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Highway safety remains a significant concern, especially in mixed traffic scenarios involving heavy-duty vehicles (HDV) and smaller passenger cars. The vulnerability of HDVs following closely behind smaller cars is evident in incidents involving the lead vehicle, potentially leading to catastrophic rear-end collisions. This paper explores how automatic speed enforcement systems, using speed cameras, can mitigate risks for HDVs in such critical situations. While historical crash data consistently demonstrates the reduction of accidents near speed cameras, this paper goes beyond the conventional notion of crash occurrence reduction. Instead, it investigates the profound impact of driver behavior changes within desired travel speed distribution, especially around speed cameras, and their contribution to the safety of trailing vehicles, with a specific focus on heavy-duty trucks in accident-prone scenarios.

This paper presents an energy-optimal plan for the allocation of a heterogeneous fleet of delivery vehicles in a dynamic network of multiple distribution centers and fulfillment centers. Each distribution center with a heterogeneous fleet of delivery vehicles is considered as a hub connected with the fulfillment centers through the routes as spokes. The goal is to minimize the overall energy consumption of the fleet while meeting the demand of each of the fulfillment centers. To achieve this goal, the problem is divided into two sub-problems that are solved in a hierarchical way. Firstly, for each spoke, the optimal number of vehicles to be allocated from each hub is determined. Secondly, given the number of allocated delivery vehicles from a hub for each spoke, the optimal selection of vehicle type from the available heterogeneous fleet at the hub is done for each of spokes based on the energy requirement and the energy efficiency of the spoke under consideration.

Eigenvalues of a simple rotating flexible disk-shaft system are obtained using different methods. The shaft is supported radially by non-rigid bearings, while the disk is situated at one end of the shaft. Eigenvalues from a finite element and a multi-body dynamic tool are compared against an established analytical formulation. The Campbell diagram based on natural frequencies obtained from the tools differ from the analytical values because of oversimplification in the analytical model. Later, detailed whirl analysis is performed using AVL Excite multi-body tool that includes understanding forward and reverse whirls in absolute and relative coordinate systems and their relationships. Responses to periodic force and base excitations at a constant rotational speed of the shaft are obtained and a modified Campbell diagram based on this is developed. Whirl of the center of the disk is plotted as an orbital or phase plot and its rotational direction noted.

The importance of fluid-structure interaction (FSI) is of increasing concern in automotive design criteria as automobile hoods become lighter and thinner. This work focuses on computational simulation and analysis of automobile hoods under unsteady aerodynamic loads encountered at typical highway conditions while trailing another vehicle. These driving conditions can cause significant hood vibrations due to the unsteady loads caused by the vortex shedding from the leading vehicle. The study is carried out using coupled computational fluid dynamics (CFD) and computational structural dynamics (CSD) codes. The main goal of this work is to characterize the importance of fluid modeling fidelity to hood buffeting response by comparing fluid and structural responses using both Reynolds-Averaged Navier-Stokes (RANS) and detached eddy simulation (DES) approaches. Results are presented for a sedan trailing another sedan.

Springback affects the dimensional accuracy and final shape of stamped parts. Accurate prediction of springback is necessary to design dies that produce the desired part geometry and tolerances. Springback occurs after stamping and ejection of the part because the state of the stresses and strains in the deformed material has changed. To accurately predict springback through finite element analysis, the material model should be well defined for accurate simulation and prediction of stresses and strains after unloading. Despite the development of several advanced material models that comprehensively describe the Bauschinger effect, transient behavior, permanent softening of the blank material, and unloading elastic modulus degradation, the prediction of springback is still not satisfactory for production parts. Dies are often recut several times, after the first tryouts, to compensate for springback and achieve the required part geometry.

The elastomeric joints (bushings or mounts) in vehicle structural frames are usually described as uncoupled springs (only with diagonal terms) in large scale system models. The off-diagonal terms of an elastomeric joint have been previously ignored as they are often unknown since their properties cannot be measured in a uniaxial elastomer test system. This paper overcomes this deficiency via a scientific study of a laboratory frame that is designed to maintain a high fidelity with real-world vehicle body subframes in terms of natural modes under free boundaries. The steel beam construction of the laboratory frame, with four elastomeric mounts at the corners, permits the development of a highly accurate, yet simple, beam finite element model. This allows for a correlation study between the experiment and model that helps shed light upon the underlying physical phenomenon.

This paper describes the mechanical design of a Suspension Parameter Identification Device and Evaluation Rig (SPIDER) for wheeled military vehicles. This is a facility used to measure quasi-static suspension and steering system properties as well as tire vertical static stiffness. The machine operates by holding the vehicle body nominally fixed while hydraulic cylinders move an “axle frame” in bounce or roll under each axle being tested. The axle frame holds wheel pads (representing the ground plane) for each wheel. Specific design considerations are presented on the wheel pads and the measurement system used to measure wheel center motion. The constraints on the axle frames are in the form of a simple mechanism that allows roll and bounce motion while constraining all other motions. An overview of the design is presented along with typical results.

Most do not consider there to be a risk in pushing on, bumping into or falling against an elevator door from the hallway side. However, the lack of the elevator cars presence alone, and the potential for severe injury or even death make this seemingly mundane situation potentially critical. Standards exist relative to such situations, and past and current designs attempt to account for this possibility, still people get injured interacting with these doors every year. In order to evaluate a real-world elevator door system's ability to withstand the quasi-static and impactive loads that can be placed on it by the general public during its life, both intentionally and unintentionally, a predictive tool is needed. This work represents the combination of empirical laboratory testing and numerical modeling of a typical elevator door system exposed to quasi-static and dynamic loading.

As we continue to create ever-lighter road vehicles, the challenge of balancing weight reduction and structural performance also continues. One of the key parts this occurs on is the hood, where lighter materials (e.g. aluminum) have been used. However, the aerodynamic loads, such as hood lift, are essentially unchanged and are driven by the front fascia and front grille size and styling shape. This paper outlines a combination CFD/FEA prediction method for hood deflection performance at high speeds, by using the surface pressures as boundary conditions for a FEA linear static deflection analysis. Additionally, custom post-processing methods were developed to enhance flow analysis and understanding. This enabled the modification of existing test methods to further improve accuracy to real world conditions. The application of these analytical methods and their correlation with experimental results are discussed in this paper.

The interface between a plenum and primary runner in log-style intake manifolds is one of the dominant sources of flow losses in the breathing system of Internal Combustion Engines (ICE). A right-angled T-junction is one such interface between the plenum (main duct) and the primary runner (sidebranch) normal to the plenum's axis. The present study investigates losses associated with the combining flow through these junctions, where fluid from both sides of the plenum enters the primary runner. Steady, incompressible-flow experiments for junctions with circular cross-sections were conducted to determine the effect of (1) runner interface radius of 0, 10, and 20% of the plenum diameter, (2) plenum-to-runner area ratio of 1, 2.124, and 3.117, and (3) runner taper area ratio of 2.124 and 3.117. Mass flow rate in each branch was varied to obtain a distribution of flow ratios, while keeping the total flow rate constant.

Long-duration space missions require high-quality, nutritious foods, which will need reheating to serving temperature, or sterilization on an evolved planetary base. The package is generally considered to pose a disposal problem after use. We are in the process of development of a dual-use package wherein the food may be rapidly reheated in situ using the technology of ohmic heating. We plan to make the container reusable, so that after food consumption, the package is reused to contain and sterilize waste. This approach will reduce Equivalent System Mass (ESM) by using a compact heating technology, and reducing mass requirements for waste storage. Preliminary tests of the package within a specially-designed ohmic heating enclosure show that ISS menu item could easily be heated using ohmic heating technology. Mathematical models for heat transfer were used to optimize the layout of electrodes to ensure uniform heating of the material within the package.

The International Harmonization Research Activities Pedestrian Safety Working Group (IHRA PSWG) has proposed design requirements for two head-forms for vehicle hood (bonnet) impact testing. This paper discusses the development of MADYMO models representing the IHRA adult and child head-forms, validation of the models against laboratory drop tests, and assessment of the effect of IHRA geometric and mass constraints on the model response by conducting a parameter sensitivity analysis. The models consist of a multibody rigid sphere covered with a finite element modeled vinyl skin. The most important part in developing the MADYMO head-form models was to experimentally determine the material properties of the energy-absorbing portion of the head-form (vinyl skin) and incorporate these properties into MADYMO using a suitable material model. Three material models (linear isotropic, viscoelastic, hyperelastic) were examined.

A vibration isolator or mount is often modeled by the Voigt model describing uni-axial (longitudinal) motion with frequency-invariant parameters. However, wave effects due to the mass distribution within the isolator are observed as the frequency is increased. Further, flexural stiffness components play an important role, leading to off-axis and coupling effects. Thus, the simplified mount models could lead to erroneous predictions of the dynamic behavior of an overall system such as automotive powertrain or chassis mounting systems. This article compares various approximate isolator models using a multi-dimensional mobility model that is based on the continuous system theory. Harmonic force and moment excitations are separately applied to a rigid body source to investigate the multi-dimensional vibratory behavior. Analysis is however limited to a linear time-invariant system and the mobility synthesis method is utilized to predict the frequency domain behavior.

Structure-borne noise within vehicle structures is often transmitted in a multi-dimensional manner and thus the vibro-acoustic model(s) of automotive powertrain or chassis must incorporate longitudinal and transverse (flexural) motions as well as their couplings. In this article, we employ the continuous system theory to model a typical vibration isolator (say the engine mounting system) and a compliant receiver that could simulate the body structure. The powertrain source is however assumed to be rigid, and both harmonic force and moment excitations are considered. Our analysis is limited to a linear time-invariant system, and the frequency domain based mobility method is utilized to synthesize the overall system. Contributions of both in-plane and flexural motions to structure-borne and radiated noise are incorporated. Two examples are considered to illustrate the methodology.

The knowledge of frequency-dependent dynamic stiffnesses of mounts, in axial and flexural motions, is needed to determine the behavior of many automotive sub-systems. Consequently, characterization and modeling of vibration isolators is increasingly becoming more important in mid and high frequency regimes where very few methods are known to exist. This paper critically examines some of the approximate identification methods that have been proposed in the literature. Then we present a new experimental identification method that yields frequency-dependent multi-dimensional dynamic stiffnesses of an isolator. The scope is however limited to a linear time-invariant system and our analysis is restricted to the frequency domain. The new characterization method uses two inertial elements at both ends of an isolator and free boundary conditions are maintained during testing.

Non-linear FEA models are applied to three different catalytic converters, with the objective of predicting structural parameters such as shell deformation, push-out force, and mounting-system contact pressure under various conditions. The FEA modeling technique uses a novel constitutive model of the intumescent mat material typically found in ceramic-monolith converter designs. The mat constitutive model accounts for reversible and irreversible thermal expansion, allowing for the prediction of the one-way converter deflection observed in hot durability tests. In addition to this mat material model, the FEA methodology accounts for elastic and plastic shell deformation, contact between materials, and a three-dimensional temperature field in the shell and mat. For each of three designs, predictions are presented for converter canning, heat-up, and cool-down (i.e., post-heating) conditions.

The component response synthesis approach utilizing frequency response function (FRF) has been used to analyze the dynamic interaction of two or more vehicle components coupled at discrete interface points. This method is somewhat suitable for computing higher frequency response because experimental component FRFs can be incorporated into the formulation directly. However its calculations are quite sensitive to measurement errors in the FRFs due to the several matrix inversion steps involved. In the past, researchers have essentially used a combined direct inverse and truncated singular valued decomposition (TSVD) technique to ensure a stable calculation, which is typically applied semi-empirically due to the lack of understanding of the influence of measurement error.

This paper describes the procedures used to reduce the tonal noise of a class eight truck engine timing gear train that was initially found to be objectionable under idle operating conditions. Initial measurements showed that the objectionable sounds were related to the fundamental gear mesh frequency, and its second and third harmonics. Experimental and computational procedures used to study and trouble-shoot the problem include vibration and sound measurements, transmission error analysis of the gears under light load condition, and a dynamic analysis of the drive system. Detail applications of these techniques are described in this paper.

With the availability of advanced machine designs and controls, tube hydroforming has become an economic alternative to various stamping processes. The technology is relatively new so that there is no large “knowledge base” to assist the product and process designers. This paper reviews the fundamentals of tube hydroforming technology and discusses how various parameters, such as tube material properties, pre-form geometry, lubrication and process control affect product design and quality. In addition, relations between process variables and achievable part geometry are discussed. Finally, using examples, the status of the current technology and critical issues for future development are reviewed.

The evolution of the flow field inside an IC engine during the intake stroke was studied using 2 different experimental techniques, namely the 2–D Particle Image Velocimetry (2–D PIV) and 3–D Particle Tracking Velocimetry (3–D PTV) techniques. Both studies were conducted using a water analog engine simulation rig. The head tested was a typical pent–roof head geometry with two intake valves and one exhaust valve, and the simulated engine operating point corresponded to an idle condition. For both the 2–D PIV and 3–D PTV experiments, high–speed CCD cameras were used to record the motion of the flow tracer particles. The camera frame rate was adjusted to correspond to 1/4° of crank angle (CA), hence ensuring excellent temporal resolution for velocity calculations. For the 2–D PIV experiment, the flow field was illuminated by an Argon–ion laser with laser–sheet forming optics and this laser sheet was introduced through a transparent piston crown to illuminate the center tumble plane.