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The objective of this paper is to develop a comprehensive non-linear finite element model for determining failure behavior of hydrogen composite storage cylinders subjected to high pressure and flame impingements. A resin decomposition model is implemented to predict the residual resin content. A material degradation model is used to account for the loss of moduli. A failure model based on Hashin's failure theory is implemented to detect various types of composite failure. These sub-models are implemented in ABAQUS finite element code using user subroutine. Numerical results are presented for thermal damage, residual properties and resin content.

The use of a predictive fatigue crack growth model to monitor progressive deterioration of initially small rib-tip flaws in automotive serpentine belts is presented in this paper. Model is based on computational fracture mechanics and fatigue coupon test data. A global-local finite element analysis procedure is used to compute the J-integral for a through-the-thickness crack in the rib tip. The three-dimensional global model is created with relatively coarse mesh using first order continuum elements in ABAQUS. The local model rib crack is constructed with significantly finer mesh utilizing second order continuum elements. Boundary conditions for the local model are driven by global displacements. Maximum and minimum J-integrals are calculated at two extreme configurations for a single belt running cycle. The range of the J-integral is input into the curve fitted power law to derive the fatigue crack growth rate and hence the fatigue life for the belt.

Two soot-containing turbulent non-premixed flames burning gaseous acetylene in atmospheric-pressure air were investigated by conducting non-intrusive optical experiments at various flame locations. The differences in burner exit Reynolds numbers of these flames were large enough to examine the influence of flow dynamics on soot formation and evolution processes in heavily-sooting flames. By accounting for the fractal nature of aggregated primary particles (spherules), the proper interpretation of the laser scattering and extinction measurements yielded all the soot parameters of principal interest. With the separation of spherule and aggregate sizes, the axial zones of the prevailing turbulent soot mechanisms were accurately identified. With the high propensity of acetylene fuel to soot, relatively fast particle nucleation process led to high concentrations immediately above the burner exit.

This paper investigates the effect of ambient temperature on the performance characteristics of an automotive poly-rib belt operating in an under-the-hood temperature environment. A three-dimensional dynamic finite element model consisting of a driver pulley, a driven pulley, and a complete V-ribbed belt was constructed. Belt tension and rotational speed were controlled by means of loading and boundary inputs. Belt construction accounts for three different elastomeric compounds and a single layer of helical wound reinforcing cord. Rubber was considered as hyperelastic material. Cord is linear elastic. The material model was implemented in ABAQUS/Explicit for the simulation. Analysis was focused on rib flank and tip since stress concentrations in these regions are known to contribute to crack initiation and fatigue failure.

Laminated glass consisting of two soda lime glass plies adhered by a polyvinyl butyral interlayer (PVB) is used for automotive glazing. This paper describes the application of a dynamic, nonlinear finite element method to investigate the failure modes of a laminated glass subjected to low-velocity impact with a spherical headform. Crack type, crack location and crack initiation time are evaluated using the maximum principal stress and J-integral criterion. Failure occurred due to flexural stresses and not bearing stresses. The first crack always initiated at the center of the outer impacted ply and PVB interface, and later on the exterior surface of the inner ply. The PVB thickness and velocity of impact had little or no effect on the first crack initiation.

An integrated optimization system has been developed to combine optimization algorithms with Finite Element Analysis for airbag design. A number of industry standard software packages are employed to work in coherence to complete the optimization procedure automatically with minimal user intervention. The system can be easily tailored to fit multiple performance requirements and various design constraints for different airbag systems. Compared with the commonly used Design of Experiment (DOE) method, time and computer resources requirements are greatly curtailed. The integrated optimization system was successfully used in single-chamber and dual-chamber airbag optimizations. The results proved the effectiveness of the system and demonstrated its capability in product design.

A comprehensive study is reported on the dynamics of critical components in the refueling process for passenger cars and light trucks. Nozzle, filler pipe, recirculation tube, tank, and canister are investigated. CFD simulations are conducted for flow rates of 4 liters/min (lpm) to 80 lpm for gasoline and up to 120 lpm for diesel fuel. Tank pressure, identified as a critical parameter controlling flow performance, is measured and utilized as a boundary condition. Flow simulation in a carbon canister, accomplished by treating the adsorbing carbon as a porous medium, indicates pressure drops which are in good agreement with published experimental data. Experiments have been conducted and used to validate simulation results. The simulations indicate that CFD can be successfully utilized as a tool to shorten the design, development and cost reduction cycle of a nozzle, filler pipe, canister, and tank system.

Automotive refueling is gaining greater importance because fuel vapors released during refueling are believed to increase ozone levels in urban areas. As a step towards On-Board Refueling Vapor Recovery (ORVR) designs, vapor generation and transport during refueling needs to be understood to develop recovery techniques. The objective of the present study is to understand the fluid flow inside the automotive gas tank filler pipe using commercially available Computational Fluid Dynamics (CFD) software. This effort is expected to yield detailed flow field information, including air entrainment. The phenomena of well-back, the process of fuel flooding the filler pipe and flowing backwards at the filler pipe mouth, and the pressure transients inside the tank leading to premature nozzle shut-off were examined. The current work includes unsteady CFD simulation with gasoline and air as the working fluids.

Two instrumented pulleys were developed to empirically measure the dynamic lateral forces of V-Ribbed belts used in automotive accessory drives. The first test pulley utilizes two cantilever beams cut into the pulley with strain gauges attached to measure the lateral dynamic forces in each individual belt rib caused by misalignment. A test stand which simulates multiple accessory drive configurations at low-end drive speeds typical in automotive engines was implemented to create the dynamic response necessary. This test stand allows variations in lateral offset, toe, camber, tension, and span length, as well as in the speed of the system through a variable speed AC motor. The second test pulley utilizes a unidirectional load cell oriented to measure the total lateral force on the test pulley. After conducting static calibration tests of the two experimental systems, dynamic results were obtained using real time data acquisition.

We describe a method for detecting and quantifying time irreversibility in experimental engine data. We apply this method to experimental heat-release measurements from four spark-ignited engines under leaning fueling conditions. We demonstrate that the observed behavior is inconsistent with a linear Gaussian random process and is more appropriately described as a noisy nonlinear dynamical process.

The goal of this work is to begin to understand and characterize the break-up of liquid fuel as it is torn from intake valve and port surfaces during the start-up period of a spark ignition engine. The lack of vaporization from warm engine surfaces causes the fuel to enter the combustion chamber as large droplets. Atomization results from the shearing effect of the intake air as it is pulled into the combustion chamber. Droplet sizes, air velocities, and break-up formations are studied using a high-resolution CCD camera and strobe. Indolene and iso-octane fuels are used to consider the effect of fuel properties on the break-up. The atomization processes that occur are characterized through the use of dimensionless groups. Results show that the fuel break-up follows the same processes seen for many other atomizing devices under the influence of co-flowing air. The role of valve gap, liquid fuel flowrate, air flowrate, and valve dimensions on the break-up process are discussed.

The goal of this investigation was to gain a better understanding of the effect of fuel/air charge composition on the dynamical structure of cyclic dispersion in lean-fueled spark ignition engines. Swirl and fuel injection timing were varied on a single-cylinder research engine to investigate the effects of charge motion and stratification on prior-cycle effects under lean operating conditions. Temporal patterns in the cycle-to-cycle combustion dynamics were analyzed using return maps, Shannon entropy, and symbol sequence statistics. Our results indicated a transition from stochastic behavior to noisy nonlinear determinism as equivalence ratio was decreased from near stoichiometric to very lean conditions. The equivalence ratio at which deterministic effects became important was strongly influenced by swirl and fuel injection timing. A comparison of our results and previous results from an eight-cylinder production engine showed similar trends.

A detailed investigation of the intake port mixing process was performed on a fired single cylinder port fuel injected research engine. The liquid fuel droplets were studied using several different methods of analysis ranging from spatially and temporally resolved to spatially and temporally averaged data. Comparisons of the port mixture preparation results were made to the combustion performance of the engine in order to develop correlations between the mixing process and resulting engine performance. It is suggested that while the nature of the fuel spray produced by the injector is important, there are several other factors that influence fuel delivery to the cylinder. Calculations are given that indicate drops must be very small to entrain in the flow and avoid wall wetting. Secondary drop formation mechanisms may ultimately determine the nature of the fuel delivery to the cylinder and have an impact on combustion performance.

A computational study of flow developments over airfoils with backward-facing steps is conducted to explore the possibility of enhancing aerodynamic performance of the airfoils by vortex generation. The study focuses on the effects of the separated flow and subsequent vortex formation generated by the step on pressure distributions around two airfoil profiles. Step location and size are varied to determine their effect on lift, drag, and L/D ratio. A discussion of the effects and trends of the various step configurations on airfoil performance is presented along with the results that may serve as a reference for employing a control criteria to optimize airfoil geometries during flight.

Wing tip sails were investigated to determine potential aerodynamic improvements for a wing having an aspect ratio of 10 and a taper ratio of 0.43. The airfoil section used for the wing was an NLF- 0215 and the wing tip was rounded. Three tip sails were utilized for all investigations with each tip sail having a root chord that was 20 percent tip chord of the wing. The wing sails were mounted at the tip of the wing along the chord line. Looking along the span towards the wing root the orientation of each sail tip was the same as the wing tip. Initial studies used sails constructed from two Wortman airfoils. A generic cambered tip-sail was also investigated. Individual sail angle of attack as well as sail dihedral and anhedral were investigated. PMARC, an aerodynamic paneling code was used to predict lift, induced drag, and viscous drag with the use of a momentum integral analysis. All viscous predictions were calculated for a Re/foot = 2.19 × 106.

The flow over a NACA 0015 airfoil with a trailing edge jet (jet flap) is investigated using computational and experimental capabilities to determine the influence of the jet on vortex developments over the airfoil. The computational modeling of steady flow at a Reynolds number of 43,000 at fifteen and twenty degrees indicates that as the jet mass flow rate is increased, the trailing edge jet suppresses vortex development, and in some cases, reattaches the flow. Experimental visualization shows the suppression of vortex structures in both steady and accelerating flow. The trailing edge jet may thus be a possibility for vortex control.

Wings constructed using the Wortmann FX 63-137 low speed airfoil, which operates in a Reynold's number range from 0.28 * 106 to 0.7 * 106, with the addition of winglets are studied to determine the winglet geometry that produces the best increase in wing efficiency. The analysis was done using VSAERO, an inviscid panel code program. All configurations are compared to a wing without winglets to determine the percent increase in efficiency. It is demonstrated that with proper selection of winglet taper ratio, tip setback, height, cant angle, geometric twist angle, and airfoil section induced drag can be significantly reduced. Wings with winglets are shown to be more efficient than wings without winglets for all cases.

A computational method was developed for investigating boundary layer control. Solutions of the Reynolds-averaged Navier-Stokes equations were obtained using the two-equation k-∈ turbulence model which includes the low-Reynolds-number effect in the near-wall region. Stream function and vorticity together with the turbulent kinetic energy and its dissipation rate were calculated for the flowfield in a body-fitted coordinate system. By increasing the amount of suction on the upper surface, flow separation could be totally eliminated. Transition from laminar to turbulent flow was delayed. Aerodynamic performance was substantially improved.

The findings of various investigators during the past decade have greatly enhanced the ability to accurately analyze, model, design, and optimize finned tube heat exchangers, including those for automotive air conditioning condensers and evaporators. One parameter quite often neglected is the thermal contact resistance which exists for interference-fitted fin-tube geometries. This paper presents the results of including thermal contact resistance as a parameter in estimating the performance of finned tube heat exchangers.

The scissor wing configuration is analyzed for unequal forward/rearward wing area ratios and for different wing sweep schedules of the forward and rearward wings. Clα, CMα, static margin, and sweep schedule results are presented as a function of flight Mach number for various sweep schedules and two wing area ratios. Complete aircraft, lift to drag ratio, and power required results are presented for the configuration that was able to maintain static margin over the largest range of Mach numbers. The potential benefits of the scissor wing configuration are presented and discussed in terms of potential increased performance potential or smaller engine.