Search results for: Automotive aerodynamics

Authors: Zoran Jovanovic, Zoran Masonicic, S. Dragutinovic, Z. Sakota

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In this paper, results concerning flame propagation of various fuels in a particular combustion chamber with four tilted valves were elucidated. Flame propagation was represented by the evolution of spatial distribution of temperature in various cut-planes within combustion chamber while the flame front location was determined by dint of zones with maximum temperature gradient. The results presented are only a small part of broader on-going scrutinizing activity in the field of multidimensional modeling of reactive flows in combustion chambers with complicated geometries encompassing various models of turbulence, different fuels and combustion models. In the case of turbulence two different models were applied i.e. standard k-ε model of turbulence and k-ξ-f model of turbulence. In this paper flame propagation results were analyzed and presented for two different hydrocarbon fuels, such as CH4 and C8H18. In the case of combustion all differences ensuing from different turbulence models, obvious for non-reactive flows are annihilated entirely. Namely the interplay between fluid flow pattern and flame propagation is invariant as regards turbulence models and fuels applied. Namely the interplay between fluid flow pattern and flame propagation is entirely invariant as regards fuel variation indicating that the flame propagation through unburned mixture of CH4 and C8H18 fuels is not chemically controlled.

Keywords: Automotive flows, flame propagation, combustion modelling.

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Authors: Guerrero Ramírez Sandra, Ramos Salinas Norma Maricela, Muriel Amezcua Vanesa

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This article presents the beginning of a wider study that intends to demonstrate how within organizations of the automotive industry from the city of Querétaro. Knowledge management and technological management are required, as well as people’s initiative and the interaction embedded at the interior of it, with the appropriate environment that facilitates information conversion with wide information technologies management (ITM) range. A company was identified for the pilot study of this research, where descriptive and inferential research information was obtained. The results of the pilot suggest that some respondents did noted entity the knowledge management topic, even if staffs have access to information technology (IT) that serve to enhance access to knowledge (through internet, email, databases, external and internal company personnel, suppliers, customers and competitors) data, this implicates that there are Knowledge Management (KM) problems. The data shows that academically well-prepared organizations normally do not recognize the importance of knowledge in the business, nor in the implementation of it, which at the end is a great influence on how to manage it, so that it should guide the company to greater in sight towards a competitive strategy search, given that the company has an excellent technological infrastructure and KM was not exploited. Cultural diversity is another factor that was observed by the staff.

Keywords: Knowledge management, technological knowledge management, technology information management.

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Authors: David Downey

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With the introduction of additive manufacturing (3D printing) to produce titanium (Ti6Al4V) components in the medical, aerospace and automotive industries, intricate geometries can be produced with virtually complete design freedom. However, the consideration of microstructural anisotropy resulting from the additive manufacturing process becomes necessary due to this design flexibility and the need to print a geometric shape that can consist of numerous angles, radii, and swept surfaces. A femoral knee implant serves as an example of a 3D-printed near-net-shaped product. The mechanical properties of the printed components, and consequently, their machinability, are affected by microstructural anisotropy. Currently, finish-machining operations performed on titanium printed parts using selective laser melting (SLM) utilize the same cutting tools employed for processing wrought titanium components. Cutting forces for components manufactured through SLM can be up to 70% higher than those for their wrought counterparts made of Ti6Al4V. Moreover, temperatures at the cutting interface of 3D printed material can surpass those of wrought titanium, leading to significant tool wear. Although the criteria for tool wear may be similar for both 3D printed and wrought materials, the rate of wear during the machining process may differ. The impact of these issues on the choice of cutting tool material and tool lifetimes will be discussed.

Keywords: Additive manufacturing, build orientation, microstructural anisotropy, printed titanium Ti6Al4V, tool wear.

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Authors: Ali Ghaffari, A. Hosein Shamekhi, Akbar Saki, Ehsan Kamrani

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In order to meet the limits imposed on automotive emissions, engine control systems are required to constrain air/fuel ratio (AFR) in a narrow band around the stoichiometric value, due to the strong decay of catalyst efficiency in case of rich or lean mixture. This paper presents a model of a sample spark ignition engine and demonstrates Simulink-s capabilities to model an internal combustion engine from the throttle to the crankshaft output. We used welldefined physical principles supplemented, where appropriate, with empirical relationships that describe the system-s dynamic behavior without introducing unnecessary complexity. We also presents a PID tuning method that uses an adaptive fuzzy system to model the relationship between the controller gains and the target output response, with the response specification set by desired percent overshoot and settling time. The adaptive fuzzy based input-output model is then used to tune on-line the PID gains for different response specifications. Experimental results demonstrate that better performance can be achieved with adaptive fuzzy tuning relative to similar alternative control strategies. The actual response specifications with adaptive fuzzy matched the desired response specifications.

Keywords: Modelling, Air–fuel ratio control, SI engine, Adaptive fuzzy Control.

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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: 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: Holographic interface, human-computer interaction, user-centered design, Gesture.

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Authors: Chang S. Woo, Hyun S. Park, Wan D. Kim

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Fatigue life prediction and evaluation are the key technologies to assure the safety and reliability of automotive rubber components. The objective of this study is to develop the fatigue analysis process for vulcanized rubber components, which is applicable to predict fatigue life at initial product design step. Fatigue life prediction methodology of vulcanized natural rubber was proposed by incorporating the finite element analysis and fatigue damage parameter of maximum strain appearing at the critical location determined from fatigue test. In order to develop an appropriate fatigue damage parameter of the rubber material, a series of displacement controlled fatigue test was conducted using threedimensional dumbbell specimen with different levels of mean displacement. It was shown that the maximum strain was a proper damage parameter, taking the mean displacement effects into account. Nonlinear finite element analyses of three-dimensional dumbbell specimens were performed based on a hyper-elastic material model determined from the uni-axial tension, equi-biaxial tension and planar test. Fatigue analysis procedure employed in this study could be used approximately for the fatigue design.

Keywords: Rubber, Material test, Finite element analysis, Strain, Fatigue test, Fatigue life prediction.

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Authors: Sunil Patel, Pallab Maji

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To study the effect of adversarial attack environment must be controlled. Autonomous driving includes mainly 5 phases sense, perceive, map, plan, and drive. Autonomous vehicles sense their surrounding with the help of different sensors like cameras, radars, and lidars. Deep learning techniques are considered Blackbox and found to be vulnerable to adversarial attacks. In this research, we study the effect of the various known adversarial attacks with the help of the Unreal Engine-based, high-fidelity, real-time raytraced simulated environment. The goal of this experiment is to find out if adversarial attacks work in moving vehicles and if an unknown network may be targeted. We discovered that the existing Blackbox and Whitebox attacks have varying effects on different traffic signs. We observed that attacks that impair detection in static scenarios do not have the same effect on moving vehicles. It was found that some adversarial attacks with hardly noticeable perturbations entirely blocked the recognition of certain traffic signs. We observed that the daylight condition has a substantial impact on the model's performance by simulating the interplay of light on traffic signs. Our findings have been found to closely resemble outcomes encountered in the real world.

Keywords: Adversarial attack simulation, computer simulation, ray-traced environment, realistic simulation, unreal engine.

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Authors: Batin Latif Aylak, Bernd Noche

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Overhead conveyor systems are in use in many installations around the world, meeting the widest range of applications possible. Overhead conveyor systems are particularly preferred in automotive industry but also at post offices. Overhead conveyor systems must always be integrated with a logistical process by finding the best way for a cheaper material flow in order to guarantee precise and fast workflows. With their help, any transport can take place without wasting ground and space, without excessive company capacity, lost or damaged products, erroneous delivery, endless travels and without wasting time. Ultra-light overhead conveyor systems are rope-based conveying systems with individually driven vehicles. The vehicles can move automatically on the rope and this can be realized by energy and signals. Crossings are realized by switches. Ultra-light overhead conveyor systems provide optimal material flow, which produces profit and saves time. This article introduces two new ultra-light overhead conveyor designs in logistics and explains their components. According to the explanation of the components, scenarios are created by means of their technical characteristics. The scenarios are visualized with the help of CAD software. After that, assumptions are made for application area. According to these assumptions scenarios are visualized. These scenarios help logistics companies achieve lower development costs as well as quicker market maturity.

Keywords: Logistics, material flow, overhead conveyor.

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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: Serial manufacturing process, production planning, wire and cable industry, goal programming approach.

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Authors: Van Thang Nguyen, Amelie Danlos, Richard Paridaens, Farid Bakir

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This article presents a study of the effect of a contra-rotating component on the efficiency of centrifugal compressors. A contra-rotating centrifugal compressor (CRCC) is constructed using two independent rotors, rotating in the opposite direction and replacing the single rotor of a conventional centrifugal compressor (REF). To respect the geometrical parameters of the REF one, two rotors of the CRCC are designed, based on a single rotor geometry, using the hub and shroud length ratio parameter of the meridional contour. Firstly, the first rotor is designed by choosing a value of length ratio. Then, the second rotor is calculated to be adapted to the fluid flow of the first rotor according aerodynamics principles. In this study, four values of length ratios 0.3, 0.4, 0.5, and 0.6 are used to create four configurations CF1, CF2, CF3, and CF4 respectively. For comparison purpose, the circumferential velocity at the outlet of the REF and the CRCC are preserved, which means that the single rotor of the REF and the second rotor of the CRCC rotate with the same speed of 16000rpm. The speed of the first rotor in this case is chosen to be equal to the speed of the second rotor. The CFD simulation is conducted to compare the performance of the CRCC and the REF with the same boundary conditions. The results show that the configuration with a higher length ratio gives higher pressure rise. However, its efficiency is lower. An investigation over the entire operating range shows that the CF1 is the best configuration in this case. In addition, the CRCC can improve the pressure rise as well as the efficiency by changing the speed of each rotor independently. The results of changing the first rotor speed show with a 130% speed increase, the pressure ratio rises of 8.7% while the efficiency remains stable at the flow rate of the design operating point.

Keywords: Centrifugal compressor, contra-rotating, interaction rotor, vacuum.

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Authors: K. N. Kiran, S. Anish

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It is well known that secondary flow loses account about one third of the total loss in any axial turbine. Modern gas turbine height is smaller and have longer chord length, which might lead to increase in secondary flow. In order to improve the efficiency of the turbine, it is important to understand the behavior of secondary flow and device mechanisms to curtail these losses. The objective of the present work is to understand the effect of a stream wise end-wall fence on the aerodynamics of a linear turbine cascade. The study is carried out computationally by using commercial software ANSYS CFX. The effect of end-wall on the flow field are calculated based on RANS simulation by using SST transition turbulence model. Durham cascade which is similar to high-pressure axial flow turbine for simulation is used. The aim of fencing in blade passage is to get the maximum benefit from flow deviation and destroying the passage vortex in terms of loss reduction. It is observed that, for the present analysis, fence in the blade passage helps reducing the strength of horseshoe vortex and is capable of restraining the flow along the blade passage. Fence in the blade passage helps in reducing the under turning by 7⁰ in comparison with base case. Fence on end-wall is effective in preventing the movement of pressure side leg of horseshoe vortex and helps in breaking the passage vortex. Computations are carried for different fence height whose curvature is different from the blade camber. The optimum fence geometry and location reduces the loss coefficient by 15.6% in comparison with base case.

Keywords: Boundary layer fence, horseshoe vortex, linear cascade, passage vortex, secondary flow.

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Authors: Hilal A. Abdelwali, Elsayed E.M. Ellaimony, Ahmad E.M. Murad, Jasem M.S. Al-Rajhi

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Due to the excess of a vehicle operation through its life, some elements may face failure and deteriorate with time. This leads us to carry out maintenance, repair, tune up or full overhaul. After a certain period, the vehicle elements deteriorations increase with time which causes a very high increase of doing the maintenance operations and their costs. However, the logic decision at this point is to replace the current vehicle by a new one with minimum failure and maximum income. The importance of studying vehicle replacement problems come from the increase of stopping days due to many deteriorations in the vehicle parts. These deteriorations increase year after year causing an increase of operating costs and decrease the vehicle income. Vehicle replacement aims to determine the optimum time to keep, maintain, overhaul, renew and replace vehicles. This leads to an improvement in vehicle income, total operating costs, maintenance cost, fuel and oil costs, ton-kilometers, vehicle and engine performance, vehicle noise, vibration, and pollution. The aim of this paper is to find the optimum replacement policies of Kuwait Passenger Transport Company (KPTCP) fleet of busses. The objective of these policies is to maximize the busses pure profits. The dynamic programming (D.P.) technique is used to generate the busses optimal replacement policies

Keywords: Replacement Problem, Automotive Replacement, Dynamic Programming, Equipment Replacement, K.P.T.C.

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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, paper proposes fault-tolerance by diversity model taking 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: Asma Perveen, M. P. Jahan

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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 EDM, Ni alloy, discharge energy, micro-holes.

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Authors: S. Chahba, R. Sehab, A. Akrad, C. Morel

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Nowadays, the electric machines used in urban electric vehicles are, in most cases, three-phase electric machines with or without a magnet in the rotor. Permanent Magnet Synchronous Machine (PMSM) and Induction Machine (IM) are the main components of drive trains of electric and hybrid vehicles. These machines have very good performance in healthy operation mode, but they are not redundant to ensure safety in faulty operation mode. Faced with the continued growth in the demand for electric vehicles in the automotive market, improving the reliability of electric vehicles is necessary over the lifecycle of the electric vehicle. Multiphase electric machines respond well to this constraint because, on the one hand, they have better robustness in the event of a breakdown (opening of a phase, opening of an arm of the power stage, intern-turn short circuit) and, on the other hand, better power density. In this work, a diagnosis approach using a neural network for an open circuit fault or more of a five-phase induction machine is developed. Validation on the simulator of the vehicle drivetrain, at reduced power, is carried out, creating one and more open circuit stator phases showing the efficiency and the reliability of the new approach to detect and to locate on-line one or more open phases of a five-induction machine.

Keywords: Electric vehicle drivetrain, multiphase drives, induction machine, control, open circuit fault diagnosis, artificial neural network.

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

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This paper represents the conception that complex problems do not necessary need similar complex solutions in order to cope with the complexity. Furthermore, a simple solution based on established methods can provide a sufficient way dealing with the complexity. To verify this conception, the presented paper focuses on the field of change management as a part of new product development process in automotive sector. In the field of complexity management, 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 in 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 change management filed 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 in to a powerful tool.

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

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Authors: Mohd Yussni Hashim, Mohd Nazrul Roslan, Azriszul Mohd Amin, Ahmad Mujahid Ahmad Zaidi, Saparudin Ariffin

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Environmental awareness and depletion of the petroleum resources are among vital factors that motivate a number of researchers to explore the potential of reusing natural fiber as an alternative composite material in industries such as packaging, automotive and building constructions. Natural fibers are available in abundance, low cost, lightweight polymer composite and most importance its biodegradability features, which often called “ecofriendly" materials. However, their applications are still limited due to several factors like moisture absorption, poor wettability and large scattering in mechanical properties. Among the main challenges on natural fibers reinforced matrices composite is their inclination to entangle and form fibers agglomerates during processing due to fiber-fiber interaction. This tends to prevent better dispersion of the fibers into the matrix, resulting in poor interfacial adhesion between the hydrophobic matrix and the hydrophilic reinforced natural fiber. Therefore, to overcome this challenge, fiber treatment process is one common alternative that can be use to modify the fiber surface topology by chemically, physically or mechanically technique. Nevertheless, this paper attempt to focus on the effect of mercerization treatment on mechanical properties enhancement of natural fiber reinforced composite or so-called bio composite. It specifically discussed on mercerization parameters, and natural fiber reinforced composite mechanical properties enhancement.

Keywords: Mercerization treatment, mechanical properties, natural fiber and bio composite

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Authors: Altab Hossain, Ataur Rahman, Jakir Hossen, A.K.M. P. Iqbal, SK. Hasan

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The measurement of aerodynamic forces and moments acting on an aircraft model is important for the development of wind tunnel measurement technology to predict the performance of the full scale vehicle. The potentials of an aircraft model with and without winglet and aerodynamic characteristics with NACA wing No. 65-3- 218 have been studied using subsonic wind tunnel of 1 m × 1 m rectangular test section and 2.5 m long of Aerodynamics Laboratory Faculty of Engineering (University Putra Malaysia). Focusing on analyzing the aerodynamic characteristics of the aircraft model, two main issues are studied in this paper. First, a six component wind tunnel external balance is used for measuring lift, drag and pitching moment. Secondly, Tests are conducted on the aircraft model with and without winglet of two configurations at Reynolds numbers 1.7×105, 2.1×105, and 2.5×105 for different angle of attacks. Fuzzy logic approach is found as efficient for the representation, manipulation and utilization of aerodynamic characteristics. Therefore, the primary purpose of this work was to investigate the relationship between lift and drag coefficients, with free-stream velocities and angle of attacks, and to illustrate how fuzzy logic might play an important role in study of lift aerodynamic characteristics of an aircraft model with the addition of certain winglet configurations. Results of the developed fuzzy logic were compared with the experimental results. For lift coefficient analysis, the mean of actual and predicted values were 0.62 and 0.60 respectively. The coreelation between actual and predicted values (from FLS model) of lift coefficient in different angle of attack was found as 0.99. The mean relative error of actual and predicted valus was found as 5.18% for the velocity of 26.36 m/s which was found to be less than the acceptable limits (10%). The goodness of fit of prediction value was 0.95 which was close to 1.0.

Keywords: Wind tunnel; Winglet; Lift coefficient; Fuzzy logic.

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Authors: K. Ö. Kartal, L. Maul, M. Hägele

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With the development of new technologies come additional opportunities for the founding of companies and new markets to be created. The barriers to entry are lowered and technology makes old business models obsolete. Incumbent companies have to be adaptable to this quickly changing environment. They have to start the process of digital maturation and they have to be able to adapt quickly to new and drastic changes that might arise. One of the biggest barriers for organizations in order to do so is their culture. This paper shows the core elements of a corporate culture that supports the process of digital maturation in incumbent organizations. Furthermore, it is explored how ideation and innovation can be used in a strategy in order to facilitate these core elements of culture that promote digital maturity. Focus areas are identified for the design of ideation strategies, with the aim to make the facilitation and incitation process more effective, short to long term. Therefore, one in-depth case study is conducted with data collection from interviews, observation, document review and surveys. The findings indicate that digital maturity is connected to cultural shift and 11 relevant elements of digital culture are identified which have to be considered. Based on these 11 core elements, five focus areas that need to be regarded in the design of a strategy that uses ideation and innovation to facilitate the cultural shift are identified. These are: Focus topics, rewards and communication, structure and frequency, regions and new online formats.

Keywords: Digital transformation, innovation management, ideation strategy, creativity culture, change.

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Authors: Reihaneh Montazeri Shatouri, Rosmini Omar, Wan Khairuzzaman Wan Ismail

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This study aims at investigating factors in research and development (R&D) growth and exploring the role of R&D management in enhancing social innovation and productivity improvement in Iran-s industrial sector. It basically explores the common types of R&D activities and the industries which benefited the most from active R&D units in Iran. The researchers generated qualitative analyses obtained from primary and secondary data. The primary data have been retrieved through interviews with five key players (Managing Director, Internal Manager, General Manager, Executive Manager, and Project Manager) in the industrial sector. The secondary data acquired from an investigation on Mazandaran, a province of northern Iran. The findings highlight Iran-s focuses of R & D on cost reduction and upgrading productivity. Industries that have benefited the most from active R&D units are metallic, machinery and equipment design, and automotive. We rank order the primary effects of R&D on productivity improvement as follows, industry improvement, economic growth, using professional human resources, generating productivity and creativity culture, creating a competitive and innovative environment, and increasing people-s knowledge. Generally, low budget dedication and insufficient supply of highly skilled scientists and engineers are two important obstacles for R&D in Iran. Whereas, R&D has resulted in improvement in Iranian society, transfer of contemporary knowledge into the international market is still lacking.

Keywords: Productivity, R&D, Transfer of Knowledge

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Authors: Atiqul Islam, Shamim Akhter, Tumnun E. Mursalin

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Least Development Countries (LDC) like Bangladesh, whose 25% revenue earning is achieved from Textile export, requires producing less defective textile for minimizing production cost and time. Inspection processes done on these industries are mostly manual and time consuming. To reduce error on identifying fabric defects requires more automotive and accurate inspection process. Considering this lacking, this research implements a Textile Defect Recognizer which uses computer vision methodology with the combination of multi-layer neural networks to identify four classifications of textile defects. The recognizer, suitable for LDC countries, identifies the fabric defects within economical cost and produces less error prone inspection system in real time. In order to generate input set for the neural network, primarily the recognizer captures digital fabric images by image acquisition device and converts the RGB images into binary images by restoration process and local threshold techniques. Later, the output of the processed image, the area of the faulty portion, the number of objects of the image and the sharp factor of the image, are feed backed as an input layer to the neural network which uses back propagation algorithm to compute the weighted factors and generates the desired classifications of defects as an output.

Keywords: Computer vision, image acquisition device, machine vision, multi-layer neural networks.

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Authors: Carine Cridelich, Pablo Juesas Cano, Emmanuel Ramasso, Noureddine Zerhouni, Bernd Weiler

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Safety is one of the most important considerations when buying a new car. While active safety aims at avoiding accidents, passive safety systems such as airbags and seat belts protect the occupant in case of an accident. In addition to legal regulations, organizations like Euro NCAP provide consumers with an independent assessment of the safety performance of cars and drive the development of safety systems in automobile industry. Those ratings are mainly based on injury assessment reference values derived from physical parameters measured in dummies during a car crash test. The components and sub-systems of a safety system are designed to achieve the required restraint performance. Sled tests and other types of tests are then carried out by car makers and their suppliers to confirm the protection level of the safety system. A Knowledge Discovery in Databases (KDD) process is proposed in order to minimize the number of tests. The KDD process is based on the data emerging from sled tests according to Euro NCAP specifications. About 30 parameters of the passive safety systems from different data sources (crash data, dummy protocol) are first analysed together with experts opinions. A procedure is proposed to manage missing data and validated on real data sets. Finally, a procedure is developed to estimate a set of rough initial parameters of the passive system before testing aiming at reducing the number of tests.

Keywords: KDD process, passive safety systems, sled test, dummy injury assessment reference values, frontal impact

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Authors: S. S. Sravanthi, Swati Ghosh Acharyya

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Automotive light weighting is of major prominence in the current times due to its contribution in improved fuel economy and reduced environmental pollution. Various arc welding technologies are being employed in the production of automobile components with reduced weight. The present study is of practical importance since it involves preferential substitution of Zinc coated mild steel with a light weight alloy such as 6061 Aluminium by means of Gas Metal Arc Welding (GMAW) – Brazing technique at different processing parameters. However, the fabricated joints have shown the generation of Al – Fe layer at the interfacial regions which was confirmed by the Scanning Electron Microscope and Energy Dispersion Spectroscopy. These Al-Fe compounds not only affect the mechanical strength, but also predominantly deteriorate the corrosion resistance of the joints. Hence, it is essential to understand the phases formed in this layer and their crystal structure. Micro area X - ray diffraction technique has been exclusively used for this study. Moreover, the crevice corrosion analysis at the joint interfaces was done by exposing the joints to 5 wt.% FeCl₃ solution at regular time intervals as per ASTM G 48-03. The joints have shown a decreased crevice corrosion resistance with increased heat intensity. Inner surfaces of welds have shown severe oxide cracking and a remarkable weight loss when exposed to concentrated FeCl₃. The weight loss was enhanced with decreased filler wire feed rate and increased heat intensity. 

Keywords: Automobiles, welding, corrosion, lap joints, Micro XRD.

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Authors: M. I. Equbal, R.K. Ohdar, B. Singh, P. Talukdar

Abstract:

Micro-alloyed steel components are used in automotive industry for the necessity to make the manufacturing process cycles shorter when compared to conventional steel by eliminating heat treatment cycles, so an important saving of costs and energy can be reached by reducing the number of operations. Microalloying elements like vanadium, niobium or titanium have been added to medium carbon steels to achieve grain refinement with or without precipitation strengthening along with uniform microstructure throughout the matrix. Present study reports the applicability of medium carbon vanadium micro-alloyed steel in hot forging. Forgeability has been determined with respect to different cooling rates, after forging in a hydraulic press at 50% diameter reduction in temperature range of 900-11000C. Final microstructures, hardness, tensile strength, and impact strength have been evaluated. The friction coefficients of different lubricating conditions, viz., graphite in hydraulic oil, graphite in furnace oil, DF 150 (Graphite, Water-Based) die lubricant and dry or without any lubrication were obtained from the ring compression test for the above micro-alloyed steel. Results of ring compression tests indicate that graphite in hydraulic oil lubricant is preferred for free forging and dry lubricant is preferred for die forging operation. Exceptionally good forgeability and high resistance to fracture, especially for faster cooling rate has been observed for fine equiaxed ferrite-pearlite grains, some amount of bainite and fine precipitates of vanadium carbides and carbonitrides. The results indicated that the cooling rate has a remarkable effect on the microstructure and mechanical properties at room temperature.

Keywords: Cooling rate, Hot forging, Micro-alloyed, Ring compression.

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Authors: Haithem Elderrat, Huw Davies, Emmanuel Brousseau

Abstract:

Elastomeric polymer foam has been used widely in the automotive industry, especially for isolating unwanted vibrations. Such material is able to absorb unwanted vibration due to its combination of elastic and viscous properties. However, the ‘creep effect’, poor stress distribution and susceptibility to high temperatures are the main disadvantages of such a system. In this study, improvements in the performance of elastomeric foam as a vibration isolator were investigated using the concept of Foam Filled Fluid (FFFluid). In FFFluid devices, the foam takes the form of capsule shapes, and is mixed with viscous fluid, while the mixture is contained in a closed vessel. When the FFFluid isolator is affected by vibrations, energy is absorbed, due to the elastic strain of the foam. As the foam is compressed, there is also movement of the fluid, which contributes to further energy absorption as the fluid shears. Also, and dependent on the design adopted, the packaging could also attenuate vibration through energy absorption via friction and/or elastic strain. The present study focuses on the advantages of the FFFluid concept over the dry polymeric foam in the role of vibration isolation. This comparative study between the performance of dry foam and the FFFluid was made according to experimental procedures. The paper concludes by evaluating the performance of the FFFluid isolator in the suspension system of a light vehicle. One outcome of this research is that the FFFluid may preferable over elastomer isolators in certain applications, as it enables a reduction in the effects of high temperatures and of ‘creep effects’, thereby increasing the reliability and load distribution. The stiffness coefficient of the system has increased about 60% by using an FFFluid sample. The technology represented by the FFFluid is therefore considered by this research suitable for application in the suspension system of a light vehicle.

Keywords: Anti-vibration devices, dry foam, FFFluid.

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Authors: C. Malça, P. Gonçalves, N. Alves, A. Mateus

Abstract:

Regardless of the manufacturing process used, subtractive or additive, material, purpose and application, produced components are conventionally solid mass with more or less complex shape depending on the production technology selected. Aspects such as reducing the weight of components, associated with the low volume of material required and the almost non-existent material waste, speed and flexibility of production and, primarily, a high mechanical strength combined with high structural performance, are competitive advantages in any industrial sector, from automotive, molds, aviation, aerospace, construction, pharmaceuticals, medicine and more recently in human tissue engineering. Such features, properties and functionalities are attained in metal components produced using the additive technique of Rapid Prototyping from metal powders commonly known as Selective Laser Melting (SLM), with optimized internal topologies and varying densities. In order to produce components with high strength and high structural and functional performance, regardless of the type of application, three different internal topologies were developed and analyzed using numerical computational tools. The developed topologies were numerically submitted to mechanical compression and four point bending testing. Finite Element Analysis results demonstrate how different internal topologies can contribute to improve mechanical properties, even with a high degree of porosity relatively to fully dense components. Results are very promising not only from the point of view of mechanical resistance, but especially through the achievement of considerable variation in density without loss of structural and functional high performance.

Keywords: Additive Manufacturing, Internal topologies, Porosity, Rapid Prototyping, Selective Laser Melting.

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Authors: Jan Langebach, Peter Fischer, Christian Karcher

Abstract:

A numerical study is presented on convective heat transfer in enclosures. The results are addressed to automotive headlights containing new-age light sources like Light Emitting Diodes (LED). The heat transfer from the heat source (LED) to the enclosure walls is investigated for mixed convection as interaction of the forced convection flow from an inlet and an outlet port and the natural convection at the heat source. Unlike existing studies, inlet and outlet port are thermally coupled and do not serve to remove hot fluid. The input power of the heat source is expressed by the Rayleigh number. The internal position of the heat source, the aspect ratio of the enclosure, and the inclination angle of one wall are varied. The results are given in terms of the global Nusselt number and the enclosure Nusselt number that characterize the heat transfer from the source and from the interior fluid to the enclosure walls, respectively. It is found that the heat transfer from the source to the fluid can be maximized if the source is placed in the main stream from the inlet to the outlet port. In this case, the Reynolds number and heat source position have the major impact on the heat transfer. A disadvantageous position has been found where natural and forced convection compete each other. The overall heat transfer from the source to the wall increases with increasing Reynolds number as well as with increasing aspect ratio and decreasing inclination angle. The heat transfer from the interior fluid to the enclosure wall increases upon decreasing the aspect ratio and increasing the inclination angle. This counteracting behaviour is caused by the variation of the area of the enclosure wall. All mixed convection results are compared to the natural convection limit.

Keywords: Enclosure, heat source, heat transfer, mixed convection.

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Authors: Mirigul Altan, Huseyin Yildirim

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Plastics occupy wide place in the applications of automotive, electronics and house goods. Especially reinforced plastics become popular because of their high strength besides their advantages of low weight and easy manufacturability. In this study, mechanical and morphological properties of polypropylene (PP) and high density polyethylene (HDPE) matrix composites reinforced with surface modified nano titan dioxide (TiO2) particles were investigated. Surface modification was made by coating the nano powders with maleic anhydride grafted styrene ethylene butylene styrene (SEBS-g-MA) and silane, respectively. After surface modification, PP/TiO2 and HDPE/TiO2 composites were obtained by using twin screw extruder at titan dioxide loading of 1 wt.%, 3 wt.% and 5 wt.%. Effects of surface modification were determined by thermal and morphological analysis. SEBS-g-MA provided bridging effect between TiO2 particles and polymer matrix while silane was effective as a dispersant. Depending on that, homogenous structures without agglomeration were obtained. Mechanical tests were performed on the injection moldings of the composites for obtaining the impact strength, tensile strength, stress at break, elongation and elastic modulus. Reinforced HDPE and PP moldings gave higher tensile strength and elastic modulus due to the rigid structure of TiO2. Slight increment was seen in stress at break. Elongation and impact strength decreased due to the stiffness of the nano titan dioxide.

Keywords: High density polyethylene, mechanical properties, nano TiO2, polypropylene.

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Authors: A. Fallahi, R. Khamedi

Abstract:

Dual phase steels (DPS)s have a microstructure consisting of a hard second phase called Martensite in the soft Ferrite matrix. In recent years, there has been interest in dual-phase steels, because the application of these materials has made significant usage; particularly in the automotive sector Composite microstructure of (DPS)s exhibit interesting characteristic mechanical properties such as continuous yielding, low yield stress to tensile strength ratios(YS/UTS), and relatively high formability; which offer advantages compared with conventional high strength low alloy steels(HSLAS). The research dealt with the characterization of damage in (DPS)s. In this study by review the mechanisms of failure due to volume fraction of martensite second phase; a new method is introduced to identifying the mechanisms of failure in the various phases of these types of steels. In this method the acoustic emission (AE) technique was used to detect damage progression. These failure mechanisms consist of Ferrite-Martensite interface decohesion and/or martensite phase fracture. For this aim, dual phase steels with different volume fraction of martensite second phase has provided by various heat treatment methods on a low carbon steel (0.1% C), and then AE monitoring is used during tensile test of these DPSs. From AE measurements and an energy ratio curve elaborated from the value of AE energy (it was obtained as the ratio between the strain energy to the acoustic energy), that allows detecting important events, corresponding to the sudden drops. These AE signals events associated with various failure mechanisms are classified for ferrite and (DPS)s with various amount of Vm and different martensite morphology. It is found that AE energy increase with increasing Vm. This increasing of AE energy is because of more contribution of martensite fracture in the failure of samples with higher Vm. Final results show a good relationship between the AE signals and the mechanisms of failure.

Keywords: Dual phase steel (DPS)s, Failure mechanisms, Acoustic Emission, Fracture strain energy to the acoustic energy.

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