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The fuel consumption and emissions of diesel engines is strongly influenced by the injection rate pattern, which influences the in-cylinder mixing and combustion process. Knowing the exact injection rate is mandatory for an optimal diesel combustion development. The short injection time of no more than some milliseconds prevents a direct flow rate measurement. However, the injection rate is deduced from the pressure change caused by injecting into a fuel reservoir or pipe. In an ideal case, the pressure increase in a fuel pipe correlates with the flow rate. Unfortunately, real measurement devices show measurement inaccuracies and errors, caused by non-ideal geometrical shapes as well as variable fuel temperature and fuel properties along the measurement pipe. To analyze the thermal effect onto the measurement results, an available rate measurement device is extended with a flexible heating system as well as multiple pressure and temperature sensors.

Designing an efficient vehicle coolant system depends on meeting target coolant flow rate to different components with minimum energy consumption by coolant pump. The flow resistance across different components and hoses dictates the flow supplied to that branch which can affect the effectiveness of the coolant system. Hydraulic tests are conducted to understand the system design for component flow delivery and pressure drops and assess necessary changes to better distribute the coolant flow from the pump. The current study highlights the ability of a complete 3D Computational Fluid Dynamics (CFD) simulation to effectively mimic a hydraulic test. The coolant circuit modeled in this simulation consists of an engine water-jacket, a thermostat valve, bypass valve, a coolant pump, a radiator, and flow path to certain auxiliary components like turbo charger, rear transmission oil cooler etc.

A study was conducted using Ford's nine standard CFD calibration models as described in SAE paper 940323. The models are identical from the B-pillar forward but have different back end configurations. These models were created for the purpose of evaluating the effect of back end geometry variations on aerodynamic lift and drag. Detailed experimental data is available for each model in the form of surface pressure data, surface flow visualization, and wake flow field measurements in addition to aerodynamic lift and drag values. This data is extremely useful in analyzing the accuracy of the numerical simulations. The objective of this study was to determine the capability of a digital physics based commercial CFD code, PowerFLOW ® to accurately simulate the physics of the flow field around the car-like benchmark shapes.

The objective of this paper is to demonstrate that frequency domain methods for calculating structural response and fatigue damage can be more widely applicable than previously thought. This will be demonstrated by comparing results of time domain vs. frequency domain approaches for a series of fatigue/durability problems with increasing complexity. These problems involve both static and dynamic behavior. Also, both single input and multiple correlated inputs are considered. And most important of all, a variety of non-stationary loading types have been used. All of the example problems investigated are typically found in the automotive industry, with measured loads from the field or from the proving ground.

Combustion in modern spark-ignition (SI) engines is increasingly knock-limited with the wide adoption of downsizing and turbocharging technologies. Fuel autoignition conditions are different in these engines compared to the standard Research Octane Number (RON) and Motor Octane Numbers (MON) tests. The Octane Index, OI = RON - K(RON-MON), has been proposed as a means to characterize the actual fuel anti-knock performance in modern engines. The K-factor, by definition equal to 0 and 1 for the RON and MON tests respectively, is intended to characterize the deviation of modern engine operation from these standard octane tests. Accurate knowledge of K is of central importance to the OI model; however, a single method for determining K has not been well accepted in the literature.

Described in this paper is a component test methodology to evaluate the door trim armrest performance in an Insurance Institute for Highway Safety (IIHS) side impact test and to predict the SID-IIs abdomen injury metrics (rib deflection, deflection rate and V*C). The test methodology consisted of a sub-assembly of two SID-IIs abdomen ribs with spine box, mounted on a linear bearing and allowed to translate in the direction of impact. The spine box with the assembly of two abdominal ribs was rigidly attached to the sliding test fixture, and is stationary at the start of the test. The door trim armrest was mounted on the impactor, which was prescribed the door velocity profile obtained from full-vehicle test. The location and orientation of the armrest relative to the dummy abdomen ribs was maintained the same as in the full-vehicle test.

In a recent study, quantitative measurements were presented of in-cylinder spatial distributions of mixture equivalence ratio in a single-cylinder light-duty optical diesel engine, operated with a non-reactive mixture at conditions similar to an early injection low-temperature combustion mode. In the experiments a planar laser-induced fluorescence (PLIF) methodology was used to obtain local mixture equivalence ratio values based on a diesel fuel surrogate (75% n-heptane, 25% iso-octane), with a small fraction of toluene as fluorescing tracer (0.5% by mass). Significant changes in the mixture's structure and composition at the walls were observed due to increased charge motion at high swirl and injection pressure levels. This suggested a non-negligible impact on wall heat transfer and, ultimately, on efficiency and engine-out emissions.

In this study the finite element method is used to simulate a light truck multi-leaf spring system and its interaction with a driven axle, u-bolts, and interface brackets. In the first part of the study, a detailed 3-D FE model is statically loaded by fastener pre-tension to determine stress, strain, and contact pressure. The FE results are then compared and correlated to both strain gage and interface pressure measurements from vehicle hardware test. Irregular contact conditions between the axle seat and leaf spring are investigated using a design of experiments (DOE) approach for both convex and discrete step geometries. In the second part of the study, the system FE model is loaded by both fastener pre-tension and external wheel end loads in order to obtain the twist motion response. Torsional deflection, slip onset, and subsequent slip motion at the critical contact plane are calculated as a function of external load over a range of Coulomb friction coefficients.

In this paper, a simplified and systematic approach to integrate reliability and durability aspects in design process is presented. A six step process is explained with the help of examples. Two alternatives for gathering means and standard deviations for key parameters are discussed. First a DOE approach based on orthogonal arrays is presented. Second approach is based on Taylor Series expansion. An example of beam design is solved with both of these approaches. The Second example also considers the degradation with time in service.

Many descriptions of product development are based on a timeline of activity. Timelines typically do not characterize the underlying strategy and flexibility embodied in the technical activity that actually takes place between activity nodes. Timelines alone will inhibit evolving to a more rational approach to product development. The view of engineering described in this paper is a functional view of engineering. It is what engineers do. It is aligned with the technical tools used by engineers. It applies to both product development and manufacturing. It's purpose is to enhance understanding of the function of engineering activities, including reliability.

There are several reasons why it can be daunting to apply Six Sigma to product creation. Foremost among them, the functional performance of new technologies is unknown prior to starting a project. Although, Design For Six Sigma (DFSS) was developed to overcome this difficulty, a lack of applicable in-class case studies makes it challenging to train the product creation community. The current paper describes an in-class project which illustrates how Six Sigma is applied to a simulated product creation environment. A toy construction set (TCS) project is used to instruct students how to meet customer expectations without violating cost, packaging volume and design-complexity constraints.

Designing a durability test for an automatic transmission that appropriately reflects customer usage during the lifetime of the vehicle is a formidable task; while the transmission and its components must survive severe usage, overdesigning components leads to unnecessary weight, increased fuel consumption and increased emissions. Damage to transmission components is a function of many parameters including customer driving habits and vehicle and transmission characteristics such as weight, powertrain calibration, and gear ratios. Additionally, in some cases durability tests are required to verify only a subset of the total parameter space, for example, verifying only component modifications. Lastly, the ideal durability test is designed to impose the worst case loading conditions for the maximum number of internal components, be as short as practicable to reduce testing time, with minimal variability between tests in order to optimize test equipment and personnel resources.

A method of predicting brake specific fuel consumption characteristics from limited specifications of engine design has been investigated. For spark ignition engines operating on homogeneous mixtures, indicated specific fuel consumption based on gross indicated power is related to compression ratio and spark timing relative to optimum values. The influence of burn rate is approximately accounted for by the differences in spark timings required to correctly phase combustion. Data from engines of contemporary design shows that indicated specific fuel consumption can be defined as a generic function of relative spark timing, mixture air/fuel ratio and exhaust gas recirculation rate. The additional information required to generate brake specific performance maps is cylinder volumetric efficiency, rubbing friction, auxiliary loads, and exhaust back pressure characteristics.

The oil distribution system of an automotive light duty engine typically has an oil pump mechanically driven through the front-endancillaries-drive or directly off the crankshaft. Delivery pressure is regulated by a relief valve to provide an oil gallery pressure of typically 3 to 4 bar absolute at fully-warm engine running conditions. Electrification of the oil pump drive is one way to decouple pump delivery from engine speed, but this does not alter the flow distribution between parts of the engine requiring lubrication. Here, the behaviour and benefits of a system with an electrically driven, fixed displacement pump and a distributor providing control over flow to crankshaft main bearings and big end bearings is examined. The aim has been to demonstrate that by controlling flow to these bearings, without changing flow to other parts of the engine, significant reductions in engine friction can be achieved.

NVH problems are often the result of mechanisms that originate through complex interactions between different physical domains (flow, structural/mechanical, control logic, etc.). Parallel-shaft spur gears subject to light torque loading caused by the dynamic pressure fluctuation of the oil used in engine accessory or transmission pump drives are likely to exhibit unusual gear whine associated with higher order meshing harmonics, even when the tooth profile has a high-quality grade finishing. Therefore, accurate integrated models are becoming a requirement to solve modern NVH problems.

The use of finite element modeling (FEM) tools is part of the most of the current product development projects of the automotive industry companies, replacing an important part of the physical tests with lower costs, higher speed and with increasing accuracy by each day. In addition to this, computer-aided engineering (CAE) tools can be either used after the product is released, at any moment of the product life, in many different situation as a new feature release, to validate a more cost-efficient design proposal or to help on solving some manufacturing problem or even a vehicular field issue. Different from the phase where the product is still under development, when standard virtual test procedures are performed in order to validate the vehicle project, in this case, where engineers expertise plays a very important role, before to proceed with any standard test it is fundamental to understand the physics of the phenomena that is causing the unexpected behavior.

In order to improve fuel economy, engine manufacturers are investigating various technologies that reduce pumping work in spark ignition engines. Current cylinder pressure analysis methods do not allow valid comparison of pumping work reduction strategies. Existing methods neglect valve timing effects which occur during the expansion and compression strokes, but are actually part of the gas exchange process. These additional pumping work contributions become more significant when evaluating non-standard valve timing concepts. This paper outlines a new analysis method for calculating the pumping work and indicated work of a 4-stroke internal combustion engine. Corrections to PMEP and IMEP are introduced which allow the valid comparison of pumping work and indicated efficiency between engines with different pumping work reduction strategies.

There is keen interest in understanding the origins of engine-out unburned hydrocarbons emitted during SI engine cold start. This is especially true for the first few firing cycles, which can contribute disproportionately to the total emissions measured over standard drive cycles such as the US Federal Test Procedure (FTP). This study reports on the development of a novel methodology for capturing and quantifying unburned hydrocarbon emissions (HC), CO, and CO2 on a cycle-by-cycle basis during an engine cold start. The method was demonstrated by applying it to a 4 cylinder 2 liter GTDI (Gasoline Turbocharged Direct Injection) engine for cold start conditions at an ambient temperature of 22°C. For this technique, the entirety of the engine exhaust gas was captured for a predetermined number of firing cycles.

The capability to drive NVH quality into vehicle frame design is often compromised by the lack of available predictive tools that can be developed and applied within the timeframe during which key architectural design decisions are required. To address this need, a new parametric frame modeling approach was developed and is presented in this paper. This fully parameterized model is capable of fast modal, static stiffness & weight assessments, as well as DSA/optimization for frame design changes. This tool has been proven to be effective in improving speed, quality and impact of NVH hardware decisions.

This Paper introduces a modular, flexible and user-friendly dynamic powertrain model of the US Army's High Mobility Multi-Wheeled Vehicle (HMMWV). It includes the DDC 6.5L diesel engine, Hydra-matic 4L80-E automatic transmission, Torsen differentials, transfer case, and flexible drive and axle shafts. This model is used in a case study on transmission optimization design to demonstrate an application of the model. This study shows how combined optimization of the transmission hardware (clutch capacity) and control strategy (shift time) can be explored, and how the models can help the designer understand dynamic interactions as well as provide useful design guidance early in the system design phase.