory Zinn, Ching-Hung Chuang, Bruno Barthelemy, Sreekanth Reddy gondipalle
Designing a vehicle body involves meeting numerous performance requirements related to different attributes such as NVH, Durability, Safety, and others. Multi-Disciplinary Optimization (MDO) is an efficient way to develop a design that optimizes vehicle performance while minimizing the weight. Since a body design evolves in course of the product development cycle, it is essential to repeat the MDO process several times as the design matures and more accurate data become available. This paper presents a real life application of the MDO process to reduce weight while optimizing performance over the design cycle of the 2015 Mustang. The paper discusses the timing and results of the applied Multi-Disciplinary Optimization process. The attributes considered during optimization include Safety, Durability and Body NVH. Several iterations of MDO have been performed at different milestones in the design cycle leading to significant weight savings of more than 11kg.
2015-04-14
Technical Paper
2015-01-1657
Ahsanul Karim, Meisam Mehravaran, Brian Lizotte, Keith Miazgowicz, Yi Zhang
A computational aero-acoustics simulation on the aerodynamic noise generation of an automotive radiator fan assembly is carried out. Three-dimensional Computational Fluid Dynamics (CFD) simulation of the unsteady flow field was performed including the entire impeller and shroud to obtain the source of an audible broad-band flow noise between 2 to 4 kHz. Static pressure probes placed around the outer-periphery and at the center of the impeller inlet side and, at the shroud cavities to capture the noise sources. The static pressure at all probe locations were FFT (Fast Fourier Transform) processed and sound pressure level (SPL) was calculated. The sound pressure levels from the fan outer-periphery probes show the dominant source of blade passing frequency (BPF) and the broad-band noise. The BPF level is the strongest in fan outer-peripheral region because of large pressure fluctuations as a result of blade-passing.
2015-04-14
Technical Paper
2015-01-0861
Matthew Younkins, Margaret S. Wooldridge, Brad A. Boyer
Hydrogen fueled internal combustion engines have potential for high thermal efficiencies; however, high efficiency conditions can produce high nitrogen oxide emissions (NOx) that are challenging to treat using conventional 3-way catalysts. This work presents the results of an experimental study to reduce NOx emissions while retaining high thermal efficiencies in a single-cylinder research engine fueled with hydrogen. Specifically, the effects on engine performance of the injection of water into the intake air charge were explored. The hydrogen fuel was injected into the cylinder directly. Several parameters were varied during the study, including the amount of water injected into the intake charge, the amount of fuel injected, the phasing of the fuel injection, the number of fuel injection events, and the ignition timing. The results were compared with expectations for a conventionally operated hydrogen engine where load was controlled through changes in equivalence ratio.
2015-04-14
Technical Paper
2015-01-1280
Ahsanul Karim, Keith Miazgowicz, Brian Lizotte
The stable operation of turbocharger compressor at low flow rates is important to provide low end engine torque for turbocharged automotive engines. Therefore, it is important to be able to predict the lowest flow rates at different turbo speed at which surge phenomenon occurs. For this purpose, a three-dimensional Computational Fluid Dynamics (CFD) simulation performed including the entire compressor wheel and volute. The wheel consisted of six main and six splitter blades. Flow bench and engine testing can be used to detect surge phenomenon. Complete 3D CFD analysis can be performed upfront in the design to calculate low end compressor operating range and to understand the fundamental mechanisms of stalled flow, the surge phenomenon, and impact of compressor inlet conditions on surge. This paper presents a CFD analysis near the low flow region at constant turbo speed to predict automotive centrifugal compressor surge phenomenon.
2015-04-14
Technical Paper
2015-01-1336
Meisam Mehravaran, Yi Zhang
Computational Fluid Dynamics (CFD) has been extensively used in predicting the behavior of automotive components. In the current work the fan, shroud and radiator assembly has been simulated using a less expensive CFD methodology. After validating the CAE tool with the test data, the similar simulation was carried on for 13 different shrouds and the effect of geometrical parameters on airflow was investigated. The CFD data show that the smoothly converging shroud will lead to higher flow rates while cavities and steps will perform as a restriction and degrade the efficiency. Besides, it is seen that decreasing the blade-shroud clearance up to 17 mm will improve the air flow as it prevents the leakage of the pumped flow, but if we go further, the airflow does not increase and may even decrease, which may be explained based on the interference of blade and shroud boundary layer.
2015-04-14
Technical Paper
2015-01-1080
Eduardo J. Barrientos, Matti M. Maricq, Andre L. Boehman, James E. Anderson
Biodiesel has been proven to have a strong impact on the oxidative reactivity of diesel soot. The fatty acid methyl esters, of which biodiesel is comprised, exhibit a more complex ignition chemistry than normal alkanes of equivalent carbon number. Studies have shown a clear dependence of soot reactivity on fuel oxygenate molecular structure, suggesting that the unique oxidation behavior of esters may be a governing factor of the enhanced soot oxidation behavior presented by biodiesel. A study and analysis of the relation of biodiesel chemical structures to the resulting soot characteristics and soot oxidative reactivity was conducted. Soot samples generated from the combustion of various methyl esters, alkanes, biodiesel and diesel fuels in laminar co-flow diffusion flames were analyzed to evaluate the impact of fuel-bound oxygen in fatty acid esters on soot oxidation behavior.
2015-04-14
Technical Paper
2015-01-0551
Qiuren Chen, Haiding Guo, John V. Lasecki, Xuming Su, John J. Bonnen
The fatigue strength and failure behavior of A5754-O adhesively bonded single lap joints by a hot-curing epoxy adhesive were investigated in this paper. The single lap joints tested include balanced substrate joints (meaning same thickness) and unbalanced substrate joints, involving combinations of different substrate thicknesses. Cyclic fatigue test results show that the fatigue strength of bonded joints increase with the increasing substrate thickness. SEM and Energy Dispersive X-ray(EDX) were employed to investigate the failure mode of the joints. Two fatigue failure modes, substrate failure and failure within the adhesive were found in the testing. The failure mode of the joint changes from cohesive failure to substrate failure as the axial load is decreased, which reveals a fatigue resistance competition between the adhesive layer and the aluminum substrate.
2015-04-14
Technical Paper
2015-01-0573
Tau Tyan, Yu-Kan Hu, Dana Sun, Leonard Shaner, Matt Niesluchowski, Nand Kochhar, Guofei Chen, Ming Shi
Motivated by a combination of increasing consumer demand for fuel efficient vehicles, more stringent greenhouse gas and 2025 Corporate Average Fuel Economy (CAFE) standards, automotive manufacturers are working to innovate in all areas of vehicle design to optimize fuel efficiency. In addition to improved aerodynamics, enhanced powertrain technologies and alternative fuel vehicles, reducing vehicle weight by using lighter materials has been identified as one of the most important strategies in future vehicle development. Weight reduction in vehicle components, sub-systems and systems not only reduces the energy needed to overcome inertia forces but also can trigger additional mass reduction elsewhere and enable significant mass reduction in full vehicle levels.
2015-04-14
Technical Paper
2015-01-0570
Horst Lanzerath
Tubular designs for the body structure enable a significant weight saving versus the conventional, stamped sheet metal designs. There are several manufacturing processes on the market than can deliver tubular structures, e.g. hydroforming. But currently the processes are limited to material grades up to 1000MPa UTS for body structure parts. Similar to the development in stamping, the target is the have tubular designs available with Ultra High Strength Steel (UHSS) properties (1500MPa) that are known from hot-stamping parts. Within stamping the development was going from Mild Steels (MS) to Advanced High Strength Steels (AHSS) and finally to hot-formed steels with 1500MPa UTS, enabling a significant weight saving potential compared to MS or AHSS. Analogous to this there are some new processes upcoming which are able to produce tubular designs with 1500 MPa strength.
2015-04-14
Technical Paper
2015-01-1617
Brien Fulton, Michiel Van Nieuwstadt, Jon Dixon, Daniel Roettger, Simon Petrovic, Andres Arevalo
Exhaust pressures (P3) are easy parameters to measure and can be readily estimated, the cost of the sensors and the temperature environment that the exhaust system creates, makes the implementation of the exhaust pressure sensor a costly endeavor. Accurate exhaust pressure inputs in vehicle and engine control systems are important for performance, fuel economy, emissions, OBD monitoring and aftertreatment control. The contention with modelling exhaust pressure is the accuracy required for proper engine and vehicle control can sometimes exceed the accuracy specification of market available sensors and existing models. The paper presents a turbine inlet exhaust pressure observer model based on isentropic expansion and heat transfer across a turbocharger turbine was developed and investigated in this paper.
2015-04-14
Technical Paper
2015-01-1240
Soon Park
Paper Title: MMLV - Lightweight Transmission Components Author: John Sabo, Magna International Abstract: The Multi-Material Lightweight Vehicle (“MMLV”) is a lightweight vehicle development project between Ford and Magna International, 50% co-funded by US Department of Energy (DOE) and Canadian Provincial grants. The goal of the project is to use lightweight material systems and manufacturing technologies to achieve significant overall weight reduction and demonstrate viability of such design by component-level testing. This paper presents a summary of the MMLV design development for lightweight transmission and driveline components, supported by extensive use of CAE analysis and component-level testing of prototype parts. A total mass reduction of 14kg (13.8%) relative to the 2012 Fusion baseline vehicle transmission and driveline components was achieved.
2015-04-14
Technical Paper
2015-01-1239
Neal J. Corey
While weight reduction in automotive design and manufacturing have been on-going for several years, in the area of powertrain technology, light-weighting has been a difficult challenge to overcome due to functional requirements, as well as material and manufacturing constraints. Ford Motor Company, as part of the Multi Material Lightweight Vehicle (MMLV) project with Vehma International and the US Department of Energy, worked with its material supplier, BASF, to design and develop a carbon fiber Front Cover and Oil Pan, based off the current Fox I3 Gasoline Turbocharged Direct Injection (GTDI) Engine. The effort produced a reduced weight Front Cover and Oil Pan, that were both structurally strong enough to support the engine attachment to the frame rail and as well as meeting all the powertrain bending stress targets that are seen in the current engine.
2015-04-14
Technical Paper
2015-01-1237
Xiaoming Chen, Jeff Coklin, Mike Carpenter, Jeff wallace, Cynthia Flanigan, David Wagner, Vijitha Kiridena, Stephane Betrancourt, Jason Logsdon
As part of the Ford and Vehma collaborative efforts on the DOE sponsored project on Multi Materials Lightweight Vehicle, several automotive chassis components were identified for development and evaluation on a lightweight passenger vehicle. The lightweight prototype chassis parts included composite and hollow steel coil springs, carbon fiber wheels, tires with a tall and narrow design, hollow steel stabilizer bars, and an aluminum front cradle. The lightweight chassis parts development included mixed and multi materials to investigate potential weight savings. The glass fiber reinforced composite front spring and hollow steel rear springs achieved 59% and 37% weight savings respectively. Both springs passed required component tests and survived proving ground durability test with no issues detected. For the lightweight tall narrow tires, evaluations were conducted on three distinct sets of tires with varying material constructions and final weight in the range of 17 pounds per tire.
2015-04-14
Technical Paper
2015-01-1615
Yuksel Gur, Jian Pan, John Huber, Jeff wallace
Ford Motor Company and Magna International Inc., co-funded by the U.S. Department of Energy, have collaborated on a lightweight vehicle concept project that uses advanced material solutions to achieve a nearly 25% weight savings over the reference vehicle. Lightweight design actions on radiating panels enclosing the vehicle cabin generate vehicle interior acoustic degradation due to the reduction of panel surface mass. In order to reduce this deficiency, an MMLV vehicle sound package development study was conducted to improve NVH performance of MMLV with industry leading ultra-light weight sound package technologies. Our goal was to improve acoustical performance of MMLV by 2 dB without increasing the total sound package weight of the “Vehicle A” which is the baseline vehicle for MMLV.
2015-04-14
Technical Paper
2015-01-1437
Tony R. Laituri, Raed El-jawahri, Scott Henry, Kaye Sullivan
Various risk curves for head injury potential were assessed theoretically relative to field data. Specifically, two AIS2+ risk curves were studied: the HIC15-based risk curve from Mertz (1997) and the provisional, BRIC-based risk curve from Takhounts et al. (2013). These two risk curves were used to estimate attendant injury potential for belted drivers in full-engagement frontal crashes in the National Automotive Sampling System (NASS). The occupant responses pertaining to those crashes were estimated from representative math models, and the risk curves were used to convert event responses into event risks. The assessment was conducted from two perspectives: aggregate (0-56 kph) and a point-estimate (56 kph, barrier-like). Finally, the point-estimate assessment was supplemented by considering corresponding laboratory tests. The results from HIC15-based risk curve were understated, whereas the results from the BRIC-based risk curve were overstated.
2015-01-14
Journal Article
2015-26-0104
Santhoji Katare, Carolyn Hubbard, Seha Son
Abstract Aftertreatment system design involves multiple tradeoffs between engine performance, fuel economy, regulatory emission levels, packaging, and cost. Selection of the best design solution (or “architecture”) is often based on an assumption that inherent catalyst activity is unaffected by location within the system. However, this study acknowledges that catalyst activity can be significantly impacted by location in the system as a result of varying thermal exposure, and this in turn can impact the selection of an optimum system architecture. Vehicle experiments with catalysts aged over a range of mild to moderate to severe thermal conditions that accurately reflect select locations on a vehicle were conducted on a chassis dynamometer. The vehicle test data indicated CO and NOx could be minimized with a catalyst placed in an intermediate location.
2014-11-17
Article
What will it take to make Lincoln a profitable global luxury brand? In this episode of Eye on Engineering, Senior Editor Lindsay Brooke looks at Ford's new plan to overhaul Lincoln. SAE Eye on Engineering can be viewed at http://youtu.be/4msox7_ALN8. 
2014-11-01
Journal Article
2014-01-9080
James E. Anderson, Timothy J. Wallington, Robert A. Stein, William M. Studzinski
Abstract Modification of gasoline blendstock composition in preparing ethanol-gasoline blends has a significant impact on vehicle exhaust emissions. In “splash” blending the blendstock is fixed, ethanol-gasoline blend compositions are clearly defined, and effects on emissions are relatively straightforward to interpret. In “match” blending the blendstock composition is modified for each ethanol-gasoline blend to match one or more fuel properties. The effects on emissions depend on which fuel properties are matched and what modifications are made, making trends difficult to interpret. The purpose of this paper is to illustrate that exclusive use of a match blending approach has fundamental flaws. For typical gasolines without ethanol, the distillation profile is a smooth, roughly linear relationship of temperature vs. percent fuel distilled.
2014-10-13
Technical Paper
2014-01-2708
Antonino La Rocca, David MacMillan, Paul Shayler, Michael Murphy, Ian Pegg
Abstract Cold idle operation of a modern design light duty diesel engine and the effect of multiple pilot injections on stability were investigated. The investigation was initially carried out experimentally at 1000rpm and at −20°C. Benefits of mixture preparation were initially explored by a heat release analysis. Kiva 3v was then used to model the effect of multiple pilots on in-cylinder mixture distribution. A 60° sector of mesh was used taking advantage of rotational symmetry. The combustion system and injector arrangements mimic the HPCR diesel engine used in the experimental investigation. The CFD analysis covers evolutions from intake valve closing to start of combustion. The number of injections was varied from 1 to 4, but the total fuel injected was kept constant at 17mm3/stroke. Start of main injection timing was fixed at 7.5°BTDC.
2014-10-13
Journal Article
2014-01-2657
Julien Manin, Scott Skeen, Lyle Pickett, Eric Kurtz, James E. Anderson
Abstract The Leaner Lifted-Flame Combustion (LLFC) strategy offers a possible alternative to low temperature combustion or other globally lean, premixed operation strategies to reduce soot directly in the flame, while maintaining mixing-controlled combustion. Adjustments to fuel properties, especially fuel oxygenation, have been reported to have potentially beneficial effects for LLFC applications. Six fuels were selected or blended based on cetane number, oxygen content, molecular structure, and the presence of an aromatic hydrocarbon. The experiments compared different fuel blends made of n-hexadecane, n-dodecane, methyl decanoate, tri-propylene glycol monomethyl ether (TPGME), as well as m-xylene. Several optical diagnostics have been used simultaneously to monitor the ignition, combustion and soot formation/oxidation processes from spray flames in a constant-volume combustion vessel.
2014-09-28
Journal Article
2014-01-2521
Jaroslaw Grochowicz, Carlos Agudelo, Shanglei Li, Harald Abendroth, Karl-Heinz Wollenweber, Achim Reich
Abstract The efforts of the ISO “Test Variability Task Force” have been aimed at improving the understanding and at reducing brake dynamometer test variability during performance testing. In addition, dynamometer test results have been compared and correlated to vehicle testing. Even though there is already a vast amount of anecdotal evidence confirming the fact that different procedures generate different friction coefficients on the same brake corner, the availability of supporting data to the industry has been elusive up to this point. To overcome this issue, this paper focuses on assessing friction levels, friction coefficient sensitivity, and repeatability under ECE, GB, ISO, JASO, and SAE laboratory friction evaluation tests.
2014-07-16
Article
Ram’s official move to adopt the SAE J2807 towing standard for validating all three (1500, 2500, and 3500) of its pickup weight classes raises the competitive bar for the industry's other pickup players. Meanwhile, Ford has engineered its latest F-450 with half the GCVW capability of a Class-8 tractor-trailer.
Viewing 1 to 30 of 1187

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