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Increased torque values passing from engine to transmission have, increasingly become a problem regarding shaft misalignment. Engineers are restricted with regard to applying ISO standards when investigating bearing life cycles as they tend only to cover normal [radial thrust] load conditions. Depending on the application, the need has arisen for numerical models to determine reduction in normal life cycles due to abnormal running conditions. The Simulia Finite Element package Abaqus v6.7 provides trends in the deformations, contact pressures and their respective distribution. It was found the most efficient profile, with regards to a uniform contact pressure, under both radial and misaligned conditions is the toroidal profile.

The upcoming latest 3-wet Technology is the most ideal design for a Green field project as well as for a brown field facility which provides the best of both worlds. The foremost take away for a brown field project emanates from this technology which demands a smaller foot prints & hence could accommodates a capacity higher than what was perceived during the green field project planning thus saving millions of dollar of investment & giving that extra capacity which today the BRIC countries are thriving for. Apart from making the ideal investment choice, 3 Wet Technology provides impetus to business case in terms of reduction of VOC emission, Energy consumption, Material and labor cost and gaining on Green Environment front as well as leading to smart and Efficient-Paint-Process. The paper depicts the journey of roll out of 3-Wet process in Ford India and creating the bench mark in terms of product quality and process standards and manufacturing practices.

Fine packaging is important for the bicycle transmission design. We are proposing a split power continuously variable transmission (SPCVT) operated with one mode. The planetary gear unit (PGU) in the SPCVT consists of two epicyclic gear trains. Both epicyclic gear trains do not include any ring gears to minimize the overall diameter of the transmission. A variator is connected to the PGU as a type of variable bridge. The variator involves two rotor pairs contacting on concave-convex spherical surfaces. This new mechanism of the variator shows a strong possibility to get high power density in comparison with other existing traction drives. A four-bar linkage is used to locate the counter rotor assembly exactly in the contact points of the rotor pair and extend the range of variator speed ratio. The crank is pulled by the wire connected to the speed control lever on the handle of bicycle.

Weight reduction of automobiles is key technology in order to improve fuel economy and driving performance. Concerning of the motorcycle engine, weight reduction is also the fundamental and important technologies. Cylinder is one of the main parts of engine and the wear characteristics of the cylinder liner are largely related to the engine performance. Gray iron liners squeezed in aluminum cylinder block have been widely used. This is due to the excellent resistance to abrasion of gray iron. In order to realize light all aluminum cylinder, the good abrasion resistant method is necessary to develop to be applied with inner surface of liners. We have developed the new Rapid Composite Plating System for the motorcycle engine cylinders. This system made it possible to adopt all aluminum cylinders without cast iron liners to new type of engine.

The need for efficient space utilization has provided a framework for the design of a 248mm family of torque converters that supports a wide choice of engine and transmission combinations. The axial length of the part and its weight have been substantially reduced while the performance range has been broadened without degradation of efficiency. The new converter operates in an expanded slipping clutch mode. It significantly contributes to the performance and fuel economy improvements of related vehicles. To meet the cost target, the comprehensive lineup and the resulting complexity have required a high level of component interchangeability. During the design phase, the manufacturing core competencies were scrutinized and process redundancies eliminated, both resulting in optimization of material selection and applicable technology.

This study focuses on variable amplitude loadings applied to automotive chassis parts experiencing carmaker’s specific proving grounds. They are measured with respect to time at the wheel centres and composed of the six forces and torques at each wheel, within the standard vehicle reference frame. In the scope of high cycle fatigue, the loadings considered are supposedly acting under the structure yield stress. Among the loadings encountered during the vehicle lifetime, two classes stand out: Driven Road: loads measured during the vehicle manoeuvre; Random Road: loads mainly coming from the road asperity. To separate both effects, a frequency decomposition method is proposed before applying any lifetime assessment methods. The usual Rainflow counting method is applied to the Driven Road signal. These loadings, depending on the vehicle dynamics, are time-correlated. Thus, the load spectra is set only thanks to the vehicle accelerations time-measurement.

The General Motors (GM) Corvette design team was challenged with providing a C6 Z06 vehicle spaceframe that maintained the structural performance of its C5 predecessor while reducing mass by at least 56 kg. An additional requirement inherent to the project was that the design must be integrated into the C6 assembly processes with minimal disruption, i.e. seamless integration. In response to this challenge, a collaborative team was formed, consisting of design engineers from General Motors, Alcoa and Dana Corporation. The result of this collaborative effort is an aluminum Z06 spaceframe that satisfies the high performance expectations of the vehicle while reducing the mass by approximately 62 kg. The frame consists of aluminum extrusions, castings and sheets joined by MIG welding, laser welding and self-piercing rivets. The extrusions are 6XXX series alloys, the castings are permanent mold A356 while the sheet panels are formed from the 5XXX series of alloys.

This paper describes the engineering, manufacturing and integration necessary to produce the Corvette's first ever all-aluminum spaceframe (see Figure 1). The engineering and manufacturing of the spaceframe was a joint venture between General Motors and suppliers ALCOA (Aluminum Company of America) and Dana Corporation. ALCOA led the initial design of the spaceframe; Dana Corp led the manufacturing; General Motors' Engineering and Manufacturing groups led the integration of the assembly. The aluminum spaceframe design is modeled after the baseline steel structure of the Corvette coupe. The aluminum spaceframe reduces 140 lbs from the steel baseline and enters the plant at 285 lbs. This frame allows the 2006 Corvette Z06 to enter the market at a 3100 lbs curb weight. Aluminum casting, extruding, stamping, hydroforming, laser welding, Metal Inert Gas (MIG) welding, Self Pierce Riveting (SPR), and full spaceframe machining make up the main technologies used to produce this spaceframe.

The Ford GT powertrain (see Figure 1) is an integrated system developed to preserve the heritage of the LeMans winning car of the past. A team of co-located engineers set out to establish a system that could achieve this result for today's supercar. Multiple variations of engines, transaxles, cooling systems, component locations and innovations were analyzed to meet the project objectives. This paper covers the results and achievements of that team.

THE development of the two-stage torque converter with automatic double clutch is presented here. The author covers particularly the substitution of casting for fabrication for several of the units in the transmission.

A theoretical model is presented for predicting springback of wide sheet metal subjected to 2D-stretch-bending operation. The material is assumed to be normal anisotropic with n-th power hardening law, σ = Fεn. Two types of stretch-bending experiment, bending with simultaneous stretching and stretch-bending followed by consecutive re-stretching, is conducted using AK sheet steel and sheet aluminum alloy A5182-O. The measured values of springback are in good agreement with analytical ones for a wide range of bending radii, stretching forces, and loading conditions. Furthermore, a calculation method for predicting springback configurations of 2D sheet metal parts with arbitrary cross-sections which include both stretch-bending and stretch-bending-unbending deformation is proposed.

In certain types of city bus service some automatic transmission fluids can fail in less than 10,000 miles. In order to provide satisfactory transmission performance for longer mileage, improved fluids are required. An investigation was undertaken to obtain improved fluids. Fifteen different fluid formulations were evaluated in 30 city buses operated in normal service for more than 2,000,000 miles. It was determined that fluids fail because of frictional deterioration and oxidation. Based on these evaluations, only two fluids were found to be satisfactory for more than 40,000 miles; one additional fluid was satisfactory for more than 30,000 miles. The remaining 12 fluids failed in less than 20,000 miles.

Recently, society has demanded better performance from motorcycle regarding comfort, fuel economy, exhaust emission, and safety, in addition to traditional performance indicators. In the development of power trains, therefore, compact and lightweight hardware with improved transmission efficiency has been introduced, along with system technologies that optimize the engine revolution speed range and reduction ratio to suit driving conditions. This approach focuses on improving overall efficiency and addressing the issues of easier drivability and greater active safety. Electronic Controlled Continuously Variable Transmission (ECCVT) with high transmission efficiency is characterized by a Dry Hybrid Belt, in addition to an electronic controlled DC motor-driven shift mechanism, and an Electronic Controlled wet multi-plates Clutch (ECC).

Handling performance of a vehicle is a key characteristic determining the response of vehicle under different operating scenarios. An insight into these vehicle-handling characteristics at early stage can be extremely useful in the design and development process. Tire characterization and tuning is important and mandatory to scrutinize each functional and individual parameter of tire. Tire force and moment data is having a significant effect in vehicle handling. Segregation of tire parameter, which is contributing vehicle-handling performance, helps to identify and perform optimization for improvisation. The main objective of this study is development and integration optimized 1D tire model into multibody dynamics model of the vehicle to observe various vehicle compliances towards its handling performance target.

This paper describes the development and application of the 1D thermo-fluid dynamic research code GASDYN to the simulation of a Lamborghini 12 cylinder, V 60°, 6.2 L automotive S.I. engine. The model has been adopted to carry out an integrated simulation (thermodynamic, fluid dynamic and chemical) of the engine coupled to its intake and exhaust manifolds, in order to predict not only the wave motion in the ducts and its influence on the cylinder gas exchange process, but also the in-cylinder combustion process and the pollutant emission concentration along the exhaust system. The gas composition in the exhaust pipe system is dictated by the cylinder discharge process, after the calculation of the combustion via a thermodynamic multi-zone model, based on a “fractal geometry” approach.

This paper describes the concept, design, and options of a new power shift transmission family for industrial equipment in the 50-100 hp range. The converter, clutch, and gearing arrangements provide the basis for various transmission configurations with both a drop and straight through output. The designs allow multiple usage of components within a transmission and between different sizes of transmissions. The various gearing, bearing, and clutch designs are based on proved experience factors, and as such will provide a new reliable family of transmissions.

A vehicle model is an important factor in the development of vehicle control systems. Various vehicle models having different complexities, assumptions, and limitations have been developed and applied to many different vehicle control systems. A 14 DOF vehicle model that includes a roll center as well as non-linear effects due to vehicle roll and pitch angles and unsprung mass inertias, is developed. From this model, the limitations and validity of lower order models which employ different assumptions for simplification of dynamic equations are investigated by analyzing their effect on vehicle roll response through simulation. The possible limitation of the 14 DOF model compared to an actual vehicle is also discussed.

Late developments in tires and in lightweight, high horsepower engines and transmissions have enabled the earthmoving and mining industry equipment manufacturers to design and produce several types of preproduction 100-ton capacity trucks. A straight-forward approach to the design of a 110-ton end dump truck on two axles with a hydro-mechanical drive was followed by KW-Dart Truck Co. to produce a low cost per ton-mile vehicle.

Diesel engines, especially CR (Common Rail) DI (Direct Injection) TCI (Turbo Charged Inter-cooled), share a wide acceptance in the passenger car market due to the enormous torque and flexibility at low engine speed. A pre - condition for the use of a diesel engine in a motorcycle is that the disadvantages like combustion noise and visible smoke are reduced or eliminated. Moreover the fuel economy and performance characteristics of a diesel engine are dedicated to be used in a touring or large displacement motorcycle. The AVL engine concept is the first high performance diesel engine to be specially designed for motorcycles in terms of packaging and styling. To compensate for the limited engine speed range a gearbox with a wide ratio spread is required. This leads to a manual transmission with at least 6 gears or an automatic transmission. For the AVL concept an AMT (Automated Manual Transmission) was selected.

Two types of One-Way Clutch (OWC) are commonly used in automotive applications – the roller and the sprag types. Some manufacturers claim the advantages of a different type of OWC having a mechanical diode OWC. The aim of this research is to study the mechanical diode system in order to point out reasons that explain why this configuration is not a spread out system in automotive applications that require lockup functionality. To achieve this objective the research work focuses on the development of 1-D models to simulate system behavior and evaluate product performance against design variables. Improvements to the system are suggested based on the simulation results.