Search Results

A multi-chamber silencer is designed by a computational approach to suppress the turbocharger whoosh noise downstream of a compressor in an engine intake system. Due to the significant levels and the broadband nature of the source spanning over 1.5 – 3.5 kHz, three Helmholtz resonators are implemented in series. Each resonator consists of a chamber and a number of slots, which can be modeled as a cavity and neck, respectively. Their target resonance frequencies are tuned using Boundary Element Method to achieve an effective noise reduction over the entire frequency range of interest. The predicted transmission loss of the silencer is then compared with the experimental results from a prototype in an impedance tube setup. In view of the presence of rapid grazing flow, these silencers may be susceptible to whistle-noise generation. Hence, the prototype is also examined on a flow bench at varying flow rates to assess such flow-acoustic coupling.

Fluid filled bushings are commonly used in vehicle suspension and sub-frame systems due to their spectrally-varying and amplitude-dependent properties. Since the literature on this topic is sparse, a controlled laboratory prototype bushing is first designed, constructed, and instrumented. This device provides different internal combination of long and short flow passages and flow restriction elements. Experiments with sinusoidal displacement excitations are conducted on the prototype, and dynamic stiffness spectra along with fluid chamber pressure responses are measured. The frequency-dependent properties of several commonly seen hydraulic bushing designs are experimentally studied and compared under two excitation amplitudes. Further, new linear time-invariant models with one long and one short flow passages (in parallel or series) are proposed along with the limiting cases.

Shaped elastomeric joints such as engine mounts or suspension bushings undergo broadband, multi-axis loading; however, in practice, the elastomeric joint properties are often measured at stepped single frequencies (non-resonant test method). This article helps provide insight into multi-axis properties with new benchmark experiments that are designed to permit direct comparison between system resonant and non-resonant identification methods of the dynamic stiffness matrices of elastomeric joints, including multi-axis (non-diagonal) terms. The joints are constructed with combinations of inclined elastomeric cylinders to control non-diagonal terms in the stiffness matrix. The resonant experiment consists of an elastic metal beam end-supported by elastomeric joints coupling the in-plane transverse and longitudinal beam motion.

The acoustic and performance characteristics of an automotive centrifugal compressor are studied on a steady-flow turbocharger test bench, with the goal of advancing the current understanding of compression system instabilities at the low-flow range. Two different ducting configurations were utilized downstream of the compressor, one with a well-defined plenum (large volume) and the other with minimized (small) volume of compressed air. The present study measured time-resolved oscillations of in-duct and external pressure, along with rotational speed. An orifice flow meter was incorporated to obtain time-averaged mass flow rate. In addition, fast-response thermocouples captured temperature fluctuations in the compressor inlet and exit ducts along with a location near the inducer tips.

This paper describes the mechanical design of a Suspension Parameter Identification Device and Evaluation Rig (SPIDER) for wheeled military vehicles. This is a facility used to measure quasi-static suspension and steering system properties as well as tire vertical static stiffness. The machine operates by holding the vehicle body nominally fixed while hydraulic cylinders move an “axle frame” in bounce or roll under each axle being tested. The axle frame holds wheel pads (representing the ground plane) for each wheel. Specific design considerations are presented on the wheel pads and the measurement system used to measure wheel center motion. The constraints on the axle frames are in the form of a simple mechanism that allows roll and bounce motion while constraining all other motions. An overview of the design is presented along with typical results.

Low frequency torsional vibrations can be a significant source of objectionable vehicle vibrations and in-vehicle boom, especially with changes in engine operation required for improved fuel economy. These changes include lower torque converter lock-up speeds and cylinder deactivation. This paper has two objectives: 1) Examine the effect of increased torsional vibrations on vehicle NVH performance and ways to improve this performance early in the program using test and simulation techniques. The important design parameters affecting vehicle NVH performance will be identified, and the trade-offs required to produce an optimized design will be examined. Also, the relationship between torsional vibrations and mount excursions, will be examined. 2) Investigate the ability of simulation techniques to predict and improve torsional vibration NVH performance. Evaluate the accuracy of the analytical models by comparison to test results.

Previously we had found significant errors in the interfacial force results for a source-path-receiver system where only translational motions were measured. This paper examines the sources of those errors by using computational finite and boundary element models. The example case consists of a source structure (with few modes), a receiver (with many modes) and three steel rod paths. We first formulate indirect, yet exact, methods for estimating interfacial forces, by assuming that six-dimensional motions at any location are available though we focus on only the driving points. One- and three-dimensional sub-sets of the proposed formulation are compared with the six-dimensional theory in terms of interfacial force and partial sound pressure spectra.

The introduction of tumble into the combustion chamber is an effective method of enhancing turbulence intensity prior to ignition, thereby accelerating the burn rates, stabilizing the combustion, and extending the dilution limit. In this study, the primary intake runners are partially blocked to produce different levels of tumble motion in the cylinder during the air induction process. Experiments have been performed with a Chrysler 2.4L 4-valve I4 engine at maximum brake torque timing under two operating conditions: 2.41 bar brake mean effective pressure (BMEP) at 1600 rpm, and 0.78 bar BMEP at 1200 rpm. A method has been developed to quantify the tumble characteristics of blockages under steady flow conditions in a flow laboratory, by using the same cylinder head, intake manifold, and tumble blockages from the engine experiments.

In-cylinder charge motion is known to significantly increase turbulence intensity, accelerate combustion rate, and reduce cyclic variation. This, in turn, extends the tolerance to exhaust gas recirculation (EGR), while the introduction of EGR results in much lowered nitrogen oxide (NOx) emissions and reduced fuel consumption. The present study investigates the effect of charge motion in a spark ignition engine on fuel consumption, combustion, and engine-out emissions with stoichiometric and EGR-diluted mixtures under part-load operating conditions. Experiments have been performed with a Chrysler 2.4L 4-valve I4 engine under 2.41 bar brake mean effective pressure at 1600 rpm over a spark range around maximum brake torque timing. The primary intake runners are partially blocked to create different levels of tumble, swirl, and cross-tumble (swumble) motion in the cylinder before ignition.

Electronic throttle control is increasingly being considered as a viable alternative to conventional air management systems in modern spark-ignition engines. In such a scheme, driver throttle commands are interpreted by the powertrain control module together with many other inputs; rather than directly commanding throttle position, the driver is now simply requesting torque - a request that needs to be appropriately interpreted by the control module. Engine management under these conditions will require optimal control of the engine torque required by the various vehicle subsystems, ranging from HVAC, to electrical and hydraulic accessories, to the vehicle itself. In this context, the real-time estimation of engine and load torque can play a very important role, especially if this estimation can be performed using the same signals already available to the powertrain control module.

The mixture formation processes of methane and air in an optical access engine operating steadily at 200 RPM have been explored in order to study charge inhomogeneity in a natural gas powered spark ignition engine during transient engine cranking. Planar Laser Induced Fluorescence has been used to create fuel/air equivalence ratio maps as a function of injection timing for various image planes at intervals throughout the intake and compression strokes. The work has been done using a Honda VTEC-E engine head that features port injection, four valves per cylinder, a pentroof style combustion chamber for the generation of tumble motion, and one nearly deactivated intake valve to generate swirl motion at low engine speeds in order to enhance mixing.

Tailor welded steel blanks have long been applied in stamping of automotive parts such as door inner, b-pillar, rail, sill inner and liftgate inner, etc. However, there are few known tailor welded aluminum blanks in production. Traditional laser welding equipment simply does not have the capability to weld aluminum since aluminum has much higher reflectivity than steel. Welding quality is another issue since aluminum is highly susceptible to pin holes and undercut which leads to deterioration in formability. In addition, high amount of springback for aluminum panels can result in dimension control problem during assembly. A tailor-welded aluminum blank can help reducing dimension variability by reducing the need for assembly. In this paper, application of friction stir and plasma arc welded blanks on a liftgate inner will be discussed.

This study attempts to develop a correlation between an airflow motion number, combustion burn rates, and initial flame kernel development. To accomplish this task, several motion plates were evaluated on a flowbench in order to calculate a motion number that would represent the dynamic motion in the combustion chamber. Afterwards, the plates were tested on a spark ignited engine at several part throttle conditions while gathering cylinder pressure measurements. These cylinder pressure measurements would then yield the combustion burn rates for each plate. In addition to the combustion measurements, the flame kernel growth, velocity and direction of the flame kernel were measured using an AVL Visio-flame. Finally, the data was evaluated and an attempt to correlate the motion number of the plates to the different measurements for describing combustion was made.

A serpentine flow channel is one of the most common and practical channel layouts for a PEM fuel cell since it ensures the removal of water produced in a cell. While the reactant flows along the flow channel, it can also leak or cross to neighboring channels via the porous gas diffusion layer due to a high pressure gradient. Such a cross flow leads to effective water removal in a gas diffusion layer thus enlarging the active area for reaction although this cross flow has largely been ignored in previous studies. In this study, neutron radiography is applied to investigate the liquid water accumulation and its effect on the performance of a PEM fuel cell. Liquid water tends to accumulate in the gas diffusion layer adjacent to the flow channel area while the liquid water formed in the gas diffusion layer next to the channel land area seems to be effectively removed by the cross leakage flow between the adjacent flow channels.

In the development of several outside mirror designs for vehicles, a high frequency noise (whistling) phenomenon was experienced. First impression was that this might be due to another source on the vehicle (such as water management channels) or a cavity noise; however, upon further investigation the source was found to be the mirror housing. This “laminar whistle” is related to the separation of a laminar boundary layer near the trailing edges of the mirror housing. When there is a free stream impingement on the mirror housing, the boundary layer starts out as laminar, but as the boundary layer travels from the impingement point, distance, speed, and roughness combine to trigger the transition turbulent. However, when the transition is not complete, pressure fluctuations can cause rapidly changing flow patterns that sound like a whistle to the observer. Because the laminar boundary layer has very little energy, it does not allow the flow to stay attached on curved surfaces.

Deformation Resistance Welding (DRW) is a process that employs resistance heating to raise the temperature of the materials being welded to the appropriate forging range, followed by shear deformation which increases the contacting surface area of the materials being welded. Because DRW is a new process, it became desirable to establish variable selection strategies which can be integrated into a production procedure. A factorial design of experiment was used to examine the influence of force, number of pulses, and weld cycles (heating/cooling time ratio) on the DRW process. Welded samples were tensile tested to determine their strength. Once tensile testing was complete, the resulting strengths were observed and compared to corresponding percent heat and percent reduction in thickness. Tensile strengths ranged from 107 kN to 22.2 kN. A relationship between the maximum current and the weld variables was established.

As we continue to create ever-lighter road vehicles, the challenge of balancing weight reduction and structural performance also continues. One of the key parts this occurs on is the hood, where lighter materials (e.g. aluminum) have been used. However, the aerodynamic loads, such as hood lift, are essentially unchanged and are driven by the front fascia and front grille size and styling shape. This paper outlines a combination CFD/FEA prediction method for hood deflection performance at high speeds, by using the surface pressures as boundary conditions for a FEA linear static deflection analysis. Additionally, custom post-processing methods were developed to enhance flow analysis and understanding. This enabled the modification of existing test methods to further improve accuracy to real world conditions. The application of these analytical methods and their correlation with experimental results are discussed in this paper.

Advanced material modeling was conducted to describe the thermal-mechanical behavior of Boron Steel during hot stamping, a process in which blanks at 900 °C are formed and quenched between cold dies. Plastic deformation, thermal dilatation and phase transformation were incorporated in the constitutive model and a user-defined subroutine was developed to interface with LS-DYNA. Simulation was conducted on the hot stamping process of a door intrusion beam to gain insight into the physics of the process. Results showed significant influence of the thermal cycle on final product. It was also demonstrated that the program developed can be used as an early feasibility tool to determine baseline processing parameters and to detect potential defects in products without physical prototyping.

The US Automotive Materials Partnership (USAMP) and the US Department of Energy launched the Magnesium Powertrain Cast Components Project in 2001 to determine the feasibility and desirability of producing a magnesium-intensive engine; a V6 engine with a magnesium block, bedplate, oil pan, and front cover. In 2003 the Project reached mid-point and accomplished a successful Decision Gate Review for entry into the second half (Phase II) of the Project. Three tasks, comprising Phase I were completed: (1) evaluation of the most promising low-cost, creep-resistant magnesium alloys, (2) design of the engine components using the properties of the optimized alloys and creation of cost model to assess the cost/benefit of the magnesium-intensive engine, and (3) identification and prioritization of scientific research areas deemed by the project team to be critical for the use of magnesium in powertrain applications.

Rapid wear out of a disk brake due to phenomena commonly known as hot spots is one of various problems faced by brake manufacturers. Hot spots are localized high temperature areas generated on the frictional surface of a disk brake during braking. The non-uniform surface expansion caused by hot spots on the disk surface may cause pedal pulsation or known as thermal judder. This effect in the long run will shorten a brake's life. Numerical simulation of a disk brake requires the use of nonlinear contact mechanics approach. The simulation is computationally very expensive and difficult to perform. A computer simulation technique has been developed at the DaimlerChrysler Brake Core Group to investigate the hot spot phenomena since 1997. The technique was implemented on 3-D finite element models to simulate frictional contacts between the disk and its pads. Computer code ABAQUS is used for these analyses and computations are performed in Silicon Graphics, Origin 2000 machines.