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Weld lines occur when melt flow fronts meet during the injection molding of plastic parts. It is important to investigate the weld line because the weld line area can induce potential failure of structural application. In this paper, a weld line factor (W-L factor) was adopted to describe the strength reduction to the ultimate strength due to the appearance of weld line. There were two engineering thermoplastics involved in this study, including one neat PP and one of talc filled PP plastics. The experimental design was used to investigate four main injection molding parameters (melt temperature, mold temperature, injection speed and packing pressure). Both the tensile bar samples with/without weld lines were molded at each process settings. The sample strength was obtained by the tensile tests under two levels of testing speed (5mm/min and 200mm/min) and testing temperatures (room temperature and -30°C). The results showed that different materials had various values of W-L factor.

The requirements of the automotive industry move along due to product competitiveness and this contributes to increase complexity in the requirements for evaluation. Simulation tools play a key role thanks to their versatility and multiple physical phenomena that can be represented. The axis of analysis for this paper is the problem of the interaction of airflow and water flow in the cowl/plenum/leaf screen components. Airflow is represented by HVAC system operating and water flow by the vehicle in torrential rain. Initially, one simulation is evaluated at a time, in one side, the airflow entering the HVAC system in which the amount of air entering is monitored and pressure drop, on the other, the water simulation on the vehicle, both using a Lagrangian CFD model (using with tools such as STAR CCM+® or Ansys Fluent®) Due to this, a CFD methodology was developed to evaluate the interaction of air and water flow.

High gas prices combined with demand for improved fuel economy have prompted increased interest in diesel engine applications for both light-duty and heavy-duty vehicles. The development of aftertreatment systems for these vehicles requires significant investments of capital and time. A reliable and robust qualification testing procedure will allow for more rapid development with lower associated costs. Qualification testing for DPFs has its basis in methods similar to DOCs but also incorporates a PM loading method and regeneration testing of loaded samples. This paper examines the effects of accelerated loading using a PM generator and compares PM generator loaded DPFs to engine dynamometer loaded samples. DPFs were evaluated based on pressure drop and regeneration performance for samples loaded slowly and for samples loaded under accelerated conditions. A regeneration reactor was designed and built to help evaluate the DPFs loaded using the PM generator and an engine dynamometer.

With the increasing number of cars on the street, the exchange of information between those cars becomes essential to improve the driving skills of each driver, resulting in a safer, intelligent and more dynamic traffic. The task now is to make it accessible for everyone. One possible and cheap way to solve this issue is to seek possibilities on free technologies within market trends. Using the smartphone platforms, which holds a high level of embedded technologies, becoming a global communication device even to interpersonal and to social networks, and AppLink Development Kit for smartphones and vehicles integration, this paper will cover aspects about the integration of the kit to an database application based on the cloud, enabling real-time interaction between two cars. Making possible to a driver have access to information and current status of other cars to aid ones life on heavy traffic.

A traditional vane type oil pump used inside the engines and the transmissions has equal angles or spacing between the vanes. The equal spacing intensifies pressure fluctuations generated within the pump leading to narrowband pressure spikes at the pump main order and its harmonics. Unequal spacing, however, can relax the severity of the spikes by breaking down the narrowband peaks and distributing them over a larger frequency range. Optimization of the angles within the pump design constraint can maximize the benefit of unequal spacing in reducing the pressure pulsations for a lower risk of engine or transmission whine. The scope of this paper is around the optimization process for vane spacing and different objective functions which can be used to obtain optimized solutions. The simulation results for optimized spacing based on two different objective functions for 7, 8 and 9 vanes are presented. The design constraints for the optimization are discussed as well.

A wind noise model of a vehicle has been developed using Statistical Energy Analysis (SEA) with measured turbulent pressure data as the source input. Empirical formulas are used to scale the input data for changes in flow and design parameters. Wind tunnel tests have been conducted on a standard and modified vehicle to validate the SEA model and the input scaling. The results show good correlation with both the exterior turbulent pressure levels and the interior sound pressure levels across the audio frequency range.

A key ingredient in designing products that are more robust is a thorough knowledge of the physics of the ideal function of those products and the physics of the failure modes of those products. We refer to the mathematical functions describing this physics as the transfer functions for that product. Dimensional analysis (DA) is a well known, but often overlooked, tool for reducing the number of experiments needed to characterize a physical system. In this paper, we demonstrate how the application of DA can be used to reduce the size of a DOE needed to estimate transfer functions experimentally. Furthermore, the transfer function generated using DOEs with DA tend to be more general than those generated using larger DOEs directly on the design parameters. With ever-increasing competitive pressure and reduced product development time, a tool such as DA, which can dramatically reduce experimental cost, is an incredibly valuable addition to an engineers toolbox.

During the Product Development Process, the experimental engineers try to acquire the most reliable data from Proving Grounds early on the development process, aiming to support CAE model correlation and in this way ensuring that the vehicle is capable of withstanding customer loads. Those data, from Proving Grounds, are correlated to the most severe customer's usage and public road conditions. The proposal of this paper is to analyze how tire pressure affects structural durability, since safety, performance and fuel economy were already discussed on other opportunities. Tire pressure is important because it's one variable where the customer can monitor and act and because TPMS (Tire Pressure Measurement System) is not available on most vehicles sold in the Brazilian Market,

A time-efficient throttle flow data collection method is described. It uses a sonic nozzle flow bench to measure air flow as a function of throttle angle and pressure in a manner analogous to on-engine dynamometer throttle flow characterization. Opening each sonic nozzle combination, then recording throttle downstream pressure and computed nozzle flow allows data to be taken in a fraction of the time normally needed. Throttle flow modeling considerations are then discussed.

The three-dimensional non-reacting flow field inside a typical dual-monolith automotive catalytic converter was simulated using finite difference analysis. The monolithic brick resistance was formulated from the pressure gradient of fully developed laminar duct-flow and corrected for the entrance effect. This correlation was found to agree with experimental pressure drop data, and was introduced as an additional source term into the non-dimensional momentum governing equation within the brick. Flow distribution within the monolith was found to depend strongly on the diffuser performance, which is a complex function of flow Reynolds number, brick resistance, and inlet pipe length and bending angles. A distribution index was formulated to quantify the degree of non-uniformity at selected test cases covering ranges of flow conditions, brick types, and inlet conditions.

It is well known that customer perception of the annoyance of steady-state wind noise can be fairly well characterized by calculating the loudness of such sounds. Commonly used is the ISO532B or Zwicker method [1]. What is not known, however, is how a customer would react to time-varying wind noise. Such situations can occur when a vehicle experiences cross-wind conditions on the highway. Turbulent air flow generated by either a passing vehicle or when traveling in the wake of another vehicle can cause the wind noise to take on time-varying characteristics. The time-varying wind noise created by such situations is commonly referred to as “buffeting.” Customer complaint field data indicates that wind buffeting is a source of annoyance, but the level of the effect has never been quantified. In this study, binaural sounds were recorded inside an aeroacoustic wind tunnel. Varying degrees of buffeting were simulated using a “blocker” vehicle situated in front of the test vehicle.

An investigation was conducted into pressure pulsation in the exhaust port, which greatly affects volumetric efficiency and engine performance. From experiments using a single blow-down generator, it was established that the amplitude of the pressure pulsation increases as the manifold branch is lengthened and that large negative pressure synchronized with the timing of valve overlap can be obtained if a proper branch length is used. The performance of a 2ℓ test engine was optimized by varying the length of both the manifold branches and front pipe forks. It was found that whereas front pipe fork length affects engine performance over only a narrow range of engine speed, optimizing manifold branch length results in a considerable improvement over a wide engine speed range. In the course of optimizing the exhaust pipe manifold length of this two-degree-of-freedom exhaust system, abnormal exhaust noises were emitted at specific engine speeds during deceleration.

Grunt is a structure-born noise caused by resonance of the steering gear torsion bar (T-bar) in an HPAS (Hydraulic Power Assist Steering) system. The goal of this work was to develop techniques to quantify and predict grunt in a RV (rotary valve) steering gear system. First, vehicle testing was used to identify an objective metric for grunt: y = dynamic pressure in the return line. Then, a computer simulation was developed to predict y as a function of two known control factors. The simulation results were correlated to measurements on a test vehicle. Finally, the simulation was expanded to include two additional control factors, and grunt predictions were demonstrated on a different test vehicle.

This paper describes methods to attain a low cost tire pneumatic pressure monitor. We already established two kinds of algorithms for indirect detection of under-inflated tires without requiring any air pressure sensors. One method is to use a disturbance observer and the least mean square method. The other method is to compare the loaded radii of the tires. We have developed an algorithm that reduces the number of calculations needed, while maintaining a relatively small program size, and realized a tire pneumatic pressure monitor that does not require any hardware cost, by incorporating it into the program for the antilock brake system (ABS).

A fuel system design objective is to have the fuel injection pressure at target pressure by the time of the first injection. In most cases, a vapor and air space forms in the highest and hottest part of the fuel injector supply as the fuel system cools following engine-off. Upon key-on, the fuel pump needs to collapse the fuel vapor and compress any air before fuel pressure can build thus delaying fuel injector re-pressurization. An inventive solution to speed re-pressurization is described. It effectively eliminates the need to collapse the fuel vapor and compress any air in the first few tenths of seconds of fuel injection re-pressurization. The factors that affect fuel injection re-pressurization time are discussed.

The natural refrigerant, R744 (CO2), remains a viable solution to replace the high GWP refrigerant R134a which is to be phased out in light-duty vehicles in EU and US market. In this study, thermodynamic analysis is performed on a R744 parallel compression system to evaluate its potential in automotive climate control. The model adopts a correlation of isentropic efficiency as a function of compression ratio based on a prototype R744 MAC compressor and accounts for the operating limits defined in the latest DIN specifications. Optimization is run over typical MAC operating conditions which covers both transcritical and subcritical domain. Comparing to the conventional single compression cycle, effectiveness of parallel compression is found most pronounced in low evaporating temperature and high ambient conditions, with up to 21% increase in COP and 5.3 bar reduction in discharge pressure observed over the considered parametric range.

Pressure-sensitive paint (PSP) technology is a technique used to experimentally determine surface pressures on models during wind tunnel tests. The key to this technique is a specially formulated pressure-sensitive paint that responds to, and can be correlated with the local air pressure. Wind tunnel models coated with pressure-sensitive paint are able to yield quantitative pressure data on an entire model surface in the form of light intensity values in recorded images. Quantitative results in terms of pressure coefficients (Cp) are obtained by correlating PSP data with conventional pressure tap data. Only a small number of surface taps are needed to be able to obtain quantitative pressure data with the PSP method. This technique is gaining acceptance so that future automotive wind tunnel tests can be done at reduced cost by eliminating most of the expensive pressure taps from wind tunnel models.

This study demonstrates the use of pressure sensing technology to predict the crash severity of frontal impacts. It presents an investigation of the pressure change in the front structural elements (bumper, crush cans, rails) during crash events. A series of subsystem tests were conducted in the laboratory that represent a typical frontal crash development series and provided empirical data to support the analysis of the concept. The pressure signal energy at different sensor mounting locations was studied and design concepts were developed for amplifying the pressure signal. In addition, a pressure signal processing methodology was developed that relies on the analysis of the air flow behavior by normalizing and integrating the pressure changes. The processed signal from the pressure sensor is combined with the restraint control module (RCM) signals to define the crash severity, discriminate between the frontal crash modes and deploy the required restraint devices.

Particle Image Velocimetry (PIV) measurements were performed on a single cylinder optically accesible version of a 3.0L 4-valve engine using a Camshaft Profile Switching (CPS) system. The flow field was investigated at two engine speeds (750 and 1500 rpm), two manifold pressures (75 and 90 kPa) and two intake cam centerlines (maximum lift at 95° and 115° aTDCi respectively). Images were taken in the swirl plane at 10 mm and 40 mm below the deck with the piston at 300° aTDC of intake (60° bTDC compression) and BDC respectively. In the tumble plane, images were taken in a plane bisecting the intake valves with the piston at BDC and 300° aTDC. The results showed that the swirl ratio was slightly lower for this system compared with a SCV system (swirl control valve in the intake port) under the same operating conditions. The swirl and tumble ratios generated were not constant over the range of engine speeds and manifold pressures (MAP) but instead increased with engine speed and MAP.