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Abstract The project of lean management is implemented in General Motors India Private Limited, Pune, India plant. The aim of the project is to improve manpower utilization by removing seven types of wastes using lean management system in kitting process. Lean manufacturing or management is the soul of Just-In-Time philosophy and is not new in Automobile manufacture sector where it born. Kitting area is analogs to the modern supermarket where required components, parts, consumables, subassemblies are kept in bins. These bins are placed in racks so that choosing right part at right time can be achieved easily. Video recording, in-person observation, feedback from online operators and other departments such as maintenance, control, supply chain etc. are taken. It is observed that the work content performed by current strength of operators can be performed by less number of operators. After executing this project, it was possible to reduce one operator and increase manpower utilization.

Abstract Exhaust manifolds are one of the most important components on the engine assembly, which is mounted on engine cylinder head. Exhaust manifolds connect exhaust ports of cylinders to the turbine for turbocharged diesel engine therefore they play a significant role in the performance of engine system. Exhaust manifolds are subjected to very harsh thermal loads; extreme heating under very high temperatures and cooling under low temperatures. Therefore designing a durable exhaust manifold is a challenging task. Computer aided engineering (CAE) is an effective tool to drive an exhaust manifold design at the early stage of engine development. Thus advanced CAE methodologies are required for the accurate prediction of temperature distribution. However, at the end of the development process, for the design verification purposes, various tests have to be carried out in engine dynamometer cells under severe operating conditions.

Abstract The mechanical efficiency of the current continuously variable transmission (CVT) suffers from high pump loss induced by a high-pressure system. A novel wedge mechanism is designed into the CVT clamp actuation system to generate the majority of clamp force mechanically. Therefore, the hydraulic system can operate at a low-pressure level most of the time, and the pump loss is greatly reduced to improve the CVT’s mechanical efficiency. Through dynamic analysis and design optimization, 90% of clamp force is contributed by the wedge mechanism and the rest of the 10% is generated by a conventional hydraulic system. The optimal design is validated through dynamic modeling using Siemens Virtual.Lab software by simulating the wedge clamp force generation, ratio change dynamics, and system response under tip-in conditions. After that, we built prototype components that target 70% of the clamp force contributed by the wedge mechanism and tested them on a transmission dynamometer.

Abstract Gasoline particulate filters (GPFs) are important aftertreatment components that enable gasoline direct injection (GDI) engines to meet European Union (EU) 6 and China 6 particulate number emissions regulations for nonvolatile particles greater than 23 nm in diameter. GPFs are rapidly becoming an integral part of the modern GDI aftertreatment system. The Active Exhaust Tuning (EXTUN) Valve is a butterfly valve placed in the tailpipe of an exhaust system that can be electronically positioned to control exhaust noise levels (decibels) under various vehicle operating conditions. This device is positioned downstream of the GPF, and variations in the tuning valve position can impact exhaust backpressures, making it difficult to monitor soot/ash accumulation or detect damage/removal of the GPF substrate. The purpose of this work is to present a unique example of subsystem control and diagnostic architecture for an exhaust system combining GPF and EXTUN.

Abstract This article presents a fault diagnosis approach for roller bearing by applying the autocorrelation approach to filtered vibration measured signal. An optimal Morlet wavelet filter is applied to eliminate the frequency associated with interferential vibrations; the raw measured signal is filtered with a band-pass filter based on a Morlet wavelet function whose parameters are optimized based on maximum Kurtosis. Autocorrelation enhancement is applied to the filtered signal to further reduce the residual in-band noise and highlight the periodic impulsive feature. The proposed technique is used to analyze the experimental measured signal of investigated vehicle gearbox. An artificial fault is introduced in vehicle gearbox bearing an orthogonal placed groove on the inner race with the initial width of 0.6 mm approximately. The faulted bearing is a roller bearing located on the gearbox input shaft - on the clutch side.

Abstract The innovations of vehicle connectivity have been increasing dramatically to enhance the safety and user experience of driving, while the rising numbers of interfaces to the external world also bring security threats to vehicles. Many security countermeasures have been proposed and discussed to protect the systems and services against attacks. To provide an overview of the current states in this research field, we conducted a systematic mapping study (SMS) on the topic area “security countermeasures of in-vehicle communication systems.” A total of 279 papers are identified based on the defined study identification strategy and criteria. We discussed four research questions (RQs) related to the security countermeasures, validation methods, publication patterns, and research trends and gaps based on the extracted and classified data. Finally, we evaluated the validity threats and the whole mapping process.

Abstract More than a decade ago, we proposed combined use of direct injection (DI) and jet ignition (JI) to produce high efficiency, high power-density, positive-ignition (PI), lean burn stratified, internal combustion engines (ICEs). Adopting this concept, the latest FIA F1 engines, which are electrically assisted, turbocharged, directly injected, jet ignited, gasoline engines and work lean stratified in a highly boosted environment, have delivered peak power fuel conversion efficiencies well above 46%, with specific power densities more than 340 kW/liter. The concept, further evolved, is here presented for unmanned aerial vehicle (UAV) applications. Results of simulations for a new DI JI ICE with rotary valve, being super-turbocharged and having gasoline or methanol as working fuel, show the opportunity to achieve even larger power densities, up to 430 kW/liter, while delivering a near-constant torque and, consequently, a nearly linear power curve over a wide range of speeds.

Abstract This study discusses the experimental investigation on WEDM of combustor material (i.e., nimonic 263). Experimentation has been executed by varying pulse-on time (Ton), pulse-off time (Toff), peak current (Ip), and spark gap voltage (Sv). Material removal rate (MRR), surface roughness (SR), and wire wear rate (WWR) are employed as process performance characteristics. Experiments are designed as per the box-Behnken design technique. Parametric optimization has also been performed using response surface methodology. Besides this, field-emission scanning electron microscope (FE-SEM) and an optical microscope are utilized to characterize WEDMed and worn-out wire surfaces. It is observed that both surfaces contain micro-cracks, craters, spherical droplets, and a lump of debris. Furthermore, the mechanism of recast layer formation has been critically evaluated to apprehend a better understanding of the technique. The key features of the experimental procedure are also highlighted.

Abstract While the design of nozzles for diatomic gases is very well established and covered by published works, the case of a diatomic gas dissociating to monatomic along a nozzle is a novel subject that needs a proper mathematical description. These novel studies are relevant to the definition of nozzles for gas-core Nuclear Thermal Rockets (NTR) that are receiving increased attention for the potential advantages they may deliver versus current generation rockets. The article thus reviews the design of the nozzles of gas-core NTR that use hydrogen as the propellant. Propellant temperatures are expected to reach 9,000-15,000 K. Above 1500 K, hydrogen begins to dissociate at low pressures, and around 3000 K dissociation also occurs at high pressures. At a given temperature, the lower the gas pressure the more molecules dissociate, and H2 → H + H. The properties of the gas are a function of the mass fractions of diatomic and monatomic hydrogen x H2 and x H = 1 − x H2.

Abstract Joining titanium (Ti) alloys with conventional processes is difficult due to their complex structural properties and ability of phase transformation. Concerning all the difficulties, diffusion bonding is considered as an appropriate process for joining Ti alloys. Ti6Al4V, which is an α+β alloy widely used for aero engine component manufacturing, is diffusion bonded in this investigation. The diffusion bonding process parameters such as bonding temperature, bonding pressure, and holding time were optimized to achieve desired bonding characteristics such as shear strength, bonding strength, bonding ratio, and thickness ratio using response surface methodology (RSM). Empirical relationships were developed for the prediction of the bond characteristics, and sensitivity analysis was performed to determine the increment and decrement tendency of the shear strength with respect to the bonding parameters.

Abstract Constant area section length downstream to the fuel injection point is a crucial dimension of scramjet duct geometry. It has a major contribution in creating the maximum effective pressure inside the combustor that is required for propulsion. The length is limited by the thermal choking phenomenon, which occurs when heat is added in a flow through constant area duct. As per theory, to avoid thermal choking the constant area section length depends upon the inlet conditions and the rate of heat addition. The complexity related to mixing and combustion process inside the supersonic stream makes it difficult to predict the rate of heat addition and in turn the length. Recent efforts of simulating the reacting flow inside scramjet combustors are encouraging and can be useful in this regard. The presented work attempts to use simulation results of scramjet combustion for predicting the constant area section length for a typical scramjet combustor.

Abstract Jet engine hot parts (e.g., jet nozzle) are a crucial source of aircraft’s infrared (IR) signature from the rearview, in 1.9-2.9 μm and 3-5 μm bands. The exhaust nozzle design used in a jet aircraft affects its performance and IR signature (which is also affected just by performance) from the engine layout. For supersonic aircraft (typically for M ∞ > 1.5), a converging-diverging (C-D) nozzle is preferred over a convergent nozzle for optimum performance. The diverging section of the C-D nozzle has a full range of visibility from the rearview; hence, it was not considered a prudent choice for low IR observability. This theoretical study compares the IR signature of the C-D nozzle with that of the convergent nozzle from the rearview in 1.9-2.9 μm and 3-5 μm bands for the same thrust.

Abstract Inline piston pumps are extensively used in aircraft hydraulic systems. They can be found in engine-driven large-sized hydraulic pumps and zonal electric motor-driven mid-small sized pumps. Inline piston pumps are positive displacement pumps with variable volumetric flow controls. Positive displacement pumps can provide a variable flow rate over a wide range of suction pressures. Aircraft fly at high altitudes, and therefore these pumps have to work in extreme conditions such as low atmospheric pressure, low temperature. At low inlet pressures, the pump is highly susceptible to cavitation, i.e., insufficient filling capacity. The pressure below which pump flow rate drops drastically is known as critical inlet pressure. Extensive research has been carried out to study cavitation in inline piston pumps.

Abstract Although ground grading is one of the most common tasks that hydraulic excavators perform in typical work sites, proper grading is not easy for less-skilled operators as it requires coordinated manipulation of multiple hydraulic cylinders. In order to help alleviate this difficulty, automated grading systems are considered as an effective alternative to manual operations of hydraulic excavators. In this article, a sliding mode controller design is presented for automated grading control of a hydraulic excavator. First, an excavator manipulator model is developed in Simulink by using SimMechanics and SimHydraulics toolboxes. Then, a sliding mode controller is designed to control the manipulator to trace a predefined trajectory for a grading task. For a comparison study, a PI controller is used to control the manipulator to perform a grading task following the same desired trajectory and the performance is compared with those obtained by the sliding mode controller.

Abstract This article serves as a proof-of-concept and feasibility analysis regarding a variable compression ratio (VCR) engine design utilizing an exhaust valve opening during the compression stroke to vary the compression ratio instead of the traditional method of changing the cylinder or piston geometry patented by Ford, Mercedes-Benz, Nissan, Peugeot, Gomecsys, et al. [1]. In this concept, an additional exhaust valve opening was used to reduce the virtual compression ratio of the engine, without geometric changes. A computational fluid dynamic model in ANSYS Forte was used to simulate a single-cylinder, cold flow, four-stroke, direct injection engine cycle. In this model, the engine was simulated at a compression ratio of 10:1. Then, the model was modified to a compression ratio of 17:1. Then, an additional valve opening at the end of the compression stroke was added to the 17:1 high compression model.

Abstract Vehicle cabin air quality depends on various parameters such as number of passengers, fan speed, and vehicle speed. In addition to controlling the temperature inside the vehicle, HVAC control system has evolved to improve cabin air quality as well. However, there is no standard test method to ensure reliable and repeatable comparison among different cars. The current study defined Cabin Air Quality Index (CAQI) and proposed a test method to determine CAQI. CAQIparticles showed dependence on the choice of metrics among particle number (PN), particle surface area (PS), and particle mass (PM). CAQIparticles is less than 1 while CAQICO2 is larger than 1. The proposed test method is promising but needs further improvement for smaller coefficient of variations (COVs).

Abstract This study investigates methods to precisely control a coolant pump in an internal combustion engine. The goal of this research is to minimize power consumption while still meeting optimal performance, reliability and durability requirements for an engine at all engine-operating conditions. This investigation achieves reduced fuel consumption, reduced emissions, and improved powertrain performance. Secondary impacts include cleaner air for the earth, reduced operating costs for the owner, and compliance with US regulatory requirements. The study utilizes mathematical modeling of the cooling system using heat transfer, pump laws, and boiling analysis to set limits to the cooling system and predict performance changes.

Abstract An accurate and rapid thermal model of an axle-brake system is crucial to the design process of reliable braking systems. Proper thermal management is necessary to avoid damaging effects, such as brake fade, thermal cracking, and lubricating oil degradation. In order to understand the thermal effects inside of a lubricated braking system, it is common to use Computational Fluid Dynamics (CFD) to calculate the heat generation and rejection. However, this is a difficult and time-consuming process, especially when trying to optimize a braking system. This article uses the results from several CFD runs to train a Stacked Ensemble Model (SEM), which allows the use of machine learning (ML) to predict the systems’ temperature based on several input design parameters. The robustness of the SEM was evaluated using uncertainty quantification.

Abstract Raceway Brinell damage is one major cause of wheel bearing (hub unit) noise during driving. Original Equipment Manufacturer (OEM) customers have asked continuously for its improvement to the wheel bearing supply base. Generally, raceway Brinelling in a wheel hub unit is a consequence of metallic yielding from high external loading in a severe environment usually involving a side impact to the wheel and tire. Thus, increasing the yielding strength of steel can lead to higher resistance to Brinell damage. Both the outer ring and hub based on Generation 3 (Gen. 3) wheel unit are typically manufactured using by AISI 1055 bearing quality steel (BQS); these components undergo controlled cooling to establish the core properties then case hardening via induction hardening (IH). This paper presents a modified grade of steel and its IH design that targets longer life and improves Brinell resistance developed by ILJIN AMRC (Advanced Materials Research Center).

Abstract In this study, an attempt is made to deduce the number of teeth in the driven sprocket of a Formula SAE (FSAE) car using Optimum Lap software based on track run simulation of the car, which comes out to be 51 teeth. The sprocket material was selected as Aluminum Alloy AL-7075 T6 because of its strength-to-weight ratio. In addition to it, the generative design strategy by Fusion-360 was utilized to automatically engender the slotted sprocket design on the ground of stress induced on it during operation. Furthermore, the design was verified virtually carrying out static structural and fatigue analysis under the worst-case scenario in CAE software. The overall weight reduction achieved was around 45%. Furthermore, the center-to-center distance between the sprockets and the number of chain links required were also calculated on the basis of space constraints and the wrap angle of the sprocket.