Search Results

Abstract Transient temperature analysis is involved in the thermal simulation of the heat treatment process, in which the hot metal temperature changes with respect to time from an initial state to the final state. The critical part of the simulation is to determine the heat transfer coefficient (HTC) between the hot part and the quenching medium or quenchant. In liquid quenching, the heat transfer between the hot metal part and water becomes complicated and it is difficult to determine HTC. In the current experimentation a medium carbon steel EN 9 rod with a diameter of 50 mm and length 100 mm was quenched in water and ethylene glycol mixture with different concentrations. A part model was created; meshed and actual boundary conditions were applied to conduct computational fluid dynamics (CFD) analysis. In order to validate CFD analysis the experimental trials were conducted.

Abstract AISI H13 hot work tool steel is commonly used for applications such as hot forging and hot extrusion in mechanical working operations that face thermal and mechanical stress fluctuations, leading to premature failures. Cryogenic treatment was applied for AISI H13 steel to improve the surface hardness and thereby fatigue resistance. This work involves failure analysis of H13 steel specimens subjected to cryogenic treatment and gas nitriding. The specimens were heated to 1020°C, oil quenched followed by double tempering at 550°C for 2 h, and subsequently, deep cryogenically treated at −185°C in the cryochamber. Gas nitriding was carried out for 24 h at 500°C for 200 μm case depth in NH3 surroundings. The specimens were subjected to rotating bending fatigue at constant amplitude loading at room temperature.

Abstract This study demonstrates the defossilized operation of a heavy-duty port-fuel-injected dual-fuel engine and highlights its potential benefits with minimal retrofitting effort. The investigation focuses on the optical characterization of the in-cylinder processes, ranging from mixture formation, ignition, and combustion, on a fully optically accessible single-cylinder research engine. The article revisits selected operating conditions in a thermodynamic configuration combined with Fourier transform infrared spectroscopy. One approach is to quickly diminish fossil fuel use by retrofitting present engines with decarbonized or defossilized alternatives. As both fuels are oxygenated, a considerable change in the overall ignition limits, air–fuel equivalence ratio, burning rate, and resistance against undesired pre-ignition or knocking is expected, with dire need of characterization.

Abstract Fossil fuel reserves are swiftly depleting when consumer demand for these fuels continues to rise. In order to meet the demand and diminish the pollution derived through conventional fuels, it is crucial to employ cleaner fuels made from substitutes such as waste biomass. Also, converting waste biomass to fuel can lower usage of landfills. There are many biomass resources that are suitable for fuel production, out of which groundnut is also a potential feedstock. Groundnut shell biomass was chosen for this study, as it is a waste leftover during shelling of groundnuts for various commercial applications. The procured groundnut shells were converted to oil using pyrolysis process and was distilled. Both the pyrolysis oil and the distilled oil were analyzed using Fourier transform infrared instrument wherein the presence of functional groups such as alcohols, amines, and carboxylic acids were identified.

Abstract A new revolution has taken place in the automobile industry in recent years, intelligent and connected vehicle (ICV) [1] has achieved a higher market share in recent years and relevant technologies have been quickly developed and widely accepted, so the auto industry needs to make regulations for automated driving system (ADS) on ICVs, mainly to assure the safety of ICV. To meet the requirements above, the definition of operational design domain (ODD) [2, 3] was put forward by the Society of Automotive Engineers (SAE) and International Organization for Standardization (ISO) a few years ago. ODD defines necessary external environment conditions for the ADS to operate, but the internal status of the vehicle is also a key part of judging whether ADS can operate safely.

Abstract The water droplet erosion (WDE) on high-speed rotating wheels appears in several engineering fields such as wind turbines, stationary steam turbines, fuel cell turbines, and turbochargers. The main reasons for this phenomenon are the high relative velocity difference between the colliding particles and the rotor, as well as the presence of inadequate material structure and surface parameters. One of the latest challenges in this area is the compressor wheels used in turbochargers, which has a speed up to 300,000 rpm and have typically been made of aluminum alloy for decades, to achieve the lowest possible rotor inertia. However, while in the past this component was only encountered with filtered air, nowadays, due to developments in compliance with tightening emission standards, various fluids also collide with the spinning blades, which can cause mechanical damage.

Abstract Super duplex stainless steel (SDSS) is a type of stainless steel made of chromium (Cr), nickel (Ni), and iron (Fe). In the present work, a 1.6 mm wide thin sheet of SDSS is joined using gas tungsten arc welding (GTAW). The ideal parameter for a bead-on-plate trial is found, and 0.216 kJ/mm of heat input is used for welding. As an outcome of the welding heating cycle and subsequent cooling, a microstructural study revealed coarse microstructure in the heat-affected zone and weld zone. The corrosion rate for welded joints is 9.3% higher than the base metal rate. Following the corrosion test, scanning electron microscope (SEM) analysis revealed that the welded joint’s oxide development generated a larger corrosive attack on the weld surface than the base metal surface. The percentages of chromium (12.5%) and molybdenum (24%) in the welded joints are less than those in the base metal of SDSS, as per energy dispersive X-ray (EDX) analysis.

Abstract This article introduces a methodology for conducting comparative evaluations of vibration-induced discomfort. The aim is to outline a procedure specifically focused on assessing and comparing the discomfort caused by vibrations. The article emphasizes the metrics that can effectively quantify vibration-induced discomfort and provides insights on utilizing available information to facilitate the assessment of differences observed during the comparisons. The study also addresses the selection of appropriate target scenarios and test environments within the context of the comparative evaluation procedure. A practical case study is presented, highlighting the comparison of wheel corner concepts in the development of new vehicle architectures. Currently, the evaluation criteria and difference thresholds available allow for comparative evaluations within a limited range of vehicle vibration characteristics.

Abstract After a severe lane change, a wind gust, or another disturbance, the driver might be unable to recover the intended motion. Even though this fact is known by any driver, the scientific investigation and testing on this phenomenon is just at its very beginning, as a literature review, focusing on SAE Mobilus® database, reveals. We have used different mathematical models of car and driver for the basic description of car motion after a disturbance. Theoretical topics such as nonlinear dynamics, bifurcations, and global stability analysis had to be tackled. Since accurate mathematical models of drivers are still unavailable, a couple of driving simulators have been used to assess human driving action. Classic unstable motions such as Hopf bifurcations were found. Such bifurcations seem almost disregarded by automotive engineers, but they are very well-known by mathematicians. Other classic unstable motions that have been found are “unstable limit cycles.”

Abstract The use of appropriate loads and regulations is of great importance in weld fatigue assessment of rail on-track maintenance equipment and similar vehicles for optimized design. The regulations and available loads, however, are often generalized for several categories, which proves to be overly conservative for some specific categories of machines. EN (European Norm) and AAR (Association of American Railroads) regulations play a pivotal role in determining the applicable loads and acceptance criteria within this study. The availability of track-induced fatigue load data for the cumulative damage approach in track maintenance machines is often limited. Consequently, the FEA-based validation of rail track maintenance equipment often resorts to the infinite life approach rather than cumulative damage approach for track-induced travel loads, resulting in overly conservative designs.

Abstract In autonomous technology, uncrewed aircraft systems have already become the preferred platform for the research and development of flight control systems. Although they are subjected to following and satisfying complicated scenarios of control stations, this high dependency on a specific control framework limits them in their application process and reduces the flight self-organizing network. In this article, we present a developed multilayer control system protocol with the additional supportive manned aircraft layer (Tender). The novelty of the introduced model is that uncrewed aircraft systems are monitored and navigated by the tender, and then based on the suggested scheme, data flows are controlled and transferred across the network by the developed cloud–robotics approach in the ground station layer.

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Abstract Fully flexible valve actuation (FFVA) is a key enabling technology of internal engine combustion research and development. Two laboratory electro-hydraulic FFVA systems have been developed and implemented in R&D test cells. These FFVA systems were designed using repetitive control (RC), which is based on internal model principle (IMP), for constant engine speed operation. With the engine operating in a steady-state condition, the valve profile input is periodic. This can be accommodated by a repetitive controller, which provides the function of flexible control to step changes in valve lift, valve opening duration, and cam phase angle position. During engine speed transients, as the valve reference trajectory becomes aperiodic in the time domain, the controllers based on the linear time invariant (LTI) IMP, such as RC, are no longer applicable. Engine speed transient control is a desired function to engine research and other similar applications, such as motor control.

Abstract This article presents a novel approach to optimize the placement of light detection and ranging (LiDAR) sensors in autonomous driving vehicles using machine learning. As autonomous driving technology advances, LiDAR sensors play a crucial role in providing accurate collision data for environmental perception. The proposed method employs the deep deterministic policy gradient (DDPG) algorithm, which takes the vehicle’s surface geometry as input and generates optimized 3D sensor positions with predicted high visibility. Through extensive experiments on various vehicle shapes and a rectangular cuboid, the effectiveness and adaptability of the proposed method are demonstrated. Importantly, the trained network can efficiently evaluate new vehicle shapes without the need for re-optimization, representing a significant improvement over classical methods such as genetic algorithms.

Abstract This research was initiated with the goal of developing a significantly stronger aircraft transparency design that would reduce transparency failures from bird strikes. The objective of this research is to demonstrate the fact that incorporating high-strength tempered glass into cockpit window constructions for commercial aircraft can produce enhanced safety protection from bird strikes and weight savings. Thermal glass tempering technology was developed that advances the state of the art for high-strength tempered glass, producing 28 to 36% higher tempered strength. As part of this research, glass probability of failure prediction methodology was introduced for determining the performance of transparencies from simulated bird impact loading. Data used in the failure calculation include the total performance strength of highly tempered glass derived from the basic strength of the glass, the temper level, the time duration of the load, and the area under load.

Abstract An automatic collision avoidance control method integrating optimal four-wheel steering (4WS) and direct yaw-moment control (DYC) for autonomous vehicles on curved road is proposed in this study. Optimal four-wheel steering is used to track a predetermined trajectory, and DYC is adopted for vehicle stability. Two single lane change collision avoidance scenarios, i.e., a stationary obstacle in front and a moving obstacle at a lower speed in the same lane, are constructed to verify the proposed control method. The main contributions of this article include (1) a quintic polynomial lane change trajectory for collision avoidance on curved road is proposed and (2) four different kinds of control method for autonomous collision avoidance, namely 2WS, 2WS+DYC, 4WS, and 4WS+DYC, are compared. In the design of DYC controller, two different feedback control methods are adopted for comparison, i.e., sideslip angle feedback and yaw rate feedback.

Abstract This study underscores the benefits of refining the intralogistics process for small- to medium-sized manufacturing businesses (SMEs) in the engineer-to-order (ETO) sector, which relies heavily on manual tasks. Based on industrial visits and primary data from six SMEs, a new intralogistics concept and process was formulated. This approach enhances the value-added time of manufacturing workers while also facilitating complete digital integration as well as improving transparency and traceability. A practical application of this method in a company lead to cutting its lead time by roughly 11.3%. Additionally, improved oversight pinpointed excess inventory, resulting in advantages such as reduced capital needs and storage requirements. Anticipated future enhancements include better efficiency from more experienced warehouse staff and streamlined picking methods. Further, digital advancements hold promise for cost reductions in administrative and supportive roles.

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Abstract All two-wheeler industries validate their product’s fatigue life on proving track before heading for mass production. Proving test tracks are made to simulate the end-user environment in order to find out the possible fatigue failures during each development stage of vehicle design, which in turn helps the CAE analysts to verify the design before it goes to the end-user hands. In this article we present the design and failure analysis of sub-frame assembly of motorbike observed during the accelerated fatigue test on proving track. Sub-frame main rod was found broken exactly between two weld endings during fatigue test before reaching 6% of the target fatigue life. Possible causes of sub-frame failures have been identified/analyzed in detail using fish bone diagram. A finite element analysis (FEA) model of sub-frame assembly was developed and a random response analysis was carried out on initial design.

Abstract The exponentially growing electrification market is driving demand for lithium-ion batteries (LIBs) with high performance. However, LIB thermal runaway events are one of the unresolved safety concerns. Thermal runaway of an individual LIB can cause a chain reaction of runaway events in nearby cells, or thermal propagation, potentially causing significant battery fires and explosions. Such a safety issue of LIBs raises a huge concern for a variety of applications including electric vehicles (EVs). With increasingly higher energy-density battery technologies being implemented in EVs to enable a longer driving mileage per charge, LIB safety enhancement is becoming critical for customers. This comprehensive review offers an encompassing overview of prevalent abuse conditions, the thermal event processes and mechanisms associated with LIBs, and various strategies for suppression, prevention, and mitigation.