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Sources of unburned hydrocarbon (UHC) emissions are examined for a highly dilute (10% oxygen concentration), moderately boosted (1.5 bar), low load (3.0 bar IMEP) operating condition in a single-cylinder, light-duty, optically accessible diesel engine undergoing partially-premixed low-temperature combustion (LTC). The evolution of the in-cylinder spatial distribution of UHC is observed throughout the combustion event through measurement of liquid fuel distributions via elastic light scattering, vapor and liquid fuel distributions via laser-induced fluorescence, and velocity fields via particle image velocimetry (PIV). The measurements are complemented by and contrasted with the predictions of multi-dimensional simulations employing a realistic, though reduced, chemical mechanism to describe the combustion process.

The local equivalence ratio, Φ, was measured in fuel jets using laser-induced spontaneous Raman scattering in an optical heavy duty diesel engine. The measurements were performed at 1200 rpm and quarter load (6 bar IMEP). The objective was to study factors influencing soot formation, such as gas entrainment and lift-off position, and to find correlations with engine-out particulate matter (PM) levels. The effects of nozzle hole size, injection pressure, inlet oxygen concentration, and ambient density at TDC were studied. The position of the lift–off region was determined from OH chemiluminescence images of the flame. The liquid penetration length was measured with Mie scattering to ensure that the Raman measurement was performed in the gaseous part of the spray. The local Φ value was successfully measured inside a fuel jet. A surprisingly low correlation coefficient between engine-out PM and the local Φ in the reaction zone were observed.

Recent measurements in transient diesel jets have shown that fuel in the wake of the injection pulse mixes with ambient gases more rapidly than in a steady jet. This rapid mixing after the end of injection (EOI) can create fuel-lean regions near the fuel injector. These lean regions may not burn to completion for conditions where autoignition occurs after EOI, as is typical of low-temperature combustion (LTC) diesel engines. In this study, transient diesel jets are analyzed using a simple one-dimensional jet model. The model predicts that after EOI, a region of increased entrainment, termed the “entrainment wave,” travels downstream at twice the initial jet propagation rate. The entrainment wave increases mixing by up to a factor of three. This entrainment wave is not specific to LTC jets, but rather it is important for both conventional diesel combustion and LTC conditions.

A dual piston Variable Compression Ratio (VCR) engine has been newly developed. This compact VCR system uses the inertia force and hydraulic pressure accompanying the reciprocating motion of the piston to raise and lower the outer piston and switches the compression ratio in two stages. For the torque characteristic enhancement and the knocking prevention when the compression ratio is being switched, it is necessary to carry out engine controls based on accurate compression ratio judgment. In order to accurately judge compression ratio switching timing, a control system employing the Hidden Markov Model (HMM) was used to analyze vibration generated during the compression ratio switching. Also, in order to realize smooth torque characteristics, an ignition timing control system that separately controls each cylinder and simultaneously performs knocking control was constructed.

The objective of this research is a detailed investigation of multiple injections in a highly-dilute diesel low temperature combustion (LTC) regime. This research concentrates on understanding the performance and emissions benefits of multiple injections via experiments and simulations in a 0.48L signal cylinder light-duty engine operating at 2000 r/min and 5.5 bar IMEP. Controlled experiments in the single-cylinder engine are then combined with three computational tools, namely heat release analysis of measured cylinder pressure, a phenomenological spray model using in-cylinder thermodynamics [1], and KIVA-3V Chemkin CFD computations recently tested at LTC conditions [2]. This study examines the effects of fuel split distribution, injection event timing, rail pressure, and boost pressure which are each explored within a defined operation range in LTC.

The objective of this research is a detailed investigation of unburned hydrocarbon (UHC) in a highly-dilute diesel low temperature combustion (LTC) regime. This research concentrates on understanding the mechanisms that control the formation of UHC via experiments and simulations in a 0.48L signal-cylinder light duty engine operating at 2000 r/min and 5.5 bar IMEP with multiple injections. A multi-gas FTIR along with other gas and smoke emissions instruments are used to measure exhaust UHC species and other emissions. Controlled experiments in the single-cylinder engine are then combined with three computational tools, namely heat release analysis of measured cylinder pressure, analysis of spray trajectory with a phenomenological spray model using in-cylinder thermodynamics [1], and KIVA-3V Chemkin CFD computations recently tested at LTC conditions [2].

In this work, a quasi-dimensional, multi-zone combustion model is analytically presented, for the prediction of performance and nitric oxide (NO) emissions of a homogeneous charge spark ignition (SI) engine, fueled with biogas-H2 blends of variable composition. The combustion model is incorporated into a closed cycle simulation code, which is also fully described. Combustion is modeled on the basis of turbulent entrainment theory and flame stretch concepts. In this context, the entrainment speed, by which unburned gas enters the flame region, is simulated by the turbulent burning velocity of a flamelet model. A flame stretch submodel is also included, in order to assess the flame response on the combined effects of curvature, turbulent strain and nonunity Lewis number mixture. As far as the burned gas is concerned, this is treated using a multi-zone thermodynamic formulation, to account for the spatial distribution of temperature and NO concentration inside the burned volume.

The startability of SI engines, especially of DISI engines, is the greatest challenge when using ethanol blended fuels. The development of a suitable injection strategy is therefore the main engineering target when developing an ethanol engine with direct injection. In order to limit the test efforts of such a program, a vaporization model has been created that provides the quantity of vaporized fuel depending on pressure and on start and end, respectively number and split relation of injections. This model takes account of the most relevant fuel properties such as density, surface tension and viscosity. It also considers the interaction of the spray with cylinder liner, cylinder head and piston. A comparison with test results shows the current status and the need for action of this simulation model.

A multi-zone, direct-injection (DI) diesel combustion model, the so-called RK-model, has been developed and implemented in a full cycle simulation of a turbocharged engine. The combustion model takes into account: transient evolution of fuel sprays, interaction of sprays with swirl and walls, evolution of near-wall flow formed after spray-wall impingement depending on impingement angle and local swirl velocity, interaction of Near-Wall Flows (NWF) formed by adjacent sprays, influence of temperatures of gas and walls in the zones on evaporation rate. In the model the fuel spray is split into a number of specific zones with different evaporation conditions including zone on the cylinder liner and on the cylinder head. The piston bowl is assumed to be a body of revolution with arbitrary shape. The combustion model supports central and non-central injector as well as the side injection system. NOx formation model uses Detail Kinetic Mechanism (199 reactions with 33 species).

Two different types of mesh used for diesel combustion with the KIVA-4 code are compared. One is a well established conventional KIVA-3 type polar mesh. The other is a non-polar mesh with uniform size throughout the piston bowl so as to reduce the number of cells and to improve the quality of the cell shapes around the cylinder axis which can contain many fuel droplets that affect prediction accuracy and the computational time. This mesh is specialized for the KIVA-4 code which employs an unstructured mesh. To prevent dramatic changes in spray penetration caused by the difference in cell size between the two types of mesh, a recently developed spray model which reduces mesh dependency of the droplet behavior has been implemented. For the ignition and combustion models, the Shell model and characteristic time combustion (CTC) model are employed.

The International Space Station (ISS) requires advanced life support to continue its mission as a permanently-manned space laboratory and to reduce logistic resupply requirements as the Space Shuttle retires from service. Additionally, as humans reach to explore the moon and Mars, advanced vehicles and extraterrestrial bases will rely on life support systems that feature in-situ resource utilization to minimize launch weight and enhance mission capability. An obvious goal is the development of advanced systems that meet the requirements of both mission scenarios to reduce development costs by deploying common modules. A high pressure oxygen generating assembly (HPOGA) utilizing a high differential pressure (HDP) water electrolysis cell stack can provide a recharge capability for the high pressure oxygen storage tanks on-board the ISS independently of the Space Shuttle as well as offer a pathway for advanced life support equipment for future manned space exploration missions.

The Soft X-Ray Telescope (SXT) is an instrument on the International X-Ray Observatory (IXO). Its flight mirror assembly (FMA) has a single mirror configuration that includes a 3.3 m diameter and 0.93 m tall mirror assembly. It consists of 24 outer modules, 24 middle modules and 12 inner modules. Each module includes more than 200 mirror segments. There are a total of nearly 14, 000 mirror segments. The operating temperature requirement of the SXT FMA is 20°C. The spatial temperature gradient requirement between the FMA modules is ±1°C or smaller. The spatial temperature gradient requirement within a module is ±0.5°C. This paper presents thermal design considerations to meet these stringent thermal requirements.

{ Natural fibre-reinforced composite has the potential to replace current materials used for automotive industrial applications. Oilseed flax fibre could be used as reinforcement for composites because it is readily available, environmentally friendly and possesses good mechanical properties. In this research, oilseed flax fibre reinforced-LLDPE and -HDPE biocomposites were developed through extrusion and injection molding. The flax fibre was chemically treated to improve the bond between the fibre and polymer. Flax fibre was mixed with low linear density polyethylene (LLDPE) and high density polyethylene (HDPE) with fibre content varying from 10 to 30% by mass and processed by extrusion and injection molding to biocomposites. The mechanical properties, surface properties, and thermal properties of biocomposites were measured to analyze the treatment and processing effect and to compare the effect of different flax fibre concentrations on the biocomposites.

The cost of human natural language translation of Service Information, Assembly Instructions, Training Materials, Operator Manuals and other similar documents is a major expense for manufacturers. One translation avoidance method involves replacing most of a document’s text with still and/or animated graphics. While the graphics with minimum text concept has savings potential, clarity of communication must be maintained for widespread application of this technique. The necessary clarity should be achieved if standards are established for the symbols and graphical conventions used. This paper provides an example of a repair procedure documented using the graphics with minimum text paradigm, describes many of the anticipated standards and provides an update on the progress towards achieving a standard development project.

Many engineers have been working to reduce brake noise in many ways for a long time. So far, a progress has been made in preventing and predicting brake noise. Nevertheless, there are some discrepancies of brake noise generation propensity between testing for the prototype and the production. As known in general, the reason for this unpredicted brake noise occurrence in production is partly due to the variation of the resonant frequency, material and the other unpredictable or unmanageable variations of the components in a brake system. In this paper, effects of chemical components and casting process of gray iron brake disc on its resonant frequency variation have been studied. Especially this paper is focused on the variation in material aspects and manufacturing parameters during disc casting in usual production condition. And their effects are investigated by the variation of out-of-plane modal resonant frequency.

The effectiveness of serial link articulated robots in aerospace drilling and fastening is largely limited by positional accuracy. Unguided production robotic systems are practically limited to +/-0.5mm, whereas the majority of aerospace applications call for tolerances in the +/-0.25mm range. The precision with which holes are placed on an aircraft structure is affected by two main criteria; the volumetric accuracy of the positioner, and how the system is affected when an external load is applied. Production use and testing of off-the-shelf robots has highlighted the major contributor to reduced stiffness and accuracy as being error ahead of the joint position feedback such as backlash and belt stretch. These factors affect the omni-directional repeatability, thus limiting accuracy, and also contribute to deflection of the tool point when process forces are applied.

The presented paper introduces the new software complex aimed at simulation of the riveting process as applied to aircraft parts. The software complex implements the novel mathematical model based on minimization of the potential energy. The paper gives the detailed description of the mathematical model and particularizes the main features of the software. The physical and numerical tests aimed at validation of the software are also described in the paper.

Manual drilling and Lockbolt installation in carbon fiber structures is a labor intensive process. To reduce man hour requirements while concurrently improving throughput and process quality levels BROETJE-Automation developed a gantry positioning system with high performance multi-function end effectors for this application. This paper presents a unique solution featuring fully automated drilling and Lockbolt installation (inclusive of automated collar installation) for the vertical tail plane (vertical stabilizer) of large commercial aircraft. A flexible and reconfigurable assembly jig facilitates high access of the end effectors and increases the equipment efficiency. The described system fulfils the demand for affordable yet flexible precision manufacturing with the capacity to handle different aircraft model panels within the work envelope.

If Design of Experiments (DOE) is so good why isn't it used more? Despite its power DOE has some demanding conditions. You don't have to be a statistician to conduct a successful DOE, however. In Aerospace we are very often faced with the design, improvement or correction of a product, process or service. The most serious task is determination of the most relevant variables or factors that affect the final result or performance of the process or product in question. Once these factors have been established, we then need to determine an optimal combination of settings or levels for each factor. There is also the complicating possibility of interaction among the factors also. Design of Experiments (DOE) is an established statistical technique used on its own or in conjunction with a Six Sigma project to determine the strongest individual factors and if there is interaction among the factors.

Once qualified, manufacturing processes for safety critical components in aero engines are “frozen”, that is no changes are permitted to be made without a time consuming and costly re-validation. Moreover, the material selection for components in modern aero engines, due to high mechanical and thermal loads in operation, is limited to a small range of super alloys. These difficult to machine titanium and nickel based alloys are on the one hand a significant expense factor themselves, and cause considerable costs due to high tool wear on the other hand. Thus, it is intended to carry out time and resource saving experiments and - ideally - being able to transfer available results to similar processes. Using smart experimental design deploying relationships of physical measures involved, the effort of testing can be reduced. This paper explains the method's mathematical background, how the selection of the regarded parameters is carried out as well as the reduction of system inputs.