Search results for: automotive exhaust

Authors: Mohamed Ben Amar, Henda Barhoumi, Hokia Siala, Foued Elhalouani

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The present contribution consists of a purely experimental investigation on the effect of Squeeze casting on the micro structural and mechanical propriety of Al-Si alloys destined to automotive industry. Accordingly, we have proceeding, by ourselves, to all the thermal treatment consisting of solution treatment at 540°C for 8h and aging at 160°C for 4h. The various thermal treatment, have been carried out in order to monitor the processes of formation and dissolution accompanying the solid state phase transformations as well as the resulting changes in the mechanical proprieties. The examination of the micrographs of the aluminum alloys reveals the dominant presence of dendrite. Concerning the mechanical characteristic the Vickers micro-hardness curve an increase as a function of the pressure. As well as the heat treatment increase mechanical propriety such that pressure and micro hardness. The curves have been explained in terms of structural hardening resulting from the various compounds formation.

Keywords: squeeze casting, process parameters, heat treatment, ductility, microstructure

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Authors: Faisal Mahroogi, Mahmoud Bady, Ahmed Alsisi

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The Saudi Vision 2030 program is a government initiative aimed at increasing economic, social, and cultural diversification. Dedicated to clean energy, the Kingdom has been working on solutions such as the circular carbon economy (CCE) and diversifying its energy mix to address energy and climate challenges. With a goal of a Net Zero future by 2060, Saudi Arabia's Vision 2030 emphasizes sustainability. Vision 2030 approa ches today's energy and climate challenges responsibly and creatively as a model for a sustainable future. As per the Ambitions of the National Environment Strategy of the Saudi Ministry of Environment, Agriculture, and Water (MEWA), raising environmental compliance across all sectors and reducing pollution and adverse environmental impacts are critical focus areas.Therefore, the present paper introduces an experimental investigation of a diesel engine's performance and exhaust emissions operating with waste cooking oil (WCO) as a diesel additive. The engine type used is a one-cylinder natural-aspirated constant-speed direct-injection diesel engine. The main variables of the study were the load and the fuel type. The engine performance and emission characteristics were investigated when fueled with three blends. The first blend (D70B10W10DD10) is composed of 70% diesel, 10% butanol,10% WCO, and 10% diethyl ether. The second blend (D60B10W20DD10) is composed of 60% diesel, 10% butanol, 20% WCO, and 10% diethyl ether. The third blend (D50B10W30DD10) comprises 50% diesel, 10% butanol, 30% WCO, and 10% diethyl ether. The study results show that the engine emissions of carbon monoxide (CO) and nitrogen oxides (NOX) vary considerably with the fuel composition and applied load. Concerning engine performance, the cylinder pressure is sensitive to the load and fuel type variation.

Keywords: ICE, waste cooking oil, bio additives, butanol, combustion and emission characteristics

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Authors: Ahbdelfattah M. Khourshid, T. Elabeidi

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Friction Stir Welding (FSW), a solid state joining technique, is widely being used for joining Al alloys for aerospace, marine automotive and many other applications of commercial importance. FSW were carried out using a vertical milling machine on Al 5083 alloy pipe. These pipe sections are relatively small in diameter, 5mm, and relatively thin walled, 2mm. In this study, 5083 aluminum alloy pipe were welded as similar alloy joints using (FSW) process in order to investigate mechanical and microstructural properties .rotation speed 1400 r.p.m and weld speed 10,40,70 mm/min. In order to investigate the effect of welding speeds on mechanical properties, metallographic and mechanical tests were carried out on the welded areas. Vickers hardness profile and tensile tests of the joints as a metallurgical investigation, Optic Microscopy and Scanning Electron Microscopy (SEM) were used for base and weld zones.

Keywords: friction stir welding (FSW), Al alloys, mechanical properties, microstructure

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Authors: S. F. Wong, S. S. Dol

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Automotive designers have been trying to use dimples to reduce drag in vehicles. In this work, a car model has been applied with dimple surface with a parameter called dimple ratio DR, the ratio between the depths of the half dimple over the print diameter of the dimple, has been introduced and numerically simulated via k-ε turbulence model to study the aerodynamics performance with the increasing depth of the dimples The Ahmed body car model with 25 degree slant angle is simulated with the DR of 0.05, 0.2, 0.3 0.4 and 0.5 at Reynolds number of 176387 based on the frontal area of the car model. The geometry of dimple changes the kinematics and dynamics of flow. Complex interaction between the turbulent fluctuating flow and the mean flow escalates the turbulence quantities. The maximum level of turbulent kinetic energy occurs at DR = 0.4. It can be concluded that the dimples have generated extra turbulence energy at the surface and as a result, the application of dimples manages to reduce the drag coefficient of the car model compared to the model with smooth surface.

Keywords: aerodynamics, boundary layer, dimple, drag, kinetic energy, turbulence

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Authors: K. Shahril, A. Nizam, M. Sabri, A. Siti Rohana, H. Salmah

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Chemical modifier (Acrylic Acid) is used as filler treatment to improve mechanical properties and swelling behavior of polypropylene/coconut fiber (PP/CF) composites by creating more adherent bonding between CF filler and PP Matrix. Treated (with chemical modifier) and untreated (without chemical modifier) composites were prepared in the formulation of 10 wt%, 20 wt%, 30 wt%, and 40 wt%. The mechanical testing indicates that composite with 10 wt% of untreated composite has the optimum value of tensile strength, and the composite with chemical modifier shows the tensile strength was increased. By increasing of filler loading, elastic modulus was increased while the elongation at brake was decreased. Meanwhile, the swelling test discerned that the increase of filler loading increased the water absorption of composites and the presence of chemical modifier reduced the equilibrium water absorption percentage.

Keywords: coconut fiber, polypropylene, acid acrylic, ethanol, chemical modifier, composites

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Authors: Wiseborn Manfe Danquah, D. Turgay Altilar

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Vehicular Ad-hoc Network (VANET) is an integral component of Intelligent Transport Systems (ITS) that has enjoyed a lot of attention from the research community and the automotive industry. This is mainly due to the opportunities and challenges it presents. Vehicular Ad-hoc Network being a class of Mobile Ad-hoc Networks (MANET) has all the security concerns existing in traditional MANET as well as new security and privacy concerns introduced by the unique vehicular communication environment. This paper provides a survey of the possible attacks in vehicular environment, as well as security and privacy concerns in VANET. It also provides an insight into the development of a comprehensive cloud framework to provide a more robust and secured communication among vehicular nodes and road side units. Our proposal, a Metropolitan Based Public Interconnected Vehicular Cloud (MIVC) infrastructure seeks to provide a more reliable and secured vehicular communication network.

Keywords: mobile Ad-hoc networks, vehicular ad hoc network, cloud, ITS, road side units (RSU), metropolitan interconnected vehicular cloud (MIVC)

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Authors: D. Reich, R. Stark

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To provide reliable and valid findings when evaluating innovative in-car devices in the automotive context highly realistic driving environments are recommended. Nowadays, in-car devices are mostly evaluated due to driving simulator studies followed by real car driving experiments. Driving simulators are characterized by high internal validity, but weak regarding ecological validity. Real car driving experiments are ecologically valid, but difficult to standardize, more time-robbing and costly. One economizing suggestion is to implement more immersive driving environments when applying driving simulator studies. This paper presents research comparing non-immersive standard PC conditions with mobile and highly immersive Oculus Rift conditions while performing the Lane Change Task (LCT). Subjective data with twenty participants show advantages regarding presence and immersion experience when performing the LCT with the Oculus Rift, but affect adversely cognitive workload and simulator sickness, compared to non-immersive PC condition.

Keywords: immersion, oculus rift, presence, situation awareness

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Authors: Mohan H., C. Elajchet Senni

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In the present of high energy consumption in every sphere of life, renewable energy sources are emerging as alternative to conventional fuels for energy security, mitigating green house gas emission and climate change. There has been a world wide interest in searching for alternatives to petroleum derived fuels due to their depletion as well as due to the concern for the environment. Vegetable oils have capability to solve this problem because they are renewable and lead to reduction in environmental pollution. But high smoke emission and lower thermal efficiency are the main problems associated with the use of neat vegetable oils in diesel engines. In the present work, performance, combustion and emission characteristics of CI engine fuelled with 20% by vol. methyl esters mixed with Karanja seed Oil, and Fuel injection pressures of 200 bar and 240 bar, injection timings (21°,23° and 25° BTDC) and Proportion B20 diesel respectively. Vegetable oils have capability to solve this problem because they are renewable and lead to reduction in environmental pollution. But, high smoke emission and lower thermal efficiency are the main problems associated with the use of neat vegetable oils in diesel engines. In the present work, performance, combustion and emission characteristics of CI engine fuelled with 20% by vol. methyl esters mixed with Karanja seed Oil, and Fuel injection pressures of 200 bar and 240 bar ,Injection timings (21°,23° and 25° BTDC) and Proportion B20 diesel respectively. Various performance, combustion and emission characteristics such as thermal efficiency, and brake specific fuel consumption, maximum cylinder pressure, instantaneous heat release, cumulative heat release with respect to crank angle, ignition lag, combustion duration, HC, NOx, CO, exhaust temperature and smoke intensity were measured.

Keywords: karanja oil, injection pressure, injection timing, karanja oil methyl ester

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Authors: Svetlana Gusarova

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The essential role in the recent development of world economy has led to the developing countries, notably to BRICS countries (Brazil, Russia, India, China, South Africa). Over the next 50 years the BRICS countries are expected to be the engines of global trade and economic growth. Trade cooperation of BRICS countries can enhance their economic development. BRICS countries were among Top 10 world exporters of office and telecom equipment, of textiles, of clothing, of iron and steel, of chemicals, of agricultural products, of automotive products, of fuel and mining products. China was one of the main trading partners of all BRICS countries, maintaining close relationship with all BRICS countries in the development of trade. Author analyzed trade complementarity of BRICS countries and revealed the high level of complementarity of their trade flows in connection with availability of specialization in different types of goods. The correlation and regression analysis of communication of Intra-BRICS merchandise turnover and their GDP (PPP) revealed very strong impact on the development of their economies.

Keywords: BRICS countries, trade cooperation, complementarity, regression analysis

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Authors: Masato Nishi, Tetsushi Kaburagi, Masashi Kurose, Tei Hirashima, Tetsusei Kurasiki

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The process of thermoforming a carbon fiber reinforced thermoplastic (CFRTP) has increased its presence in the automotive industry for its wide applicability to the mass production car. A non-isothermal forming for CFRTP can shorten its cycle time to less than 1 minute. In this paper, the textile reinforcement FE model which the authors proposed in a previous work is extended to the CFRTP model for non-isothermal forming simulation. The effect of thermoplastic is given by adding shell elements which consider thermal effect to the textile reinforcement model. By applying Reuss model to the stress calculation of thermoplastic, the proposed model can accurately predict in-plane shear behavior, which is the key deformation mode during forming, in the range of the process temperature. Using the proposed model, thermoforming simulation was conducted and the results are in good agreement with the experimental results.

Keywords: carbon fiber reinforced thermoplastic, finite element analysis, pre-impregnated textile composite, non-isothermal forming

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Authors: Martha Ndeley, John Ikome

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In this paper, we expand the scope of constraint-directed techniques to deal with the case of transportation schedule with capacity restrictions where the scheduling problem includes alternative activities. That is, not only does the scheduling problem consist of determining when an activity is to be executed, but also determining which set of alternative activities is to be executed at all level of transportation from input to output. Such problems encompass both alternative resource problems and alternative process plan problems. We formulate a constraint-based representation of alternative activities to model problems containing such choices. We then extend existing constraint-directed scheduling heuristic commitment techniques and propagators to reason directly about the fact that an activity does not necessarily have to exist in a final transportation schedule without being completed. Tentative results show that an algorithm using a novel texture-based heuristic commitment technique propagators achieves the best overall performance of the techniques tested.

Keywords: production, transportation, scheduling, integrated

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Authors: Wuttikorn Chayapanja, Sutep Charoenpongpool, Manit Nithitanakul, Brian P. Grady

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Poly (trimethylene terephthalate) (PTT) is a linear aromatic polyester with good strength and stiffness, good surface appearance, low shrinkage and war page, and good dimensional stability. However, it has low impact strength which is a problem in automotive application. Thus, modification of PTT with the other polymer or polymer blending is a one way to develop a new material with excellence properties. In this study, PTT/High Density Polyethylene (HDPE) blends and PTT/Linear Low Density Polyethylene (LLDPE) blends with and without compatibilizers base on maleic anhydride grafted HDPE (MAH-g-HDPE) and ethylene-methacrylic acid neutralized sodium metal (Na-EMAA) were prepared by a twin-screw extruder. The blended samples with different ratios of polymers and compatibilizers were characterized on mechanical and rheological properties. Moreover, the phase morphology and dispersion size were studied by using SEM to give better understanding of the compatibility of the blends.

Keywords: poly trimethylene terephthalate, polyethylene, compatibilizer, polymer blend

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Authors: Ali Raza, Rizwan Latif, Syed Adnan Qasim, Imran Shafi

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Diesel engines are most efficient and reliable in terms of efficiency, reliability, and adaptability. Most of the research and development up till now have been directed towards High Speed Diesel Engine, for Commercial use. In these engines, objective is to optimize maximum acceleration by reducing exhaust emission to meet international standards. In high torque low speed engines, the requirement is altogether different. These types of engines are mostly used in Maritime Industry, Agriculture Industry, Static Engines Compressors Engines, etc. On the contrary, high torque low speed engines are neglected quite often and are eminent for low efficiency and high soot emissions. One of the most effective ways to overcome these issues is by efficient combustion in an engine cylinder. Fuel spray dynamics play a vital role in defining mixture formation, fuel consumption, combustion efficiency and soot emissions. Therefore, a comprehensive understanding of the fuel spray characteristics and atomization process in high torque low speed diesel engine is of great importance. Evaporation in the combustion chamber has a rigorous effect on the efficiency of the engine. In this paper, multiphase evaporation of fuel is modeled for high torque low speed engine using the CFD (computational fluid dynamics) codes. Two distinct phases of evaporation are modeled using modeling soft wares. The basic model equations are derived from the energy conservation equation and Naiver-Stokes equation. O’Rourke model is used to model the evaporation phases. The results obtained showed a generous effect on the efficiency of the engine. Evaporation rate of fuel droplet is increased with the increase in vapor pressure. An appreciable reduction in size of droplet is achieved by adding the convective heat effects in the combustion chamber. By and large, an overall increase in efficiency is observed by modeling distinct evaporation phases. This increase in efficiency is due to the fact that droplet size is reduced and vapor pressure is increased in the engine cylinder.

Keywords: diesel fuel, CFD, evaporation, multiphase

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Authors: Saud Hassan

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This paper shows simulation for the prediction of the flow around the backlight angle of the passenger vehicle. The CFD simulations are carried out on different car models. The Ahmed model “bluff body” used as the stander model to study aerodynamics of the backlight angle. This paper described the airflow over the different car models with different backlight angles and also on the Ahmed model to determine the trailing vortices with the varying backlight angle of a passenger vehicle body. The CFD simulation is carried out with the Ahmed body which has simplified car model mainly used in automotive industry to investigate the flow over the car body surface. The main goal of the simulation is to study the behavior of trailing vortices of these models. In this paper the air flow over the slant angle of 0,5o, 12.5o, 20o, 30o, 40o are considered. As investigating on the rear backlight angle two dimensional flows occurred at the rear slant, on the other hand when the slant angle is 30o the flow become three dimensional. Above this angle sudden drop occurred in drag.

Keywords: aerodynamics, Ahemd vehicle , backlight angle, finite element method

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Authors: Alaa Fezai, Anuj Sharma, Wolfgang Mueller-Hirsch, André Zimmermann

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Viscoelastic materials have been widely used in the automotive industry over the last few decades with different functionalities. Besides their main application as a simple and efficient surface damping treatment, they may ensure optimal operating conditions for on-board electronics as thermal interface or sealing layers. The dynamic behavior of viscoelastic materials is generally dependent on many environmental factors, the most important being temperature and strain rate or frequency. Prior to the reliability analysis of systems including viscoelastic layers, it is, therefore, crucial to accurately predict the dynamic and lifetime behavior of these materials. This includes the identification of the dynamic material parameters under critical temperature and frequency conditions along with a precise damage localization and identification methodology. The goal of this work is twofold. The first part aims at applying an inverse viscoelastic material-characterization approach for a wide frequency range and under different temperature conditions. For this sake, dynamic measurements are carried on a single lap joint specimen using an electrodynamic shaker and an environmental chamber. The specimen consists of aluminum beams assembled to adapter plates through a viscoelastic adhesive layer. The experimental setup is reproduced in finite element (FE) simulations, and frequency response functions (FRF) are calculated. The parameters of both the generalized Maxwell model and the fractional derivatives model are identified through an optimization algorithm minimizing the difference between the simulated and the measured FRFs. The second goal of the current work is to guarantee an on-line detection of the damage, i.e., delamination in the viscoelastic bonding of the described specimen during frequency monitored end-of-life testing. For this purpose, an inverse technique, which determines the damage location and size based on the modal frequency shift and on the change of the mode shapes, is presented. This includes a preliminary FE model-based study correlating the delamination location and size to the change in the modal parameters and a subsequent experimental validation achieved through dynamic measurements of specimen with different, pre-generated crack scenarios and comparing it to the virgin specimen. The main advantage of the inverse characterization approach presented in the first part resides in the ability of adequately identifying the material damping and stiffness behavior of soft viscoelastic materials over a wide frequency range and under critical temperature conditions. Classic forward characterization techniques such as dynamic mechanical analysis are usually linked to limitations under critical temperature and frequency conditions due to the material behavior of soft viscoelastic materials. Furthermore, the inverse damage detection described in the second part guarantees an accurate prediction of not only the damage size but also its location using a simple test setup and outlines; therefore, the significance of inverse numerical-experimental approaches in predicting the dynamic behavior of soft bonding layers applied in automotive electronics.

Keywords: damage detection, dynamic characterization, inverse approaches, vibration testing, viscoelastic layers

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Authors: Gia Surguladze, Nino Topuria, Lily Petriashvili, Giorgi Surguladze

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Modeling of building processes of a multimodal freight transportation support information system is discussed based on modern CASE technologies. Functional efficiencies of ports in the eastern part of the Black Sea are analyzed taking into account their ecological, seasonal, resource usage parameters. By resources, we mean capacities of berths, cranes, automotive transport, as well as work crews and neighbouring airports. For the purpose of designing database of computer support system for Managerial (Logistics) function, using Object-Role Modeling (ORM) tool (NORMA – Natural ORM Architecture) is proposed, after which Entity Relationship Model (ERM) is generated in automated process. The software is developed based on Process-Oriented and Service-Oriented architecture, in Visual Studio.NET environment.

Keywords: seaport resources, business-processes, multimodal transportation, CASE technology, object-role model, entity relationship model, SOA

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Authors: Miroslav Gutten, Jozef Jurcik, Daniel Korenciak, Milan Sebok, Matej Kuceraa

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This paper deals with the phenomenon of the undesirable detonation combustion in internal combustion engines. A control unit of the engine monitors these detonations using piezoelectric knock sensors. With the control of these sensors the detonations can be objectively measured just outside the car. If this component provides small amplitude of the output voltage it could happen that there would have been in the areas of the engine ignition combustion. The paper deals with the design of a simple device for the detection of this disorder. A construction of the testing device for the knock sensor suitable for diagnostics of knock combustion in internal combustion engines will be presented. The output signal of presented sensor will be described by Bessel functions. Using the first voltage extremes on the characteristics it is possible to create a reference for the evaluation of the polynomial residue. It should be taken into account that the velocity of sound in air is 330 m/s. This sound impinges on the walls of the combustion chamber and is detected by the sensor. The resonant frequency of the clicking of the motor is usually in the range from 5 kHz to 15 kHz. The sensor worked in the field to 37 kHz, which shall be taken into account on an own sensor resonance.

Keywords: diagnostics, knock sensor, measurement, testing device

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Authors: Lakshminarayanan, Vijayaraghavan, Krishnamurthy

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The ever-increasing demand for high efficiency in automotive and aerospace applications requires new materials to suit to high temperature applications. The Ceramic Matrix Composites nowadays find its applications for high strength and high temperature environments. In this paper, Al2O3 and Sic ceramic materials are taken in particulate form as matrix and reinforcement respectively. They are blended together in Ball Milling and compacted in Cold Compaction Machine by powder metallurgy technique. Scanning Electron Microscope images are taken for the samples in order to find out proper blending of powders. Micro harness testing is also carried out for the samples in Vickers Micro Hardness Testing Equipment. Surface grinding of the samples is also carried out in Surface Grinding Machine in order to find out grinding force estimates. The surface roughness of the grounded samples is also taken in Surface Profilometer. These are yielding promising results.

Keywords: ceramic matrix composite, cold compaction, material characterization, particulate and surface grinding

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Authors: Shengyi Huang, Chenju Liang

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Volatile organic compounds such as benzene, toluene, ethyl-benzene, and xylene (BTEX) are common contaminants in environment, which could come from asphalt concrete or exhaust emissions of vehicles. The BTEX may invade to the subsurface environment via wet and dry atmospheric depositions. If there aren’t available ways for controlling contaminants’ fate and transport, they would extensively harm natural environment. In the 1st phase of this study, various adsorbents were screened for a suitable one to be an additive in the porous asphalt mixture. In the 2nd phase, addition of the selected adsorbent was incorporated with the design of porous asphalt concrete (PAC) to produce the permeable reactive pavement (PRP), which was subsequently tested for the potential of adsorbing aqueous BTEX as compared to the PAC, in the 3rd phase. The PRP was prepared according to the following steps: firstly, the suitable adsorbent was chosen based on the analytical results of specific surface area analysis, thermal-gravimetric analysis, adsorption kinetics and isotherms, and thermal dynamics analysis; secondly, the materials of coarse aggregate, fine aggregate, filler, asphalt, and fiber were tested in order to meet regulated specifications (e.g., water adsorption, soundness, viscosity etc.) for preparing the PRP; thirdly, the amount of adsorbent additive was determined in the PRP; fourthly, the prepared PAC and PRP were examined for their physical properties (e.g., abrasion loss, drain-down loss, Marshall stability, Marshall flow, dynamic stability etc.). As a result of comparison between PRP and PAC, the PRP showed better physical performance than the traditional PAC. At last, the Marshall Specimen column tests were conducted to explore the adsorption capacities of PAC and PRPs. The BTEX adsorption capacities of PRPs are higher than those obtained from traditional PAC. In summary, PRPs showed superior physical performance and adsorption capacities, which exhibit the potential of PRP to be applied as a replacement of PAC for better controlling the transport of non-point source pollutants.

Keywords: porous asphalt concrete, volatile organic compounds, permeable reactive pavement, non-point source pollution

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Authors: Hammad Majeed, Hanna Knuutila, Magne Hillestad, Hallvard F. Svendsen

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Formation of aerosols can cause serious complications in industrial exhaust gas CO2 capture processes. SO3 present in the flue gas can cause aerosol formation in an absorption based capture process. Small mist droplets and fog formed can normally not be removed in conventional demisting equipment because their submicron size allows the particles or droplets to follow the gas flow. As a consequence of this aerosol based emissions in the order of grams per Nm3 have been identified from PCCC plants. In absorption processes aerosols are generated by spontaneous condensation or desublimation processes in supersaturated gas phases. Undesired aerosol development may lead to amine emissions many times larger than what would be encountered in a mist free gas phase in PCCC development. It is thus of crucial importance to understand the formation and build-up of these aerosols in order to mitigate the problem. Rigorous modelling of aerosol dynamics leads to a system of partial differential equations. In order to understand mechanics of a particle entering an absorber an implementation of the model is created in Matlab. The model predicts the droplet size, the droplet internal variable profiles and the mass transfer fluxes as function of position in the absorber. The Matlab model is based on a subclass method of weighted residuals for boundary value problems named, orthogonal collocation method. The model comprises a set of mass transfer equations for transferring components and the essential diffusion reaction equations to describe the droplet internal profiles for all relevant constituents. Also included is heat transfer across the interface and inside the droplet. This paper presents results describing the basic simulation tool for the characterization of aerosols formed in CO2 absorption columns and gives examples as to how various entering droplets grow or shrink through an absorber and how their composition changes with respect to time. Below are given some preliminary simulation results for an aerosol droplet composition and temperature profiles.

Keywords: absorption columns, aerosol formation, amine emissions, internal droplet profiles, monoethanolamine (MEA), post combustion CO2 capture, simulation

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Authors: Rafal Sochaczewski, Marcin Szlachetka, Miroslaw Wendeker

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Increasing requirements to reduce exhaust emissions and fuel consumption while increasing the power factor is increasingly becoming applicable to internal combustion engines intended for aircraft applications. As a result, intensive research work is underway to develop a diesel-powered unit for aircraft propulsion. Due to a number of advantages, such as lack of the head (lower heat loss) and timing system, opposite movement of pistons conducive to balancing the engine, the two-stroke compression-ignition engine with the opposite pistons has been developed and upgraded. Of course, such construction also has drawbacks. The main one is the necessity of using a gear connecting two crankshafts or a complicated crank system with one shaft. The peculiarity of the arrangement of pistons with sleeves, as well as the fulfillment of rigorous requirements, makes it necessary to apply the most modern technologies and constructional solutions. In the case of the fuel supply system, it was decided to use common rail system elements. The paper presents an analysis of the possibility of using a common rail pump to supply an aircraft compression-ignition engine. It is an engine with a two-stroke cycle, three cylinders, opposing pistons, and 100 kW power. Each combustion chamber is powered by two injectors controlled by electromagnetic valves. In order to assess the possibility of using a common rail pump, four high-pressure pumps were tested on a bench. They are piston pumps differing in the number and geometry of the pumping sections. The analysis included the torque on the pump drive shaft and the power needed to drive the pump depending on the rotational speed, pumping pressure and fuel dispenser settings. The research allowed to optimize the engine power supply system depending on the fuel demand and the way the pump is mounted on the engine. Acknowledgment: This work has been realized in the cooperation with The Construction Office of WSK ‘PZL-KALISZ’ S.A.’ and is part of Grant Agreement No. POIR.01.02.00-00-0002/15 financed by the Polish Nation-al Centre for Research and Development.

Keywords: diesel engine, fuel pump, opposing pistons, two-stroke

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Authors: Achim Kampker, Heiner Hans Heimes, Mathias Ordung, Nemanja Sarovic

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A key component of the drive train of electric vehicles is the lithium-ion battery system. Among various other components, such as the battery management system or the thermal management system, the battery system mostly consists of several cells which are integrated mechanically as well as electrically. Due to different vehicle concepts with regards to space, energy and power specifications, there is a variety of different battery systems. The corresponding assembly lines are specially designed for each battery concept. Minor changes to certain characteristics of the battery have a disproportionally high effect on the set-up effort in the form of high change-related costs. This paper will focus on battery systems which are made out of battery cells with a prismatic format. The product architecture and the assembly process will be analyzed in detail based on battery concepts of existing electric cars and key variety-causing drivers will be identified. On this basis, several measures will be presented and discussed on how to change the product architecture and the assembly process in order to reduce change-related costs.

Keywords: assembly, automotive industry, battery system, battery concept

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Authors: V. E. Messerle, A. L. Mosse, O. A. Lavrichshev, A. N. Nikonchuk, A. B. Ustimenko

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One of the most serious environmental problems today is pollution by biomedical waste (BMW), which in most cases has undesirable properties such as toxicity, carcinogenicity, mutagenicity, fire. Sanitary and hygienic survey of typical solid BMW, made in Belarus, Kazakhstan, Russia and other countries shows that their risk to the environment is significantly higher than that of most chemical wastes. Utilization of toxic BMW requires use of the most universal methods to ensure disinfection and disposal of any of their components. Such technology is a plasma technology of BMW processing. To implement this technology a thermodynamic analysis of the plasma processing of BMW was fulfilled and plasma-box furnace was developed. The studies have been conducted on the example of the processing of bone. To perform thermodynamic calculations software package Terra was used. Calculations were carried out in the temperature range 300 - 3000 K and a pressure of 0.1 MPa. It is shown that the final products do not contain toxic substances. From the organic mass of BMW synthesis gas containing combustible components 77.4-84.6% was basically produced, and mineral part consists mainly of calcium oxide and contains no carbon. Degree of gasification of carbon reaches 100% by the temperature 1250 K. Specific power consumption for BMW processing increases with the temperature throughout its range and reaches 1 kWh/kg. To realize plasma processing of BMW experimental installation with DC plasma torch of 30 kW power was developed. The experiments allowed verifying the thermodynamic calculations. Wastes are packed in boxes weighing 5-7 kg. They are placed in the box furnace. Under the influence of air plasma flame average temperature in the box reaches 1800 OC, the organic part of the waste is gasified and inorganic part of the waste is melted. The resulting synthesis gas is continuously withdrawn from the unit through the cooling and cleaning system. Molten mineral part of the waste is removed from the furnace after it has been stopped. Experimental studies allowed determining operating modes of the plasma box furnace, the exhaust gases was analyzed, samples of condensed products were assembled and their chemical composition was determined. Gas at the outlet of the plasma box furnace has the following composition (vol.%): CO - 63.4, H2 - 6.2, N2 - 29.6, S - 0.8. The total concentration of synthesis gas (CO + H2) is 69.6%, which agrees well with the thermodynamic calculation. Experiments confirmed absence of the toxic substances in the final products.

Keywords: biomedical waste, box furnace, plasma torch, processing, synthesis gas

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Authors: Safa Boudhaouia, Mohamed Amen Gahbiche, Eliane Giraud, Wacef Ben Salem, Philippe Dal Santo

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Multi-point forming (MPF) and asymmetric incremental forming (ISF) are two flexible processes for sheet metal manufacturing. To take advantages of these two techniques, a hybrid process has been developed: The Multipoint Incremental Forming (MPIF). This process accumulates at once the advantages of each of these last mentioned forming techniques, which makes it a very interesting and particularly an efficient process for single, small, and medium series production. In this paper, an experimental and a numerical investigation of this technique are presented. To highlight the flexibility of this process and its capacity to manufacture standard and complex shapes, several pieces were produced by using MPIF. The forming experiments are performed on a 3-axis CNC machine. Moreover, a numerical model of the MPIF process has been implemented in ABAQUS and the analysis showed a good agreement with experimental results in terms of deformed shape. Furthermore, the use of an elastomeric interpolator allows avoiding classical local defaults like dimples, which are generally caused by the asymmetric contact and also improves the distribution of residual strain. Future works will apply this approach to other alloys used in aeronautic or automotive applications.

Keywords: incremental forming, numerical simulation, MPIF, multipoint forming

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Authors: Sireesha Tamada, Debraj Bhattacharjee, Pranab K. Dan, Prabha Bhola

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The most important component in an automotive transmission system is the gearbox which controls the speed of the vehicle. In an automatic transmission, the right positioning of actuators ensures efficient transmission mechanism embodiment, wherein the challenge lies in formulating the number of actuators associated with modelling a gearbox. Data with respect to actuation and gear shifting sequence has been retrieved from the available literature, including patent documents, and has been used in this proposed heuristics based methodology for modelling actuation sequence in a gear box. This paper presents a methodological approach in designing a gearbox for the purpose of obtaining an optimal shifting sequence. The computational model considers factors namely, the number of stages and gear teeth as input parameters since these two are the determinants of the gear ratios in an epicyclic gear train. The proposed transmission schematic or stick diagram aids in developing the gearbox layout design. The number of iterations and development time required to design a gearbox layout is reduced by using this approach.

Keywords: automatic transmission, gear-shifting, multi-stage planetary gearbox, rank ordered clustering

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Authors: İmren Öztürk Yılmaz, Abdullah Yasin Bilici, Yasin Atalay Candemir

Abstract:

The system consists of 4 main elements: motion system, image acquisition system, image processing software, and control interface. The parts coming out of the production line to enter the image processing system with the conveyor belt at the end of the line. The 3D scanning of the produced part is performed with the laser scanning system integrated into the system entry side. With the 3D scanning method, it is determined at what position and angle the parts enter the system, and according to the data obtained, parameters such as part origin and conveyor speed are calculated with the designed software, and the robot is informed about the position where it will take part. The robot, which receives the information, takes the produced part on the belt conveyor and shows it to high-resolution cameras for quality control. Measurement processes are carried out with a maximum error of 20 microns determined by the experiments.

Keywords: quality control, industry 4.0, image processing, automated fault detection, digital visual inspection

Procedia PDF Downloads 79

Authors: Un-Hwan Park, Jun-Hyeok Heo, In-Sung Lee, Tae-Hyeon Oh, Dae-Gyu Park

Abstract:

Automotive interior material consisting of several material layers has the sound-absorbing function. It is difficult to predict sound absorbing coefficient because of several material layers. So, many experimental tunings are required to achieve the target of sound absorption. Therefore, while the car interior materials are developed, so much time and money is spent. In this study, we present a method to predict the sound absorbing performance of the material with multi-layer using physical properties of each material. The properties are predicted by Foam-X software using the sound absorption coefficient data measured by impedance tube. Then, we will compare and analyze the predicted sound absorption coefficient with the data measured by scaled reverberation chamber and impedance tubes for a prototype. If the method is used instead of experimental tuning in the development of car interior material, the time and money can be saved, and then, the development effort can be reduced because it can be optimized by simulation.

Keywords: multi-layer nonwoven, sound absorption coefficient, scaled reverberation chamber, impedance tubes

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Authors: Hyo Lim Kang, Tae An Kim, Seung Ho Han

Abstract:

A 3-way reversing valve has been used in automotive washing machines to remove remaining oil and dirt on machined engine and transmission blocks. It provides rapid and accurate changes of water flow direction without any precise control device. However, due to its complicated bottom-plug shape, a cavitation occurs in a wide range of the bottom-plug in a downstream. In this study, the cavitation index and POC (percent of cavitation) were used to evaluate quantitatively the cavitation phenomena occurring at the bottom-plug. An optimal shape design was carried out via parametric study for geometries of the bottom-plug, in which a simple CAE-model was used in order to avoid time-consuming CFD analysis and hard to achieve convergence. To verify the results of numerical analysis, a flow visualization test was carried out using a test specimen with a transparent acryl pipe according to ISA-RP75.23. The flow characteristics such as the cavitation occurring in the downstream were investigated by using a flow test equipment with valve and pump including a flow control system and high-speed camera.

Keywords: cavitation, flow visualization test, optimal shape design, percent of cavitation, reversing valve

Procedia PDF Downloads 271

Authors: Young-Doo Kwon, Seong-Hwa Jun, Dong-Jin Lee, Hyung-Seok Lee

Abstract:

Ball joints support and guide certain automotive parts that move relative to the frame of the vehicle. Such ball joints are covered and protected from dust, mud, and other interfering materials by ball-joint boots made of rubber—a flexible and near-incompressible material. The boots may experience twisting and bending deformations because of the motion of the joint arm. Thus, environmental and endurance tests of ball-joint boots apply both bending and twisting deformations. In this study, environmental and endurance testing was simulated via the finite element method performed by using a commercial software package. The ranges of principal stress and principal strain values that are known to directly affect the fatigue lives of the parts were sought. By defining these ranges, the number of iterative tests and modifications of the materials and dimensions of the boot can be decreased. Therefore, instead of performing actual part tests, manufacturers can perform standard fatigue tests in trials of different materials by applying only the defined range of stress or strain values.

Keywords: boot, endurance tests, rubber, FEA

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Authors: Ksenia Siadkowska, Tytus Tulwin, Rafał Sochaczewski

Abstract:

Selecting appropriate materials is presently a complex task as material databases cover tens of thousands of different types of materials. Product designing proceeds in numerous stages and in most of them there are open questions with not only one correct solution but better and worse ones. This paper overviews the Diesel engine body construction materials mentioned in the literature and discusses a certain practical method to select materials for a cylinder head and a Diesel engine block as a prototype. The engine body, depending on its purpose, is most frequently iron or aluminum. If it is important to optimize parts to achieve low weight, aluminum alloys are usually applied, especially in the automotive and aviation industries. In the latter case, weight is even more important so new types of magnesium alloys which are even lighter than aluminum ones are developed and used. However, magnesium alloys are, for example, more flammable and not enough strong so, for safety reasons, this type of material is not used solely in engine bodies. Acknowledgement: This work has been realized in the cooperation with The Construction Office of WSK "PZL-KALISZ" S.A." and is part of Grant Agreement No. POIR.01.02.00-00-0002/15 financed by the Polish National Centre for Research and Development.

Keywords: aluminum alloy, cylinder head, Diesel engine, materials selection

Procedia PDF Downloads 368