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Direct fuel injection is becoming mandatory in two-stroke S.I. engines, since it prevents one of the major problems of these engines, that is fuel loss from the exhaust port. Another important problem is combustion irregularity at light loads, due to excessive presence of residual gas in the charge, and can be solved by charge stratification. High-pressure liquid fuel injection is able to control the mixing process inside the cylinder for getting either stratified charge at partial loads or quasi-stoichiometric conditions, as it is required at full load. This paper shows the development of this solution for a small engine for moped and light scooter, using numeric and experimental tools. In order to obtain the best charge characteristics at every load and engine speed, different combustion chambers have been conceived and studied, examining the effects of combustion chamber geometry, together with injector position and injection timing

CHEVROLET has made its new air-suspension system easily interchangeable in production line assembly with standard full-coil suspension by adopting a 4-link-type rear suspension with short and long arms. A feature of the system is the mounting of the leveling valves within the air-spring assemblies. These valves correct riding height continually at a moderate rate, regardless of whether the springs are leveling or operating in ride motion. The system provides constant frequency ride—ride comfort remains the same whether the car is occupied by the driver alone or is fully loaded.

This paper presents 1D engine simulation used for engine control strategy optimization for a twin-scroll turbocharged gasoline direct injection 2.0 L engine with twin camphaser. The results show good agreement of the engine model behavior with testbed acquisitions for a large amount of steady state set points and under transient operating conditions. The presented method demonstrates that a 1D engine code represents a useful and efficient tool during all steps of the engine control development process from design to real-time for such an advanced engine technology.

Controlled Auto Ignition (CAI), also known as Homogeneous Charge Compression Ignition (HCCI), is one of the most promising combustion technologies to reduce the fuel consumption and NOx emissions. Currently, CAI combustion is constrained at part load operation conditions because of misfire at low load and knocking combustion at high load, and the lack of effective means to control the combustion process. Extending its operating range including high load boundary towards full load and low load boundary towards idle in order to allow the CAI engine to meet the demand of whole vehicle driving cycles, has become one of the key issues facing the industrialisation of CAI/HCCI technology. Furthermore, this combustion mode should be compatible with different fuels, and can switch back to conventional spark ignition operation when necessary. In this paper, the CAI operation is demonstrated on a 2-stroke gasoline direct injection (GDI) engine equipped with a poppet valve train.

The present study compares the NVH performance of three different materials used on cam covers in automobiles, Aluminum (Al), Magnesium (Mg) and Thermoplastic (TP). The cam cover design used for this comparison was the 2004 Nissan Maxima 3.5L production cam cover which is made of a thermoplastic (TP). The Al and Mg covers for this study were created by sandcast, due to time constraints, via laser scanning techniques using the 2004 Nissan Maxima 3.5L production thermoplastic cover design. Note that sand-cast covers generally provide a less quiet sound field than the standard casting method. The Nissan production cover comes with a production baffle made of a similar material as the cover. Testing was conducted with and without the production baffle for all covers. The study was conducted for the production boundary condition of a non-isolated cover and a Freudenberg-NOK (FNGP) partially isolated cover. Isolated bolt assemblies using elastomeric grommets were used to isolate the cover.

The 2005 Ford GT high performance sports car was designed and built in keeping with the heritage of the 1960's LeMans winning GT40 while maintaining the image of the 2002 GT40 concept vehicle. This paper reviews the technical challenges in designing and building a super car in 12 months while meeting customer expectations in performance, styling, quality and regulatory requirements. A team of dedicated and performance inspired engineers and technical specialists from Ford Motor Company Special Vehicle Teams, Research and Advanced Engineering, Mayflower Vehicle Systems, Roush Industries, Lear, and Saleen Special Vehicles was assembled and tasked with designing the production 2005 vehicle in record time.

The Ford GT Program Team was allocated just 22 months from concept to production to complete the Electrical and Electronics systems of the Ford GT. This reduced vehicle program timing - unlike any other in Ford's history -- demanded that the team streamline the standard development process, which is typically 54 months. This aggressive schedule allowed only 12 weeks to design the entire electrical and electronic system architecture, route the wire harnesses, package the components, and manufacture and/or procure all components necessary for the first three-vehicle prototype build.

Each year car manufacturers release new production models that are unique and innovative. These cars begin as concepts then go through the process of prototyping. The process of creating a new model can take years, involving extensive testing and refining of aerodynamics, safety, engine components, and vehicle styling. The production model is the result of this lengthy process, and its new technologies reflect the latest engineering standards as well as market trends. The 2014 Passenger Car Yearbook details the key engineering developments in the passenger vehicle industry of the year. Each new car model is profiled in its own chapter with one or more articles that were previously published and written by the award-winning editors of Automotive Engineering International. The novel engineering aspects of each new model are explored in depth.

Durability tests have been initiated on olefinic and production painted fascias. Both 2D and 3D tests have provided insights into Friction Induced Damage (FID) failure mechanics. Full scale, 3D tests of automotive fascia mimic the parking lot rubbing contact between cars with friction forces exceeding 5000. N. 2D tests provide the cost effective approach to materials research by isolating the failure mechanics in the upper 250 μm of the decorated TPO where the cosmetic damage is initiated. Initial findings show some olefinic paint, TPO combinations to be more damage resistant for realistic frictional contact scenarios.

During sheet metal forming processes, the friction conditions have a decisive influence on forming limits, the robustness of the production process and the quality of the parts produced, with significant forces required to overcome friction between the sheet and the tools. If lot-to-lot reproducibility is to be guaranteed, an appropriate method of characterizing the sheet surface topography is needed to monitor the sheet metal fabrication process. Newly developed optical measurement techniques and computer workstation technology are presented which enable the topography of sheet surfaces to be described in three dimensions.

3D Printing is a revolutionizing technology extensively used in automotive and aerospace industries. It is an additive layer manufacturing process by which a scale model is quickly fabricated from CAD data in just a matter of hours. In Automotive trims, 3D Printing technology is a boon. It is used: To simulate the ‘tooled up/production part’ in terms of assembly, defined function, limited CMF and fit & finish. To evaluate and capture early feedback from top management with respect to aesthetic, design, etc. For early prediction and plan of action towards improvement for craftsmanship. To reduce design iterations, interface concerns, product lifecycle time and cost. In this paper, we will discuss on the technical aspects of how the trims 3D printed models have been effectively put to use. We have covered case studies under door trims, floor console, tail gate trim, glove box latch, molded spare wheel cover, Instrumental panel duct and bumper mask-painting template.

The AVL International Commercial Powertrain Conference is the premier forum for truck, agricultural and construction equipment manufacturers to discuss powertrain technology challenges and solutions across their industries. The topics of the conference, which happens every two years, cover all five elements of a modern powertrain: engine, transmission, electric motor, battery and the electronic control which are used basically the same way in the quest for optimal efficiency and environmental compatibility. This event offers a unique opportunity for highly regarded professionals to address the synergy effects and distinctive characteristics of commercial vehicles, agricultural tractors and non-road vehicles, and industrial machinery.

Developing lightweight, stiff and crash-resistant vehicle body structures requires a balance between part geometry and material properties. High strength materials suitable for crash resistance impose geometry limitations on depth of draw, radii and wall angles that reduce geometric efficiency. The introduction of 3rd generation Advanced High Strength Steels (AHSS) can potentially change the relationship between strength and geometry and enable simultaneous improvements in both. This paper will demonstrate applicability of 3rd generation AHSS with higher strength and ductility to replace the 780 MPa Dual Phase steel in a sill reinforcement on the current Jeep Cherokee. The focus will be on formability, beginning with virtual simulation and continuing through a demonstration run on the current production stamping tools and press.

Today's agri-businessman is challenged to improve his efficiency to meet higher operating costs and to counter the effects of inflation. New concepts in John Deere's line of 4-wheel-drive tractors are targeted toward this goal and provide increased productivity through power increases, improved fuel economy, comfortable convenient operator environment and controls, increased hydraulic power, improved serviceability and repairability and monitoring of more critical vehicle functions.

Titanium alloy for forging and pure titanium material for exhaust systems have been developed. The forging alloy will be applied to production of lightweight motorcycle frames and the pure titanium will be applied to improve engine performance. The materials have been made inexpensive by the use of off-grade sponge that includes many impurities for production of titanium ingot. Stable characteristics have been obtained by controlling oxygen equivalent after setting the volume of tolerable impurities by considering mechanical properties and production engineering. In spite of low-cost, the material provides the same design strength compared to conventional material, and enables parts production with existing equipment. A review of manufacturing and surface treatment processes indicated a reduction in the price of titanium parts produced with this new material.

The personal watercrafts (PWC's) are operated in various ways; going around on certain course again and again, repeating acceleration and deceleration, or prolonged idling operation, for instance. The procedure of ISO 14509 has been applied in the traditional sound measurement for powered recreational craft. However, the standard is designed to measure the sound from the typical small crafts, on the assumption that they run straight in a constant speed. It is believed to be inappropriate to use this procedure for the measurement of PWC sound. In trying to establish the suitable procedure for PWC, evaluation by the auditory sense of 15 raters was carried out in parallel with the traditional sound pressure level measurement. As the candidate, four (4) measurement methods were employed in this test. 5 models of PWC's including modified crafts were used. Correlation between the results of traditional sound measurement and the auditory sense ratings was examined.

There is a movement to apply emission control in a marine engine as well due to high public awareness of environmental concern in the United States. We started at the development of 3-seater Personal Watercraft (PWC) equipped with 4-stroke engines in taking environment conformity and potential into account. The PWC employed series 4-cylinder 1100cc displacement engine that has been used for mass production motorcycles. The engine was modified to satisfy requirements for PWC, as a marine engine, such as performance function and corrosion. In order to achieve greater or equal power/weight ratio as against two-stroke PWCs, a four-stroke engine for PWC with an exhaust turbo charger was developed. As a result, we succeeded in developing an engine that attained top-level running performance and durability superior to competitors' 2-stroke engines.

A new compact skid steer loader has been developed. Along with productivity and cost, the design of this loader was concentrated on improving ease of operation, operator comfort and safety, and serviceability. This paper discusses how serviceability was improved over previous model Bobcats. That is; improved accessibility to regulary serviced items, reduced service parts and improved reliability.

A five-year development program by the American Metal Products Co. to process stamped axle housings has culminated in the application of cold extrusion to spindles. The new process involved the installation of a 5500 ton press capable of driving a punch through a 20 lb billet, as well as modification and rearrangement of existing equipment. The system has not only resulted in considerable production savings but has also contributed to an overall expansion program. The company, although fully preoccupied with the basic spindle for production of axle housings, has already investigated other applications of the new equipment toward product diversification.

A new six-speed transaxle has been introduced by the Chrysler Group of DaimlerChrysler AG. Along with the six forward ratios in the normal upshift sequence, this transaxle features a seventh forward ratio used primarily in a specific downshift sequence. A significant technical challenge in this design was the control of so-called double-swap shifts, the exchange of two shift elements for two other shift elements. In the case at hand, one of the elements is a freewheel. A unique solution is discussed for successful control of double-swap shifts. The new design replaces a four-speed transaxle but makes use of a large percentage of parts and processes from the four-speed design. This approach enabled the new transaxle to reach production in three years from concept. The new transaxle, referred to as the 62TE, has substantially improved performance and passing maneuvers coupled with a new 4.0L high output engine for which the 62TE was developed.