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Technical Paper

Piston and Guide-Pin Rattle Noise Mitigation in Electro-Mechanical Brake Caliper

The hydraulic brake caliper utilizes pressurized brake fluid to actuate one or multiple pistons generating friction between the brake pads and disc. Calipers are classified into floating and fixed type caliper. Floating caliper slides inboard/outboard direction to apply and release pressure on the outer pad. This type of caliper has rubber or spring components to maintain specific clearance for sliding characteristics. Therefore, caliper rattle noise could occur due to wheel vibrations when the vehicle is driven on unpaved roads or rough surfaces. Rattle noise is particularly pronounced in front calipers positioned closer to the driver and its susceptibility tends to increase with the weight of the caliper. The Electro-Mechanical Brake (EMB) caliper has gained substantial attention in automotive industry for its advantages features including reduced brake drag, optimized vehicle layout and precise brake control.
Technical Paper

Glow-discharge Optical Emission Spectroscopy Study of Cr(III) Sealing in Anodized Aluminium-Silicon Alloys for Brake Component

Calipers and pistons for high-end car braking systems are typically realized using anodized Aluminium-Silicon alloys. Indeed, Aluminium-Silicon alloys are light materials with optimal mechanical properties and, when anodized, excellent corrosion and wear resistances. To achieve these top-notch surface properties, the anodizing process is followed by a sealing post-treatment, which significantly improves the corrosion resistance and tunes the tribological properties (e.g., hardness and friction coefficient) of the anodized pieces. Sealing consists in the precipitation of insoluble hydroxides and functional compounds (e.g., corrosion inhibitors) inside the nano-pores of the anodic layer. Nevertheless, sealing might not penetrate through all the nano-porous structure of the anodic layer. Thus, in light of possible post-machining of sealed, anodized components, it appears fundamental to develop a tool to determine the depth penetration of sealing inside the anodic layer.
Technical Paper

A computational study of hydrogen direct injection using a pre-chamber in an opposed-piston engine

Opposed-piston two-stroke engines offer numerous advantages over conventional four-stroke engines, both in terms of fundamental principles and technical aspects. The reduced heat losses and large volume-to-surface area ratio inherently result in a high thermodynamic efficiency. Additionally, the mechanical design is simpler and requires fewer components compared to conventional four-stroke engines. When combining this engine concept with alternative fuels such as hydrogen and pre-chamber technology, a potential route for carbon-neutral powertrains is observed. To ensure safe engine operation using hydrogen as fuel, it is crucial to consider strict safety measures to prevent issues such as knock, pre-ignition, and backfiring. One potential solution to these challenges is the use of direct injection, which has the potential to improve engine efficiency and expand the range of load operation.
Technical Paper

Optimization of Hydroformed Exhaust Gas Recirculation Tube under Vibrational Load by Finite Element Analysis

This study emphasizes the importance of CAE approach in optimizing EGR tube under vibrational load. EGR tube is a weak link in the EGR system and chances of failure due to vibration and relative displacement of mating parts, i.e., overhang or improper support at exhaust manifold, intake manifold, or EGR system. Consideration of the mating parts for the EGR tube is very important to get the realistic resonance frequencies, otherwise it could have some different results in the CAE, which will deviate from the reality. So, it’s important to study the dynamic response on the EGR tube, which needs to be taken care during the design phase. This paper aims to optimize the EGR tube under vibrational load by using CAE techniques and the industry experience as a product expertise. some critical parameter such as damping is very important during the CAE, which can be generated by doing the rigorous testing and how it affects the stress and correspondingly FOS.