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2017-09-28 ...
  • September 28, 2017 (8:30 a.m. - 4:30 p.m.) - Ft. Worth, Texas
Training / Education Classroom Seminars
The challenges associated with using composites as a replacement for aluminum reside primarily in the complex manufacturing processes and technologies for fabricating composite parts. The high cost of composites material and its manufacturing complexity have been inhibitors to the wide transfer of this technology to the non-aerospace market. The search for solutions to high manufacturing costs and efficient manufacturing processes have resulted in intense research by government, aerospace industry companies, and space agencies worldwide.
2017-07-26 ...
  • July 26-27, 2017 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
  • December 4-5, 2017 (8:30 a.m. - 4:30 p.m.) - Puyallup, Washington
Training / Education Classroom Seminars
The requirements for producing an FAA approved replacement part can be daunting. Understanding the steps required in the FAA Parts Manufacturer Approval (PMA) process can greatly streamline the approval life-cycle and reduce unnecessary costs and delays, thereby shortening the time and cost to market. This course is designed for those organizations and individuals interested in designing and manufacturing replacement parts for civil aviation aircraft. This two-day course covers the crucial subjects and steps of the FAA-PMA approval process.
2017-04-04
Event
This technical session focuses on fundamental and applied research that lowers frictional energy losses and enhances reliability and durability of automotive components. The topics include, but not limited to engine and drivetrain tribology, seals, bearing and gear lubrication, materials tribology, surface engineering, lubricants and additives, computer-aided tribology, tribotesting, as well as friction, wear and lubrication fundamentals.
2017-04-04
Event
This technical session focuses on fundamental and applied research that lowers frictional energy losses and enhances reliability and durability of automotive components. The topics include, but not limited to engine and drivetrain tribology, seals, bearing and gear lubrication, materials tribology, surface engineering, lubricants and additives, computer-aided tribology, tribotesting, as well as friction, wear and lubrication fundamentals.
2017-03-28
Technical Paper
2017-01-1124
Enrico Galvagno, Mauro Velardocchia
This paper investigates the effect of the powertrain mounting system on the linear and nonlinear torsional dynamical behaviour of a transmission system. To this aim, two dynamic models, namely rigid mounts model and flexible mounts model, are presented and compared, the first considering only the torsional dynamics of the transmission and driveline, the second considering also a 3 degrees-of-freedom powertrain block dynamics. The mechanical coupling and interaction between the powertrain block and transmission system is discussed and formulated. These models are then analysed in terms of vibrational mode shapes, natural frequencies and Frequency Response Functions (FRFs), considering also the sensitivity to the main transmission parameters on the system vibrations.
2017-03-28
Technical Paper
2017-01-0461
R. Rajendran, Ravikumar N, S.S.M Abdul Majeed
Brake disc provides friction force with minimum weight loss on application of brake. The pad material only experiences more wear and friction. Disc and pad materials are selected to give a stable and high coefficient of friction (0.25-0.40). COF is directly proportional to braking force generated and inversely proportional to the stopping distance. Brake pad is mainly produced from asbestos materials. Asbestos is an excellent material for brake pad application.. Considering the environmental pollution and human health safety, the asbestos cannot be used and there is a need to find an alternate material. The aim of the study is to identify a new material for replacement of pad material in practice. In this study, wear, hardness and friction properties of E glass fibre with epoxy resin and cashew friction dust composite are studied and compared with brake pad material in practice.
2017-03-28
Technical Paper
2017-01-1090
Praveen Kumar Tumu, KungHao Wang, Juhchin Yang, Selvakumar Palani, Balaji Srinivasan
In the shop floor, cracking issue was noticed during assembly of valve seat and valve guide in the engine cylinder head, especially near the valve seating area. This paper reveals a non- linear finite element methodology to verify the structural integrity of a cylinder head during valve seat and valve guide assembly press-in operation under the maximum material condition. Material and geometrical nonlinearities, and contact are included in this method to replicate the actual seat and guide press-in operation which is being carried out in shop floor. The press-in force required for each valve seat and valve guide assembly is extracted from simulation results to find out the tonnage capacity of pressing machine for cylinder head assembly line. Stress and plastic deformation due to assembly load are the criteria checked against the respective material yield.
2017-03-28
Technical Paper
2017-01-1122
Yashodhan V. Joshi
Vehicle noise has reduced over the years due to the customer demand for quieter vehicles. As engines have become quieter by efforts to reduce the combustion noise, as well as, by moving away from mechanical fuel pumps to common rail fuel pumps, the geartrain noise has come under increased scrutiny. Gear whine could be a result of multiple factors, and gear profile distortion is one of those factors. ISO 10064 provides guidance on the distortion due to temperature effects, but does not describe other influences in detail. There is not much published literature about gear whine due to profile distortion. The work attempts to fill that gap by describing a gear whine problem due to profile distortion and load change and it’s resolution by changing the gear design.
2017-03-28
Technical Paper
2017-01-0446
Xiao Chuan Xu
Aiming at the variable displacement oil pump, the modal and noise were studied, and structural optimization and test verification were carried out. The modal analysis of the variable displacement oil pump was carried out by ABAQUS. Three dimensional unsteady flow field in the variable pump was calculated by Pumplinx. Sound field was calculated by ACTRAN acoustic software. The NVH and comprehensive performance test of the oil pump was carried out by oil pump test bench and B&K PULSE vibration and noise test equipment. The modal of the variable displacement oil pump was analyzed by ABAQUS. Three dimensional unsteady flow field in the variable pump was calculated by Pumplinx. The sound field was calculated by ACTRAN acoustic software. The NVH and comprehensive performance test of the oil pump was carried out by oil pump test bench and B&K PULSE vibration and noise test equipment.
2017-03-28
Technical Paper
2017-01-1075
Wen Chen, Reda Adimi, Xingfu Chen, Todd Brewer, Ling Shi
In CAE analysis of cylinder bore distortion, valve seat distortion, valve guide-to-seat misalignment and cam bore misalignment, nodal displacements on the cylinder bore inner surface and on the gage lines of valve seats, valve guides and cam bores are typically output. Best fit cylinders, best fit circles and best fit lines are computed by utilizing the output displacements of the deformed configuration. Based on the information of the best fit geometry, distortions and misalignments are assessed. Some commercial and in-house software is available to compute the best fit cylinders, best fit circles and best fit lines. However, they suffer from the drawback that only one best-fit geometry can be computed at a time. For example, in the valve seat distortion analysis of a typical 4-cylinder, 4-valve engine, 16 best fit circles are needed.
2017-03-28
Technical Paper
2017-01-1091
Todd Brewer, Xingfu Chen
Typically, modern automotive engine designs include separate cylinder heads and cylinder blocks with a multilayer steel head gasket to seal the resulting joint. Cylinder head bolts are typically used to hold the joint together and non-linear properties of head gasket provide sealing capabilities of this joint, which is essential for engine durability and performance. There are three major failure modes for head gasket joint: fluid leakage due to low sealing pressure, bead cracking due to high gap alternation and scrubbing/fretting due to pressure and temperature fluctuations causing lateral movement in the joint. During engine operation, head gasket design should be robust enough to prevent all three failure modes. Analysis methods to address two failure modes (fluid leakage and bead cracking) are common within the industry. This paper will be focused on gasket scrubbing/fretting failure mode. First gasket scrubbing and fretting mechanisms are investigated.
2017-03-28
Technical Paper
2017-01-1316
Dhaval Vaishnav, Mohsen Ehteshami, Syed Ali, Vylace Collins, Alan Gregory, Matthew Werner
A jet pump, or an ejector, functions on the ability of a high velocity jet to entrain surrounding stationary fluid. When a high pressure flow from a primary inlet passes through a nozzle, it creates low pressure zone due to venturi effect. The low pressure zone allows flow entrainment from a secondary inlet. For a given pressure at primary inlet, it is desired to entrain maximum flow from secondary inlet. Jet pumps have been used in automobiles for a variety of applications such as: transferring liquid fuel between two halves of the saddle type fuel tank and entraining fresh coolant in the cooling circuit. Recently, jet pumps have been used in evaporative emission control system to remove gaseous hydrocarbons stored in carbon canister and supply it to intake manifold (canister purging). Naturally aspirated engines use vacuum pressure inside the intake manifold for canister purging. However, turbocharged engines operate at or above atmospheric pressure.
2017-03-28
Technical Paper
2017-01-0131
Chiranth Srinivasan, Chonglin Zhang, Haiyang Gao, De Ming Wang, Jody Slike
In an automotive cooling circuit, the wax melting process determines the net and time history of the energy transfer between the engine and its environment. A numerical process that gives insight into the mixing process outside the wax chamber, the wax melting process, and the effect on the poppet valve displacement will be advantageous to both the engine and automotive system design. A fully three dimensional, transient, system level simulation of an inlet controlled automotive cooling circuit is undertaken in this paper. A proprietary CFD algorithm, PumpLinx®, is used to solve this complex problem. A two-phase model is developed in PumpLinx® to simulate the wax melting process. The hysteresis effect of the wax melting process is also considered in the simulation. The coolant circulated using a centrifugal pump, which operates via a constant ratio with respect to the engine speed, is modeled as part of the computational domain.
2017-03-28
Technical Paper
2017-01-0387
Deepak Anand Subramanian, Shanmugam Mathaiya, Srinivasa Chandra V
In today's commercial vehicle scenario, designing and developing a component which will never fail throughout its lifespan is next to impossible. For a long time especially in the field of automotive, any crack initiation shall deem the component as failed and the design requires further modification. This paper deals with studying the failure of one such component and understanding the effect the crack has on the overall life of the component i.e. understanding the remnant life of the component. The component under study was gear shift lever bracket and is mounted on the engine exhaust manifold. It experiences two types of loads: inertial load due to the engine vibration and gear shift load. Frequent failures were observed in the field and in order to simulate it at lab, an accelerated test approach was adopted. The engine operating speed was used to identify the possible excitation frequency which the component might experience.
2017-03-28
Technical Paper
2017-01-1147
Hyunjun Kim, Jingeon Kang, Dongsuk Kum
Input- and output-split hybrids, which use a single planetary gear (PG), have a good fuel economy, but a relatively low acceleration performance. In order to improve their acceleration performance, speed reduction gears (SRG) have been employed in various commercialized split hybrids. However, the full potential of using SRGs has not yet been investigated. In fact, adding one SRG to input- or output-split hybrids can improve not only their acceleration performance, but also their fuel economy. Nevertheless, the design space of input- and output-split configurations using one SRG is huge; 864 configurations are using two PGs connected through one interconnection and having one node grounded to a fixed platform. Thus, in order to solve this high computational load problem, an efficient comprehensive design methodology is highly required.
2017-03-28
Technical Paper
2017-01-0445
Muthukumar Arunachalam, Arunkumar S, PraveenKumar Sampath, Abdul Haiyum
In recent years, there is increasing demand for every CAE engineer on their confidence level of the virtual simulation results due to the upfront robust design requirement during early stage of an automotive product development. Apart from vehicle feel factor NVH characteristics, there are certain vibration target requirements at system or component level which need to be addressed during design stage itself in order to achieve the desired functioning during vehicle operating conditions. Vehicle passive safety system is one of which primarily consists of acceleration sensors, control module and air-bag deployment system. As the sensors act as the front-end of passive safety system and control module’s decision is based on these sensors signals, its mounting locations should meet the sufficient inertance or dynamic stiffness performance in order to avoid distortion in signals due to its structural resonances.
2017-03-28
Technical Paper
2017-01-0250
Jizhou Zhang, Jianhua zhou PhD, Mian LI, Min Xu
To improve the system performance, precision manufacturing is required for production of the internal combustion engines (ICEs), a typical complex nonlinear system. Previous studies show that tolerances of critical dimensions have significant impacts on the engine performance. Among many critical factors, friction loss is one of the most important ones that affect the output performance of ICEs. It is necessary to recognize and control the tolerances which affect the friction loss. Of all the friction pairs for the engine, it is observed that the piston-cylinder friction pair and the bearing system take up nearly 70% of the total friction loss. In this work a novel multi-objective tolerance design optimization problem considering two friction systems mentioned above is proposed and solved. First two separated simulation models, the piston-cylinder and the bearing are built using AVL Excite Piston & Ring® and AVL Excite Power Unit®, respectively.
2017-03-28
Technical Paper
2017-01-0860
PengBo Dong, Jun Yamauchi, Keiya Nishida, Youichi Ogata
With the aim of improving engine performance, recent trend of fuel injection nozzle design followed by engineers and researchers is focusing on more efficient fuel break up, atomization, and fuel evaporation. Therefore, it is crucial to characterize the effect of nozzle geometric design on fuel internal flow dynamics and the consequent fuel-air mixture properties. In this study, the internal flow and spray characteristics generated by the practical multi-hole (10 holes) nozzles with different nozzle hole length and hole diameter were investigated in conjunction with a series of computational and experimental methods. Specifically, the CFD commercial code was used to predict the internal flow variation inside different nozzle configurations, and the high-speed video observation method was applied to visualize the spray evolution processes under non-evaporating conditions. Moreover, the Laser Absorption Scattering method was implemented to explore the spray evaporation characteristics.
2017-03-28
Technical Paper
2017-01-0543
Oliver Hofmann, Shijin Han, Daniel Rixen
This study discusses model-based injection rate estimation in common rail diesel injectors exhibiting aging phenomena. Since they result in unexpected injection behavior, aging effects like coking or cavitation may impair combustion performance, which justifies the need for new modeling and estimation approaches. To predict injection characteristics, a simulation model for the bottom section of the injector is introduced, with a main focus on modeling the hydraulic components. Using rail pressure and control piston lift as inputs, a reduced model is then derived in state-space representation, which may be used for the application of an observer in hardware-in-the-loop (HIL) environments. Both models are compared and validated with experimental data, with which they show good agreement. Aging efects and nozzle wear, which result in model uncertainties, are considered using a fault model in combination with an extended Kalman filter (EKF) observer scheme.
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