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Structural Health Monitoring (SHM), especially in the field of rotary machinery diagnosis, plays a crucial role in determining the defect category as well as its intensity in a machine element. This paper proposes a new framework for real-time classification of structural defects in a roller bearing test rig using time domain-based classification algorithms. Along with the bearing defects, the effect of eccentric shaft loading has also been analyzed. The entire system comprises of three modules: sensor module – using accelerometers for data collection, data processing module – using time-domain based signal processing algorithms for feature extraction, and classification module – comprising of deep learning algorithms for classifying between different structural defects occurring within the inner and outer race of the bearing.

The goal of this paper is to estimate near-side injury risk in vehicles with the best side impact performance in the U.S. New Car Assessment Program (NCAP). The longer-term goal is to predict the incidence of crashes and injury outcomes in the U.S. in a future fleet of the 2025-time frame after current active and passive safety countermeasures are fully implemented. Our assumption was that, by 2025, all new vehicles will have side impact passive safety performance equivalent to current U.S. NCAP five star ratings. The analysis was based on real-world crashes extracted from case years 2010-2015 in the National Automotive Sampling System / Crashworthiness Data System (NASS/CDS) in which front-row occupants of late-model vehicles (Model Year 2011+) were exposed to a near-side crash.

Analysis and design of total temperature probes for accurate measurements in hot, high-speed flows remains a topic of great interest in aerospace propulsion and a number of other engineering areas. Despite an extensive prior literature on the subject, prediction of error sources from convection, conduction and radiation is still an area of great concern. For hot-flow conditions, the probe is normally mounted in a cooled support, leading to substantial axial conduction along the length of the probe. Also, radiation plays a very important role in most hot, high-speed conditions. One can apply detailed computational methods for simultaneous convection, conduction and radiation heat transfer, but such approaches are not suitable for rapid, routine analysis and design studies. So, there is still a place for low-order approximate methods, and that is the subject of this paper.

Binder jetting of sand molds and cores for metal casting provides a scalable and efficient means of producing metal components with complex geometric features made possible only by Additive Manufacturing. Topology optimization software that can mathematically determine the optimum placement of material for a given set of design requirements has been available for quite some time. However, the optimized designs are often not manufacturable using standard metal casting processes due to undercuts, backdraft and other issues. With the advent of binder-based 3D printing technology, sand molds and cores can be produced to make these optimized designs as metal castings.

A blast buck (Accelerative Loading Fixture, or ALF) was developed for studying underbody blast events in a laboratory-like setting. It was designed to provide a high-magnitude, high-rate, vertical loading environment for cadaver and dummy testing. It consists of a platform with a reinforcing cage that supports adjustable-height rigid seats for two crew positions. The platform has a heavy frame with a deformable floor insert. Fourteen tests were conducted using fourteen PMHS (post mortem human surrogates) and the Hybrid III ATD (Anthropomorphic Test Device). Tests were conducted at two charge levels: enhanced and mild. The surrogates were tested with and without PPE (Personal Protective Equipment), and in two different postures: nominal (knee angle of 90°) and obtuse (knee angle of 120°). The ALF reproduces damage in the PMHS commensurate with injuries experienced in theater, with the most common damage being to the pelvis and ankle.

Nano-silver sintered bonding was carried out at 275°C and under 3MPa pressures, and soldering in a vacuum reflowing oven to reduce voiding. Both joints are subject to large shear stresses due to the mismatch in coefficients of thermal expansion (CTE) between the chip and the substrate. In this study, residual stresses in the chip-on-substrate assemblies were determined by measuring the bending curvatures of the bonded structures. An in-house optical setup measured the bending curvatures using a thin-film stress measurement technique. From the measured bending curvatures and the mechanical properties of the constituent materials, residual stresses were calculated. The thermo-mechanical reliabilities of both joining techniques were tested by thermal cycling. The chip assemblies were cycled between -40°C and 125°C (100 minutes of cycle time, 10 minutes of dwell time) and the changes in their bending curvatures were measured.

In order to evaluate a human surrogate, the human and surrogate response must be defined. The purpose of this study was to evaluate the response of cadaver subjects to blunt impacts to the frontal bone, nasal bone and maxilla. Force-displacement corridors were developed based on the impact response of each region. Variation in the force-displacement response of the cadaver subjects due to the occurrence of fracture and fracture severity was demonstrated. Additionally, impacts were performed at matched locations using the Facial and Ocular CountermeasUre Safety (FOCUS) headform. The FOCUS headform is capable of measuring forces imposed onto facial structures using internal load cells. Based on the tests performed in this study, the nasal region of the FOCUS headform was found to be the most sensitive to impact location. Due to a wide range in geometrical characteristics, the nasal impact response varied significantly, resulting in wide corridors for human response.

The objective of this study was to investigate potential for traumatic brain injuries (TBI) using a newly developed, geometrically detailed, finite element head model (FEHM) within the concept of a simulated injury monitor (SIMon). The new FEHM is comprised of several parts: cerebrum, cerebellum, falx, tentorium, combined pia-arachnoid complex (PAC) with cerebro-spinal fluid (CSF), ventricles, brainstem, and parasagittal blood vessels. The model's topology was derived from human computer tomography (CT) scans and then uniformly scaled such that the mass of the brain represents the mass of a 50th percentile male's brain (1.5 kg) with the total head mass of 4.5 kg. The topology of the model was then compared to the preliminary data on the average topology derived from Procrustes shape analysis of 59 individuals. Material properties of the various parts were assigned based on the latest experimental data.

3D digital human modeling (DHM) tools for vehicle packaging facilitate ergonomic design and evaluation based on anthropometry, comfort, and force analysis. It is now possible to quickly predict postures and positions for drivers with selected anthropometry based on ergonomics principles. Despite their powerful visual representation technology for human movements and postures, these tools are still questioned with regard to the validity of the output they provide, especially when predictions are made for different populations. Driving postures and positions of two populations (i.e. North Americans and Koreans) were measured in actual and mock-up SUVs to investigate postural differences and evaluate the results provided by a DHM tool. No difference in driving postures was found between different stature groups within the same population. Between the two populations, however, preferred angles differed for three joints (i.e., ankle, thigh, and hip).

Computer simulations, dummy experiments with a new enhanced upper extremity, and small female cadaver experiments were used to analyze the small female upper extremity response under side air bag loading. After establishing the initial position, three tests were performed with the 5th percentile female hybrid III dummy, and six experiments with small female cadaver subjects. A new 5th percentile female enhanced upper extremity was developed for the dummy experiments that included a two-axis wrist load cell in addition to the existing six-axis load cells in both the forearm and humerus. Forearm pronation was also included in the new dummy upper extremity to increase the biofidelity of the interaction with the handgrip. Instrumentation for both the cadaver and dummy tests included accelerometers and magnetohydrodynamic angular rate sensors on the forearm, humerus, upper and lower spine.

The effect of Si-phase on the axial, low-cycle fatigue behavior of Al-Si eutectic alloys was investigated using test specimens prepared from alloys processed either by continuous casting or extrusion. Results indicate that, for continuous casting, all fatigue fractures resulted from shear-type crack initiation and propagation with an attendant shortening of fatigue life. For extruded material, fatigue cracks originated in the Si phase. In both instances, initiation and growth mechanisms were essentially identical to those observed in high-cycle fatigue. Cyclic properties obtained from phenomenological models are presented and discussed.