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Technical Paper

High Durable PU Metallic Monocoat system for tractor sheet metal application.

2019-11-21
2019-28-2541
In sheet metal painting for various applications like Tractor, Automobile, most attractive coating is metallic paints and it is widely applied using 3 coats 2 bake or 3 coat 1 bake technology. Both options, results in high energy consumption, higher production throughput time & lower productivity in manufacturing process. During various brainstorming & sustainable initiatives, paint application process was identified for alternative thinking to reduce burden on environment & save energy. Various other industry benchmarking & field performance requirement studies helped us identify the critical to quality parameters. We worked jointly with supplier to develop mono-coat system without compromising the performance & aesthetical properties. This results in achieving better productivity, elimination of two paint layers, substantial reduction in volatile organic content, elimination of one baking cycle and energy saving.
Technical Paper

An alternate cost effective material for rocker arm used in heavy commercial vehicles

2019-11-21
2019-28-2550
Rocker arm in internal combustion engine is very important part which transfer the cam motion and force to the valve. In heavy commercial vehicles, the engine components are design for an infinite life (considerable higher than other components). Recently industries are working for light weight and optimized cost material. Hence it is required to have an optimized cost effective design of rocker arm without affecting its performance. A rocker arm should meet the stiffness and strength requirement. The objective of this study is to find out the alternate material for rocker arm which can provide the similar strength & stiffness as conventional rocker arm material. To achieve the performance and cost target, alternate material cast iron has been evaluated for rocker arm. Cast iron is lighter than the forged steel rocker arm, also it has a good frictional characteristic. Further bush is eliminated from the rocker arm assembly due to self-lubricant property of the cast iron rocker arm.
Technical Paper

Design and Analysis of Automotive Steering Sheet Metal Yoke for High Strength and Rigidity Requirement

2019-10-11
2019-28-0122
The increasing demand for light weighting products due to introduction of various standards and norms for controlling CO2 emissions and to meet the customer requirement of low cost with higher strength and rigidity of product in automotive industry, sheet metal manufacturing technique is adopted for automotive steering yoke for light commercial vehicle. Currently forged yokes are used for higher strength requirement, while sheet metal yokes are being used for small tonnage vehicle. The attempt has been made to improve overall strength and rigidity of the yoke produced by sheet metal operation using SAPH 440 steel with 6.5mm thickness for light commercial vehicle segments. The major challenge identified for this development was developing such a high strength and thickness material with consistency of dimension during forming process and meeting the torsional strength requirement of 500 Nm.
Journal Article

Electrifying Long-Haul Freight - Part I: Review of Drag, Rolling Resistance, and Weight Reduction Potential

2019-10-01
Abstract Electric heavy-duty tractor-trailers (EHDTT) offer an important option to reduce greenhouse gases (GHG) for the transportation sector. However, to increase the range of the EHDTT, this effort investigates critical vehicle design features that demonstrate a gain in overall freight efficiency of the vehicle. Specifically, factors affecting aerodynamics, rolling resistance, and gross vehicle weight are essential to arrive at practical input parameters for a comprehensive numerical model of the EHDTT, developed by the authors in a subsequent paper. For example, drag reduction devices like skirts, deturbulators, vortex generators, covers, and other commercially available apparatuses result in an aggregated coefficient of drag of 0.367. Furthermore, a mixed utilization of single-wide tires and dual tires allows for an optimized trade-off between low rolling resistance tires, traction, and durability.
Standard

Seven Conductor Cable - Truck and Bus

2019-09-12
WIP
J1067
This SAE standard establishes the minimum construction and performance requirements for seven conductor 1/8 1/10 5/12 cable for use on trucks, trailers and converter dollies. Where appropriate, the standard refers to two types of cables, (Type F and S, described later in the standard), due to the variation in the performance demands of cables used in flexing and stationary applications.
Standard

Seven Conductor Cable for ABS Power - Truck and Bus

2019-09-12
WIP
J2394
This SAE standard establishes the minimum construction and performance requirements for seven conductor 1/8 2/10 4/12 cable for use on trucks, trailers and converter dollies. Where appropriate, the standard refers to two types of cables, (Type F and S, described later in the standard), due to the variation in the performance demands of cables used in flexing and stationary applications. While the document’s title refers to ABS Power to differentiate the document from the SAE J1067 standard that it supersedes, the scope applies to both the primary green cable for powering ABS and lighting and the yellow auxiliary cable of the same construction.
Standard

Flares for Tubing

2019-09-11
WIP
J533
This SAE Standard covers specifications and performance requirements for 37° and 45° single and double flares for tube ends intended for use with SAE J512, SAE J513, SAE J514, and ISO 8434-2 connectors. The flares described in this document are intended for use with SAE metallic tube materials. Considerations such as the effects of wall thickness selection for specific working pressures, identifying appropriate length of thread engagements for specific applications with mating connectors and other associated criteria, shall be the responsibility of the user. For applicable nominal reference working pressures for hydraulic tubing, see SAE J1065 and ISO 10763.
Standard

Heavy-Duty Wiring Systems for On-Highway Trucks

2019-06-23
WIP
J2202
This SAE Recommended Practice provides general guidelines on the material selection, construction and qualification of components and wiring systems used to construct wiring systems for Heavy Duty Vehicles The guidelines are limited to primary wiring systems of less than 50 V and includes cable sizes American Wire Gage 20 to AWG 4 on heavy-duty on-highway trucks. The document identifies appropriate operating performances requirements. This document excludes the male to female connection of the SAE J560 connectors.
Article

Stronger, quieter cabs

2019-06-12
Worthington expert sees AHSS and active noise cancellation making off-highway cabs safer and less-stressful places to work.
Technical Paper

Vibro-Acoustic Analysis for Modeling Propeller Shaft Liner Material

2019-06-05
2019-01-1560
In recent truck applications, single-piece large-diameter propshafts, in lieu of two-piece propshafts, have become more prevalent to reduce cost and mass. These large-diameter props, however, amplify driveline radiated noise. The challenge presented is to optimize prop shaft modal tuning to achieve acceptable radiated noise levels. Historically, CAE methods and capabilities have not been able to accurately predict propshaft airborne noise making it impossible to cascade subsystem noise requirements needed to achieve desired vehicle level performance. As a result, late and costly changes can be needed to make a given vehicle commercially acceptable for N&V performance prior to launch. This paper will cover the development of a two-step CAE method to predict modal characteristics and airborne noise sensitivities of large-diameter single piece aluminum propshafts fitted with different liner treatments.
Technical Paper

Optimization of Multi-Layer Panel Constructions Using Experimental Modeling via Transfer Matrix Method

2019-06-05
2019-01-1577
In a previous paper [1], a method was introduced to predict the sound transmission loss (STL) performance of multi-layer panel constructions using a measurement-based transfer matrix method. The technique is unique because the characterization of the poro-elastic material is strictly measurement based and does not require modeling the material. In this paper, it is demonstrated how the technique is used to optimize the STL of lightweight, multi-layer panel constructions. Measured properties of several decoupler materials (shoddy and foam) are combined with sheet metal and barrier layers to find optimal combinations. The material properties are measured with the impedance tube per ASTM E2611 [2].
Standard

Fasteners - Part Standard - Cap Screws, Hex Bolts, and Hex Nuts (Metric)

2019-05-10
CURRENT
J2295M_201905
This SAE Part Standard covers selected metric screws, hex bolts, and nuts manufactured in accordance with American Society for Testing and Materials (ASTM) and SAE fastener standards. This document covers fastener materials often used in ship systems and equipment but its use may be applied wherever fasteners of the covered materials are used. This document permits the fasteners to be identified and ordered by a part or identifying number (PIN) as defined in this document.
Article

NASA highlights material and coating technology ready for commercial applications

2019-05-10
Four of these technologies – smart coatings for corrosion detection and protection, aluminum alloys for high temperature applications, particle contamination mitigation technologies, and thermal and environmental barrier coating systems – are among NASA’s most in-demand technologies and have been applied to mainstream engineering projects.
Training / Education

Metals Bundle

Anytime
Almost 75% of all elements are metals. Metals can be classified as either ferrous or non-ferrous and generally conduct electricity and heat well. Most metals are malleable and ductile and are, in general, heavier than other elemental substances.The following six on-demand courses are included in the Materials bundle.  Each course is approximately one-hour in duration. See Topics/Outline for additional details.
Training / Education

High Temperature Materials Bundle

Anytime
Metals and alloys all have different melting ranges depending on their chemistry. High temperature metals are much harder at room temperature, have exceptionally high melting points (usually above 2000 degree Celsius), and are resistant to wear, corrosion and deformation. The following five on-demand courses are included in the High Temperature Materials bundle.  Each course is approximately one-hour in duration. See Topics/Outline for additional details.
Training / Education

Nonferrous Metals Bundle

Anytime
Nonferrous materials are malleable, are non-magnetic, and have no iron content which gives them higher resistance to rust and corrosion. The following five on-demand courses are included in the Nonferrous Metals bundle.  Each course is approximately one-hour in duration. See Topics/Outline for additional details. Introduction to Physical Properties  This course provides an an overview of manufacturing materials and their physical properties, including thermal, electrical, and magnetic properties and introduces volumetric characteristics, such as mass, weight, and density.
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