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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

ENHANCE STRENGTH, ACCURACY AND PRECISION OF THE 3D PRINTED ASSEMBLY AID GAUGES

2019-11-21
2019-28-2568
ENHANCE STRENGTH, ACCURACY AND PRECISION OF THE 3D PRINTED ASSEMBLY AID GAUGES Ramesh Kavalur1, Raghavendra Rao 1 1 Body in White, Manufacturing Engineering, General Motors Technical Centre India Pvt. Ltd, India, Keywords - Additive manufacturing, assembly aid gauges, 3D printer. Research Objective - Automotive manufacturing impressively implementing 3D printed jigs and fixtures. Traditional manufacturing of metal assembly aid gauges have limitations such as lead time and causes dent and rough marks on the outer panel of the body. On the other hand, 3D printed jigs and fixtures, demands more time (depends on complexity), have low level of precision and they offer lower strength. It is observed that this occurs because of the inefficient design and manufacturing without understanding the functionality and capability of the 3D printer.
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

Development of a Simulation Model for Computing Stable Configurations for Off–Road Vehicle

2019-10-11
2019-28-0126
Off-highway vehicles operate under complex duty cycles which consist of handling varying terrain conditions under dynamic loads. A challenge for the equipment operator is to maintain stability of the vehicle during various field operations. The operator must make judgement calls on whether terrain and loading conditions are suitable for vehicle stability. In view of the increasing emphasis being placed on operator comfort and vehicle autonomy, a methodology to predict the degree of vehicle stability in varying terrains and dynamic loads will be an aid in designing safer vehicles. In this paper, we describe a mathematical model capable of predicting the longitudinal overturning behavior of off-highway vehicle. A mathematical kinematic and dynamic model of the system is developed using Newton-Euler approach. This yields a system of non-linear equations which are solved iteratively using commercial software to predict stability for varying terrains and dynamic loads.
Technical Paper

Optimization of Multi Stage Direct Injection-PSCCI Engines

2019-09-09
2019-24-0029
The more stringent regulations on emissions induce the automotive companies to develop new solutions for engine design, including the use of advanced combustion strategies and the employment of mixture of fuels with different thermochemical properties. The HCCI combustion coupled with the partial direct injection of the charge, in order to control the performance and emissions and to extend the operating range, is a promising technique. In this work an in-house developed multi-dimensional CFD software package was used to analyse the behaviour of a multi stage direct injection (DI)-partially stratified charge compression ignition engine fueled with PRF. A skeletal kinetic mechanism for PRF oxidation was employed, with a dynamic adaptive chemistry technique to reduce the computational cost and a model based on the partially stirred reactor model to couple turbulence and chemistry.
Technical Paper

CFD Modeling of Compact Heat Exchangers for I.C. Engine Oil Cooling

2019-09-09
2019-24-0179
In the last years, the increase of the specific power of the modern engines has required a parallel improvement of the performances of the cooling system. In this context, also the control of the oil temperature has become an important issue, leading to the introduction of dedicated cooling circuits (air-cooled or liquid-cooled). Among the two, the liquid-cooled solution results in a more compact installation in which the oil-to-liquid heat exchanger is directly mounted on the engine block and integrated in the engine cooling system. It is clear that, in a liquid-cooled solution, the design of the heat exchanger represents an issue of extreme concern, which requires a compromise between different objectives: high compactness, low pressure drop, high heat-transfer efficiency. In this work, a computational framework for the CFD simulation of compact oil-to-liquid heat exchangers, including offset-strip fins as heat transfer enhancer (turbolator), has been developed.
Technical Paper

Experimental and Computational Investigation of Particle Filtration Mechanisms in Partially Damaged DPFs

2019-09-09
2019-24-0149
Since September 2018 new threshold limits are applied in the European Union for On-Board Diagnosis (OBD) of particulate mass (PM) leakage. OBD systems are obliged to detect exhaust system malfunctions that account to 2.5 times higher PM emissions compared to the type approval limit. Often the malfunction is located in the Diesel Particulate Filter (DPF), which might suffer substrate crack or melting during harsh regeneration events. In addition, DPF systems have become a tampering target, usually to avoid the high cost of replacement or lower fuel consumption. In this context, understanding the filtration mechanisms in partially damaged DPFs can facilitate the assessment of their environmental effects and the design of exhaust systems with efficient OBD functionality. Two common types of DPF failure are included in this study, namely partial rear plug removal and internal crack development due to uncontrolled regeneration with excessive soot loading.
Standard

Guidelines for Aerodynamic Assessment of Medium and Heavy Commercial Ground Vehicles Using Computational Fluid Dynamics

2019-08-01
WIP
J2966
This document outlines general requirements for the use of CFD methods for aerodynamic simulation of medium and heavy commercial ground vehicles weighing more than 10 000lbs. The document provides guidance for aerodynamic simulation with CFD methods to support current vehicle characterization, vehicle development, vehicle concept development and vehicle component development. The guidelines presented in the document are related to Navier-Stokes and Lattice-Boltzmann based solvers. This document is only valid for the classes of CFD methods and applications mentioned. Other classes of methods and applications may or may not be appropriate to simulate the aerodynamics of medium and heavy commercial ground vehicle weighing more than 10 000lbs.
Standard

Design and Testing of Antiskid Brake Control Systems for Total Aircraft Compatibility

2019-07-22
CURRENT
ARP1070E
This document outlines the development process and makes recommendations for total antiskid/aircraft systems compatibility. These recommendations encompass all aircraft systems that may affect antiskid brake control and performance. It focuses on recommended practices specific to antiskid and its integration with the aircraft, as opposed to more generic practices recommended for all aircraft systems and components. It defers to the documents listed in Section 2 for generic aerospace best practices and requirements. The documents listed below are the major drivers in antiskid/aircraft integration: 1. ARP4754 2. ARP4761 3. RTCA DO-178 4. RTCA DO-254 5. RTCA DO-160 6. ARP490 7. ARP1383 8. ARP1598 In addition, it covers design and operational goals, general theory, and functions, which should be considered by the aircraft brake system engineer to attain the most effective skid control performance, as well as methods of determining and evaluating antiskid system performance.
Journal Article

Impact of Dynamic Characteristics of Wheel-Rail Coupling on Rail Corrugation

2019-07-02
Abstract To gain a better understanding of the characteristics of corrugation, including the development and propagation of corrugation, and impact of vehicle and track dynamics, a computational model was established, taking into account the nonlinearity of vehicle-track coupling. The model assumes a fixed train speed of 300 km/h and accounts for vertical interaction force components and rail wear effect. Site measurements were used to validate the numerical model. Computational results show that (1) Wheel polygonalisation corresponding to excitation frequency of 545-572 Hz was mainly attributed to track irregularity and uneven stiffness of under-rail supports, which in turn leads to vibration modes of the bogie and axle system in the frequency range of 500-600 Hz, aggregating wheel wear. (2) The peak response frequency of rail of the non-ballasted track coincides with the excitation frequency of wheel-rail coupling; the resonance results in larger wear amplitude of the rail.
Standard

Rotor Blade Electrothermal Ice Protection Design Considerations

2019-06-14
WIP
AIR1667B
This SAE Aerospace Information Report (AIR) identifies and summarizes the various factors that should be considered during design, development, certification, or testing of helicopter rotor blade ice protection systems. Although various concepts of ice protection are mentioned in this report, the text is limited generally to those factors associated with design and substantiation of cyclic electrothermal ice protection systems as applicable to the protection of helicopter rotor blades. Other systems are described briefly in Appendix A. Applications consider main rotor blades, conventional tail rotor blades, and other types of antitorque devices. The information contained in this report is also limited to the identification of factors that should be considered and why the factor is important. Specific design, analysis and test methodologies are not included. For additional information refer to the references listed in 2.1.
Technical Paper

Focus on Challenges in SLD Regime: Reemitted Droplet Modelling

2019-06-10
2019-01-2001
A lot of studies have been carried out over the last decades on SLD ice accretion challenges. Many of them referred to SLD physics modelling such as break-up, splashing, bouncing, etc… and relied on numerous physics experiments. Different models have been developed in Europe and North-America and have been implemented in several numerical tools, widely in 2D but more and more in 3D. As these tools are intended to be used increasingly among the community, deficiencies have to be deeper investigated. This paper provides some highlights on specific needs linked to SLD impingement and ice accretion, especially for 3D high fidelity computations. Regarding the results, deficiencies on the numerical side and on experimental needs will be highlighted in order to feed brainstorming for ongoing SLD projects such as in European Union H2020 ICE-GENESIS.
Technical Paper

Experimental and Computer Model Results for a Carbon Nanotubes Electrothermal De-Icing System

2019-06-10
2019-01-2005
Results from a three-dimensional computer model of a Carbon Nanotubes (CNT) based de-icing system are compared to experimental data obtained at COLLINS-Ohio Icing Wind Tunnel (IWT). The experiments were performed using a prototype of a CNT based de-icing system installed in a section of a business jet horizontal tail. The 3D numerical analysis tools used in the comparisons are AIPAC [1] and CFD++. The former was derived from HASPAC, an anti-icing computer model developed at Wichita State University in 2010 [3, 9, 10]. AIPAC uses the finite volumes method for the solution of the icing problem on an airfoil leading edge (or other 3D surfaces) and relies on any CFD solver to obtain the external flow properties used as boundary conditions. AIPAC is capable of predicting 3D multi-step ice shapes under rime, glaze and mixed regimes, and can also deal with the complex dynamics of cyclic ice accretion, melting, and shedding present in the realm of aircraft electrothermal de-icing systems.
Technical Paper

Computational Simulation of an Electrically Heated Ice Protection System for Composite Leading Edges of Aircraft

2019-06-10
2019-01-2041
The performance of an electrically heated aircraft ice protection system for a composite leading edge was evaluated. The composite leading edge of the model is equipped with a Ni alloy resistance heater. A state-of-the-art icing code, FENSAP-ICE, was used for the analysis of the electrothermal de-icing system. Computational results, including detailed information of conjugate heat transfer, were validated with experimental data. The computational model was then applied to the composite leading edge wing section at various metrological conditions selected from FAR Part 25 Appendix C.
Technical Paper

Vibroacoustic Model’s Likelihood Computation Based on a Statistical Reduction of Random FRF Matrices

2019-06-05
2019-01-1593
Improvement of vibroacoustic models prediction capabilities requires an adapted indicator to compare experimental measurements with the results of the computational model. When dealing with highly uncertain objects such as series production cars, a probabilistic approach is mandatory to be able to describe the dispersion of experimental results. Moreover, a probabilistic non-parametric model also account for modeling uncertainties and simplifications that are part of any engineering process. The proposed approach deals with Frequency Response Functions since FRFs are the common way to handle vibroacoustic models. When considering multiple input and output points configuration, FRFs are frequency dependent complex matrices. Since the probabilistic modeling is available in current vibroacoustic software, collections of random realizations of the FRF matrix can be computed from the existing FE model.
Technical Paper

Drivetrain Noise Source Identification and Active Noise Control of a Heavy Off-Road Vehicle

2019-06-05
2019-01-1566
Drivetrain noise from heavy off-road vehicles mainly includes engine noise, drive shaft noise, wheel-side gear noise, tire pattern noise etc. They are the main noise sources for such vehicles as they greatly influence the ride comfort of the passengers inside. This paper solved the drivetrain noise problems of a heavy off-road vehicle using the method of active noise control (ANC). Firstly, the vehicle is benchmarked and the noise problems are analyzed, while the noise sources are identified by analyzing the transmission principles of the drivetrain. Secondly, ANC strategies are made for the vehicle based on the noise profiles under various operating conditions. Thirdly, the multiple parameters for ANC are computed from simulations modeling the vehicle in idle, constant speed and acceleration respectively. Lastly, road tests are conducted using the multiple parameters from the simulations and a noise reduction of 2-4 dB can be achieved in the whole vehicle.
Technical Paper

Effectiveness of Power-Law Profile Indentations on Structure-Borne Noise

2019-06-05
2019-01-1496
A study on the effect of indenting power-law shaped profiles on the flexible structures for investigating the vibration damping characteristics using computational simulation method is discussed. The simulation results are checked to see the impact of such features on the damping behavior of flexible structures responsible for radiating noise when excited with fluctuating loads. Though the conventional remedies for solving Noise and vibration issues generally involves tuning of structure stiffness or damping treatment this paper gives an insight on the idea of manipulation of elastic waves within the flexible structure itself to minimize the cross-reflections of the mechanical waves. The simulation studies mentioned in this paper not only hovers over the effectiveness of such features but also will be helpful for the engineers to look through a different perspective while solving N&V issues using simulation tools.
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