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Technical Paper

A new appraisal of the thermomechanical behaviour of a hybrid composite brake disc in a formula vehicle

2019-11-21
2019-28-2572
A new appraisal of the thermomechanical behaviour of a hybrid composite brake disc in a formula vehicle Research Objective This paper presents a hybrid composite brake disc with reduced Un Sprung Weight clearing thermal and structural analysis in a formula vehicle.Main purpose of this study is to analyse thermomechanical behaviour of composite brake disc for a formula vehicle under severe braking conditions. Methodology In the disk brake system, the disc is a major part of a device used for slowing or stopping the rotation of a wheel. Repetitive braking of the vehicle leads to heat generation during each braking condition. Based on the practical understanding the brake disc was remodelled with unique slotting patterns and grooves, using the selected aluminium alloy of (AA8081) with reinforcement particle of Silicon carbide (SiC) and Graphite (Gr) as a hybrid composite material for this proposed work.
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

Self-Sensing, Lightweight and High Modulus Carbon Nanotube Composites for Improved Efficiency and Safety of Electric Vehicles

2019-11-21
2019-28-2532
Carbon Composites (CFRP) have been touted to be an essential component of future automobiles due to their mechanical properties and lightweight. CFRP has been adopted successfully for secondary and primary structures in Aerospace industry. In Automobiles, they are incorporated in models like the BMW i-series. CFRP suffers from 2 major problems. Delamination of Composites leads to catastrophic and rapid failure which could be dangerous in passenger vehicles. Delamination occurs whenever there is a shock on the composite. Secondly, Composites need regular expensive maintenance to ensure that the material is intact and will not compromise passenger safety. Carbon Nanotubes in composites have shown a substantial increase in delamination resistance. A 0.1wt% addition of HiPCO® Single-walled Carbon Nanotube provides both self-sensing and improved fracture resistance.
Technical Paper

Mechanical Property Evaluation of Paper Honeycomb reinforced Plastics

2019-11-21
2019-28-2538
Mechanical Property Evaluation of Paper Honeycomb Reinforced Plastics Vignesh Balaji S G, Pradeep Hyundai Motor India Engineering Pvt. Ltd, Chennai. India Key Words: Paper Honeycomb, Epoxy Composites, Mechanical Properties, Tensile, Impact & Flexural Test Research and/or Engineering Questions/Objective : Composite Materials are widely being used in many engineering applications because of their desirable properties & Cost, Weight Effectiveness. They are widely being used as their Strength-Weight Ratio is Higher than any Other Material. Paper Honeycomb Material is basically a paper made of honeycomb shapes enforced between layers of Glass Mat. This paper deals with the evaluation of Tensile Strength, Flexural (Three-Point Bending) Strength & Flexural Modulus, Impact Strength of Paper Honeycomb Reinforced Epoxy Composites. The Scope of this Material defines the quality of Paper Honeycomb Reinforced Composites which can be used for Automotive Trim Parts.
Technical Paper

Employing natural plant based fiber in interior automotive parts for cost & weight benefit

2019-11-21
2019-28-2559
The Automotive industry is in ever more need for a lesser weight car due to progressively stringent emission norms and the demand of customer to have better mileage. It can be a gargantuan challenge for automotive manufacturers to search for lesser weight material to meet both customers as well as regulatory norms. But in some cases such lower weight material can increase the cost and adding a expensive material which increases overall cost to a price sensitive market like India is not favorable. One such solution is using the indigenous plant fiber (Jute) in combination with propylene (PP) to make Interior plastics components. Jute a vegetable fiber also referred to as "the golden fiber" has high tensile strength, low extensibility and is well established in fabric, packing, agriculture, construction industries. The biodegradable Jute lesser weight & abundance (India is the leading manufacturer of the Jute) can be utilized in making automobile trim parts in India.
Technical Paper

NEXT GENERATION POWER DISTRIBUTION UNIT IN WIRING HARNESS

2019-11-21
2019-28-2571
Keywords – Miniaturization, Low Profile (LP) Relays, Low Profile (LP) Fuses, Fuse box, Wiring Harness Research and/or Engineering Questions/Objective With the exponential advancement in technological features of automobile’s EE architecture, designing of power distribution unit becomes complex and challenging. Due to the increase in the number of features, the overall weight of power distribution unit increases and thereby affecting the overall system cost and fuel economy. The scope of this document is to scale down the weight and space of the power distribution unit without compromising with the current performance. Methodology Miniaturization involves replacing the mini fuses and J-case fuses with LP mini and LP J-case fuses respectively. The transition doesn’t involve any tooling modification and hence saves the tooling cost.
Technical Paper

Development of low cost life saving system for Automotive vehicles during Road Accidents.

2019-11-21
2019-28-2460
According to research study 45% of death cause due to not getting help on time to the injured person. Research has proven that if injured person is not found any option of help then they also loose the power to fight such critical situation due to psychological effect. When vehicle met accident, people are not getting on time support, this delay is the major cause of death in developing nations. Presently there is no any robust system available in market for passenger & commercial vehicles which helps to provide on time help to the injured persons & saves human life. In current situation low cost life saving device is need of our society. This paper deals with the design & development of the low cost-life saving device. This paper also comprises the scenario when any vehicle meet an accidents within certain speed limit then how the intelligent life saving device will work & save the life's.
Technical Paper

SIMULATION OF SOFTENING AND RUPTURE IN MULTILAYERED FUEL TANK MATERIAL

2019-11-21
2019-28-2557
Research and/or Engineering Questions/Objective Plastic automotive fuel tanks made up of blow molded, multi-layered, high-density polyethylene (HDPE) material can take complex shapes with varying thickness. Accidental drop of fuel tank from a height during handling can lead to development of cracks. Damage can also occur due to an impact during a crash. This can be catastrophic due to flammability of the fuel. The objective of this work is to characterize and develop a failure model for the fuel tank material to simulate damage and enhance predictive capability of CAE for chassis and safety load cases. Methodology Different aspects were considered to develop a characterization and modelling strategy for the HDPE fuel tank. Material properties can be influenced by factors such as, service temperature, rate of deformation, state of stress etc.
Technical Paper

Thermal Challenges in Automotive Exhaust System through Heat Shield Insulation

2019-11-21
2019-28-2539
While advanced automotive system assemblies contribute greater value to automotive safety, reliability, emission/noise performance and comfort, they are also generating higher temperatures that can reduce the functionality and reliability of thesystem over time. Thermal management and insulation are extremely important and highly demanding in BSVI, RDE and Non-IC engine operating vehicles. Passenger vehicle and Commercial vehicle exhaust systems are facing multiple challenges such as packaging constraints, weight reduction andthermalmanagement requirements.Frugal engineering is mandatory to develop heat shield in the exhaust system with minimum heat loss. The focus of the paper is to design, develop and validate heat shield products with different variables such as design gap, insulation material, sheet metal thickness and manufacturing processes. 1D and 3D computational simulations are performed with different gaps from 3 mm to 14 mm are considered.
Technical Paper

Sensor Perception and Motion Planning for an Autonomous Material Handling Vehicle.

2019-10-28
2019-01-2611
The ground mobile robotics study is structured on the two pivotal members namely Sensor perception and Motion planning. Sensor perception or Exteroception comprises the ability of measurement of the layout of environment relative to vehicle’s frame of reference which is a necessity for the implementation of safe navigation towards the goal destination in an unstructured environment. Environment scanning has played a significant role in mobile robots application to investigate the unexplored environment in the sector of defence while transporting and handling material in warehouse and hospitals. Motion Planning is a conjunction of analysing the sensor’s information about the local frame and global map while being able to plan the route from starting point to the target destination. In this paper, a 3600 2-D LiDAR is used to capture the spatial information of the surrounding, the scanning results are presented in a local and global map.
Technical Paper

Banana Stem Based Activated Carbon as Filler in Polymer Composites for Automobile Applications

2019-10-11
2019-28-0093
Activated carbon was produced from a new part of banana plant namely true stem in this current research and used as fillers in polymer composites for automobile application. True stems of banana plants are the main wastes in banana or fruit markets which refer to the remains after banana fruits are removed from the supporting stems. Conversion of raw material into activated carbon particles is done by chemical and heat activation. The raw material used here were dried samples of banana plant’s true stem. This material was heated in a crucible at 400°C and then powdered. These crushed samples were activated using hydro-chloric acid at 120°C for 5 hours and finally in a furnace for thermal activation at 700°C for 1 hour. These particles were incorporated as fillers in composites at proportions of 10%, 15%, 20% and 25%. The activated carbon samples were characterized by determining its fixed carbon content and bulk density.
Technical Paper

Design and Analysis of Natural Fibre Reinforced Epoxy Composites for Automobile Hood

2019-10-11
2019-28-0086
The need for eco-friendly materials is recently increasing in the automobile and aerospace sectors. Material selection for automobile components is influenced by various factors such as cost, weight and strength. Natural fibers offers various advantages over conventional materials such as environmental friendly, easily available, recyclable and higher specific strength. Among the natural fibers Sisal and Kenaf fibers are selected for present study due to their good mechanical properties and availability. Kenaf fibers have great potential to be used as construction and automotive materials due to their long fibers which are derived from the bast. Sisal fibers do not absorb moisture and posses good impact, sound absorbing properties and high fire resistance properties. Epoxy LY556 is selected as matrix material to bind the combination of these two natural fibers due to its high temperature resistance and adherence to reinforcements.
Technical Paper

A Comparative Study on Microstructures and Mechanical Properties of Al-Gnps Composites Fabricated By Casting Method

2019-10-11
2019-28-0139
This paper describes an investigation on microstructures and mechanical properties of pure aluminium graphene nano platelets (GNPs) composites prepared by ultrasonic assisted stir casting technique. The proportion of GNPs varied from 0.5 to 2.0 wt. % in pure aluminium matrix with 99% purity. The investigations on composites revealed that Pure Al -1.0 % GNPs composite exhibited better mechanical properties with 48.49 % (~49%) increase in tensile strength and 34.53 % (~35%) increase in micro hardness compared to results of composites fabricated by stir casting technique. FESEM analysis was done to examine the surface morphology, whereas the Fractography of the tested composites and the XRD analysis was to inspect the phase analysis. The analysis revealed that there was uniform distribution of GNPs in the pure aluminium matrix due to cavitation effect with less porosity due to which there is significant enhancement in mechanical properties compare to composites by stir casting technique.
Technical Paper

Experimental Investigation on Mechanical Properties and Vibration Damping Frequency Factor of Kenaf Fibers Reinforced Epoxy Composite

2019-10-11
2019-28-0167
Kenaf fiber regarded as industrial crop for different applications. It is one of the most important plants cultivated for natural fibers globally. Natural fibers such as Kenaf fibers are getting attention of researchers and industries to utilize it in different composites due to its biodegradable nature. In this present investigation mechanical properties, vibration damping frequency factor and thermogravimetric analysis of Kenaf fiber reinforced epoxy composite (KFREC) have been evaluated and reported. The tests were conducted with different weight categories of Kenaf fiber such as 20%, 25%, 30% and 35%. The effects of fiber content on tensile, flexural, impact strengths, hardness and thermal decomposition properties of the composite were determined. The failure mechanism and damage features of the KFREC were categorized using Scanning Electron Microscope (SEM). The results indicate that the increase in the fiber content decreases the damping vibration factor (ζ) correspondingly.
Technical Paper

Study of Mechanical Properties of Similar and Dissimilar Metals of Monel 400 and SS 321by using Gas Tungsten Arc Welding (GTAW) Process

2019-10-11
2019-28-0141
In the present study the fabrication of joints between the nickel base alloys and steels of various grades have been under taken, joining of these metals has assumed new importance by virtue of their widespread in nuclear and aerospace applications. Such joints provide excellent strength, oxidation and corrosion resistance. This paper deals with the study of weldability, and mechanical properties of weld joints of two different alloys such as nickel based alloy- monel 400 and austenitic stainless steel AISI 321. The joining of the similar and dissimilar metals is carried out by GTAW process by employing two different types of filler rods such as SS321 and ERNiCrMo-3.
Technical Paper

Experimental Investigation Mechanical and Corrosion Characteristics of Friction Stir Welded Aluminum Alloy 7075-T6

2019-10-11
2019-28-0175
Friction Stir Welding (FSW) is a quite new solid-state joining process. This joining technique is energy efficient, environment friendly, and adaptable. In particular, it can be used to join high-strength Aluminium alloys and other metallic alloys that are difficult to weld by conventional fusion welding. Friction Stir Welding heats metal to the temperature below re crystallization. FSW avoids welding defects like porosity and hot cracking which are frequently in conventional welding techniques due to alloy’s very low re-crystallization temperature and higher heat dissipating nature. This process combining deformation heating and mechanical work to obtain high defect free joints. Aluminum alloy 7075-T6 is generally used in various industrial applications such as automobile, ship building and aerospace due to their light weight, good mechanical properties and high corrosion resistance.
Technical Paper

Tensile and Fatigue behavior of shallow cryogenically treated En19 alloy steel

2019-10-11
2019-28-0100
Wear, tensile and axial fatigue tests were conducted on shallow cryogenically treated En19 medium carbon alloy steel to investigate its mechanical behavior. The test samples are conventionally heat treated then oil quenched at 34 ˚C. Followed by the samples were kept under shallow cryogenic treatment to -80˚C for 12 hours using liquid nitrogen. Then the samples were tempered in a muffle furnace to relieve the induced residual stresses. Wear, Tensile and axial fatigue test was carried out on both treated and non-treated samples to measure its wear resistance, tensile strength and fatigue behavior respectively. Microscopic examination also done using scanning electron microscope to compare the effect of shallow cryogenic treatment on its microstructure. The results exposed that there is a reduction in the tensile strength and fatigue life of shallow cryogenically treated samples over base metal and improved wear resistance.
Technical Paper

Amelioration of modular mobility by adopting split cell solar panel cleaning and cooling therof

2019-10-11
2019-28-0078
In photovoltaic system the efficiency of solar cells is determined in combination with latitude and climate. The electricity generation in photovoltaic cell is more in the morning time than in the afternoon time. This is due to the fact that an increase in solar cell temperature leads to a decrease in efficiency of the solar panel. This work aims to provide necessary cooling to the solar panel for favourable output during noon time. Normally electrical modular vehicles use non-split cell solar panels. In order to increase the efficiency, we are using split cell solar panel as it increases voltage by halving the size of the silicon chips. Thus, halving the cells results in increasing efficiency and lowering the operation temperature. The solar panel should be maintained at a particular temperature by adopting sprinkling of water method in solar panel for hybrid vehicles.
Technical Paper

A Case Study on the Importance of Implementing an Obsolescence Material Management in an Aerospace Manufacturing Supplier Industry Environment

2019-10-11
2019-28-0145
Obsolescence Material management plays an important and vital role in today’s modern Aerospace manufacturing, Aerospace Maintenance, Repair and Overhaul industry as well as Aerospace Distributors. Aerospace vehicles have a considerable longer product life-cycle when compared to any other consumer goods like automobile and electronics industry. With the advent of new, disruptive technologies, many sources and supplies of materials including COTS and Standard catalogue parts, components and goods, which are widely used in an Aerospace manufacturing environment, are diminishing at a considerable rate and thus result in their obsolescence before the end disposal of the product life cycle. It is one of the leading causes to the sale of counterfeit and fraudulent parts and components, which can result in considerable deterioration of Quality and Cost to Customer.
Technical Paper

Advances in Laser Welding of Stainless Steel Alloys

2019-10-11
2019-28-0056
As a fusion welding process, Laser welding has proven to be the most promising method for joining of different materials it can be either a similar or dissimilar material category.
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