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Technical Paper

Reduction of Flow-induced Noise in Refrigeration Cycles

2024-07-02
2024-01-2972
In electrified vehicles, auxiliary units can be a dominant source of noise, one of which is the refrigerant scroll compressor. Compared to vehicles with combustion engines, e-vehicles require larger refrigerant compressors, as in addition to the interior, also the battery and the electric motors have to be cooled. Currently, scroll compressors are widely used in the automotive industry, which generate one pressure pulse per revolution due to their discontinuous compression principle. This results in speed-dependent pressure fluctuations as well as higher-harmonic pulsations that arise from reflections. These fluctuations spread through the refrigeration cycle and cause the vibration excitation of refrigerant lines and heat exchangers. The sound transmission path in the air conditioning heat exchanger integrated in the dashboard is particularly critical. Various silencer configurations can be used to dampen these pulsations.
Technical Paper

The Potential of Hydrogen High Pressure Direct Injection Toward Future Emissions Compliance: Optimizing Engine-Out NOx and Thermal Efficiency

2024-06-12
2024-37-0005
By building on mature internal combustion engine (ICE) hardware combined with dedicated hydrogen (H2) technology, the H2-ICE has excellent potential to accelerate CO2 reduction. H2-ICE concepts can therefore contribute to realizing the climate targets in an acceptable timeframe. In the landscape of H2-ICE combustion concepts, High Pressure Direct Injection (HPDI™) is an attractive option considering its high thermal efficiency, wide load range and its applicability to on-road as well as off-road heavy-duty equipment. Still, H2-HPDI is characterized by diffusion combustion, giving rise to significant NOx emissions. In this paper, the potential of H2-HPDI toward compliance with future emissions legislation is explored on a 1.8L single-cylinder research engine. With tests on multiple load-speed points, Exhaust Gas Recirculation (EGR) was shown to be an effective measure for reducing engine-out NOx, although at the cost of a few efficiency points.
Technical Paper

A Numerical Study of the Laminar Flame Speed of Hydrogen/Ammonia Mixtures under Engine-like Conditions

2024-06-12
2024-37-0020
In the effort to achieve the goal of a climate-neutral transportation system, the use of hydrogen and other synthetic fuels plays a key role. As battery electric vehicles become more widespread, e-fuels could be used to defossilize the hard-to-electrify transportation sectors and to store energy produced from renewable and non-continuous energy sources. Among e-fuels, hydrogen and ammonia are very attractive because they are carbon-neutral and their oxidation does not lead to any CO2 emissions. Furthermore, hydrogen/ammonia mixtures overcome the issues that arise as each of the two fuels is separately used. In the automotive sector, the use of either hydrogen, ammonia or their blends require a characterization of such mixtures under engine-like conditions, that is, at high pressures and temperatures. The aim of this work is to evaluate the Laminar Flame Speed (LFS) of hydrogen/ammonia mixtures by varying the thermodynamic conditions and the molar composition of the reactants.
Technical Paper

The irrotational intensity: an efficient tool to understand the vibration energy propagation in complex structures using an FE Model.

2024-06-12
2024-01-2942
Although structural intensity was introduced in the 80's, this concept never found practical applications, neither for numerical nor experimental approaches. Quickly, it has been pointed out that only the irrotational component of the intensity offers an easy interpretation of the dynamic behavior of structures by visualizing the vibration energy flow. This is especially valuable at mid and high frequency where the structure response understanding can be challenging. A new methodolodgy is proposed in order to extract this irrotational intensity field from the Finite Element Model of assembled structures such as Bodies In White. This methodology is hybrid in the sense that it employs two distinct solvers: a dynamic solver to compute the structural dynamic response and a thermal solver to address a diffusion equation analogous to the thermal conduction built from the previous dynamic response.
Technical Paper

Transmission of sound under the influence of various environmental conditions

2024-06-12
2024-01-2933
Electrified vehicles are particularly quiet, especially at low speeds due to the absence of combustion noises. This is why there are laws worldwide for artificial driving sounds to warn pedestrians. These sounds are generated using a so-called Acoustic Vehicle Alerting System (AVAS) which must maintain certain minimum sound pressure levels in specific frequency ranges at low speeds. The creation of the sound currently involves an iterative and sometimes time-consuming process that combines composing the sound on a computer with measuring the levels with a car on an outside noise test track. This continues until both the legal requirements and the subjective demands of vehicle manufacturers are met. To optimize this process and reduce the measurement effort on the outside noise test track, the goal is to replace the measurement with a simulation for a significant portion of the development.
Technical Paper

Knockdown Factor Estimation of Stiffened Cylinders under Combined Loads - A Numerical Study

2024-06-01
2024-26-0417
Airframe section of rockets, missiles and launch vehicles are typically cylindrical in shape. The cylindrical shell is subjected to high axial load and an external pressure during its operation. The design of cylinders subjected to such loads is generally found to be critical in buckling. To minimize the weight of cylinders, it is typically stiffened with rings and stringers on the inner diameter to increase the buckling load factor. Conventionally the buckling load estimated by analytical or numerical means is multiplied by an empirical factor generally called Knockdown factor (kdf) to get the critical buckling load. This factor is considered to account for the variation between theory and experiment and is specified by handbooks or codes. In aerospace industry, NASA SP 8007 is commonly followed and it specifies the kdf as a lower bound fit curve for experimental data .
Technical Paper

Numerical Investigation of Aerodynamic Characteristics on a Blunt Cone Model at Various Angles of Attack under Hypersonic Flow Regimes

2024-06-01
2024-26-0446
The study of aerodynamic forces in hypersonic environments is important to ensure the safety and proper functioning of aerospace vehicles. These forces vary with the angle of attack (AOA) and there exists an optimum angle of attack where the ratio of the lift to drag force is maximum. In this paper, computational analysis has been performed on a blunt cone model to study the aerodynamic characteristics when hypersonic flow is allowed to pass through the model. The flow has a Mach number of 8.44 and the angle of attack is varied from 0º to 20º. The commercial CFD solver ANSYS FLUENT is used for the computational analysis and the mesh is generated using the ICEM CFD module of ANSYS. Air is selected as the working fluid. The simulation is carried out for a time duration of 1.2 ms where it reaches a steady state and the lift and drag forces and coefficients are estimated. The pressure, temperature, and velocity contours at different angles of attack are also observed.
Magazine

Aerospace & Defense Technology: May 2024

2024-05-09
Explaining MOSA from the Team that Led the Army Aviation Mission Computing Environment Task Order What's the Best DC Motor for Your Commercial Aerospace Application? Aerospace Production: Overcoming Challenges in Composite Machining Understanding the Limits of Artificial Intelligence for Predictive Maintenance Pushing the Limits: Engineering Advanced RF Interconnects to Meet the Challenges of Hypersonic Missile Development Expanding Possibilities for Superconducting Qubits With Niobium Researchers Help Robots Navigate Efficiently in Uncertain Environments A new algorithm reduces travel time by identifying shortcuts a robot could take on the way to its destination.
Journal Article

Experimental Analysis of Heat Transfer Post Quenching of Medium Carbon Steel

2024-05-08
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.
Technical Paper

Anti-Rollover Control for All-Terrain Vehicle Based on Zero-Moment Point

2024-04-30
2024-01-5055
To investigate the rollover phenomena experienced by all-terrain vehicles (ATVs) during their motion caused by input from the road surface, a combined simulation using CarSim and Simulink has been employed to validate an active anti-rollover control strategy based on differential braking for ATVs, followed by vehicle testing. In the research process, a nonlinear three-degrees-of-freedom vehicle model has been developed. By utilizing a zero-moment point index as a rollover warning indicator, this approach could accurately detect the rollover status of the vehicle, particularly in scenarios involving low road adhesion on unpaved surfaces, which are characteristic of ATV operation. The differential braking, generating a roll moment by adjusting the amount of lateral force each braked tire can generate, was proved as an effective method to enhance rolling stability.
Technical Paper

Influence of Machining Parameters on Tungsten Carbide Inserts in ANSYS Analysis of Maraging Steel Machining

2024-04-29
2024-01-5057
The machining process is employed to transform a workpiece into a predefined geometry with the assistance of a cutting tool. Throughout this process, the cutting tool undergoes various adverse effects, including deformation, stress, thermal gradient, and more, all of which impact tool sharpness, surface finish, and tool life. These outcomes are also influenced by cutting parameters, specifically cutting speed, feed rate, and depth of cut. The present investigation aims to demonstrate the application of ANSYS analysis software in predicting stress, deformation, thermal gradient, and other factors on the tool insert tip for various machining parameters. To achieve this, an experimental setup was arranged to collect cutting force and temperature data using a dynamometer and thermocouples during the machining process of maraging steel with a tungsten carbide tool insert. Experiments were conducted with different combinations of machining parameters using design of experiments (DoE).
Journal Article

Failure Analysis of Cryogenically Treated and Gas Nitrided Die Steel in Rotating Bending Fatigue

2024-04-24
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.
Technical Paper

Mathematical Model for the Rotation of a Door Including Vehicle Inclination

2024-04-17
2024-01-5045
The analysis presented in this document demonstrates the mathematical model approach for determining the rotation of a door about the hinge axis. Additional results from the model are the torque due to gravity about the axis, opening force, and the door hold open check link force. Vector mechanics, equations of a plane, and parametric equations were utilized to develop this model, which only requires coordinate points as inputs. This model allows for various hinge axis angles and door rotation angles to quickly be analyzed. Vehicle pitch and roll angles may also be input along with door mass to determine the torque about the hinge axis. The vector calculations to determine the moment arm of the door check link and its resulting force are demonstrated for both a standard check link design and an alternate check link design that has the link connected to a slider translated along a shaft.
Standard

Rings, Retaining – Spiral Wound, Uniform Section Corrosion and Heat Resistant, UNS S66286

2024-04-10
CURRENT
AS4299B
This procurement specification covers retaining rings of the spiral wound type with uniform rectangular cross-section, made of a corrosion and heat resistant age hardenable iron base alloy of the type identified under the Unified Numbering System as UNS S66286, work strengthened and heat treated to a tensile strength of 185 to 240 ksi at room temperature.
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