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Viewing 1 to 30 of 15318
2015-10-05 ...
  • October 5, 2015 (8:30 a.m. - 4:30 p.m.) - Norwalk, California
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.
2015-08-05 ...
  • August 5, 2015 (8:30 a.m. - 4:30 p.m.) - Tysons, Virginia
Training / Education Classroom Seminars
Counterfeit electronic parts have been found in almost every sector of the electronics industry and continue to be an increasing threat to electronic hardware. This threat poses significant performance, reliability and safety risks. Aerospace industry organizations, in particular, must produce and continually improve safe and reliable products that meet or exceed customer and regulatory authority requirements.
2015-08-03 ...
  • August 3-4, 2015 (8:30 a.m. - 4:30 p.m.) - Tysons, Virginia
Training / Education Classroom Seminars
Through the years there has been a significant and increasing volume of fraudulent and counterfeit electronic parts entering the aerospace supply chain. Left undetected, these parts can pose significant performance, reliability, and safety risks. In response to these threats, the SAE AS6081 Counterfeit Electronic Parts Avoidance – Distributors standard was developed to provide uniform requirements, practices, and methods to mitigate the risk of electronics distributors purchasing and supplying these counterfeit electronic parts throughout the aerospace supply chain.
2015-05-04 ...
  • May 4-5, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
  • September 21-22, 2015 (8:30 a.m. - 4:30 p.m.) - Seattle, 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.
2015-04-20 ...
  • April 20-21, 2015 (8:30 a.m. - 4:30 p.m.) - Detroit, Michigan
  • August 3-4, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
  • December 14-15, 2015 (8:30 a.m. - 4:30 p.m.) - Troy, Michigan
Training / Education Classroom Seminars
Attendees to the seminars held in conjunction with the SAE 2015 World Congress will receive COMPLETE access to Congress activities for only $55 per day. If interested, please contact our Customer Service department at +1.877.606.7323 (U.S. and Canada only) or +1.724.776.4970 (outside U.S. and Canada) to register for this special Congress daily rate. This seminar introduces participants to all aspects of threaded fasteners including nomenclature, geometric considerations, metallurgy, material properties, applied stresses, and considerations for fatigue, corrosion, brittle fracture and temperature.
2015-04-14
Technical Paper
2015-01-1740
Kelsie S. Richmond, Stephen Henry, Russell Richmond, David Belton
Gasket materials are utilized for various different types of high temperature testing to prevent leaking at bolted joints. In particular, the automotive test services field uses flanged-gasket bolted exhaust joints to provide a convenient method for installation & removal of exhaust components like catalytic converters for aging, performance testing, etc. Recent improvements in the catalyst aging methods require flanged-gasket joints that can withstand exhaust temperatures as high as 1200°C. Gasket materials previously used in these applications like the graphite based gasket materials have exhibited physical breakdowns, severe leakage, and general thermal failures under these extreme temperatures. In order to prevent these leaks, metal-reinforced gasket materials in a number of configurations were introduced to these extreme temperature environments to evaluate their robustness to these temperatures.
2015-04-14
Technical Paper
2015-01-0867
Ashish Shah, Per Tunestal, Bengt Johansson
This article is related to application of pre-chamber ignition device in heavy duty natural gas engine which, as previously shown by the authors, is capable of extending lean limit of operation and hence achieve better operating efficiency and reduce emissions. The effect of pre-chamber volume and nozzle diameter has been studied while operating with fuel rich combustion in the pre-chamber. The two parameters varied are the ratio of pre-chamber volume to engine’s clearance volume and the ratio of total area of connecting nozzle to the pre-chamber volume. Each parameter is varied in 3 steps hence forming a 3 by 3 test matrix. The experiments are performed on a single cylinder 2L engine fitted with a custom made pre-chamber which is capable of spark ignition, fuel injection and pressure measurement.
2015-04-14
Technical Paper
2015-01-1499
Tadatsugu Takada, Kazuki Tomioka
Honda developed the right and left independent toe-angle control system (first-generation P-AWS) in the Acura RLX in 2013 and announced it as the first in the world. As indicated in a previous paper, “Independent Left and Right Rear Toe Control System,” with this system Honda has realized an excellent balance between the fun of handling that is at the driver’s will (INOMAMA) and driving performance with a sense of stability. This first-generation P-AWS is designed to be optimal to the vehicle specifications (suspension axial force, steering gear ratio, etc.) of the Acura RLX. Honda is due to widely adapt P-AWS to other models from now on. Following this, we developed the next-generation P-AWS system (second-generation P-AWS) in order to reconcile system performance and low cost wherever possible, in order to be adaptable for all ACURA models.
2015-04-14
Technical Paper
2015-01-0686
Kenji Matsumoto, Hideharu Koga, Yuji Mihara
 When evaluating the wear properties of slide bearings for car engines, it is common to conduct long-term physical tests using a bearing tester for screening according to the revolution speed of the shaft, supply oil temperature and bearing pressure in the actual use of engines. The loading waveform applied depends on the capability of the tester that is loaded, and it is often difficult to apply a loading waveform equivalent to that of actual engines. To design an engine that is more compact or lighter, it is necessary to reduce the dimensions of slide bearings and the distance between bearings. This requires loading tests on a newly-designed engine by applying a loading waveform equivalent to that of actual engines to slide bearings and their vicinity before conducting a firing test. We conducted an engine firing test by attaching thin-film sensors to the slide bearing part of the engine and measured the actual load distribution.
2015-04-14
Technical Paper
2015-01-1371
Samuel T. Bartlett
With the many model variations produced on the same production line because of increasing power train options, fuel efficiency targets, performance and customer demands we saw limitations with our existing suspension mount equipment. Layout options were limited due to guided shifts and transfers. Large supporting frame work took up valuable floor space. Model wheelbase sizes and suspension pallets were limited to the model requirements of the original equipment. We needed an adaptable system to install the engine/front suspension assemblies and the rear suspension assemblies. We found a solution by utilizing the capabilities of 6-axis industrial robots to make the core components of the equipment simpler; many of the functions of a traditional machine can now be accomplished by the robot. We were able to vary install position to optimize handling characteristics and accommodate the model-to-model varieties on the same production line.
2015-04-14
Technical Paper
2015-01-1326
Guru Prasad Mani, Sundaravadivelu M, Kavin Raja
Generation of discretization with prescribed element sizes are adapted to the geometry. From Rules of thumb, for a complicated geometry it is important to select the reasonable element order, shapes and size for accurate results. In order to that, this paper describes the influence of elemental algorithm of the catalytic converter mounting brackets. Brackets are main source of mounting of various systems mainly intake and exhaust in the engine .In exhaust hot end system, bracket designs play a vital role because it has to withstand heavy structural vibrations without isolation combined with thermal loads. Bracket design and stiffness determines the whole Catalytic converter system's rigidity. So, here discretization of converter brackets by linear and parabolic elements is studied with different elements types and compared.
2015-04-14
Technical Paper
2015-01-0605
Guoyu Yang, Scott Kish
Abstract Heavy stamping parts of HSLA (high strength low alloy) steel are widely used in the automotive industry for design optimization. The material properties of the heavy stamping parts however, change during the stamping process, making simulation and analysis difficult. Traditional tensile tests, used to obtain the material properties, might not be applicable due to the size of specimens required. Without reliable material properties, it is very hard for FEA simulations to predict accurate results. A method for characterizing the material properties of a heavy stamped steel part was presented in this paper. Based on monotonic and fatigue test results, gathered in cooperation with The University of Toledo, we developed specific material models for strength and fatigue analysis. Instead of employing commercial fatigue analysis software, we can perform the fatigue life prediction by using traditional static analysis in ABAQUS with more accurate results.
2015-04-14
Technical Paper
2015-01-0918
Daniel Duke, Andrew Swantek, Alan Kastengren, Kamel Fezzaa, Christopher Powell
Cavitation plays an important role in fuel injection systems. It alters the nozzle’s internal flow structure and discharge coefficient, and also contributes to injector wear. Quantitatively measuring and mapping the cavitation vapor distribution in a fuel injector is difficult, as cavitation occurs on very short time and length scales. Optical measurements of transparent model nozzles can indicate the morphology of large-scale cavitation, but are generally limited by the substantial amount of scattering that occurs due to large changes in refractive index between vapor and liquid phases. These limitations can be overcome with x-ray diagnostics, as x-rays refract, scatter and absorb much more weakly. Here, we present an overview of some recent developments in quantitative x-ray diagnostics for cavitating flows. Measurements were conducted at the Advanced Photon Source at Argonne National Laboratory, using a submerged plastic test nozzle 500µm in diameter.
2015-04-14
Technical Paper
2015-01-0921
Raul Payri, Jaime Gimeno, Pedro Marti-Aldaravi, Marcos Carreres
Proper initial conditions are essential to successfully perform a simulation, specially for highly transient problems such Diesel spray injection. Until now, no much attention has been paid to the internal nozzle flow initialization because spray simulations are usually decoupled from the nozzle. However, new homogeneous models, such Eulerian Spray Atomization (ESA) model, allow simulating the internal nozzle flow and the spray seamlessly. Therefore, behavior of the spray for the first microseconds is highly influenced by the initial conditions inside the nozzle. Furthermore, last experiments confirm the presence of gas inside the nozzle between following injections. This work deals with the initilialization procedure in a way that mass flow rate, momentum flux and spray penetration curves are well predicted by the model.
2015-04-14
Technical Paper
2015-01-0948
Le (Emma) Zhao, Ahmed Abdul Moiz, Jeffrey Naber, Seong-Young Lee, Sam Barros, William Atkinson
Liquid spray breakup and atomization, two multi-phase phenomena, strongly affect the ignition and combustion processes. High-speed jet-to-jet impingement in water sprays could be an effective phenomenon for the spray propagation and droplet vaporization. To achieve higher vaporization efficiency, impingement from two-hole nozzles is analyzed in this paper. This paper focuses on investigating vaporization mechanism as a function of the impingement location and the collision breakup process provided by two-hole impinging jet nozzles. CFD (Computational Fluid Dynamics) is adopted to do simulation. Lagrangian model is used to predict jet-to-jet impingement and droplet breakup conditions while KH-RT breakup and O’Rourke collision models are implemented for the simulation.
2015-04-14
Technical Paper
2015-01-0529
Jody N. Hall, Jason Coryell, Bill Wendt, Donald Adamski
Several production parts have been randomly splitting from trimmed edges even at strains well below the forming limit and hole expansion capabilities of the material. These parts are all Dual Phase (DP) steel with one exception of a multiphase version of a DP980 grade. The fractures were not limited to a specific strength, supplier, or stamping plant. Each part was studied to determine the root cause of failure for each edge fracture and to document the solutions in appropriate standards and specifications. As typical for dual phase steel, the edge fractures involved a stretch condition. However, these fractures are unexpected at such low strains. This paper will review the importance of the trimmed edge condition that must be maintained to eliminate fractures at low strains. A comparison will be made between good and poor trim quality along with an updated specification for a good trimmed edge.
2015-04-14
Technical Paper
2015-01-0527
Pierre-Olivier Santacreu, Guillaume Badinier, Jean-Benoit Moreau, Jean-Marc herbelin
A new Ni-free martensitic stainless steel was developed for hot stamped automotive parts, especially in order to design lightweight chassis. After hot stamping simulation, the material exhibits 1.2 GPa ultimate tensile strength with 8% total elongation, in the as-quenched condition (without any tempering treatment). Moreover the material’s chemical composition was optimised to improve the ductility at low temperature and during high strain rate mechanical testing. As a result, no brittle fracture in impact testing at -40°C was observed, and a good behaviour in crash was recorded. To further assess the material’s performance, high cycle and low-cycle fatigue properties of the grade were characterized and the effects of machining and surface were studied. Results show that the fatigue limits at 2 million cycles for a stress ratio of -1 for rough bare surface and shot peened surface are quite high at 0.45 and 0.55 times the ultimate tensile strength (in the range of 540 MPa to 640 MPa).
2015-04-14
Technical Paper
2015-01-1743
TANMAY SANTRA, Vikas Kumar Agarwal
An inadequate sealing of the combustion chamber gasket interface may have severe consequences on both the performance & emission of an engine. In this investigation, both the distribution of the contact pressure on the gasket and the stresses of the cylinder head at different loading conditions are explored and improved by modifying the design. A single cylinder gasoline engine cylinder head assembly has been analyzed by means of an uncoupled FEM simulation to find the sealing pressure of the multi-layer steel gasket (MLS), strength & deformation of the components involved. The thermal loads are computed separately from CFD simulations of cylinder head assembly. The cylinder head assembly consisting of head, block, liner, cam shaft holder, bolts, gaskets, valve guides & valve seats, is one of the most complicated sub-assembly of an IC engine.
2015-04-14
Technical Paper
2015-01-0669
Nagarjun Jawahar, Saharash Khare
Automotive OEM’s are looking for innovative solutions to capture the possible failure due to warpage and shrinkage of an insert molded part through virtual simulations with help of FEA tools, thereby saving the mold cost, material cost and time. This work demonstrates an approach to study and simulate the failure of an insert molded part which happened after few days of the part molding under idle condition. To simulate the above failure, an innovative approach coupling Moldflow and Abaqus software was derived. First, a flow simulation including phase change of plastic material was carried out with derived parameters, results of which were exported as input to the Abaqus structural solver. Secondly, a thermo-mechanical analysis of the model was then carried out considering the thermal and moisture effect on material property. A good correlation was achieved between the actual failure location and max stress location as predicted by said coupled approach.
2015-04-14
Technical Paper
2015-01-0520
Takaaki Kitahara, Takuo Imai, Osamu Ishigo, Miodrag Perovic
In recent years, there has been a requirement for automotive bearings materials to be free of the toxic material lead, in accordance with ELV regulations and from the perspective of environmental problems. Currently, bismuth is often used as a replacement for lead in copper alloy based main bearings and connecting rod bearings for automotive engines. Previous bismuth-containing copper alloy bearing materials have shown satisfactory seizure resistance, but conformability has not been as good as for lead-containing bearing materials. As a result, they have been successfully applied to automotive diesel engines, but not for truck engines where improved conformability is required to better accommodate irregularities such as foreign particles. To improve the conformability, a softer bearing material is desirable. Furthermore, in recent years bearing materials containing hard particles have been widely used with the improvement of seizure resistance and wear resistance.
2015-04-14
Technical Paper
2015-01-0779
Gerald Gentz, Bryce Thelen, Paul Litke, John Hoke, Elisa Toulson
Turbulent Jet Ignition (TJI) is a prechamber ignition enhancement method that allows for fast burning durations due to the distributed nature of ignition. In this paper combustion visualization and characterization was performed for the combustion of a premixed propane/air mixture initiated by a TJI system in a Rapid Compression Machine. Three different single orifice TJI nozzles with orifice diameters of 1.5mm, 2mm, and 3mm were tested for the TJI pre-chamber over a range of air to fuel ratios. The performance of the TJI system based on nozzle orifice diameter was characterized by considering both the 0-10% and the 10-90% burn durations of the pressure rise due to combustion. It was found that the 1.5 mm orifice exhibited the shortest 0-10% burn duration, which corresponded to the fastest flame initiation. The orifice diameter did not significantly affect the 10-90% burn duration near stoichiometric air to fuel ratios.
2015-04-14
Technical Paper
2015-01-1377
Hiroshi Yokoyama, Atsushi Otani, Naoyuki Shirota, Takao Umezawa
Windshield wipers and washers are essential for safety driving of motor vehicles and expected to steadily provide a good field of vision under various weather and environment conditions. However, there is a concern that washers are likely to be affected by several factors such as fast air flow at high speed driving and high washer fluid viscosity at low temperature, which may result in unsatisfactory distribution of washer fluid onto windshields. As another example, particularly-high cleaning performance is required while vehicles are running on a winter road with mud and salt. Conversely, if these concerns are resolved, washers can contribute more to vehicle safety. Thus, we have developed a washer nozzle with a self-oscillating flow passage focusing on distributing appropriate amount of washer fluid.
2015-04-14
Technical Paper
2015-01-0221
Soham Banerjee, Anand Ganesan, Sudharsan sundaram, Kiran Jasti
The life of a two wheeler and its parts depends much on its usage during its years of running. The quality of its parts determines the life and the efficiency; however the handling of the two-wheeler also plays a major role in estimating the life and the other performance parameters of the two-wheeler. Hence it is beneficial to have an efficient system which enhances the life of a two-wheeler and gives better fuel efficiency. This paper describes an efficient drive pattern system which addresses the above. This system consists of two main parts, the data collection system and a software application which runs on a mobile phone. The data collection system collects data from various sensors present in the vehicle during the run time of the two-wheeler. The data is further processed and sent to the mobile phone of the driver.
2015-04-14
Technical Paper
2015-01-0596
Oliver Scholz, Nikolas Doerfler, Lars Seifert, Uwe Zöller
Rubber seals are used throughout the automobile for a variety of purposes, and the consequences of a failure of such a seal can range from annoying in case of an A/C component to catastrophic in the case of brake components. With the constantly increasing requirements for these components regarding e.g. pressure or new refrigerants comes the requirement for ensuring surface properties according to the specification of the application. While automatic inspection systems are available for a variety of problems, the area of seal inspection is still dominated by manual labor, partly because handling of these small, inexpensive parts is difficult and partly because visual coverage of the entire sealing surface poses a problem. It is also difficult for a human inspector to objectively assess whether or not a surface defect is critical or not, especially given that inspection of each seal must be completed within a few seconds.
2015-04-14
Technical Paper
2015-01-0600
Marc Rosenbaum
A new generation of 3D inspection machines is now available to verify in line 3D dimensional conformity of complex parts – especially Powertrain ones – with accuracy down to 0.1 µm within manufacturing cycle time of large series. Inspecting in line 100% of production with an accuracy and at speed compatible with the most demanding part accuracy and fastest cycle time is presently already a reality for some large tier1 suppliers in Europe. Purpose of this paper is to introduce this breakthrough technology using state of the art non contact sensing technology allied with innovative mechanics and the latest developments in 3D metrology software
2015-04-14
Technical Paper
2015-01-0944
Maryam Moulai, Ronald Grover, Scott Parrish, David Schmidt
A computational and experimental study was performed to characterize the flow within a gasoline injector and the ensuing sprays. The computations used an in-house code that captures the effects of turbulence, cavitation, flash-boiling, and the presence of non-condensible gases. The flow conditions corresponded to the Spray G target conditions of the Engine Combustion Network. First, the rate of injection was measured using a Bosch-style flow meter. The nozzle was then simulated under submerged conditions for direct comparison of discharge coefficient. Next, the internal flow and external spray into pressurized nitrogen were simulated under the base spray G conditions. Finally, injection under flashing conditions was simulated, where the ambient pressure was below the vapor pressure of the fuel.
Viewing 1 to 30 of 15318

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