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Laws concerning to emissions from heavy duty (HD) internal combustion engines are becoming increasingly stringent. New engine technologies are therefore needed to satisfy these new legal requirements and reduce fossil fuel dependency. One way to achieve both objectives is to partially replace fossil fuels with alternatives that are more sustainable with respect to emissions of greenhouse gas, particulates and NOx. As a first step towards the development of a direct injected dual fuel engine using diesel fuel and renewable alcohols such as methanol or ethanol, we have studied ethanol (E100) sprays generated with a standard high pressure diesel fuel injection system in a high pressure/temperature spray chamber with optical access. The experiments were performed at a gas density of ∼27kg/m3 at ∼550 °C and ∼60 bar, representing typical operating conditions for a HD engine at low loads.

Refuse Trucks are used to pick up garbage from houses. These trucks have huge robotic arms connected to the frame which are operated by hydraulic mechanism operated by the driver sitting inside the cab of the truck. The operator of the truck controls the robotic arm using a lever. Once the truck is positioned aside the garbage can, the operator moves the robotic arm outwards, grabs hold of the garbage can, picks up the garbage can and dumps the garbage into the truck. During this operation, the frame articulates and moves due to the frame suspension causing the cab to move along with the frame. This operation is performed about 1000 times a day, 5days a week for 12 years which could result in some amount of damage to the cab over its life. Since the time rate of application of the forces during the Automatic Side Loading operation is small compared to the lowest flexible mode of the cab, modal amplification is considered unlikely.

A specific objective of the European Mg-Engine project is to qualify at least two die cast Mg alloys with improved high temperature properties, in addition to satisfactory corrosion resistance, castability and costs. This paper discusses the selection criteria for high temperature alloys leading to four candidate alloys, AJ52A, AJ62A, AE44 and AE35. Tensile-, creep- and fatigue testing of standard die cast test specimens at different temperatures and conditions have led to a very large amount of material property data. Numerous examples are given to underline the potential for these alloys in high temperature automotive applications. The subsequent use of the basic property data in material models for design of automotive components is illustrated.

Eight partners from Europe and one from North America have joined efforts in a EU-supported project to find new ways for sustainable production of Mg-based engine blocks for cars. The ultimate aim of the work is to reduce vehicle weight, thereby reducing fuel consumption and CO2 emissions from operation of the vehicle. Four new magnesium alloys are considered in the project and an engine block has been series cast - 20 each in two alloys. An extensive mechanical testing program has been initiated to identify in particular the high temperature limits of the four alloys and a significant experimental study of proper bolt materials for joining is being done in parallel. Engine redesign and life cycle analysis has also been completed to secure the future sustainable exploitation of the project results. This paper presents an overview of the work and results obtained until now - 3 months before the ending date of the project.

The purpose of the 4-SPACE (4-Stroke Powered gasoline Auto-ignition Controlled combustion Engine) industrial research project is to research and develop an innovative controlled auto-ignition combustion process for lean burn automotive gasoline 4-stroke engines application. The engine concepts to be developed could have the potential to replace the existing stoichiometric / 3-way catalyst automotive spark ignition 4-stroke engines by offering the potential to meet the most stringent EURO 4 emissions limits in the year 2005 without requiring DeNOx catalyst technology. A reduction of fuel consumption and therefore of corresponding CO2 emissions of 15 to 20% in average urban conditions of use, is expected for the « 4-SPACE » lean burn 4-stroke engine with additional reduction of CO emissions.

The aim of the paper is to describe how Volvo Construction Equipment uses a virtual product development process to analyze potential risks, find root causes and optimize future product development. A model based method is used to analyze a potential risk in the design of Wheel Loader transmissions. The risk was recognized from failure mode and effect analysis (FMEA), and a simulation model using AMESim modeling tool was developed to analyze the behavior of the new design. Together with test rig result, it is proved that the model based method gives a considerably accurate prediction of the system behavior. By using the model based approach, lead time for development process is reduced and important feedbacks from simulation model are obtained on early stage of the development. This paper further presents the use of the simulation model as a tool to predict the potential risks in the extreme operating conditions, which are difficult to test on the vehicle test bench.