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Introduction to Commercial and Off-Road Vehicle Cooling Airflow Systems

2024-09-12
Vehicle functional requirements, emission regulations, and thermal limits all have a direct impact on the design of a powertrain cooling airflow system. Given the expected increase in emission-related heat rejection, suppliers and vehicle manufacturers must work together as partners in the design, selection, and packaging of cooling system components. The goal of this two-day course is to introduce engineers and managers to the basic principles of cooling airflow systems for commercial and off-road vehicles.
Technical Paper

Thermal Analysis of Prismatic Core Sandwich Structural Panel for Hypersonic Application

2024-06-01
2024-26-0422
Hypersonic flight vehicles have potential applications in strategic defence, space missions, and future civilian high-speed transportation systems. However, structural integration has significant challenges due to extreme aero-thermo-mechanical coupled effects. Scramjet-powered air-breathing hypersonic vehicles experience extreme heat loads induced by combustion, shock waves and viscous heat dissipation. An active cooling thermal protection system for scramjet applications has the highest potential for thermal load management, especially for long-duration flights, considering the weight penalty associated with the heavier passive thermal insulation structures. We consider the case of active cooling of scramjet engine structural walls with endothermic hydrocarbon fuel. We have developed a semi-analytical one-dimensional heat transfer model considering a prismatic core single cooling channel segment as a representative volume element (RVE) to analyse larger scale problems.
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

1D Modeling Approach for Prediction of Heat Transfer in Aftertreatment System and Sensors Module

2024-04-09
2024-01-2739
The study of temperature distribution and heat transfer over non-uniform geometry is of great importance to engineers because of universal occurrence in many engineering applications such as diesel engine, boilers, heaters, radiators, dosers, etc. Performance of engine and its components (mechanical and electronic) is highly depending upon efficient thermal management. An accurate heat transfer analysis is necessary in automotive application and power plant. This study presents one dimensional model for prediction of conjugate heat transfer in Aftertreatment system and Sensors Module (Nox Sensor, PM Sensor, EGTS etc..) for diesel engine. Three-dimensional conductive, convective and radiative thermal analysis is computationally expensive as underhood models are of complex shape in nature and total turnaround time for product development project is also significantly high.
Technical Paper

Investigation of Propagation of Viruses and Risk of Infection in Automobile Cabins

2024-04-09
2024-01-2579
The author has developed UV based photocatalytic air purification system (Mathur, 2021, 2023) that can eliminate all pathogens from the cabin air including COVID-19. In this study, the focus is to determine the risk of infection due to pathogens/germs in the cabin of an automobile. Author has determined the risk of infection by using Wells-Riley model and the conducted CFD analysis to determine propagation of virus in cabin.: 1. Cabin Volume & Number of Occupants (Wells-Riley Model in OSA mode): (i) Cabin volume from: Small Sedan, Large Sedan and a SUV; with 4 occupants (males & females); Number of infector 1; Air flowrate (m3/min); (ii) A 15-seater minibus - with 10 occupants(males); Number of infectors 1 & 2; Air flowrate (m3/min) 2.
Technical Paper

Study and Analysis on 3-Dimensional Simulation of The Transient Flow Process of Engine Electronic Control Throttle

2024-04-09
2024-01-2417
Based on the basic structure and operation function of engine throttle, according to the actual structure of a throttle, a 3-dimensional simulation of the transient airflow during the rotation of the throttle from the closed position to the fully open position is realized by using CFD together with the moving mesh technology and the user-defined program. The influence of the throttle movement on the airflow process is studied. The velocity field, pressure field, and flow noise field are analyzed at different angles of throttle rotation. The numerical simulation results show that at the beginning period of the throttle rotation, the vortex appears in the flow field behind the throttle, and the drop of the air pressure between the front and back of the throttle is sharp.
Technical Paper

Impact of Injection Valve Condition on Data-driven Prediction of Key Combustion Parameters Based on an Intelligent Diesel Fuel Injector for Large Engine Applications

2024-04-09
2024-01-2836
The advent of digitalization opens up new avenues for advances in large internal combustion engine technology. Key engine components are becoming "intelligent" through advanced instrumentation and data analytics. By generating value-added data, they provide deeper insight into processes related to the components. In addition, these data form the basis for novel condition monitoring, predictive maintenance and controls approaches. Changes to the intelligent component’s operational characteristics due to wear or faults pose a particular challenge for developers of such approaches for later series application. A previous study has already demonstrated that an intelligent common rail diesel fuel injection valve for large engine applications in combination with machine learning allows reliable prediction of key combustion parameters such as maximum cylinder pressure, combustion phasing and indicated mean effective pressure.
Technical Paper

Fully Retractable Easy Access Spare Wheel Carrier Mechanism for Commercial Vehicles.

2024-04-09
2024-01-2225
In today's market practise & standard mechanism being provided from OEM, tyre changing mechanism is a tedious job, took long time & much higher efforts in Indian trucking industry harsh environments. Heavy commercial vehicles are fitted with spare wheel carrier that has a rope mechanism to load and unload the spare wheel. The mounting of this system is generally on side of frame/ chassis or within the limits of side member. The invention reduces effort and time required to remove spare tyre. The invention brings the spare wheel to a vertical position where it is easy to remove its bolts and remove it from its mountings. Also, this innovative mechanism is well supported by 3 way actuation system (Air Actuated system, Electric motor driven system or Hydraulic cylinder actuated mechanisms), which reduced human efforts and gives benefit to drivers in terms of comfort.
Technical Paper

New Solution for Material Damage Characterization of CFRP Laminate with Filament Winding Structure Using a Hexagonal-Shaped Mandrel

2024-04-09
2024-01-2884
CFRP manufactured by a filament winding process has a unique laminate structure. So far, a material damage model applied to design CFRP component manufactured by FW process was identified using a material property of a CFRP flat plate laminated unidirectionally with predetermined angle. However, from these material properties the effect of filament winding structure cannot be evaluated nor can be introduced to the material model. In this study, a newly hexagonal shaped mandrel with flat parts on the cylinder and dome region of the high-pressure vessel was devised and a procedure of a flat plate laminate with filament winding structure was proposed. Filament winding structure on a flat surface by this method matched well with that of the curved surface simulated by ComposCad. In addition, the FEM simulation result of meso-scale laminate coupon model using material damage model obtained from material property of coupon matched well with the experimental result. 
Technical Paper

Virtual Chip Test and Washer Simulation for Machining Chip Cleanliness Management Using Particle-Based CFD

2024-04-09
2024-01-2730
Metal cutting/machining is a widely used manufacturing process for producing high-precision parts at a low cost and with high throughput. In the automotive industry, common engine components such as cylinder heads or cylinder blocks are all manufactured using such processes. Despite its cost benefits, manufacturers often face the problem of machining chips and cutting oil residue remaining on the finished surface after machining operations, and these wastes can be very difficult to clean. While part cleaning/washing equipment suppliers often claim that their washers have superior performance, determining the washing efficiency is challenging without knowledge of chip clogging locations and water jet flow patterns. In this paper, a virtual engineering methodology using particle-based CFD is developed to manage the metal chip cleanliness issue resulting from engine component machining operations. This methodology comprises two simulation methods.
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