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Training / Education

Fundamentals of Threaded Fasteners

2019-12-18
Fastener experts believe that upwards of 95% of all fastener failures are the result of either the wrong fastener for the job or improper installation. Whether this shocking figure is accurate or not, it is irrefutable that threaded fasteners are poorly misunderstood by many in both the fastener and user communities. In October 1990 the USS Iwo Jima suffered a catastrophic steam valve accident minutes after leaving port following repairs to its steam plant. In one of the single most deadly events of Operation Desert Storm, ten of the eleven crewmen present in the engine compartment would lose their lives.
Training / Education

FEA Beyond Basics Thermal Analysis

2019-12-16
Finite Element Analysis (FEA) is a powerful and well recognized tool used in the analysis of heat transfer problems. However, FEA can only analyze solid bodies and, by necessity thermal analysis with FEA is limited to conductive heat transfer. The other two types of heat transfer: convection and radiation must by approximated by boundary conditions. Modeling all three mechanisms of heat transfer without arbitrary assumption requires a combined use of FEA and Computational Fluid Dynamics (CFD).
Training / Education

Principled Negotiation

2019-12-12
This highly interactive workshop focuses training on negotiation strategy and skills. This is not the manipulative, win-lose negotiation approach frequently taught today, where the winner eventually spends time and effort protecting his negotiated advantage against erosion, while the loser continually exploits loopholes and shortcuts to recover lost ground. Traditional negotiation is a wary dance based on mistrust, the true cost of which is lost in quality and brain fatigue - usually for someone other than the negotiator - over the life of the agreement.
Training / Education

Weibull-Log Normal Analysis Workshop

2019-12-09
RMS (Reliability-Maintainability-Safety-Supportability) engineering is emerging as the newest discipline in product development due to new credible, accurate, quantitative methods. Weibull Analysis is foremost among these new tools. New and advanced Weibull techniques are a significant improvement over the original Weibull approach. This workshop, originally developed by Dr. Bob Abernethy, presents special methods developed for these data problems, such as Weibayes, with actual case studies in addition to the latest techniques in SuperSMITH® Weibull for risk forecasts with renewal and optimal component replacement.
Training / Education

Combustion and Emissions for Engineers

2019-12-09
Public awareness regarding pollutants and their adverse health effects has created an urgent need for engineers to better understand the combustion process as well as the pollutants formed as by-products of that process. To effectively contribute to emission control strategies and design and develop emission control systems and components, a good understanding of the physical and mathematical principles of the combustion process is necessary. This seminar will bring issues related to combustion and emissions "down to earth," relying less on mathematical terms and more on physical explanations and analogies.
Training / Education

Vibration Analysis Using Finite Element Analysis (FEA)

2019-12-02
Finite Element Analysis (FEA) has been used by engineers as a design tool in new product development since the early 1990's. Until recently, most FEA applications have been limited to static analysis due to the cost and complexity of advanced types of analyses. Progress in the commercial FEA software and in computing hardware has now made it practical to use advanced types as an everyday design tool of design engineers. In addition, competitive pressures and quality requirements demand a more in-depth understanding of product behavior under real life loading conditions.
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

Future hybrid Vehicles with advanced 48V electrified drive train technology to reduce Co2 emission

2019-11-21
2019-28-2487
Future hybrid vehicles with advanced 48V electrified drive train technology to reduce CO2 emission. Chandrakant Palve* Pushkaraj Tilak * * Mercedes-Benz Research & Development India Pvt. Ltd. Bangalore. India. Key Words: 48V, CO2, P3 Hybrid, Electrified powertrain, AMT, emission, shift comfort, motor Research and/or Engineering Questions/Objective Global automotive industry is putting effort in moving from conventional powertrain technology to hybrid & electric powertrains. This efforts plays a vital role to achieve cleaner environment, improved performance, reduced fossil-fuel dependency, low noise for meeting regulatory & customer requirements. Automotive industry is facing a challenge of meeting stringent CO2 emission targets of 95g & 175g per kilometer for passenger cars & light commercial vehicles respectively. 48V is an important stepping stone in this direction.
Technical Paper

Machine Learning considerations in the context of Automotive Functional Safety Requirements for Autonomous Vehicles

2019-11-21
2019-28-2519
We are currently in the age of developing Autonomous Vehicles (AV). Never before in history, the environment has been as conducive as today for these developments to come together to deliver a mass produced autonomous car for use by general public on the roads. Several enhancements in hardware, software, standards and even business models are paving the way for rapid development of AVs, bringing them closer to production reality. Safety is an indispensable consideration when it comes to transportation products, and ground vehicle development is no different. We have several established standards. When it comes to Autonomous Vehicle development, an important consideration is ISO 26262 for, Automotive Functional Safety. Going from generic frameworks such as Failure Mode and Effects Analyses (FMEA) and Hazard and operability study (HAZOP) to Functional Safety, Safety of Intended Functionality, and Automotive Safety Integrity Levels specific is a natural progression.
Technical Paper

AUTOMOTIVE VEHICLE TRANSMISSION SYSTEMS

2019-11-21
2019-28-2521
Abstract:At present there are a few types of transmission system available in automated industry, there might some variation in transmission system but the basic working and principle is still the same. Many big automotive manufacturers use different technologies in their transmission system but they still use the same basic principle in their transmission systems. This new technology which is brought by Koenigsegg has changed the way people think about transmission system. This new transmission system is known as Koenigsegg Direct Drive and is currently used by one automotive manufacturer and in one vehicle only, but it soon might change the way it is now.
Technical Paper

LIGHT WEIGHTING OF ADDITIVE MANUFACTURED PARTS FOR AUTOMOTIVE PRODUCTION APPLICATIONS THROUGH TOPOLOGY OPTIMIZATION TECHNIQUES

2019-11-21
2019-28-2544
Rapidly enhancing engineering techniques to manufacture components in quick turnaround time have gained importance in recent time. Manufacturing strategies like Additive Manufacturing (AM) are a key enabler for achieving them. Unlike traditional manufacturing techniques such as injection molding, casting etc., AM unites advanced materials, machines, and software which will be critical for Industry 4.0. Successful application of AM involves a specific combination and understanding of these three key elements. In this paper the AM approach used is Fused Deposition Modelling (FDM). Since material costs contribute to 60% of the overall FDM costs, it becomes a necessity to optimize the material consumption of the produced parts. This paper reports case studies of 3D printed parts used in an Automobile plant’s production aids, which utilize computational methods(CAE), topology optimization and FDM constrains (build directions) to manufacture the part in the most optimal way.
Technical Paper

A review on influence of different flushing methods on Material Removal Rate using EDM.

2019-11-21
2019-28-2543
Electrical release machining (EDM), is a material removal procedure whereby a coveted shape is acquired by utilizing electrical releases (sparks). Material is expelled from the work piece by a progression of quickly repeating current releases between cathode and anode, isolated by a dielectric fluid and subject to an electric voltage. At the point when the voltage between the two terminals is expanded, the power of the electric field in the volume between the anodes winds up more prominent than the quality of the dielectric (in any event in a few spots), which separates, enabling current to stream between the two cathodes. This wonder is the equivalent as the breakdown of a capacitor (condenser). Accordingly, material is expelled from the cathodes.
Technical Paper

Photo oxidation analysis method for automotive coating weathering performance evaluation

2019-11-21
2019-28-2555
RESEARCH OBJECTIVE Accelerated artificial weathering performance has been always observed as critical and most important factor for durability prediction of colour and resin for a coating system. Photo oxidation of resin is the phenomenon behind coating’s ageing. Though accelerated weathering tests protocols are widely used in industry, they are very costly and still very time consuming. One automotive grade accelerated testing can go as long as 8 months duration. METHODOLOGY (maximum 150 words) Photo oxidation value (POV) is proportionate to the degradation of the resin material used in coating. During the accelerated weathering POV is measured for the coating at stipulated interval during initial phase and trend is plotted for deterioration verses weathering test duration. POV can be analysed with the help of FTIR analysis to observe bond absorption energy and bond separation energy in the resin system. This trend can be extrapolated to predict the weathering performance of coating.
Technical Paper

Enhancement of safety features of steering wheel using experimentally validated finite element model

2019-11-21
2019-28-2556
Automotive safety is the primary concern in the current world. In order to develop safe and crashworthy vehicles, phenomena behind the energy absorption characteristics of every automotive component must be known. Steering wheel is one of the key players which could cause severe injuries to the driver if sufficient safety measures are not considered. This research focuses on the crash performance of commercial vehicle steering as per head form and body block test prescribed in ECE R12. Detailed FE (Finite Element) model of the steering wheel including armature, horn pad was developed using nonlinear material properties. The model was first validated using the test results. Comparisons between experimental results and finite element analysis results were conducted and correlated using load versus displacement profiles over the duration of impact. A good relationship between test and FE results was found which allows for investigation into the energy analysis of the steering components.
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

To establish the correlation in between Computer Aided Engineering & physical testing of automotive parts returnable case (Stacktainer).

2019-11-21
2019-28-2569
Automotive returnable cases (Stacktainers) are being used to transport the automotive parts through surface & seaways. No automotive manufacturer wants to spend money on woods, paper & cardboard again and again, it`s better to pay once for robust & reusable cases. these provide better protection to parts from its manufacturing to assembly line of vehicle. While transporting, any kind of crack or failure of returnable cases may lead to loss of money, human & time. To ensure the safety, these pallets have to be validated for vibrations coming from surface irregularities, sea waves & load due to stacking of cases one above other. The objective of this study is to establish a correlation in between the physical testing & simulation in Computer added Engineering (CAE) of automotive returnable case (Stacktainers). There are different types of tests considered to validate the returnable case, rough road evaluation, Multi-axial Vibration & strength evaluation.
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

Accelerated structural durability testing of backhoe loader by creation of duty cycle from field data to predict failure modes.

2019-11-21
2019-28-2583
These days backhoe loader have become main part of construction equipment vehicles. The main function of backhoe is to dig ditches to lay pipes and underground cable, set up foundations for buildings and create drainage systems. During these operations, many failures are observed in backhoe loader structure/parts. With the help of Accelerated structural durability testing, life of backhoe loader & its part can be estimated; through which we can understand different failure modes. The real time data was collected during various operations which includes pit digging, duck walk, ditch climbing, levelling, dozing, piling, truck loading etc. We have used software based approach to process the strain, displacement and other data collected during real time operation to create the duty cycle. The same duty cycle was simulated in the lab condition using servo hydraulic actuators.
Technical Paper

Improved update-over-the-air solution through standardization of ‘software/firmware package format and flash jobs’

2019-11-21
2019-28-2435
This paper investigates and proposes the possibilities of standardizing the software/firmware package format and flash jobs in order to provide the possibility of productizing the update-over-the-air solution regarding on-board vehicle components and make use of it in all OEMs with minimum configuration changes and customization. The update-over-the-air solution in the automotive sector is provided by various suppliers and needs to be customized to meet various OEMs requirements. Possible Variants of OEM requirements are: • Variant 1 o Customer Portal + Backend + vehicle on-board components solution from supplier • Variant 2 o Customer Portal + Backend solution from OEM o Vehicle on-board components from supplier • Variant 3 o Backend from OEM o Customer Portal + vehicle on-board components from supplier ODX, VBF, and many other formats from OEMs include software/firmware packages.
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