Search results for: automotive

Authors: Ahmad K. Jassim, Raheem Kh. Al-Subar

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Friction stir welding is a modern and an environmentally friendly solid state joining process used to joint relatively lighter family of materials. Recently, friction stir spot welding has been used instead of resistance spot welding which has received considerable attention from the automotive industry. It is environmentally friendly process that eliminated heat and pollution. In this research, friction stir spot welding has been used to study the possibility to weld AA1100 aluminum alloy sheet with 3 mm thickness by overlapping the edges of sheet as lap joint. The process was done using a drilling machine instead of milling machine. Different tool rotational speeds of 760, 1065, 1445, and 2000 RPM have been applied with manual and automatic compression to study their effect on the quality of welded joints. Heat generation, pressure applied, and depth of tool penetration have been measured during the welding process. The result shows that there is a possibility to weld AA1100 sheets; however, there is some surface defect that happened due to insufficient condition of welding. Moreover, the relationship between rotational speed, pressure, heat generation and tool depth penetration was created.

Keywords: friction, spot, stir, environmental, sustainable, AA1100 aluminum alloy

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Authors: Gurmeet Singh Cheema, Gurjinder Singh, Amardeep Singh Kang

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Aluminium alloy 6061 is a medium to high strength heat-treatable alloy which has very good corrosion resistance and very good weldability. Friction Stir Welding was developed and this technique has attracted considerable interest from the aerospace and automotive industries since it is able to produce defect free joints particularly for light metals i.e aluminum alloy and magnesium alloy. In the friction stir welding process, welding parameters such as tool rotational speed, welding speed and tool shoulder diameter play a major role in deciding the weld quality. In this research work, an attempt has been made to understand the effect of tool rotational speed, welding speed and tool shoulder diameter on friction stir welded AA6061 aluminium alloy joints. Statistical tool such as central composite design is used to develop the mathematical relationships. The mathematical model was developed to predict mechanical properties of friction stir welded aluminium alloy joints at the 95% confidence level.

Keywords: aluminium alloy, friction stir welding, central composite design, mathematical relationship

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Authors: Nicholas Lambert, Seungyeon Ryu, Mehmet Mulla, Albert Kim

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In this paper, an interactive in-car interface called HoloDash is presented. It is intended to provide information and infotainment in both autonomous vehicles and ‘connected cars’, vehicles equipped with Internet access via cellular services. The research focuses on the development of interactive avatars for this system and its gesture-based control system. This is a case study for the development of a possible human-centred means of presenting a connected or autonomous vehicle’s On-Board Diagnostics through a projected ‘holographic’ infotainment system. This system is termed a Holographic Human Vehicle Interface (HHIV), as it utilises a dashboard projection unit and gesture detection. The research also examines the suitability for gestures in an automotive environment, given that it might be used in both driver-controlled and driverless vehicles. Using Human Centred Design methods, questions were posed to test subjects and preferences discovered in terms of the gesture interface and the user experience for passengers within the vehicle. These affirm the benefits of this mode of visual communication for both connected and driverless cars.

Keywords: gesture, holographic interface, human-computer interaction, user-centered design

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Authors: Tytus Tulwin, Rafal Sochaczewski, Ksenia Siadkowska

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Designing a new engine requires a large number of different cases to be considered. Especially different injector parameters and combustion chamber geometries. This is essential when developing an engine with unconventional build – compression ignition, two-stroke operating with direct side injection. Computational Fluid Dynamics modelling allows to test those different conditions and seek for the best conditions with correct combustion. This research presents the combustion results for different injector and combustion chamber cases. The shape of combustion chamber is different than for conventional engines as it requires side injection. This completely changes the optimal shape for the given condition compared to standard automotive heart shaped combustion chamber. Because the injection is not symmetrical there is a strong influence of cylinder swirl and piston motion on the injected fuel stream. The results present the fuel injection phenomena allowing to predict the right injection parameters for a maximum combustion efficiency and minimum piston heat loads. 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: CFD, combustion, injection, opposed piston

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Authors: Asmae Chraibi, Rachid Lghoul, Nabil Rhiati

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In the era of Industry 4.0, enterprises are increasingly employing digital technologies in order to improve their product development processes. This research focuses on the strategic deployment of Product Lifecycle Management (PLM) solutions during production as a key tracker of traceability and digital transformation activities. The study explores the integration of PLM within a larger organizational framework, examining its impact on product lifecycle efficiency, corporation, and innovation. Through a comprehensive analysis of a real case study from the automotive industry, this project evaluates the critical success factors and challenges associated with implementing PLM solutions for digital transformation. Moreover, it explores the synergic relationship between PLM and emerging technologies such as 3D experience and SOLIDWORKS, elucidating their combined potential in optimizing production workflows and enabling data-driven decision-making. The study's findings provide global approaches for firms looking to embark on a digital transformation journey by implementing PLM technologies. This research contributes to a better understanding of how PLM can be effectively used to foster innovation and competitiveness in the changing landscape of modern industry by shining light on best practices, critical considerations, and potential obstacles.

Keywords: product lifecyle management (PLM), industry 4.0, traceability, digital transformation, solution, innovation, 3D experience, SOLIDWORKS

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Authors: B. Soni, S. Biswas

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Metal foams of Al find diverse applications in several industrial sectors such as in automotive and sports equipment industry as impact, acoustic and vibration absorbers, the aerospace industry as structural components in turbines and spatial cones, in the naval industry as low frequency vibration absorbers, and in construction industry as sound barriers inside tunnels, as fire proof materials and structure protection systems against explosions and even in heat exchangers, orthopedic components, and decorative items. Here, we report on the development of Al foams by a low cost and convenient technique of salt replication method with efficient control over size, geometry and distribution of the pores. Sodium bicarbonate was used as the foaming agent to form the porous refractory salt pattern. The mixed refractory salt slurry was microwave dried followed by sintering for selected time periods. Molten Al was infiltrated into the salt pattern in an inert atmosphere at a pressure of 2 bars. The final products were obtained by leaching out the refractory salt pattern. Mechanical properties of the derived samples were studied with a universal testing machine. The results were analyzed in correlation with their microstructural features evaluated with a scanning electron microscope (SEM).

Keywords: metal foam, Al, salt replication method, mechanical properties, SEM

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Authors: Sylvia Villarreal, Edna Bravo

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Knowledge management focuses on coordinating technologies, people, processes, and structures to generate a competitive advantage and considering that networks are perceived as mechanisms for knowledge creation and transfer, this research presents the stages and practices related to the creation of knowledge networks. The methodology started with a literature review adapted from the systematic literature review (SLR). The descriptive analysis includes variables such as approach (conceptual or practical), industry, knowledge management processes and mythologies (qualitative or quantitative), etc. The content analysis includes identification of reference cases. These cases were characterized based on variables as scope, creation goal, years, network approach, actors and creation methodology. It was possible to do a comparative analysis to determinate similarities and differences in these cases documented in knowledge network scientific literature. Consequently, it was shown that even the need and impact of knowledge networks in organizations, the initial guidelines for their creation are not documented, so there is not a guide of good practices and lessons learned. The reference cases are from industries as energy, education, creative, automotive and textile. Their common points are the human approach; it is oriented to interactions to facilitate the appropriation of knowledge, explicit and tacit. The stages of every case are analyzed to propose the main successful elements.

Keywords: creation, knowledge management, network, stages

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Authors: George Madalin Danila, Mihaiella Cretu, Cristian Puscasu

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Glycol-based anti-freeze liquids, commonly composed of ethylene glycol or propylene glycol, have important uses in automotive cooling, but they should be handled with care due to their toxicity; ethylene glycol is highly toxic to humans and animals. A fast, accurate, precise, and robust method was developed for the simultaneous quantification of 7 most important glycols and their isomers. Glycols were analyzed from diluted sample solution of coolants using gas-chromatography coupled with mass spectrometry in single ion monitoring mode. Results: The method was developed and validated for 7 individual glycols (ethylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, propylene glycol, dipropylene glycol and tripropylene glycol). Limits of detection (1-2 μg/mL) and limit of quantification (10 μg/mL) obtained were appropriate. The present method was applied for the determination of glycols in 10 different anti-freeze liquids commercially available on the Romanian market, proving to be reliable. A method that requires only a two-step dilution of anti-freeze samples combined with direct liquid injection GC-MS was validated for the simultaneous quantification of 7 glycols (and their isomers) in 10 different types of anti-freeze liquids. The results obtained in the validation procedure proved that the GC-MS method is sensitive and precise for the quantification of glycols.

Keywords: glycols, anti-freeze, gas-chromatography, mass spectrometry, validation, recycle

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Authors: Kamil Dydek, Szymon Demski, Kamil Majchrowicz, Paulina Kozera, Bogna Sztorch, Dariusz Brząkalski, Zuzanna Krawczyk, Robert Przekop, Anna Boczkowska

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Carbon fibre reinforced polymers (CFRPs) are characterized by very high strength and stiffness in relation to their weight. In addition, properties such as corrosion resistance and low thermal expansion allow them to replace traditional materials, i.e., wood or metals, in many industries such as aerospace, automotive, marine, and sports goods. However, CFRPs, have some disadvantages -they have relatively low electrical conductivity and break brittle, which significantly limits their application possibilities. Moreover, conventional CFRPs are usually manufactured based on thermosets, which makes them difficult to recycle. The solution to these drawbacks is the use of the innovative thermoplastic resin (ELIUM from ARKEMA) as a matrix of composites and the modification by introducing into their structure thermoplastic nonwovens based on PET-G with the addition of multi-wall carbon nanotubes (MWCNTs). The acrylic-carbon composites, which were produced by the infusion technique, were tested for mechanical, thermo-mechanical, and electrical properties, and the effect of modifications on their microstructure was studied. Acknowledgment: This study was carried out with funding from grant no. LIDER/46/0185/L-11/19/NCBR/2020, financed by The National Centre for Research and Development.

Keywords: CFRP, MWCNT, ELIUM, electrical properties, infusion

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Authors: Mohamed Amine El Hameur, Lyes Tarabet, Mahfoudh Cerdoun, Boubkr Zebiri, Giovanni Ferrara

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Due to the drastic environmental and energy regulations regarding the reduction of exhaust emissions and fuel consumption, added to the increasing demand for powerful performance, several automotive manufacturers are constantly obliged to redesign their existing products and/or develop novel powertrain techniques to respond to the aforementioned restrictions. In this aspect, an implemented approach is proposed in the present work to boost a 1.5 L, three-cylinder Diesel engine with a new turbocharger, based on 1D preliminary design codes, 3D design, and numerical assessment of a suitable radial turbine followed by an accurate selection procedure of an adequate centrifugal compressor. Furthermore, to investigate the effect of the turbine’s rotor position on the simulation convergence, stability, and calculation time; two combinations (rotor blade- volute) have been assessed. Consequently, significant results are obtained when comparing the original turbocharged engine and the new one at the engine’s full load and rated speed (@4500rpm) conditions. A maximum improvement in terms of brake-specific fuel consumption, thermal efficiency, total-to-static turbine efficiency, and total-to-total compressor efficiency equal 6.5% (corresponding to a decrease of 2.3 litre/hr in fuel consumption), 7%, 10.9%, and 19.9%, respectively.

Keywords: CFD investigation, engine boosting, turbine design, turbocharger, rotor blade positioning

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Authors: M. Fette, J. P. Wulfsberg, A. Herrmann, R. H. Ladstaetter

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Present and future lightweight design represents an important key to successful implementation of energy-saving, fuel-efficient and environmentally friendly means of transport in the aerospace and automotive industry. In this context the use of carbon fibre reinforced plastics (CFRP) which are distinguished by their outstanding mechanical properties at relatively low weight, promise significant improvements. Due to the reduction of the total mass, with the resulting lowered fuel or energy consumption and CO2 emissions during the operational phase, commercial aircraft and future vehicles will increasingly be made of CFRP. An auspicious technology for the efficient and economic production of high performance thermoset composites and hybrid structures for future lightweight applications is the combination of carbon fibre sheet moulding compound (SMC), tailored continuous carbon fibre reinforcements and metallic components in a one-shot pressing and curing process. This paper deals with a new hybrid composite technology for aerospace industries, which was developed with the help of a universal innovation and development system. This system supports the management of idea generation, the methodical development of innovative technologies and the achievement of the industrial readiness of these technologies.

Keywords: development system, hybrid composite, innovation system, prepreg, sheet moulding compound

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Authors: Rosa Sobreira, Paula Arriscado

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Marketers are aware that media relations is an important touch point, which is also cheaper, to bring their products and their brands to the consumer. They recognize the role of journalists as moderators and transformers of public opinion, and they realize their influence on brand image. And also, they know that readers, listeners, viewers and internet users "believe" more what they read, hear and see in the news than in an advertisement. The study is focused on the automotive industry and analyses the news published about three brands that share industrial facilities and components. We wanted to understand the role of the information created by the brand`s media team in the journalists’ work, and the impact on management, activation and differentiation of brands and their products` attributes and benefits. Based on a qualitative methodology, the analysis focused on press news, making comparison between media coverage and their “narratives” about the three cars from different brands. The results point to the fact that journalists easily integrate speech from the marks on their products. In the case of this study, we found that apart from the description of the many similarities between the three cars, the average speech also "struggled" for revealing the attributes that differentiate them. This interpretation of the results helps us to understand the "marriage" between branding and media. We believe also this paper let us to understand how journalists, through news, join the speech of the brands.

Keywords: brand management, media relations, differentiation, positioning

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Authors: Setenay Nil Doğan, Ece Oztan

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Research and development (R&D) as a term denotes the innovative studies conducted systematically to increase knowledge and its practices. As R&D intensity of Turkey (0,84%) is quite below the EU average intensity score, it has displayed a continuous increase since the 2000s. Also, the development of human capital in R&D has been one of the basic aims of National Strategy of Science, Technology, and Innovation, and National Innovation System 2023 of Turkey. R&D is considered to one of the fields in which the gender gap is wide. The reflections of the analogy of leaky pipeline, a term used for vertical differentiation in academy can also be observed in those scientific activities related with the private sector. In the private sector, the gender gap becomes wider: the percentage of female researchers in the universities (41%) decreases to 24% in the private sector. Though half of the undergraduates and gradutes are female in Turkey, a widening gender gap is observed in terms of employment in R&D. Given this background, this paper will focus on gendered dynamics of careers in R&D through the interviews conducted with 25 female and 25 male employees, working in a university technopark and some of the large RD centers in Turkey working in several sectors such as electronics, automotive etc. Focusing on some aspects of gender differences in terms of career experiences in R&D and innovation, mobility, participation to the projects, patents and inclusion to other innovatory activities, home-work balance, it aims to explore the relationships between science, technology, innovation and gender.

Keywords: gender, innovation, R&D, science, technology

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Authors: Atef Alaaeddine Sarraj, Brendan Jackman, Frank Walsh

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Tomorrow’s car will be more automated and increasingly connected. Innovative and intuitive interfaces are essential to accompany this functional enrichment. For that, today the automotive companies are competing to offer an advanced driver assistance system (ADAS) which will be able to provide enhanced navigation, collision avoidance, intersection support and lane keeping. These vision-based functions require an accurately calibrated camera. To achieve such differentiation in ADAS requires sophisticated sensors and efficient algorithms. This paper explores the different calibration methods applicable to vehicle-mounted fish-eye cameras with arbitrary fields of view and defines the first steps towards a self-calibration method that adequately addresses ADAS requirements. In particular, we present a self-calibration method after comparing different camera calibration algorithms in the context of ADAS requirements. Our method gathers data from unknown scenes while the car is moving, estimates the camera intrinsic and extrinsic parameters and corrects the wide-angle distortion. Our solution enables continuous and real-time detection of objects, pedestrians, road markings and other cars. In contrast, other camera calibration algorithms for ADAS need pre-calibration, while the presented method calibrates the camera without prior knowledge of the scene and in real-time.

Keywords: advanced driver assistance system (ADAS), fish-eye, real-time, self-calibration

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Authors: Vimanyu Chadha, Ranganath M. Singari

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Drilling composite materials is a frequently practiced machining process during assembling in various industries such as automotive and aerospace. However, drilling of glass fiber reinforced plastic (GFRP) composites is significantly affected by damage tendency of these materials under cutting forces such as thrust force and torque. The aim of this paper is to investigate the influence of the various cutting parameters such as cutting speed and feed rate; subsequently also to study the influence of number of layers on delamination produced while drilling a GFRP composite. A plan of experiments, based on Taguchi techniques, was instituted considering drilling with prefixed cutting parameters in a hand lay-up GFRP material. The damage induced associated with drilling GFRP composites were measured. Moreover, Analysis of Variance (ANOVA) was performed to obtain minimization of delamination influenced by drilling parameters and number layers. The optimum drilling factor combination was obtained by using the analysis of signal-to-noise ratio. The conclusion revealed that feed rate was the most influential factor on the delamination. The best results of the delamination were obtained with composites with a greater number of layers at lower cutting speeds and feed rates.

Keywords: analysis of variance, delamination, design optimization, drilling, glass fiber reinforced plastic composites, Taguchi method

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Authors: Linyue Jia, Wenbo Du, Zhaohui Wang, Ke Liu, Shubo Li

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Due to the great potential for weight reduction in aerospace and automotive industries, magnesium-rare earth (Mg-RE) based alloys with outstanding mechanical performance have been widely investigated for decades. However, magnesium alloys are still restricted in engineering applications because of their lower strength and ductility. Hence, there are large spaces and challenges in achieving high-performance Mg alloys. This work reports an Mg-Gd-Er-Zn-Zr alloy with ultrahigh strength and good ductility developed via hot extrusion, pre-deformation, and two-stage aging. The extruded alloy comprises fine dynamically recrystallized (DRXed) grains and coarse worked grains with a large aspect ratio. Pre-deformation has little effect on the microstructure and macro-texture and serves primarily to introduce a large number of dislocations, resulting in strain hardening and higher precipitation strengthening during subsequent aging due to more nucleation sites. As a result, the alloy exhibits a yield strength (YS) of 506 MPa, an ultimate tensile strength (UTS) of 549 MPa, and elongation (EL) of 8.2% at room temperature, showing superior strength-ductility balance than the other wrought Mg-RE alloys previously reported. The current study proposes a combination of pre-deformation and two-stage aging to further improve the mechanical properties of wrought Mg alloys for engineering applications.

Keywords: magnesium alloys, mechanical properties, microstructure, pre-deformation, two-stage aging

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Authors: Desislav Andreev, Veselin Stanev

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Linux operating system continues to gain popularity with every passed year. This is due to its open-source license and a great number of distributions, covering users’ needs. At first glance it seems that Linux can be integrated in every type of systems – it is already present in personal computers, smartphones and even in some embedded systems like Raspberry Pi. However, Linux still does not meet the performance and security requirements to run effectively on a real-time system. Real-time systems are very time-restricted – their processes have to execute and finish at strict time intervals. The Completely Fair Scheduler present in Linux does not have such scheduling capabilities and it is not able to ensure that critical-time processes will execute on time. One of the ways to solve this problem is implementing an Adaptive Partition Scheduler solution similar to that present in QNX Neutrino operating system. This type of scheduling divides the CPU in multiple adaptive partitions where each partition holds a percentage of CPU usage called budget, which allows optimal usage of the CPU resources and also provides protection against cyber attacks such as Denial of Service. This approach will also benefit systems, where functional safety is highly demanded, such as the instrumental clusters in the Automotive industry. The purpose of this paper is to present a concept of Adaptive Partition Scheduler designed for Linux-based operating systems.

Keywords: adaptive partitions, Linux kernel modules, real-time systems, scheduling

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Authors: Laidi Babouri

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The remarkable properties of steel, such as hardness and impact resistance, motivate their use in the automotive manufacturing industry. However, due to the very vulnerable environmental conditions of use, the steel that makes up the car body can corrode. This situation is motivating more and more automobile manufacturers to develop research to develop processes minimizing the rate of degradation of the physicomechanical properties of these materials. The present work falls within this perspective; it presents the results of a research study focused on the use of synthetic wax for the protection of steel, type XES (DC04), against corrosion in aggressive environments. The media used in this study are an acid medium with a pH=5.6, a 3% chloride medium, and a dry medium. Evaluation of the protective power of synthetic wax in different environments was carried out using mass loss techniques (immersion), completed by electrochemical techniques (stationary and transient). The results of the immersion of the steel samples, with a surface area of (1.44 cm²), in the various media, for a period of 30 days, using the immersion technique, showed high protective efficiency of synthetic wax in acidic and saline environments, with a lesser degree in a dry environment. Moreover, the study of the protective power, using electrochemical techniques, confirmed the results obtained in static mode (loss of mass), the protective efficiency of synthetic wax, against the corrosion of steel, in different environments, which reaches a maximum rate of 99.87% in a saline environment.

Keywords: corrosion, steel, industrial wax, environment, mass loss, electrochemical techniques

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Authors: Rachit Marwaha, Rahul Dev Gupta, Vivek Jain, Krishan Kant Sharma

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Metal matrix hybrid composites (MMHCs) are now gaining their usage in aerospace, automotive and other industries because of their inherent properties like high strength to weight ratio, hardness and wear resistance, good creep behaviour, light weight, design flexibility and low wear rate etc. Al alloy base matrix reinforced with silicon carbide (10%) and graphite (5%) particles was fabricated by stir casting process. The wear and frictional properties of metal matrix hybrid composites were studied by performing dry sliding wear test using pin on disc wear test apparatus. Experiments were conducted based on the plan of experiments generated through Taguchi’s technique. A L9 Orthogonal array was selected for analysis of data. Investigation to find the influence of applied load, sliding speed and track diameter on wear rate as well as coefficient of friction during wearing process was carried out using ANOVA. Objective of the model was chosen as smaller the better characteristics to analyse the dry sliding wear resistance. Results show that track diameter has highest influence followed by load and sliding speed.

Keywords: Taguchi method, orthogonal array, ANOVA, metal matrix hybrid composites

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Authors: Mahnaz Hosseinzadeh, Shaghayegh Rezaee Amiri

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This paper presents a methodology for serial production planning problem in wire and cable manufacturing process that addresses the problem of input-output imbalance in different consecutive stations, hoping to minimize the halt of machines in each stage. To this end, a linear Goal Programming (GP) model is developed, in which four main categories of constraints as per the number of runs per machine, machines’ sequences, acceptable inventories of machines at the end of each period, and the necessity of fulfillment of the customers’ orders are considered. The model is formulated based upon on the real data obtained from IKO TAK Company, an important supplier of wire and cable for oil and gas and automotive industries in Iran. By solving the model in GAMS software the optimal number of runs, end-of-period inventories, and the possible minimum idle time for each machine are calculated. The application of the numerical results in the target company has shown the efficiency of the proposed model and the solution in decreasing the lead time of the end product delivery to the customers by 20%. Accordingly, the developed model could be easily applied in wire and cable companies for the aim of optimal production planning to reduce the halt of machines in manufacturing stages.

Keywords: goal programming approach, GP, production planning, serial manufacturing process, wire and cable industry

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Authors: Ammar Maziz, Prateek Gupta, Thiago Vasconcellos Birro, Benoit Gely

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Hydrogen as a sustainable fuel has the highest energy density per mass as compared to conventional non-renewable sources. As the world looks to move towards sustainability, especially in the sectors of aviation and automotive, it becomes important to address the issue of storage of hydrogen as compressed gas in high-pressure tanks. To improve the design for the efficient storage and transportation of Hydrogen, this paper presents the design and stress analysis of Dome Composite Overwrapped Pressure Vessels (COPVs) using the geodesic trajectory approach. The geodesic trajectory approach is used to optimize the dome design, resulting in a lightweight and efficient structure. Python scripting is employed to implement the mathematical modeling of the COPV, and after validating the model by comparison to the published paper, stress analysis is conducted using Abaqus commercial code. The results demonstrate the effectiveness of the geodesic trajectory approach in achieving a lightweight and structurally sound dome design, as well as the accuracy and reliability of the stress analysis using Abaqus commercial code. This study provides insights into the design and analysis of COPVs for aerospace applications, with the potential for further optimization and application in other industries.

Keywords: composite overwrapped pressure vessels, carbon fiber, geodesic trajectory approach, dome design, stress analysis, plugin python

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Authors: H. Selcuk Halkacı, Mevlüt Türköz, Ekrem Öztürk, Murat Dilmec

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Various attempts concerning the low formability issue for lightweight materials like aluminium and magnesium alloys are being investigated in many studies. Advanced forming processes such as hydroforming is one of these attempts. In last decades sheet hydroforming process has an increasing interest, particularly in the automotive and aerospace industries. This process has many advantages such as enhanced formability, the capability to form complex parts, higher dimensional accuracy and surface quality, reduction of tool costs and reduced die wear compared to the conventional sheet metal forming processes. There are two types of sheet hydroforming. One of them is hydromechanical deep drawing (HDD) that is a special drawing process in which pressurized fluid medium is used instead of one of the die half compared to the conventional deep drawing (CDD) process. Another one is sheet hydroforming with die (SHF-D) in which blank is formed with the act of fluid pressure and it takes the shape of die half. In this study, transition of cup height according to cup diameter between the processes was determined by performing simulation of the processes in Finite Element Analysis. Firstly SHF-D process was simulated for 40 mm cup diameter at different cup heights chancing from 10 mm to 30 mm and the cup height to diameter ratio value in which it is not possible to obtain a successful forming was determined. Then the same ratio was checked for a different cup diameter of 60 mm. Then thickness distributions of the cups formed by SHF-D and HDD processes were compared for the cup heights. Consequently, it was found that the thickness distribution in HDD process in the analyses was more uniform.

Keywords: finite element analysis, HDD, hydroforming sheet metal forming, SHF-D

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Authors: Hamed Khani Arani, Mohammad Shariyat, Armaghan Mohammadian

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In this research, the free vibration of a rectangular sandwich nano-plate (SNP) made of three smart layers in the visco Pasternak foundation is studied. The core of the sandwich is a piezo magnetic nano-plate integrated with two layers of piezoelectric materials. First-order shear deformation plate theory is utilized to derive the motion equations by using Hamilton’s principle, piezoelectricity, and modified couple stress theory. Elastic medium is modeled by visco Pasternak foundation, where the damping coefficient effect is investigated on the stability of sandwich nano-plate. These equations are solved by the differential quadrature method (DQM), considering different boundary conditions. Results indicate the effect of various parameters such as aspect ratio, thickness ratio, shear correction factor, damping coefficient, and boundary conditions on the dimensionless frequency of sandwich nano-plate. The results are also compared by those available in the literature, and these findings can be used for automotive industry, communications equipment, active noise, stability, and vibration cancellation systems and utilized for designing the magnetostrictive actuator, motor, transducer and sensors in nano and micro smart structures.

Keywords: free vibration, modified couple stress theory, sandwich nano-plate, visco Pasternak foundation

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Authors: Selin Kunc, Srinivas Koushik Gundimeda, John A. Gallagher, Roselita Fragoudakis

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This study investigates the behavior of Glass Fiber Reinforced Plastic (GFRP) laminated beams additionally reinforced with piezoelectric fibers. The electromechanical behavior of piezoelectric materials coupled with high strength/low weight GFRP laminated beams can have significant application in a wide range of industries. Energy scavenging through mechanical vibrations is the focus of this study, and possible applications can be seen in the automotive industry. This study examines the behavior of such composite laminates using Classical Lamination Theory (CLT) under three-point bending conditions. Fiber orientation is optimized for the desired stiffness and deflection that yield maximum energy output. Finite element models using ABAQUS/CAE are verified through experimental testing. The optimum stacking sequences examined are [0o]s, [ 0/45o]s, and [45/-45o]s. Results show the superiority of the stacking sequence [0/45o]s, providing higher strength at a lower weight, and maximum energy output. Furthermore, laminated GFRP beams additionally reinforced with piezoelectric fibers can be used under bending to not only replace metallic component while providing similar strength at a lower weight but also provide an energy output.

Keywords: classical lamination theory (CLT), energy scavenging, glass fiber reinforced plastics (GFRP), piezoelectric fibers

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Authors: Bahar Basturk, Secil Celik Erbas, Sevket Can Sarikaya

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Composites combining the particulates and polymer components have attracted great interest in various application areas such as packaging, furniture, electronics and automotive industries. For strengthening the plastic matrices, the utilization of natural fillers instead of traditional reinforcement materials has received increased attention. The properties of natural filler based polymer composites (NFPC) may be improved by applying proper surface modification techniques to the powder phase of the structures. In this study, acorn powder-epoxy and pine corn powder-epoxy composites containing up to 45% weight percent particulates were prepared by casting method. Alkali treatment and acetylation techniques were carried out to the natural particulates for investigating their influences under mechanical forces. The effects of filler type and content on the tensile properties of the composites were compared with neat epoxy. According to the quasi-static tensile tests, the pine cone based composites showed slightly higher rigidity and strength properties compared to the acorn reinforced samples. Furthermore, the structures independent of powder type and surface modification technique, showed higher tensile properties with increasing the particle content.

Keywords: natural fillers, polymer composites, surface modifications, tensile properties

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Authors: Anil Ranjitbhai Patel, Clement John Shaji, Peter Liggesmeyer

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Safety and security of autonomous vehicles (AVs) is a growing concern, first, due to the increased number of safety-critical functions taken over by automotive embedded systems; second, due to the increased exposure of the software-intensive systems to potential attackers; third, due to dynamic interaction in an uncertain and unknown environment at runtime which results in changed functional and non-functional properties of the system. Frequently occurring environmental uncertainties, random component failures, and compromise security of the AVs might result in hazardous events, sometimes even in an accident, if left undetected. Beyond these technical issues, we argue that the safety and security of AVs against accidental and deliberate faults are poorly understood and rarely implemented. One possible way to overcome this is through a well-known diversity approach. As an effective approach to increase safety and security, diversity has been widely used in the aviation, railway, and aerospace industries. Thus, the paper proposes fault-tolerance by diversity model takes into consideration the mitigation of accidental and deliberate faults by application of structure and variant redundancy. The model can be used to design the AVs with various types of diversity in hardware and software-based multi-version system. The paper evaluates the presented approach by employing an example from adaptive cruise control, followed by discussing the case study with initial findings.

Keywords: autonomous vehicles, diversity, fault-tolerance, adaptive cruise control, safety, security

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Authors: Azeez Shaik, Amit Salvi, B. P. Gautham

Abstract:

Fiber reinforced polymer resin composite materials are finding wide variety of applications in automotive and aerospace industry because of their high specific stiffness and specific strengths when compared to metals. New class of 2D and 3D textile and woven fabric composites offer excellent fracture toughens as they bridge the cracks formed during fracture. Due to complexity of their fiber architectures and its resulting composite microstructures, optimized design and analysis of these structures is very complicated. A traditional homogenization approach is typically used to analyze structures made up of these materials. This approach usually fails to predict damage initiation as well as damage propagation and ultimate failure of structure made up of woven and textile composites. This study demonstrates a methodology to analyze woven and textile composites by using the multi-level multi-scale modelling approach. In this approach, a geometric repetitive unit cell (RUC) is developed with all its constituents to develop a representative volume element (RVE) with all its constituents and their interaction modeled correctly. The structure is modeled based on the RUC/RVE and analyzed at different length scales with desired levels of fidelity incorporating the damage and failure. The results are passed across (up and down) the scales qualitatively as well as quantitatively from the perspective of material, configuration and architecture.

Keywords: cohesive zone, multi-scale modeling, rate dependency, RUC, woven textiles

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Authors: Expedito Pinto De Paula Junior

Abstract:

Current systems such as artificial satellites, airplanes, automobiles, turbines, power systems and air traffic controls are becoming increasingly more complex and/or highly integrated as defined in SAE-ARP-4754A (Society Automotive Engineering - Certification considerations for highly-integrated or complex aircraft systems standard). Among other processes, the development of such systems requires careful Change and Configuration Management (CCM) to establish and maintain product integrity. Understand the maturity of CCM process based in historical approach is crucial for better implementation in hardware and software lifecycle. The sense of work organization, in all fields of development is directly related to the order and interrelation of the parties, changes in time, and record of these changes. Generally, is observed that engineers, administrators and managers invest more time in technical activities than in organization of work. More these professionals are focused in solving complex problems with a purely technical bias. CCM process is fundamental for development, production and operation of new products specially in the safety critical systems. The objective of this paper is open a discussion about the historical revision based in standards focus of CCM around the world in order to understand and reflect the importance across the years, the contribution of this process for technology evolution, to understand the mature of organizations in the system lifecycle project and the benefits of CCM to avoid errors and mistakes during the Lifecycle Product.

Keywords: changes, configuration management, historical, revision

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Authors: Asma Perveen, M. P. Jahan

Abstract:

Ni alloys have managed to cover wide range of applications such as automotive industries, oil gas industries, and aerospace industries. However, these alloys impose challenges while using conventional machining technologies. On the other hand, Micro-Electro-Discharge machining (micro-EDM) is a non-conventional machining method that uses controlled sparks energy to remove material irrespective of the materials hardness. There has been always a huge interest from the industries for developing optimum methodology and parameters in order to enhance the productivity of micro-EDM in terms of reducing machining time and tool wear for different alloys. Therefore, the aims of this study are to investigate the effects of the micro-EDM process parameters, in order to find their optimal values. The input process parameters include voltage, capacitance, and electrode rotational speed, whereas the output parameters considered are machining time, entrance diameter of hole, overcut, tool wear, and crater size. The surface morphology and element characterization are also investigated with the use of SEM and EDX analysis. The experimental result indicates the reduction of machining time with the increment of discharge energy. Discharge energy also contributes to the enlargement of entrance diameter as well as overcut. In addition, tool wears show reduction with the increase of discharge energy. Moreover, crater size is found to be increased in size along with the increment of discharge energy.

Keywords: micro holes, micro EDM, Ni Alloy, discharge energy

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Authors: Mohammad Rostami Mehr, Seyed Arya Mir Rashed, Arndt Lueder, Magdalena Missler-Behr

Abstract:

This paper represents the conception that complex problems do not necessarily need a similar complex solution in order to cope with the complexity. Furthermore, a simple solution based on established methods can provide a sufficient way to deal with the complexity. To verify this conception, the presented paper focuses on the field of change management as a part of the new product development process in the automotive sector. In this field, dealing with increasing complexity is essential, while only non-flexible rigid processes that are not designed to handle complexity are available. The basic methodology of this paper can be divided into four main sections: 1) analyzing the complexity of the change management, 2) literature review in order to identify potential solutions and methods, 3) capturing and implementing expertise of experts from the change management field of an automobile manufacturing company and 4) systematical comparison of the identified methods from literature and connecting these with defined requirements of the complexity of the change management in order to develop a solution. As a practical outcome, this paper provides a method to capture the complexity of engineering changes (EC) and includes it within the EC evaluation process, following case-related process guidance to cope with the complexity. Furthermore, this approach supports the conception that dealing with complexity is possible while utilizing rather simple and established methods by combining them into a powerful tool.

Keywords: complexity management, new product development, engineering change management, flexibility

Procedia PDF Downloads 170