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Flexible polyurethane foam is the main cushioning element used in car seats. Optimization of an occupied seat's static and dynamic behavior requires models of foam that are accurate over a wide range of excitation and pre-compression conditions. In this research, a method is described to estimate the parameters of a global model of the foam behavior from data gathered in a series of impulse tests at different settling points. The estimated model is capable of describing the responses gathered from all the impulse tests using a unique set of parameters. The global model structure includes a nonlinear elastic term and a hereditary viscoelastic term. The model can be used to predict the settling point for each mass used and, by expanding the model about that settling point, local linear models of the response to impulsive excitation can be derived. From this analysis the relationship between the local linear model parameters and the global model parameters is defined.

Numerical simulations are performed to investigate noise generated by flow in automotive HVAC ducts. A hybrid computational method for analyzing flow noise is applied: Large Eddy Simulation (LES) for predicting flow fields and Multi-domain boundary element method for predicting acoustic propagation. LES gives time-resolved solutions of flow velocity and pressure fields. By applying the acoustic analogy theory, the unsteady flow parameters are translated into sound source in evaluating the acoustic propagation. The computational result shows the noise caused by the HVAC ducts is strong. The noise is of broadband with a peak value at 370Hz. A major contribution of the noise generation is from the center ducts. Two design modifications of the center ducts are explored to regulate the flow structures with the ducts for reducing noise generation. Test results demonstrate the effectiveness of the modifications.

A unique concept for a multi-body test rig enabling the simulation of longitudinal, steering and vertical dynamics was developed at the Institute for Mechatronic Systems (IMS) at TU Darmstadt. A prototype of this IMS test rig is currently being built. In conjunction with the IMS test rig, the Vehicle Terrain Performance Laboratory (VTPL) at Virginia Tech further developed a full car, seven degree of freedom (7 DOF) simulation model capable of accurately reproducing measured displacement, pitch, and roll of the vehicle body due to terrain excitation. The results of the 7 DOF car model were used as the reference input to the multi-body IMS test rig model. The goal of the IMS/VTPL joint effort was to determine whether or not a controller for the IMS test rig vertical actuator could accurately reproduce wheel displacements due to different measured terrain constraints.

Extensive experimental data was collected for CBN surface grinding of M2 tool steel to determine the relative grinding performance of three different vitrified CBN abrasive grit sizes. The results define the relationships between the grinding forces, the material removal rate and the resulting specific energy, while providing an evaluation of the ground surface characteristics including surface finish, microstructure, hardness and residual stress. The interaction of grinding process inputs including wheel grit size, workpiece velocity and depth of cut are considered, and a series of single factor tests and a 23 factorial test are conducted. The grinding forces increase linearly with increasing material removal rate for the range of parameters tested.

The identification of the propulsion noise of turbofan engines plays an important role in the design of low-noise aircraft. The noise generation mechanisms of a typical turbofan engine are very complicated and it is not practical, if not impossible, to identify these noise sources efficiently and accurately using numerical or experimental techniques alone. In addition, a major practical concern for the measurement of acoustic pressure inside the duct of a turbofan is the placement of microphones and their supporting frames which will change the flow conditions under normal operational conditions. The measurement of acoustic pressures on the surface of the duct using surface-mounted microphones eliminates this undesirable effect. In this paper, a generalized acoustical holography (GAH) method that is capable of estimating aeroacoustic sources using surface sound pressure is developed.

Energy budgets for future Controlled Ecological Life-Support Systems (CELSS) must balance not only with respect to primary productivity (i.e., photosynthesis) vs. utilization steps (human maintenance plus preparative and recycling processes), but also with respect to necessary and desired nonlife-support activities of crews (e.g., exploration, research). Present objectives of the NSCORT program at Purdue University include identification of critical paths for biomass conversion to desired forms with energetics and rate-constant properties that are compatible with life-support sustainability within a CELSS. Physico-chemical recycling systems working in conjunction with bioregenerative ones likely will be required to keep time constants of critical processes within reasonable limits.

This research provides a capacitance based method for monitoring the integrity of tires and other polymeric products during manufacturing and throughout the useful product life. Tire and wheel failures and tire degradation were the reported cause for approximately 19320 vehicle crashes over a two and a half year period according to the U.S. Department of Transportation National Highway Traffic Safety Administration's 2008 survey. Tires are complex composite structures composed of layers of formulated cross-linked rubber, textiles, and steel reinforcement layers. Tire production requires precise manufacturing through chemical and mechanical methods to achieve secure attachment of all layers. Tires are subjected to a variety of harsh environments, experience heavy loads, intense wear, heat, and in many cases lack of maintenance. These conditions make tires extremely susceptible to damage.

Two structure-borne and two airborne paths were measured on 99 “identical” Isuzu RODEOs and 57 “identical” Isuzu pickup trucks. Significant effort was made to control measurement variability but not environmental (climate) variations. A record was kept of the tests of a reference vehicle over the variation of environmental factors. The frequency response functions (FRFs) of the reference vehicle varied by approximately 2-4 dB over the frequency range 0-500 Hz for the structure-borne paths and over 0-1000 Hz for the airborne paths due to measurement and environmental variations. The FRFs of the fleet varied by as much as 5-10 dB over the same frequency range. In this paper, the vehicle tests are described. The reference and the fleet data are shown in raw form. Reduced data and implications of the results are also discussed.

The mobility modeling technique is applied to the structure-borne noise path through a vehicle suspension. The model is developed using measured FRF data taken on the isolated components of the suspension and body structure of a midsize sedan. Several important modeling issues of suspensions are resolved. It was determined that multiple degrees of freedom are required to model the coupling at joints between the suspension and body structure. The investigation also demonstrated that bushings should not be included in the measurements used to develop these models and should be added later using simplified bushing parameters. The importance of transfer mobility information between the various suspension attachments was also investigated. The agreement between the mobility model predictions and the measured FRF data for the overall system is better than similar data published in the literature to date.

The Nexus vehicle was designed and built for Transport Canada at the University of Saskatchewan to demonstrate that a safety compliant single passenger commuter vehicle could attain extremely low fuel consumption rates at modest highway speeds. Experimentally determined steady state fuel consumption rates of the Nexus prototype ranged from 1.6 L/100 km at 61 km/hr up to 2.8 L/100 km at 121 km/hr. Fuel consumption rates for the Society of Automotive Engineers (SAE) driving cycle tests were 4.5 L/100 km for the SAE Urban cycle and 2.0 L/100 km for the SAE Interstate 55 cycle. The efficiency of the power train was determined using a laboratory dynamometer, enabling the road test results to be compared to the results from an energy and performance simulation program. Predicted fuel economy was in good agreement with that determined experimentally. Widespread use of single passenger commuter vehicles would substantially reduce current transportation energy consumption.

A finite element model (FEM) of elastic noise control materials like polyurethane foams is presented in this paper, and its implementation in two-dimensional form as a computer program is discussed. So that realistic noise control treatments could be studied, methods for coupling the foam FEM with conventional acoustical and structural finite elements are also described. The validity of the foam FEM is demonstrated by computing the sound absorption and transmission characteristics of simple coupled air/foam/panel systems and by comparing the results with existing experimental and analytical results for such arrangements. The FEM has been used to show that the constraint of a foam layer at its edge stiffens the foam acoustically. In addition, it has been found that the constraint of the ends of the facing panels in a foam-lined double panel system increases the sound transmission loss significantly at low frequencies.

The object of the work reported here was to relate the acoustic intensity level measured near the contact patch of a driven tire on a passenger vehicle with the passby noise levels measured at a sideline microphone during coast and cruise conditions. Based on those measurements it was then possible to estimate the tire noise contribution to the passby level measured when the vehicle under test was accelerating. As part of this testing program, data was collected using five vehicles at fourteen passby sites in the United States: in excess of 800 data sets were obtained.

The Porous Ceramic Tube - Nutrient Delivery System (PCT-NDS) offers means to control water availability to plants under non-standard gravities. It is hypothesized that control can be obtained by applying suction pressure within the ceramic tubes. The research objectives include verifying the presented control equation for the PCT-NDS under micro-(less than 1 g) and hyper- (greater than 1 g) gravities. Experiments were conducted on a KC-135 subjecting the system to near-zero to 2 g's and to sustained hyper-gravities upto 10 g's using a centrifuge. Results indicated that the water availability can be controlled through applied suction pressure.

This paper describes sensors and systems developed, or under development, by researchers at Purdue University including: an automated soil nutrient mapping system; a real-time acoustic soil texture sensor; an improved, real-time soil organic matter (SOM) sensor; a real-time soil compaction sensor; and an animal manure application monitoring and control system. Issues to consider for sensor use and development, criteria for evaluating the potential for successful sensor implementation, and likely future sensors for site-specific crop management (SSCM) are also discussed.

It is generally agreed that adequate resolution is required to reproduce the structure of spray and gas jets in numerical computations. It has not been clarified what this resolution should be although it would appear reasonable to assume that it should be such that the physical scales of the problem are resolved. In the case of a jet, this implies that near the orifice, the jet diameter has to be resolved since this is the appropriate length scale. It is shown in this work that if such a resolution is not used in computing transient jets, the structure of the jet is not reproduced with adequate accuracy. In fact, unexpected, erroneous and misleading dependence on ambient turbulence length and time scales will be predicted when the initial ambient turbulence diffusivity is small relative to the jet diffusivity. When the ambient turbulence diffusivity is of the same order as the jet diffusivity or greater, entrainment rates are significantly underpredicted.

Modern diesel engines typically utilize pulse-turbocharging where an increase in exhaust gas transport efficiency is achieved at the expense of creating a highly unsteady flow through the turbine which may have a detrimental effect on turbine performance. As the turbocharger plays a major role in the performance and emissions of the engine system, the characterization of on-engine turbocharger aerodynamics is critical. Thus, this paper is directed at the investigation of the turbocharger turbine volute inlet flowfield on an in-line, six cylinder, diesel engine. Specifically, Particle Image Velocimetry (PIV), a quantitative non-intrusive whole flowfield measurement technique, is used to perform a detailed study of the on-engine pulsating flowfield at the volute inlet of the twin-entry turbocharger turbine.

A feedback controller bas been developed using robust control techniques to control the sound radiated from turbulent flow driven plates. The control design methodology uses frequency domain loop shaping techniques. System uncertainty, sound pressure level reductions, and actuator constraints are included in the design process. For the wind noise problem, weighting factors have been included to distinguish between the importance of modes that radiate sound and those that do not radiate. The wind noise controller has been implemented in the quiet wind tunnel facility at the Ray W. Herrick Laboratories at Purdue University. A multiple-input, multiple-output controller using accelerometer feedback and shaker control was able to achieve control up to 1000 Hz. Sound pressure level reductions of as much as 15 dB were achieved at the frequencies of the plates modes. Overall reductions over the 100-1000 Hz band were approximately 5 dB.

A new laboratory method has been developed to evaluate the acoustical properties of expandable and other automotive sealants. These materials are used to reduce wind, road, and powertrain noise transmission into passenger compartments. In the new method, ASTM E 1050 absorption measurement equipment is used along with a new sample holder, a downstream microphone holder (providing two additional microphone locations) and an anechoic termination. These additions permit measurement of normal incidence transmission loss as well as absorption. It is intended to encourage adoption of this method as a standard way of quantifying the acoustical performance of sealants and sealing composites in automotive noise control applications.

An analytical model based on “vortex sound” theory was investigated for predicting the frequency, the relative magnitude, the onset, and the offset of self-sustained interior pressure fluctuations inside a vehicle with an open sunroof. The “buffeting” phenomenon was found to be caused by the flow-excited resonance of the cavity. The model was applied to investigate the optimal sunroof length and width for a mid-size sedan. The input parameters are the cavity volume, the orifice dimensions, the flow velocity, and one coefficient characterizing vortex diffusion. The analytical predictions were compared with experimental results obtained for a system which geometry approximated the one-fifth scale model of a typical vehicle passenger compartment with a rectangular, open sunroof. Predicted and observed frequencies and relative interior pressure levels were in good agreement around the “critical” velocity, at which the cavity response is near resonance.

Structural sound transmission through primary bulb (PB) sealing systems was investigated. A two-degrees-of-freedom analytical model was developed to predict the sound transmission characteristics of a PB seal assembly. Detailed sound transmission measurements were made for two different random excitations: acoustic and aerodynamic. A reverberation room method was first used, whereby a seal sample installed within a test fixture was excited by a diffuse sound field. A quiet flow facility was then used to create aerodynamic pressure fluctuations which acted as the excitation. The space-averaged input pressure within the pseudo door gap cavity and the sound pressure transmitted on the quiescent side of the seal were obtained in each case for different cavity dimensions, seal compression, and seal designs. The sound transmission predictions obtained from the lumped element model were found to be in reasonable agreement with measured values.