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Rolling element bearings provide near frictionless relative motion between two rotating parts. Automotive transmissions use various ball and rolling element bearings to accommodate the relative motion between rotating elements. In order to understand changes in bearing performance due to the loads imposed through the transmission, advanced modeling of the bearing is required. This paper focuses on the effects of cage flexibility on bearing performance. A flexible cage model was developed and incorporated into a six degree-of-freedom dynamic, deep groove ball bearing model. A lumped mass approach was used to represent the cage flexibility and was validated through an ANSYS forced response analyses of the cage. Results from the newly developed Flexible Cage Model (FCM) and an identical numerical model employing a rigid bearing cage were compared to determine the effects of varying ball-to-cage pocket clearance and cage stiffness on cage motion and ball-to-cage pocket contact forces.

The identification of the dominant noise sources in diesel engines and the assessment of their contribution to far-field noise is a process that can involve both fired and motored testing. In the present work, the cross-spectral densities of signals from cylinder pressure transducers, accelerometers mounted on the engine surface, and microphones (in the near and far fields), were used to identify dominant noise sources and estimate the transfer paths from the various “inputs” (i.e., the cylinder pressures, the accelerometers and the near field microphones) to the far field microphones. The method is based on singular value decomposition of the input cross-spectral matrix to relate the input measurements to independent virtual sources. The frequencies at which a particular input is strongly affected by an independent source are highlighted, and with knowledge of transducer locations, inferences can be drawn as to possible noise source mechanisms.

Nowadays, the increasing number of structural high pressure die casting (HPDC) aluminum parts need to be joined with high strength steel (HSS) parts in order to reduce the weight of vehicle for fuel-economy considerations. Self-Pierce Riveting (SPR) has become one of the strongest mechanical joining solutions used in automotive industry in the past several decades. Joining HPDC parts with HSS parts can potentially cause joint quality issues, such as joint button cracks, low corrosion resistance and low joint strength. The appropriate heat treatment will be suggested to improve SPR joint quality in terms of cracks reduction. But the heat treatment can also result in the blister issue and extra time and cost consumption for HPDC parts. The relationship between the microstructure of HPDC material before and after heat treatment with the joint quality is going to be investigated and discussed for interpretation of cracks initiation and propagation during riveting.

Design optimization for functionality, and manufacturability was virtually impossible in the past. However, recent standardization of file storing formats resulted in seamless data transfer from one software package to another; thus, allowing integration of all facets of product design optimization. This paper describes a metalcasting design optimization process. It focuses on the design of cast parts according to functional requirements while optimizing shape with respect to structural integrity, while ascertaining that the part can be manufactured (cast) without defects.

Typical vehicle dynamics simulations demand a trade-off between short computation times and accuracy. Many of the more simple models are based on the kinematic roll center and the more accurate models tend to be multi-body dynamics simulation programs. There is a need for a model that improves the accuracy of the kinematic roll center models while still maintaining short computation times. Such a model could be used track-side during races to guide race teams toward improved handling. The model presented in this paper removes many of the assumptions and limitations of the kinematic roll center model. The model accounts for three-dimensional forces present at the contact patch and predicts deflections of suspension components. The modeling approach is applied to a NASCAR Craftsman Truck to predict the effects of suspension design and tuning on steady-state understeer characteristics of the vehicle. Braking and acceleration forces can also be applied to the vehicle.

Structures with multiple materials have now become one of the perceived necessities for automotive industry to address vehicle design requirements such as light-weight, safety, and cost. The objective of this study is to develop a design methodology for multi-material structures accountable for vehicle crash durability. The heuristic topology synthesis approach of Hybrid Cellular Automaton (HCA) framework is implemented to generate multi-material structures with the constraint on the volume fraction of the final design. The HCA framework is integrated with ordered-SIMP (solid isotropic material with penalization) interpolation, artificial material library, as well as statistical analysis of material distribution data to ensure a smooth transition between multiple practical materials during the topology synthesis.

Today, there are several hundreds of manufacturing processes available to the designer to choose from, and the number is constantly increasing. The ability to choose a manufacturing process for a particular user need set in the early stage of the design process is necessary. In metalcasting alone, there are over forty different processes with different capabilities. A designer can benefit from knowing the manufacturing process alternatives available to him. Inaccurate process selection can lead to financial losses and market share erosion. This paper discusses a methodology for selection of a metalcasting process based on a number of user specified attributes or requirements. A model of user requirements was developed and these requirements were matched with the capabilities of each metalcasting process. The metalcasting process which best meets these needs is suggested.

In this paper, computations of pulsating flows in a duct with multiple inlets using the lattice Boltzmann method (LBM) are reported. As future emissions standards present a significant challenge for Diesel engine manufacturers, several options are being investigated to identify strategies to meet such regulations. Exhaust gas aftertreatment is one of the most important among them. As the performance of the various aftertreatment devices is sensitive to the flow conditions in the exhaust, a greater understanding of the flows under pulsating conditions in the presence of multiple cylinders is needed. The Lattice Boltzmann Method (LBM) is a relatively new and promising computational approach for applications to fluid dynamics problems. Two advantages of the method relative to traditional methods are ease of implementation and ease of parallelization and performance on parallel computers.

This paper presents a method for indirect measurement of tire slip angles from chassis acceleration, yaw rate, and steer angle measurements. The chassis is assumed to be rigid so that acceleration data can be integrated to estimate velocities of the front and rear of the vehicle, from which slip angles can be predicted. The difference in front and rear slip angles is indicative of vehicle oversteer/understeer. Understeer data can then be correlated with position on the track to better understand vehicle handling behavior, aiding the tuning process. The technique is presented, and shown to work well with simulated data, even when the data is corrupted with up to 20% noise. Therefore, the inversion process presented here is theoretically sound. However, when the technique is applied to measured data from race cars, it is shown to be inaccurate. One suspected problem is the difficulty of getting accurate yaw rate data.

Conventional suspension analysis of three-dimensional suspensions typically use two-dimensional analyses. This is done by projecting suspension components onto two-dimensional planes and then performing a two-dimensional analysis in each of these orthogonal planes or neglecting motions in one of the planes entirely. This requires multiple iterations because changes in one plane require a checking of their effects on motion in the other orthogonal planes. In doing so, much of the insight and accuracy gained from a three-dimensional analysis can be lost. A three-dimensional kinematic analysis approach is presented and applied to a dual A-Arm suspension system. All motions are considered instantaneously about a screw axis instead of a point as used by the usual two-dimensional modeling approach. The model predicts deflections of suspension components in response to the three-dimensional forces present at the contact patch.

Diesel engine cylinder deactivation (CDA) can be used to reduce petroleum consumption and greenhouse gas (GHG) emissions of the global freight transportation system. Heavy duty trucks require complex exhaust aftertreatment (A/T) in order to meet stringent emission regulations. Efficient reduction of engine-out emissions require a certain A/T system temperature range, which is achieved by thermal management via control of engine exhaust flow and temperature. Fuel efficient thermal management is a significant challenge, particularly during cold start, extended idle, urban driving, and vehicle operation in cold ambient conditions. CDA results in airflow reductions at low loads. Airflow reductions generally result in higher exhaust gas temperatures and lower exhaust flow rates, which are beneficial for maintaining already elevated component temperatures. Airflow reductions also reduce pumping work, which improves fuel efficiency.

An experimental-analytic method of determining the stress distribution in narrow faced spur gear teeth is presented. The successful application of photostress to this contact problem is reported. It utilizes a digital computer routine developed for separating stresses in any general two-dimensional region. Results for two pairs of gears are presented. Comparison is made with values predicted by the modified Lewis formula, the Kelley and Pedersen equation, and by the Belajef solution of the Hertz contact problem for two cylinders.

An experimental apparatus and a numerical model have been designed and developed to examine the lubrication condition and frictional losses at the piston and cylinder interface. The experimental apparatus utilizes components from a single cylinder, ten horsepower engine in a novel suspended liner arrangement. The test rig has been specifically designed to reduce the number of operating variables while utilizing actual components and geometry. A mixed lubrication model for the complete ring-pack and piston skirt was developed to correlate with experimental measurements and provide further insight into the sources of frictional losses. The results demonstrate the effects of speed and viscosity on the overall friction losses at the piston and cylinder liner interface. Comparisons between the experimental and analytical results show good agreement.