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Technical Paper

C123 Methodology for concept design of the Chassis Frame

2019-11-21
2019-28-2534
Objective This paper explores the usage of Altair simulation driven concept process, C123 for developing the chassis frame of the SUV along with Multidisciplinary optimisation tool. C123 process is useful for strategic & systematic usage of optimisation to generate design alternatives, trade-off information, best balanced designs, design sensitivities, to actively support the concept development process on daily basis. Methodology C123 is used for developing initial concept design of the chassis frame of the SUV. C123 process is independent of vehicle architectures, manufacture process (e.g. extrusions, sheet metal) & material selection (e.g. metals, composites, mixed etc.) and platform sharing strategy. C1 process is used for identification of optimum Structural Layout, C2 is for rapid optimum Sizing of idealized Sections, C3 is used for detailed optimum Sizing of Manufacturable Sections. Automatic process is used for handling pre and post processing process very efficiently.
Technical Paper

High rigidity and light weight bumper material development in India

2019-11-21
2019-28-2553
Vehicle weight reduction becomes important at the view point of fuel efficiency improvement and CO2 reduction in India also as well as developed countries. With this background, High tensile and Super high tensile steel application has become increasing. Similary, weight reduction of big plastic parts like bumper face is one of the most important items, so Honda has developed Thin-wall and light weight bumper face. In the development of light weight bumper, rigidity, impact strength and flowability which are main requirement are cotradictory property. It is necessary to develop new material to achieve this technical concern. Moreover, we verified part shape and thickness optimization to achieve part requirement. Established high property material and part manufacturing technology were applied for current CITY firstly, and it has been expanded to other models sequentially to contribute weight reduction for Honda vehicles.
Technical Paper

An alternate cost effective material for rocker arm for 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

A Mathematical Approach to Determine Die Wear during Forging Process and Validation by Experimental Technique

2019-11-21
2019-28-2563
The automotive industry is constantly trying to develop cost effective, high strength and lightweight components to meet the emission and safety norms while remaining competitive in the market. Forging process plays an important role to produce most of the structural components in a vehicle. Precision forging technology is used to produce components with little or no flash leading to elimination of machining process after forging. The load acting on the dies during net or near net forging is very high and leads to wear in the die. In order to have a good die it is important that die wear which is an inevitable phenomenon in a bulk metal forming processes is predicted mathematically. In this study a review on the vast number of studies done in the area of wear and various predictive models is carried out.
Technical Paper

STATISTICAL ANALYSIS OF LOW CYCLE FATIGUE PROPERTIES IN METALS FOR ROBUST DESIGN

2019-11-21
2019-28-2576
Objective: In ground vehicle industry, strain life approach is commonly used for predicting fatigue life. This approach requires use of fatigue material properties such as fatigue strength coefficient (σf'), fatigue strength exponent (b), fatigue ductility coefficient (εf'), fatigue ductility exponent (c), cyclic strength coefficient (K′) and cyclic strain hardening exponent (n′). These properties are obtained from stable hysteresis loop of constant amplitude strain-controlled uniaxial fatigue tests. Usually fatigue material properties represent 50th percentile experimental data and doesn't account possible material variation in the fatigue life calculation. However, for robust design of vehicle components, variation in material properties need to be taken into account. In this paper, methodology to develop 5th percentile (B5), 10th percentile (B10) and 20th percentile (B20) fatigue material properties are discussed.
Technical Paper

Optimization of the critical parameters affecting the fuel lid performance

2019-11-21
2019-28-2413
Fuel lid is one of the parts which are mostly operated mechanically by the end user while filling the fuel. Therefore part design should be done in such a manner that it can be operated smoothly without any hassles. The conventional steel fuel filler doors are of two types: Three-piece type fuel filler doors also known as the dog-leg type and two-piece type fuel filler doors also known as the butterfly type. Both types of fuel filler doors have a pin that acts as a rotational hinge axis about which the fuel filler door opens and closes. Depending on the styling and shape of the side body outer, fuel lid type is decided. In the current study, dog-leg type fuel lid is considered. The factors that primarily affect the opening-closing performance are the weight of fuel lid, hinge axis, and the friction at the hinge area. The orientation of the hinge axis is derived from the profile of the side body outer panel. The fuel lid weight and hinge axis are decided in the initial design stage.
Technical Paper

FABRICATION AND WEAR CHARACTERISTICS BASALT FIBER REINFORCED POLYPROPYLENE MATRIX COMPOSITES

2019-11-21
2019-28-2570
Generally brake pads are manufacturing by use of asbestos materials, these materials are chemically harmful and toxic, affects human health. The present investigation fabricates polypropylene composites with mixing constant volume [5 Vol.%] of alumina nano particles and different volume percentages [0%, 5%, 10% & 15%] of basalt fibre by hand layup compression technique. The wear characteristics of polypropylene matrix composites were tested by dry sliding condition using pin on disc apparatus configuration with hardened steel counter-face at elevated temperature. The load was applied 30N to 70N with the interval of 20N and varying of sliding speed 300 rpm to 900rpm with the interval of 300rpm for the time period of 0-180 sec. The wear rate was decreases with addition of alumina nano particle and also increases the frictional force for the effect of basalt fibre content present in the composites. The co-efficient of friction was increases from 0.1 to 0.66 under normal loading condition.
Training / Education

Materials Degradation in Mechanical Design Wear, Corrosion, Fatigue and their Interactions

2019-10-08
Materials degradation from environmental conditions is a common factor that will often occur in mechanical equipment used in every type of environment. These processes can frequently materialize in unpredicted and harmful ways, especially when they interact and lead to early component damage or failure. This five-session course will summarize the mechanisms that cause materials and mechanical components to degrade in service through exposure to deleterious mechanical and environmental conditions.
Training / Education

Introduction to Advanced High Strength Steel Applications and Manufacturing

2019-10-08
Advanced High Strength Steels (AHSS) are now commonly used in automotive body structural applications. The high strength of this grade classification is attractive to help reduce mass in the automotive body through reduction in thickness. Strength also supports improvements in safety requirements so that mass increases are minimized. In some specific grades of AHSS, energy absorption is possible in addition to the high strength. This course will review the definition and properties of AHSS and cover several common applications in automotive body structures.
Technical Paper

A New Positioning Device Designed for Aircraft Automated Alignment System

2019-09-16
2019-01-1883
Accurate and fast positioning of large aircraft component is of great importance for Automated Alignment System. The Ball joint is a widely-used mechanical device connecting the aircraft component and Automated Alignment System. However, there are some shortcomings for the device in man-machine engineering, such as the entry state of the ball-head still needs to be confirmed by the workers and then switched to the locking state manually. To solve above problems, a new positioning mechanism is present in this paper, which consists of a ball-head and a ball-socket. The new device is equipped with a monocular vision system, in which a calibrated industrial camera is used to collect the images of the ball-head. And then, the 3-D coordinate of the ball-head center is calculated by a designed algorithm, which combines the symmetry of the sphere and the principle of projection transformation, guiding the positioner to capture the ball-head.
Technical Paper

A Study of the Disc Scoring Generation Principle and Reduction(III)

2019-09-15
2019-01-2112
In the latest works, we presented the guideline for reducing Metal pick up(MPU,the main component of disc scoring) by controlling the location of the roughness of disc, the brake pad frictioncoefficients and the disc slot's size. In this study, the previously studied iron transfer theory to 'Cu free' brake pad and the disc surface roughness controlling methods which are based on the mass production manufacturing process are applied. It is possible to suggest the ways to improve the scoring-free disc without reducing friction coefficient between the disc and pad, and any demerit such as increased wear and airplane noise like conventional slot discs.
Technical Paper

The Influence of Differential Pad Wear on Low-Frequency and High-Frequency Brake Squeal

2019-09-15
2019-01-2130
The NVH behavior of disc brakes in particular, is in the focus of research since a long time. Measurements at a chassis dynamometer shows that brake pad wear has a significant influence on the occurrence of low- and high-frequency squealing [1]. It is suspected that high-frequency squealing is more likely to occur when the wear difference between the inner and outer brake linings is small. In the other case, if the differential wear rate between the inner and outer pads becomes higher, the prevalence of low-frequency squealing increases. In order to examine this hypothesis, this work focuses on a simplified model of a commercial brake system [2]. In a first step, the inner pad’s wear is iteratively increased, while the wear on the outer pad remains unaffected. In a second step, the coefficient of friction at the worn pad is iteratively increased to investigate the influence on the low and high-frequency squealing.
Technical Paper

Aging Effect on Disc Pad Properties

2019-09-15
2019-01-2108
One Low-copper formulation and one Copper-free formulation were made into disc pad, and both of them were cured under 4 different conditions. These pads had no backing layer and no scorched layer. Pad thickness, dynamic modulus and natural frequencies were continuously monitored over a period of 12 months. After 12 months at room temperature, pad thickness, dynamic modulus and natural frequencies all increased to higher values. The Low-copper formulation increased rapidly during the first 60 days and the Copper-free formulation increased rapidly for the first 90 days, and then slowly thereafter. Two competing processes are found to be taking place; internal stress relief leading to expansion and cross-linking of the resin leading to shrinkage. As the pad properties are changing continuously, the timing of property measurement becomes an important issue for quality assurance.
Technical Paper

The Normal-Load and Sliding-Speed Dependence of the Coefficient of Friction, and Wear Particle Generation Contributing to Friction: High-Copper and Copper-Free Formulations

2019-09-15
2019-01-2131
Automotive brakes operate under varying conditions of speed and deceleration. In other words, the friction material is subjected to a wide range of normal loads and sliding speeds. One widely accepted test procedure to evaluate, compare and screen friction materials is the SAE J2522 Brake Effectiveness test, which requires full-size production brakes to be tested on an inertia brake dynamometer. For the current investigation, disc pads of two types of 10 different formulations (5 high-copper and 5 copper-free formulations) were prepared for testing on a front disc brake suitable for a pickup truck of GVW 3,200 kg. Each pad had 2 vertical slots, and one chamfer on the leading edge and also on the trailing edge of the pad. One segment of the test procedure looks at the coefficient of friction (Mu) under different brake line pressures and different sliding speeds to determine its stability or variability.
Technical Paper

Influence of Amount of Phenolic Resin on the Tribological Performance of Environment-Friendly Friction Materials

2019-09-15
2019-01-2105
The binder in friction materials (FMs) plays a very crucial role of binding all the ingredients firmly so that they can function efficiently and reliably. The type and amount of binder, both are very critical for manipulating the desired performance properties, which mainly include friction and its sensitivity towards operating parameters, wear resistance, counter-face friendliness, noise, vibration etc. Although a lot is reported on the influence of types of resins on the tribo-performance of FMs, hardly any paper pertains to paint this on a bigger canvas with a more detailed understanding of the amount of resin in FMs on the performance properties including noise. The present study addresses these aspects by developing brake-pads with identical composition, but varying in amount (wt.%) of straight phenolic resins (6, 8, 10 and 12) by compensating the difference by barite, a space filler.
Technical Paper

Role of Graphite Particles Size in Brake-Pads in Controlling Tribological and Noise Performance.

2019-09-15
2019-01-2106
Graphite plays a crucial role in friction materials, since it has good thermal conductivity, lubricity and act as a friction modifier. The right type, amount, shape and size of the particles control the performance of the brake-pads. In this study, particles of synthetic graphite produced in a unique highly controlled graphitization process were selected to develop NAO- Cu-free brake-pads. The four types of pads had identical composition except variation in average particle size of the graphite (60 µm, 120 µm, 200 µm and 400 µm). Physical, mechanical and chemical characterization of the developed brake-pads was done. Tribological performance was studied using a full- scale inertia brake dynamometer following a Japanese automobile testing standard (JASO C406) and noise studies were done on reduced scale prototype following SAE J2521 standard.
Technical Paper

A Study on the Optimum Reduction of Required Brake Fluid Level for Improvement of The High Speed Continuous Brake Distance

2019-09-15
2019-01-2121
The high speed continuous braking distance assessment is the worst condition for thermal fades. This study was conducted to investigate the relationship between fade characteristic and friction materials & brake fluid amount for improving braking distance. So, we used the dynamometer to measure the friction coefficient, braking distance and required brake fluid amount. First of all, we studied the influence of friction coefficient on the same friction material shape (chamfer shape, area of the friction material, number of slots). Secondly, we knew the effects of braking distance by the shape of the friction material. Through these two studies, the shape of the friction material favorable to the fade characteristics was obtained. Finally, we measured the amount of required brake fluid in caliper after 10 consecutive braking cycles through Dynamometer. And then, we measured the amount of compression deformation and uneven wear of the friction material.
Technical Paper

Divergence of Thickness Loss vs. Weight Loss, Friction and Wear Behavior of Heavy Truck Brake Blocks: Development of A New Test Procedure for the Chase Tester

2019-09-15
2019-01-2107
Heavy truck brake blocks are found to swell (or expand) permanently during testing or usage, especially so at high temperatures, thus leading to longer durability as measured by thickness loss, similar to light vehicle disc pads. This swelling phenomenon occurs continuously in the layer adjacent to the friction surface during testing or usage; not a one time event. The thickness loss estimated from the weight loss is always greater than measured thickness loss. Brake block wear does not increase linearly with increasing normal load, and the load-sensitivity of block wear is very much dependent on the products. A new test procedure has been developed for generating friction-vs.-temperature and wear-vs.-temperature data at a constant temperature employing intermittent braking on the Chase Brake Lining Quality Tester (SAE J661) and friction material wear can be compared on equivalent-work basis.
Technical Paper

Ceramic Bound Materials: A Suitable Solution for Light Brakes

2019-09-15
2019-01-2109
A ceramic bound matrix has been investigated to be used as a friction material. The materials were produced by means of ceramic technology, and four formulations were tested by means of a tribometer (pin-on-disc tester) using a gray cast iron counterpart. Test sections included speeds between 1 and 12 m/s, and loads between 25 and 400 N. The characterization of the tribolayers was carried out by means of scanning electron microscopy. The four developed materials were named A, B, C, and D with different ratio of components. They exhibited different wear rates and coefficients of friction. All the materials exhibited sensitivity to speed, while showed a lower sensitivity to load. The coefficient of friction level seems to be suitable for brake applications, oscillating between 0.6 and 0.4, depending on the test section. This kind of materials with further efforts can be possibly useful in future electric vehicles that will not demand large and expensive brakes.
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