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Moir� method is useful to measure the shape and the whole-field distributions of displacement and strain of structures. There are many kinds of moir� methods such as geometric moir� method, sampling moir� method, Fourier transform moir� method, moir� interferometry, shadow moir� method and moir� topography. Grating method analyzing directly deformation of a grating without any moir� fringe pattern is considered as an extended technique of moire method. Phase analysis of the moire fringe patterns and the grating patterns provides accurate measurements of shapes or displacement and strain distributions. Some applications of these moir� methods and grating methods to dynamic shape and strain distribution measurements of a rotating tire, sub-millimeter displacement measurements from long distance for landslide prediction, real-time shape measurements with micro-meter order accuracy, etc. are shown. Presenter Yoshiharu Morimoto, Moire Institute Inc.

Virtual testing is a method that simulates lab testing using multi-body dynamic analysis software. The main advantages of this approach include that the design can be evaluated before a prototype is available and virtual testing results can be easily validated by subsequent physical testing. The disadvantage is that accurate specimen models are sometimes hard to obtain since nonlinear components such as tires, bushings, dampers, and engine mounts are hard to model. Therefore, virtual testing accuracy varies significantly. The typical virtual rigs include tire and spindle coupled test rigs for full vehicle tests and multi-axis shaker tables for component tests. Hybrid simulation combines physical and virtual components, inputs and constraints to create a composite simulation system. Hybrid simulation enables the hard to model components to be tested in the lab.

This paper covers the mathematical modeling of governing equations for the coupled heat and mass transfer phenomena during adsorption and desorption. Also the main focus is given on the methodology for numerical simulation for solving these partial differential equations for carbon canister. A comprehensive literature review is presented to summarize the target requirements of allowed evaporative emission level of gasoline vapour in grams per day based on global standards like, EU6, EPA stage II enhanced, CARB LEVII, PZEV and SULEV. In order to meet these stringent emission norms, presence of carbon canister is mandatory. The simulation results are compared for the gasoline vehicle application at various climatic temperature conditions in India, in which the canister sizing vs allowable emission targets are summarized.

Vehicle collisions are a major concern in the modern automotive industry. To ensure the passenger safety, major focus has been given on energy absorption pattern on the crumple zone during collision, which lead to the implementation of new design of the crash box for low speed collision. The main aim of this research is optimization of the conical shaped structure based on its mean diameter, graded thickness and semi apical angle. Further, to decrease initial peak load of the conical crash box, corrugations are integrated on structure and optimized based on different parameters, such as number of corrugations, pattern of corrugation relative to both tubes and amplitude of corrugation. The concept of bi-tubular structure is proposed to improve both specific energy absorption and initial peak load during crash event. A finite element model is created to perform parametric study on corrugated conical tube based on axial load conditions at low velocity.

Design and simulation analysis of braking system for ATV is carried out with the assistance of Ansys and MATLAB. Heat generated increases the temperature of the disc brake at the rubbing surface resulting in thermal stresses in the components of the braking system. Static, structural, thermal, computational flow dynamics, vibrational & fatigue behavior of ventilated brake disc rotor, hub and upright are analyzed. Stainless Steel, SS-410 material configuration has been considered for disc brake rotor and results obtained are analyzed in terms of performance, longevity and efficiency. Braking efficiency and stopping distance curve are analyzed from their characteristics plot. Vibrational behavior, structural behavior, thermal behavior, performance efficiency, flow behavior of ventilated disc brake rotor can be easily depicted with respect to bump and droop during acceleration, high climb and maneuverability. Ventilated disc brake Rotor with outer diameter of 220 mm is used.

The objective of the research is to develop a lightweight yet stiff, 2 piston fixed brake caliper which can be used in formula student race car. To make a race car, its components need to be lighter. To stop a car with minimum stopping distance, it needs to have a sophisticated braking system with well-designed components. The designing of the caliper is carried out on the Altair Inspire software. The topology optimisation algorithm is used to minimise the weight of the caliper without compromising the stiffness. The structural analysis is also carried out on the Altair Inspire. The caliper is also tested for fatigue failure using Ansys.

Natural fibers are one of the major ways to improve environmental pollution. In this study experimental investigation and simulation of honeycomb filled with cotton fabric, wood dust and polyurethane were carried out. This study determines the potential use of cotton fabric, wood dust as good sound absorbers. Automotive industries are looking forward to materials that have good acoustic properties, lightweight, strong and economical. This study provides a better understanding of sound-absorbing material with other mechanical properties. With simulation and experimental results, validation of works provides a wider industrial application for the interior of automotive industries including marine, aviation, railway industry and many more.

Hybrid vehicle simulation methods combine physical test articles (vehicles, suspensions, etc.) with complementary virtual vehicle components and virtual road and driver inputs to simulate the actual vehicle operating environment. Using appropriate components, hybrid simulation offers the possibility to develop more accurate physical tests earlier, and at lower cost, than possible with conventional test methods. MTS Systems has developed Hybrid System Response Convergence (HSRC), a hybrid simulation method that can utilize existing durability test systems and detailed non-real-time virtual component models to create an accurate full-vehicle simulation test without requiring road load data acquisition. MTS Systems and Audi AG have recently completed a joint evaluation project for the HSRC hybrid simulation method using an MTS 329 road simulator at the Audi facility in Ingolstadt, Germany.

A numerical integration method is developed for solving more general singular perturbation problems. Firstly, we discuss the problems with mixed boundary conditions and a left end boundary layer. Secondly, we discuss the singular-singular perturbation problems. Finally, we discuss the problems with mixed boundary conditions and a right end layer. Numerical experiments with the method for several model linear and non-linear examples with left end boundary layer or right end boundary layer are presented and compared with exact solutions.

To meet the latest trends in Internal Combustion engines regarding efficiency, emissions and durability, an integrated approach to engine development is required. This paper describes about a Robust, Reliable and an integrated approach used in design and development of an engine for high power density which can be adopted for both Off-highway application as well as Genset application. The engine is developed to meet US - EPA Tier-III Emission Norms and MoEF (Genset Emission Norms for India formulated by Ministry of Environment and Forest) emission norms respectively. This paper discusses various technologies applied in developing this engine to achieve high power density, low exhaust emissions, and low noise and vibrations. This 4 valve per cylinder engine is created largely within a digital environment using the latest computer aided design (CAD) and computer aided engineering (CAE) techniques and simulation tools.

Product development processes generate large quantities of experimental and analytical data. The data evaluation process is usually quite lengthy since the data needs to be extracted from a large number of individual output files and arranged in suitable formats before they can be compared. When the data quantity grows extremely large, manual extraction cannot be done in a limited timeframe. This paper describes a set of tools developed by MTS engineers to automatically extract the desired information from a large number of files and perform data post-processing. The tools greatly improved both speed and accuracy of the evaluation process during the development of a sound quality-based end-of-line inspection system for seat tracks [1]. It allowed engineers to quickly gather a comprehensive understanding of the relative importance of individual design parameters and of their correlation to the subjective perception of the sound quality of the seat track.

Rapid development of advanced multi-axial load transducer systems now requires the use of computer-based analytical tools to assist the development engineer optimize the design to meet often-conflicting design targets. This paper presents a case study based on the development of a wheel force load transducer to meet a challenging set of performance goals including accuracy, repeatability, durability and insensitivity to the external environment. The paper also highlights the limitations of some of the current analytical tools when used for load transducer design, and how these limitations can be overcome by cost-effective combinations of analytical performance prediction and physical test confirmation.

A numerical method for generating a blockloading profile from a rainflow histogram is described. Unlike previous techniques, this method produces a blockloading profile which, when rainflow-counted, yields a rainflow histogram identical to the original. When implemented with modern data acquisition and signal-processing techniques, this generation method provides a means of developing blockloading test profiles which are correlated with actual service data. This key benefit elevates existing simple testing systems as useful and productive tools despite the emrgence of more complex testing systems.

ADAMS, SIMULINK, and ADAMS-SIMULINK co-simulation models of component test systems, Multi-Axis-Simulation-Table (MAST) systems, and spindle-coupled vehicle testing system (MTS 329) were created. In the ADAMS models, the mechanical parts, joints, and bushings were modeled. Hydraulic and control elements were absent. The SIMULINK models modeled control and hydraulic elements including actuator dynamics, servo valve dynamics, closed loop control, three-variable control, matrix control, and coordinate transformation. However, the specimen had to be simplified due to the limitation of SIMULINK software. The ADAMS-SIMULINK co-simulation models considered hydraulic and control components in the SIMULINK portion and mechanical components in ADAMS portion. The interaction between the ADAMS and SIMULINK portions was achieved using ADAMS/Control.

Environmental pollution is of great concern; hence the emission norms for the diesel engines are made more stringent. The purpose of this work is to develop a process to optimize the FIS parameters and select a most suitable FIS by simulation to meet the target emissions. During the combustion optimization exercise of diesel engine, different hardware combinations like injector, HPP etc are matched through testing to achieve the required performance and emissions. The process requires the real testing of the engine on engine dynamometer with various hardware combinations, which is expensive and time consuming. A simulation model of diesel FIS is constructed using ‘AVL Hydsim’. The model is validated by comparing the predicted and the experimental results. The validated model is used for further work. Critical parameters were listed based on the sensitivity analysis on the base model.

Suspension development is one of the key steps in a complete vehicle development program. Computer simulation and analysis tools such as Multi Body Dynamics (MBD) simulation are used to refine initial concept and suspension parameters. Later on when a physical prototype is available the suspension system can be experimentally optimized at vehicle level. In this paper a new methodology is proposed which integrates virtual and experimental tools so that design, development and validation of the suspension system is carried out in the early phase of the vehicle development cycle with actual suspension components and without the need of a vehicle prototype. With this new approach, the design of any critical suspension components such as dampers can be optimized at the vehicle level. The new approach consists of combining the actual physical components on loading rig in closed loop with vehicle dynamic model running in real time.

Anthropometric data of a country is vital database for automotive design and other design applications. It is also an important parameter in population studies. Most developed countries have invested resources over the years to develop such a database and this information is accessed by many OEMs and major Design Houses. However, an updated and comprehensive Anthropometry of Indian Population is largely unknown. In the past, a few institutions have done projects to bring out a picture of the Indian Anthropometry. However, keeping in view the rapid industrialization and increase of India-specific designs which require an access to latest Anthropometric database, the project “SIZE INDIA” has been initiated. For the first time in India, a state of the art 3D Whole body scanner technology has been used and thereby large volume of data has been generated in a very short span of time.

Exhaust noise is the major noise source for the automotive vehicle contributing to its interior as well as exterior noise. The Transmission Loss (TL), noise reduction, Insertion Loss (IL) and radiated noise are the major characteristics used to describe the performance of a muffler in an automotive exhaust system. Out of these characteristics, Insertion loss and exhaust radiated sound pressure levels plays a significant role in muffler design as it is a measure of true performance of muffler along with engine/vehicle and very much useful for the designers to compare different silencer configurations. In present work, the sound source is modelled by acoustic impedance and volume velocity of the engine. Since it is difficult to estimate the sound source impedance of the exhaust by measurements either with direct or indirect methods as both are prone to errors and difficult to implement, the empirical equations are used to define exhaust source, to have reasonable accuracy.

Seat system resonant frequencies play an important role in seat design and ride dynamics. So NVH performance of the seats should be assessed from the viewpoint of tactile, acoustic and visual sense. Tactile response is the response of sub-systems, which is induced when the human body contacts steering wheel, footrest or seats. Acoustic response is the behavior of the seat system at the cavity resonance frequencies and visual sense is what we perceive under actual operating conditions. The objective of the present work is to conduct and correlate experimental modal test with FE modal test to identify tactile vibrations. Then the identified main seat modes will be used to set the mode map (seat target) at the stage of full vehicle level. This work will present a practical approach in understanding varied methods and techniques for determining resonant characteristics and for subsequent refinement of FE model.

The Partially Pre-mixed Charge Compression Ignition (PCCI) combustion was experimentally and computationally investigated with retarded injection timing for mixture homogeneity and for lower emissions. PCCI combustion concept was experimentally evaluated with retarded injection timing close to TDC with high EGR levels up to 50%. The CFD analysis has carried out for mixture homogeneity with different injection pressures and timings. A 4-cylinder TCIC engine having 2valves/cylinder were selected for experiments and speed vs. torque mapped for LCV applications. A Visio technique has been used to study the in-cylinder combustion. After fine tuning of injection pressure, injection timing and EGR ratio over entire range of engine speeds and loads, a 13-mode ESC test cycle has been carried out for EURO-IV and EURO-V emissions. Experimental results shows that it is possible to meet EURO-IV emissions with combined PCCI-DI combustion concept with economical aftertreatment solution.