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The current ability of the Virtual Aerodynamic/ Aeroacoustic Wind Tunnel to predict interior vehicle sound pressure levels is demonstrated using an automobile model which has variable windshield angles. This prediction method uses time-averaged flow solutions from a lattice gas CFD code coupled with wave number-frequency spectra for the various flow regimes to calculate the side window vibration from which the sound pressure level spectrum at the driver's ear is determined. These predictions are compared to experimental wind tunnel data. The results demonstrate the ability of this methodology to correctly predict wind noise spectral trends as well as the overall loudness at the driver's ear. A more sophisticated simulation method employing the same lattice gas code is investigated for prediction of the time-accurate flow field necessary to compute the actual side glass pressure spectra.

Shadowgraph/schlieren imaging techniques have often been used for flow visualization of reacting and non-reacting systems. In this paper we show that high-speed shadowgraph visualization in a high-pressure chamber can also be used to identify cool-flame and high-temperature combustion regions of diesel sprays, thereby providing insight into the time sequence of diesel ignition and combustion. When coupled to simultaneous high-speed Mie-scatter imaging, chemiluminescence imaging, pressure measurement, and spatially-integrated jet luminosity measurements by photodiode, the shadowgraph visualization provides further information about spray penetration after vaporization, spatial location of ignition and high-temperature combustion, and inactive combustion regions where problematic unburned hydrocarbons exist. Examples of the joint application of high-speed diagnostics include transient non-reacting and reacting injections, as well as multiple injections.

A test cell was developed for evaluating a 6-speed automatic transmission. The target vehicle had an internal combustion 5.4L gasoline V8 engine. An electric dynamometer was used to closely simulate the engine characteristics. This included generating mean torque from the ECU engine map, with a transient capability of 10,000 rpm/second. Engine inertia was simulated with a transient capability of 20,000 rpm/second, and torque pulsation was simulated individually for each piston, with a transient capability of 50,000 rpm/second. Quantitative results are presented for the correlation between the engine driven and the dynamometer driven transmission performance over more than 60 test cycles. Concerns about using the virtual engine in validation testing are discussed, and related to the high frequency transient performance required from the electric dynamometer. Qualitative differences between the fueled engine and electric driven testing are presented.

A series of tests have been performed on a production vehicle to determine the characteristics of the external turbulent flow field in wind tunnel and road conditions. Empirical formulas are developed to use the measured data as source levels for a Statistical Energy Analysis (SEA) model of the vehicle structural and acoustical responses. Exterior turbulent flow and acoustical subsystems are used to receive power from the source excitations. This allows for both the magnitudes and wavelengths of the exterior excitations to be taken into account - a necessary condition for consistently accurate results. Comparisons of measured and calculated interior sound levels show good correlation.

Sound package engineering has always been an art developed through experience and much subjective road testing. Because the problem is complex, it is essential to have a logical procedure to achieve the most efficient sound package. The quiet car concept is proposed as a solution. Additionally, a plea is made for relevant automobile-oriented material test procedures to be recognized industry-wide.

A time cost effective methodology has been developed for the prediction of the A-pillar vortex formation and the side and the rear window flow separation for the purpose of wind noise assessment. This methodology combines a simplified Computational Fluid Dynamics (CFD) model and wind tunnel test data by CFD post-processing tools. The solution of the simplified CFD model provides background data for the whole flow field, but it lacks detail features such as mirror, sealing groove and glass in-set, which are locally important but difficult to mesh and require a very fine mesh resolution. The wind tunnel test data was taken in the specific areas of interest at the A-pillar, side window, rear window area, and roof from a real automotive. Then the wind tunnel test data was superposed upon the simplified CFD model to correct the numerical error due to geometry simplification and insufficient mesh resolution.

This paper explores the extent to which standard dilution tunnel measurements of motor vehicle exhaust particulate matter modify particle number and size. Steady state size distributions made directly at the tailpipe, using an ejector pump, are compared to dilution tunnel measurements for three configurations of transfer hose used to transport exhaust from the vehicle tailpipe to the dilution tunnel. For gasoline vehicles run at a steady 50 - 70 mph, ejector pump and dilution tunnel measurements give consistent results of particle size and number when using an uninsulated stainless steel transfer hose. Both methods show particles in the 10 - 100 nm range at tailpipe concentrations of the order of 104 particles/cm3.

Due to several indeterminate factors, the assessment of the durability performance of a vehicle body is traditionally accomplished using test methods. An analytical fatigue life prediction method (four-step durability process) that relies mainly on numerical techniques is described in this paper. The four steps comprising this process include the identification of high stress regions, recognizing the critical load types, determining the critical road events and calculation of fatigue life. In addition to utilizing a general purpose finite element analysis software for the application of the Inertia Relief technique and a previously developed fatigue analysis program, two customized programs have been developed to streamline the process into an integrated, user-friendly tool. The process is demonstrated using a full body, finite element model.

A generalized re-normalization group (RNG) turbulence model based on the local "dimensionality" of the flow field is proposed. In this modeling approach the model coefficients C₁, C₂, and C₃ are all constructed as functions of flow strain rate. In order to further validate the proposed turbulence model, the generalized RNG closure model was applied to model the backward facing step flow (a classic test case for turbulence models). The results indicated that the modeling of C₂ in the generalized RNG closure model is reasonable, and furthermore, the predictions of the generalized RNG model were in better agreement with experimental data than the standard RNG turbulence model. As a second step, the performance of the generalized RNG closure was investigated for a complex engine flow.

During frontal and rear end type collisions, very large forces will be imparted to the passenger compartment by the collapse of either front or rear structures. NCAP tests conducted by NHTSA involve, among other things, a door openability test after barrier impact. This means that the plastic/irreversible deformations of door openings should be kept to a minimum. Thus, the structural members constituting the door opening must operate during frontal and rear impact near the elastic limit of the material. Increasing the size of a structural member, provided the packaging considerations permit it, may prove to be counter productive, since it may lead to premature local buckling and possible collapse of the member. With the current trend towards lighter vehicles, recourse to heavier gages is also counterproductive and therefore a determination of an optimum compartment structure may require a number of design iterations. In this article, FEA is used to simulate front side door behavior.

The feasibility of using experimentally determined flow fields at intake valve closing, IVC, as initial conditions for computing the in-cylinder flow dynamics during the compression stroke is demonstrated by means of a computer simulation of the overall approach. A commercial CFD code, STAR-CD, was used for this purpose. The study involved two steps. First, in order to establish a basis for comparison, the in-cylinder flow field throughout the intake and compression strokes, from intake valve opening, IVO, to top dead center, TDC, was computed for a simple engine geometry. Second, experimental initial conditions were simulated by randomly selecting and perturbing a set of velocity vectors from the computed flow field at IVC.

To cope with regulatory standards, minimizing tailpipe emissions with rapid catalyst light-off during cold-start is critical. This requires catalyst-heating operation with increased exhaust enthalpy, typically by using late post injections for retarded combustion and, therefore, increased exhaust temperature. However, retardability of post injection(s) is constrained by acceptable pollutant emissions such as unburned hydrocarbon (UHC). This study provides further insight into the mechanisms that control the formation of UHC under catalyst-heating operation in a medium-duty diesel engine, and based on the understanding, develops combustion strategies to simultaneously improve exhaust enthalpy and reduce harmful emissions. Experiments were performed with a full boiling-range diesel fuel (cetane number of 45) using an optimized five-injections strategy (2 pilots, 1 main, and 2 posts) as baseline condition.

For better understanding of soot formation and oxidation processes applicable to diesel engines, the size, morphology, and nanostructure of soot particles directly sampled in a diesel spray flame generated in a constant-volume combustion chamber have been investigated using Transmission Electron Microscopy (TEM). For this soot diagnostics, the effects of the sampling processes, TEM observation methodology and image processing methods on the uncertainty in the results have not been extensively discussed, mainly due to the complexity of the analysis.

This paper compares the emissions performance of four ultra thin wall ceramic substrates with standard wall thickness product on a chassis dynamometer for two different substrate volumes. This comparison helps establish performance trends and provides useful information for selection of substrates in designing catalytic converter systems. This experimental study tests and compares four ultra thin wall products (400/4, 600/3, 600/4, and 900/2) with a standard wall product (400/6.5) at two different substrate volumes. Engine bench aging is used to simulate typical aged conditions. Temperature data as well as second by second and bag emissions data for hydrocarbons, carbon monoxide and oxides of nitrogen were used to evaluate the relative performances of the substrates. The US FTP and US06 driving cycles were used as protocols for the comparison. Results suggest that lower bulk density and higher geometric surface area interact to lead to lower emissions.

Unburned hydrocarbon (UHC) and carbon monoxide (CO) emission sources are examined in an optical, light-duty diesel engine operating under low load and engine speed, while employing a highly dilute, partially premixed low-temperature combustion (LTC) strategy. The impact of engine load and charge dilution on the UHC and CO sources is also evaluated. The progression of in-cylinder mixing and combustion processes is studied using ultraviolet planar laser-induced fluorescence (UV PLIF) to measure the spatial distributions of liquid- and vapor-phase hydrocarbon. A separate, deep-UV LIF technique is used to examine the clearance volume spatial distribution and composition of late-cycle UHC and CO. Homogeneous reactor simulations, utilizing detailed chemical kinetics and constrained by the measured cylinder pressure, are used to examine the impact of charge dilution and initial stoichiometry on oxidation behavior.

In-cylinder concentrations of nitric oxide (NO) in a diesel engine were studied using a laser-induced fluorescence (LIF) technique that employs two-photon excitation. Two-photon NO LIF images were acquired during the expansion and exhaust portions of the engine cycle providing useful NO fluorescence signal levels from 60° after top dead center through the end of the exhaust stroke. The engine was fueled with the oxygenated compound diethylene glycol diethyl ether to minimize soot within the combustion chamber. Results of the two-photon NO LIF technique from the exhaust portion of the cycle were compared with chemiluminescence NO exhaust-gas measurements over a range of engine loads from 1.4 to 16 bar gross indicated mean effective pressure. The overall trend of the two-photon NO LIF signal showed good qualitative agreement with the NO exhaust-gas measurements.

Despite ongoing research efforts directed at reducing engine-out emissions, diesel engines are known to be one of the largest sources of atmospheric particulate matter (i.e., soot). Quantitative measurements are of primary importance to address soot production during the combustion process in the cylinder of diesel engines. This study presents the capabilities of an extinction-based diagnostic developed to quantitatively measure the soot volume fraction in n-dodecane sprays injected in a high-pressure, high-temperature vessel. Coupled with high-speed imaging, the technique yields time-resolved measurements of the soot field by relying on a diffused back-illumination scheme to improve extinction quantification in the midst of intense beam steering. The experiments performed in this work used two wavelengths, which, when combined with the Rayleigh-Debye-Gans theory, provide information about the optical and physical properties of soot.

For better understanding of soot formation and oxidation processes in a biodiesel spray flame, the morphology, microstructure and sizes of soot particles directly sampled in a spray flame fuelled with soy-methyl ester were investigated using transmission electron microscopy (TEM). The soot samples were taken at different axial locations in the spray flame, 40, 50 and 70 mm from injector nozzle, which correspond to soot formation, peak, and oxidation zones, respectively. The biodiesel spray flame was generated in a constant-volume combustion chamber under a diesel-like high pressure and temperature condition (6.7 MPa, 1000K). Density, diameter of primary particles and radius of gyration of soot aggregates reached a peak at 50 mm from the injector nozzle and was lower or smaller in the formation or oxidation zones of the spray.

For a better understanding of soot formation and oxidation processes in conventional diesel and biodiesel spray flames, the morphology, microstructure and sizes of soot particles directly sampled in spray flames fuelled with US#2 diesel and soy-methyl ester were investigated using transmission electron microscopy (TEM). The soot samples were taken at 50mm from the injector nozzle, which corresponds to the peak soot location in the spray flames. The spray flames were generated in a constant-volume combustion chamber under a diesel-like high pressure and high temperature condition (6.7MPa, 1000K). Direct sampling permits a more direct assessment of soot as it is formed and oxidized in the flame, as opposed to exhaust PM measurements. Density of sampled soot particles, diameter of primary particles, size (gyration radius) and compactness (fractal dimension) of soot aggregates were analyzed and compared. No analysis of the soot micro-structure was made.

Diesel low-temperature combustion strategies often rely on early injection timing to allow sufficient fuel-ambient mixing to avoid NOx and soot-forming combustion. However, these early injection timings permit the spray to penetrate into a low ambient temperature and density environment where vaporization is poor and liquid impingement upon the cylinder liner and piston bowl are more likely to occur. The objective of this study is to measure the transient liquid and vapor penetration at early-injection conditions. High-speed Mie-scatter and shadowgraph imaging are employed in an optically accessible chamber with a free path of 100 mm prior to wall impingement and using a single-spray injector. The ambient temperature and density within the chamber are well-controlled (uniform) and selected to simulate in-cylinder conditions when injection occurs at -40 crank-angle degrees (CAD) or fewer before top-dead center (TDC).