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Technical Paper

Adhesive Failure Prediction in Crash Simulations

Structural adhesive is a good alternative to provide required strength at joinery of similar and dissimilar materials. Adhesive joinery plays a critical role to maintain structural integrity during vehicle crash scenario. Robust adhesive failure definitions are critical for accurate predictions of structural performance in crash Computer Aided Engineering (CAE) simulations. In this paper, structural adhesive material characterization challenges like comprehensive In-house testing and CAE correlation aspects are discussed. Considering the crash loading complexity, test plan is devised for identification of strength and failure characteristics at 0°, 45°, 75°, 90°, and Peel loading conditions. Coupon level test samples were prepared with high temperature curing of structural adhesive along with metal panels. Test fixtures were prepared to carryout testing using Instron VHS machine under quasi-static and dynamic loading.
Technical Paper

Derivation of Test Schedule for Clutch Using Road Load Data Analysis and Energy Dissipation as Basis

During every clutch engagement energy is dissipated in clutch assembly because of relative slippage of clutch disc w.r.t. flywheel and pressure plate. Energy dissipated in clutch is governed by many design parameters like driveline configuration of the vehicle vis-a-vis vehicle mass, and operational parameters like road conditions, traffic conditions. Clutch burning failure, which is the major failure mode of clutch assembly, is governed by energy dissipation phenomenon during clutch engagement. Clutch undergoes different duty cycles during usage in city traffic, highways or hilly regions during its lifetime. A test schedule was derived using energy dissipated during every clutch engagement event as a base and using road load data collected on the vehicle. Road load data was collected in different road mix conditions comprised of city traffic, highway, hilly region, rough road for few hundred kilometers.
Technical Paper

An Effort to Build Mathematical Model using Time Series Analysis to Aid Steering Auto-Correction in Heavy Commercial Vehicle during High Speed Braking

Steering pull during high speed braking of heavy commercial vehicles possesses a potential danger to the occupants. Even with negligible wheel-to-wheel brake torque variation, steering pull during the high speed braking has been observed. If the steering pull (i.e. steering rotation) is forcibly held at zero degree during high speed braking, the phenomena called axle twist, wheel turn and shock absorber deflection arise. In this work the data have been collected on the mentioned measures with an intention to develop a mathematical model which uses real time data, coming from feedback mechanism to predict the values of the measures in coming moments in order to aid steering system to ‘auto-correct’. Driven by the intention, ‘Time Series Analysis’, a well-known statistical methodology, has been explored to see how suitable it is in building the kind of model.
Technical Paper

Combustion Mechanical Breakdown: A Comparison of the Multiple Regression Method versus the Coherence Method for a HSDI Diesel Powertrain

In the automotive industry there are now several methodologies available to estimate the Combustion Mechanical Breakdown (CMB) of engine radiated noise. This paper compares the results of two different CMB analysis methodologies (multiple regression vs. coherence) performed on a HSDI diesel powertrain installed in an Engine Noise Test Cell (ENTC) and highlights the specific differences in the way each method defines combustion and mechanical noise.
Technical Paper

A Simple, Cost Effective, Method of Evaluating Bump Steer and Brake Steer, and Achieving Correlation with ADAMS Analysis

This paper proposes a cost effective method, with simple techniques, to evaluate Bump Steer and Brake Steer on a rigid axle vehicle under dynamic conditions. A relationship between calculated values, measured values and a subjective assessment of the vehicle lateral deviation is established. An array, of inter-relationship of the parameters such as offset of steering arm, draglink length, front spring stiffness, height of spring hanger bracket is done. Percentage of influence of the parameter change on the performance of the vehicle is evaluated and standard statistical analysis is used to arrive at inter-relationship of various parameters and ranking of their influence on lateral deviation of the vehicle under braking is established, there by resulting in reduction in iterative process. The results obtained display a good correlation with ADAMS Analysis to the tune of 90% and are in agreement with subjective assessment.
Technical Paper

Experiments Planning for Robust Design through CAE

This paper presents a systematic approach for designing an experiment in situations where expensive and time consuming computer simulations are used to evaluate product characteristics. In the presence of many design parameters, the critical step is to find the best possible experimental set up with minimum number of simulations. Usually in such situations, designers use their intuition and experience to carry out a number of simulation runs and choose the design that gives better performance. This intuitive approach can be considerably improved by using statistical methods. “Classical experimental designs” were compared with “space filling designs” in terms of their results and requirements. A typical clutch booster bracket is used as an example to demonstrate the methodology.