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This paper presents on-going finite element modeling efforts of friction stir spot welding (FSSW) process using Abaqus/Explicit as a finite element solver. Three-dimensional coupled thermal-stress model was used to calculate thermo-mechanical response of FSSW process. Adaptive meshing and advection schemes, which makes it possible to maintain mesh quality under large deformations, is utilized to simulate the material flow and temperature distribution in FSSW process. The predicted overall deformation shape of the weld joint resembles that experimentally observed. Temperature and stress graphs in the radial direction as well as temperature-deformation distribution plots are presented.

The Army continues to improve its Reliability-based Design Optimization (RBDO) process, expanding from component optimization to system optimization. We are using the massively parallel computing power of the Department of Defense (DoD) High Performance Computing (HPC) systems to simultaneously optimize multiple components which interact with each other in a mechanical system. Specifically, we have a subsystem of a military ground vehicle, consisting of more than four components and are simultaneously optimizing five components of that subsystem using RBDO methods. We do not simply optimize one component at a time, sequentially, and iterate until convergence. We actually simultaneously optimize all components together. This can be done efficiently using the parallel computing environment. We will discuss the results of this optimization, and the advantages and disadvantages of using HPC systems for this work.

Scale-resolving turbulence modeling for engine flow simulation has constantly increased its popularity in the last decade. In contrast to classical RANS modeling, LES-like approaches are able to resolve a larger number of unsteady flow features. In principle, this capability allows to accurately predict some of the key parameters involved in the development and optimization of modern engines such as cycle-to-cycle variations in a DI engine. However, since multiple simulated engine cycles are required to extract reliable flow statistics, the spatial and temporal resolution requirements of pure LES still represent a severe limit for its wider application on realistic engine geometries. In this context, Hybrid URANS-LES methodologies can therefore become a potentially attractive option. In fact, their task is to preserve the turbulence scale-resolving in the flow core regions but at a significantly lower computational cost compared to standard LES.

The basic design of a purely rotary motion engine has potentially many advantages over the conventional piston-crank internal combustion engine. Although only one rotary engine has been successfully placed into production, rotary mechanisms still show promise in the market place. A comprehensive review of rotary engine concepts is presented with an emphasis placed on the last 30 years. Suggestions are made as to where research concentrations should be placed to improve the progress of a rotary engine.

Regenerative braking coupled to small high power density engines are becoming more and more popular in motorsport applications delivering improved performances while increasing similarities and synergies in between road and track applications. Computer aided engineering (CAE) tools integrated with the telemetry data of the car are an important component of the product development. This paper presents the CAE model developed to describe the race track operation of a LMP1-H racing car covering one lap of the Le Mans circuit. The friction and regenerative braking is discussed.

The high demand for traditional air traffic as well as increased use of unmanned aerial systems (UAS) has resulted in researchers examining alternative technologies which would result in safer, more reliable, and better performing aircraft. Active methods of aerodynamic flow control may be the most promising approach to this problem. Research in the area of aerodynamic control is transitioning from traditional mechanical flow control devices to, among other methods, plasma actuators. Plasma actuators offer an inexpensive and energy efficient method of flow control. Dielectric Barrier Discharge (DBD), one of the most widely studied forms of plasma actuation, employs an electrohydrodynamic (EHD) device which uses dominant electric fields for actuation. Unlike traditional flow control methods, a DBD device operates without moving components or mass injection methods.

Beginning 2007, heavy-duty engine certification would require that in-use emissions from vehicles be measured under ‘real-world’ operating conditions using on-board measurement devices. An on-board portable emissions measurement system called Mobile Emissions Measurement System (MEMS) was developed at West Virginia University (WVU) to record in-use, continuous and brake-specific emissions from heavy-duty diesel-powered vehicles. The objective of this paper is to present a preliminary development of a test data quality assurance methodology for emissions measured using the any portable emissions measurement system (PEMS). The first stage of the methodology requires ensuring the proper operation of the different sensors and transducers during data collection. The second stage is data synchronization and pre-processing. The next stage is systematic checking of possible errors from transducers and sensors.

Tube Launched-Unmanned Air Vehicles (TL-UAV) are munitions that alter their trajectories during flight to enhance the capabilities by possibly extending range, increasing loiter time through gliding, and/or having guided targeting capabilities. Traditional munition systems, specifically the tube-launched mortar rounds, are not guided. Performance of these "dumb" munitions could be enhanced by updating to TL-UAV and still utilize existing launch platforms with standard propellant detonation firing methods. The ability to actively control the flight path and extend range of a TL-UAV requires multiple onboard systems which need to be identified, integrated, assembled, and tested to meet cooperative function requirements. The main systems, for a mortar-based TL-UAV being developed at West Virginia University (WVU), are considered to be a central hub to process information, aerodynamic control devices, flight sensors, a video camera system, power management, and a wireless transceiver.

As unmanned aerial vehicle applications continue their rise in popularity in the public and private sectors, there is an increasing demand in many cases for smaller, more efficient low speed unmanned aerial vehicles (UAVs). Although the primary drivers for the continued performance improvement of smaller UAV platforms tend to be in the areas of electronics miniaturization and improved energy storage, aerodynamics, particularly in the low Reynolds number regime, still have a significant role in the overall performance enhancement of small UAVs. This paper focuses on the study of the nearfield aerodynamic effects of a low-power active flow enhancement technique known as dielectric barrier discharge (DBD) in very low speed/low Reynolds number flows most closely associated with small and micro unmanned aerial vehicles.

Air cargo containers are used to load freight on various types of aircrafts to expedite their handling. Fuel cost is the largest contributor to the total cost of ownership of an air cargo container. Therefore, a better fuel economy could be achieved by reducing the weight of such containers. This paper aims at developing innovative, lightweight design concepts for air cargo containers that would allow for weight reduction in the air cargo transportation industry. For this purpose, innovative design and assembly concepts of lightweight design configurations of air cargo containers have been developed through the applications of lightweight composites. A scaled model prototype of a typical air cargo container was built to assess the technical feasibility and economic viability of creating such a container from fiber-reinforced polymer (FRP) composite materials. The paper is the authoritative source for the abstract.

Significant efforts have been made in the research of Pulsed Detonation Engines (PDEs) to increase the reliability and longevity of detonation based propulsion systems for use in manned aircraft. However, the efficiency, durability, and low mechanical complexity of PDEs opens up potential for use in disposable unmanned-vehicles. This paper details the steps taken for producing a miniaturized pulse detonation engine at West Virginia University (WVU) to investigate the numerically generated constraining dimensions for Deflagration to Detonation Transition (DDT) cited in this paper. Initial dimensions for the WVU PDE Demonstrator were calculated using fuel specific DDT spatial properties featured in the work of Dr. Phillip Koshy Panicker, of The University of Texas at Arlington. The WVU demonstrator was powered using oxygen and acetylene mixed in stoichiometric proportions.

In this research, the magnetoplasmadynamic (MPD) effects of applying a toroidal magnetic field around an ionized exhaust plume were investigated to manipulate the exhaust profile of the plasma jet under near vacuum conditions. Tests for this experiment were conducted using the West Virginia University (WVU) Hypersonic Arc Jet Wind Tunnel. A series of twelve N52 grade neodymium magnets were placed in different orientations around a steel toroid mounted around the arc jet’s exhaust plume. Four different magnet orientations were tested in this experiment. Two additional configurations were run as control tests without any imposed magnetic fields surrounding the plume. Each test was documented using a set of 12 photographs taken from a fixed position with respect to the flow. The photographic data was analyzed by comparing images of the exhaust plume taken 10, 20, and 30 seconds after the plasma jet was activated.

Longitudinal impact tests were conducted on the knees of four seated embalmed cadavers using an impact pendulum. Impact force and femur strain histories were recorded, and peak force at fracture was determined. The results show that femur stiffness (average = 3.29 MN) for impacts is nearly the same as for static loads. Peak fracture loads varied from 8731-11570 N, all above the fracture criterion proposed by King, Fan and Vargovick. Strain histories and fracture patterns suggest that bending effects play a major role in determining the response of embalmed cadaver femurs to longitudinal impact.

There is an ever growing need in the aircraft industry to increase the performance of a flight vehicle. To enhance performance of the flight vehicle one active area of research effort has been focused on the control of the boundary layer by both active and passive means. An effective flow control mechanism can improve the performance of a flight vehicle by eliminating boundary layer separation at the leading edge (as long as the energy required to drive the mechanism is not greater than the savings). In this paper the effectiveness of a novel active flow control technique known as dynamic roughness (DR) to eliminate flow separation in a stalled NACA 0012 wing has been explored. As opposed to static roughness, dynamic roughness utilizes small time-dependent deforming elements or humps with amplitudes that are on the order of the local boundary layer height to energize the local boundary layer. DR is primarily characterized by the maximum amplitude and operating frequency.

The objective of this paper is to devise innovative lightweight design concepts for heavy vehicle structures. A 1 to 4 prototype of a trailer was built to assess the feasibility of use of polymer composites and to have first hand experience with possible bonding methods to join the design parts. In the current trailer configurations, floor assembly constitutes 70% of the overall weight. The results indicated that sandwich technology with a lightweight core that adds flexural stiffness to the overall design provides a solution to decrease the weight of heavy vehicle systems.

Process planning, whether generative or variant, can be used effectively as through the incorporation of computer aided tools that enhance the evaluator impact of the dialogue between the design and manufacturing functions. Expert systems and algorithms are inherently incorporated into the software tools used herein. This paper examines the materials related implications that influence design for manufacturing issues. Generative process planning software tools are utilized to analyze the sensitivity of the effectiveness of the process plans with respect to changing attributes of material properties. The shift that occurs with respect to cost and production rates of process plans with respect to variations in specific material properties are explored. The research will be analyzing the effect of changes in material properties with respect to the design of a specific product that is prismatic and is produced exclusively by machining processes.

A Hybrid Projectile (HP) is a tube launched munition that transforms into a gliding UAV, and is currently being researched at West Virginia University. In order to properly transform, the moment of transformation needs to be controlled. A simple timer was first envisioned to control transformation point for maximum distance. The distance travelled or range of an HP can directly be modified by varying the launch angle. In addition, an internal timer would need to be reprogrammed for any distance less than maximum range due to the nominal time to deployment varying with launch angle. A method was sought for automatic wing deployment that would not require reprogramming the round. A body angle estimation system was used to estimate the pitch of the HP relative to the Earth to determine when the HP is properly oriented for the designed glide slope angle. It also filters out noise from an inertial measurement unit (IMU).

This paper discusses the design and qualification of a High Temperature Sampling System (HTSS), capable of stripping the volatile fraction from a sample flow stream in order to provide for quantification of total, solid and volatile particulate matter (PM) on a near real-time basis. The sampling system, which incorporates a heated diesel oxidation catalyst, is designed for temperatures up to 450°C. The design accounts for molecular diffusion of volatile compounds, solid particles diffusion and reaction kinetics inside one channel of the oxidation catalyst. An overall solid particle loss study in the sampling was performed, and numerical results were compared with experimental data gathered at the West Virginia University Engine and Emissions Research Laboratory (EERL) and West Virginia University's Transportable Heavy-Duty Vehicle Emissions Testing Laboratory (THDVETL).

Aerodynamic drag testing is a key component of the CO2 certification schemes for heavy-duty vehicles around the world. This paper presents and compares the regulatory approaches for measuring the drag coefficient of heavy-duty vehicles in Europe, which uses a constant-speed test, and in the United States and Canada, which use a coastdown test. Two European trucks and one North American truck were tested using the constant-speed and coastdown methods. When corrected to zero yaw angle, a difference of up to 12% was observed in the measured drag coefficients from the US coastdown procedure and the EU constant-speed test.

The dielectric barrier discharge (DBD) has been studied significantly in the past two decades for its applications to various aerodynamic problems. The most common aerodynamic applications have been stall/separation control and boundary layer modification. Recently several researchers have proposed utilizing the DBD in various configurations to act as viable propulsion systems for micro and nano aerial vehicles. The DBD produces stable atmospheric-pressure non-thermal plasma in a thin sheet with a preferred direction of flow. The plasma flow, driven by electrohydrodynamic body forces, entrains the quiescent air around it and thus develops into a low speed jet on the order of 10-1 to 101 m/s. Several researchers have utilized DBDs in an annular geometric setup as a propulsion device. Other researchers have used them to alter rectangular duct flows and directional jet devices. This study investigates 2-D duct flows for applications in micro plasma thrusters.