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The primary objective of design is to achieve the target value of its function. While principles and techniques of Robust Design address the issue of achieving target values in the presence of different types of variations and disturbances, there exists a unique challenge in achieving design targets when multiple response functions are interrelated. In order to overcome the challenge, we must avoid functional couplings and obtain the interrelationship structure as flexible as possible. In the Axiomatic Design process, such interrelationships are represented by coupling terms in a design matrix. From the targeting aspect of design, it is important to achieve a desirable design matrix structure to, first, avoid any functional coupling in a design matrix and, secondly, maximize allowable sequences of adjusting DPs.

This paper presents tribological modeling, experimental work, and validation of tribology parameters of a single cylinder turbocharged diesel engine run at various loads, speeds, intake boost pressures, and cylinder liner temperatures. Analysis were made on piston rings and liner materials, rings mechanical and thermal loads, contact pressure between rings and liner, and lubricant conditions. The engine tribology parameters were measured, and used to validate the engine tribology models. These tribology parameters are: oil film thickness, coefficient of friction between rings and liner, friction force, friction power, friction torque, shear rate, shear stress and wear of the sliding surfaces. In order to measure the oil film thickness between rings and liner, a single cylinder AVL turbocharged diesel engine was instrumented to accept the difference in voltage drop method between rings, oil film, and liner.

The life of an automotive engine is often limited by the ability of its components to resist wear. Zinc dialkyldithiophosphate (ZDDP) is an engine oil additive that reduces wear in an engine by forming solid antiwear films at points of moving contact. The effects of this additive are fairly well understood, but there is little theory behind the kinetics of antiwear film formation and removal. This lack of dynamic modeling makes it difficult to predict the effects of wear at the design stage for an engine component or a lubricant formulation. The purpose of this discussion is to develop a framework for modeling the formation and evolution of ZDDP antiwear films based on the relevant chemical pathways and physical mechanisms at work.

This paper illustrates a methodology in which complete material-manufacturing process cases for closure panels, reinforcements, and assembly are modeled and compared in order to identify the preferred option for a lightweight closure design. First, process-based cost models are used to predict the cost of lightweighting the closure set of a sample midsized sports utility vehicle (SUV) via material and process substitution. Weight savings are then analyzed using a powertrain simulation to understand the impact of lightweighting on fuel economy. The results are evaluated in the context of production volume and total mass change.

The presence of liquid fuel inside the engine cylinder is believed to be a strong contributor to the high levels of hydrocarbon emissions from spark ignition (SI) engines during the warm-up period. Quantifying and determining the fate of the liquid fuel that enters the cylinder is the first step in understanding the process of emissions formation. This work uses planar laser induced fluorescence (PLIF) to visualize the liquid fuel present in the cylinder. The fluorescing compounds in indolene, and mixtures of iso-octane with dopants of different boiling points (acetone and 3-pentanone) were used to trace the behavior of different volatility components. Images were taken of three different planes through the engine intersecting the intake valve region. A closed valve fuel injection strategy was used, as this is the strategy most commonly used in practice. Background subtraction and masking were both performed to reduce the effect of any spurious fluorescence.

A novel approach to condition the lubricant at a fixed station in the oil circuit is explored as a potential means to reduce additive requirements or increase oil drain interval. This study examines the performance of an innovative oil filter which releases no additives into the lubricant, yet enhances the acid control function typically performed by detergent and dispersant additives. The filter chemically conditions the crankcase oil during engine operation by sequestering acidic compounds derived from engine combustion and lubricant degradation. Long duration tests with a heavy-duty diesel engine show that the oil conditioning with the strong base filter reduces lubricant acidity (TAN), improves Total Base Number (TBN) retention, and slows the rate of viscosity increase and oxidation. The results also indicate that there may be a reduction in wear and corrosion.

This paper explores the combined effects of boosting, intake air temperature, trapped residual gas fraction, and dilution on the Maximum Pressure Rise Rate (MPRR) in a boosted single cylinder gasoline HCCI engine with combustion controlled by negative valve overlap. Dilutions by both air and by cooled EGR were used. Because of the sensitivity of MPRR to boost, the MPRR constrained maximum load (as measured by the NIMEP) did not necessarily increase with boosting. At the same intake temperature and trapped residual gas fraction, dilution by recirculated burn gas was effective in reducing the MPRR, but dilution by air increased the value of MPRR. The dependence of MPRR on the operating condition was interpreted successfully by a simple thermodynamic analysis that related the MPRR value to the volumetric heat release rate.

An extravehicular activity (EVA) path-planning and navigation tool, called the Mission Planner, has been developed to assist with pre-mission planning, scenario simulation, real-time navigation, and contingency replanning during astronaut EVAs, The Mission Planner calculates the most efficient path between user-specified waypoints. Efficiency is based on an exploration cost algorithm, which is a function of the estimated astronaut metabolic rate. Selection of waypoints and visualization of the generated path are realized within a 3D mapping interface through terrain elevation models. The Mission Planner is also capable of computing the most efficient path back home from any point along the path.

Battery packs for Hybrids, Plug-in Hybrids, and Electric Vehicles are assembled from a system of modules (sheets) with a tight sheet metal casing around them. Each module consists of an array of individual cells which vary in the composition of electrodes and separator from one manufacturer to another. In this paper a general procedure is outlined on the development of a constitutive and computational model of a cylindrical cell. Particular emphasis is placed on correct prediction of initiation and propagation of a tearing fracture of the steel can. The computational model correctly predicts rupture of the steel can which could release aggressive chemicals, fumes, or spread the ignited fire to the neighboring cells. The initiation site of skin fracture depends on many factors such as the ductility of the casing material, constitutive behavior of the system of electrodes, and type of loading.

A comprehensive and robust analytical tool was developed to study three-dimensional (3D) ring-bore and ring-groove interactions for piston rings with either symmetric or asymmetric cross-section. The structural response of the ring is modeled with 3D finite element beam method, and the interfaces between the ring and the bore as well as between the ring and the groove are modeled with a simple asperity contact model. Given the ring free shape and the geometry of the cross-section, this analytical tool can be used to evaluate the ring-bore and ring-groove conformability as well as ring twist angle distribution under different constraints. Conversely, this tool can be used to calculate the free shape to provide the desired ring-bore contact pressure distribution for specific applications.

Hydrogen can be readily used in spark-ignition engines as a clean alternative to fossil fuels. However, a larger burning velocity and a shorter quenching distance for hydrogen as compared with hydrocarbons bring a larger cooling loss from burning gas to the combustion-chamber wall. Because of the large cooling loss, the thermal efficiency of a hydrogen-fueled engine is sometimes lower than that of a conventionally fueled engine. Therefore, the reduction of the cooling loss is very important for improving the thermal efficiency in hydrogen-combustion engines. On the other hand, the direct-injection stratified charge can suppress knocking in spark-ignition engines at near stoichiometric overall mixture conditions. Because this is attributed to a leaner end gas, the stratification can lead to a lowered temperature of burning gas around the wall and a reduced cooling loss.

The existing vehicle designs exhibit a high level of coupling. For instance the coupling in the suspension and steering systems manifests itself through the change in wheel alignment parameters (WAP) due to suspension travel. This change in the WAP causes directional instability and tire-wear. The approach of the industry to solve this problem has been twofold. The first approach has been optimization of suspension link lengths to reduce the change in WAP to zero. Since this is not possible with the existing architecture, the solution used is the optimization of the spring stiffness K to get a compromise solution for comfort (which requires significant suspension travel and hence a soft spring) and directional stability (which demands least possible change in wheel alignment parameters and hence a stiff spring).

A thermodynamic based cycle simulation which uses a thermal boundary layer, either, a fully mixed or layered adiabatic core, and a crevice combustion inefficiency routine has been used to explore the sensitivity of NO concentration predictions to critical physical modeling assumptions. An experimental database, which included measurements of residual gas fraction, was obtained from a 2.0 liter Nissan engine while firing on propane. A model calibration methodology was developed to ensure accurate predictions of in-cylinder pressure and burned gas temperature. Comparisons with experimental NO data then showed that accounting for temperature stratification during combustion with a layered adiabatic core and including a crevice/combustion inefficiency routine, improved the match of modeling predictions to data, in comparison to a fully mixed adiabatic core.

A gasoline direct injection fuel spray was observed using a fired, optical access, square cross-section single cylinder research engine and high-speed video imaging. Spray interaction with the piston is described qualitatively, and the results are compared with Computational Fluid Dynamics (CFD) simulation results using KIVA-3V version 2. CFD simulations predicted that within the operating window for stratified charge operation, between 1% and 4% of the injected fuel would remain on the piston as a liquid film, dependent primarily on piston temperature. The experimental results support the CFD simulations qualitatively, but the amount of fuel film remaining on the piston appears to be under-predicted. High-speed video footage shows a vigorous spray impingement on the piston crown, resulting in vapor production.

Determining the fundamental role of gravity in vital biological systems in space is one of six science and research areas that provides the philosophical underpinning for why NASA exists. The study of cells, tissues, and microorganisms in a spaceflight environment holds the promise of answering multiple intriguing questions about how gravity affects living systems. To enable these studies, specimens must be maintained in an environment similar to that used in a laboratory. Cell culture studies under normal laboratory conditions involve maintaining a highly specialized environment with the necessary temperature, humidity control, nutrient, and gas exchange conditions. These same cell life support conditions must be provided by the International Space Station (ISS) Cell Culture Unit (CCU) in the unique environment of space. The CCU is a perfusion-based system that must function in microgravity, at unit gravity (1g) on earth, and from 0.1g up to 2g aboard the ISS centrifuge rotor.

Computer simulation of extravehicular activity (EVA) is increasingly being used in planning and training for EVA. A space suit model is an important, but often overlooked, component of an EVA simulation. Because of the inherent difficulties in collecting angle and torque data for space suit joints in realistic conditions, little data exists on the torques that a space suit’s wearer must provide in order to move in the space suit. A joint angle and torque database was compiled on the Extravehicular Maneuvering Unit (EMU), with a novel measurement technique that used both human test subjects and an instrumented robot. Using data collected in the experiment, a hysteresis modeling technique was used to predict EMU joint torques from joint angular positions. The hysteresis model was then applied to EVA operations by mapping out the reach and work envelopes for the EMU.

The piston skirt is an important contributor of friction in the piston assembly. This paper discusses friction contributions from various aspects of the piston skirt. A brief study of piston skirt patterns is presented, with little gains being made by patterning the piston skirt coating. Next the roughness of the piston skirt coating is analyzed, and results show that reducing piston skirt roughness can have positive effects on friction reduction. Finally, an introductory study into the profile of the piston skirt is presented, with the outcome being that friction reduction is possible by optimizing the skirt profile.

The piston’s skirt shape is a key design parameter since it critically influences lateral displacement, tilting movement, oil transport and consequently engine performances. This study proposes an alternative skirt profile that aims to reduce frictional losses between the piston and cylinder liner. Qualitatively, the proposed profile, aims to reduce solid-to-solid contact friction by increasing the total hydrodynamic forces generated on the skirt to balance side forces, and to prevent both sides of the skirt to interact with the liner simultaneously. The new skirt’s profile has been first studied and optimized using a piston secondary motion model and then prototyped and tested on a floating liner test bench, showing a 12% average reduction in total piston FMEP.

This paper evaluates the lag time in a turbocharged single cylinder engine in order to determine its viability in transient applications. The overall goal of this research is to increase the power output, reduce the fuel economy, and improve emissions of single cylinder engines through turbocharging. Due to the timing mismatch between the exhaust stroke, when the turbocharger is powered, and the intake stroke, when the engine intakes air, turbocharging is not conventionally used in commercial single cylinder engines. Our previous work has shown that it is possible to turbocharge a four stroke, single cylinder, internal combustion engine using an air capacitor, a large volume intake manifold in between the turbocharger compressor and engine intake. The air capacitor stores compressed air from the turbocharger during the exhaust stroke and delivers it during the intake stroke.

Understanding oil transport mechanisms is critical to developing better tools for oil consumption and piston skirt lubrication [1]. Our existing Two-Dimensional Laser Induced Fluorescence (2DLIF) system with an acquisition rate of 1 frame every one or two cycles was proven to be effective to display oil accumulation patterns and their evolution over many cycles in the piston ring pack system [2,3,4]. Yet, the existing system is unable to resolve instantaneous oil flow patterns in the piston-liner interface. In this work, a high-speed LIF system was developed. After a number of iterations the finalized high speed LIF system includes a 23 W, 100 kHz, 532 nm laser and a high speed camera capable of 100,000 FPS at 384 × 264 pixel resolution. After each component was selected, optimization of the quality of images taken from the system began.