Browse Topic: Failure analysis

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Analysis of Lane Departure Caused by Inadequate Motorcycle Driving Maneuvers Due to Road Alignment2024-32-003404/18/2025
There are many riders who drive motorcycles on winding mountain roads and caused single motorcycle traffic accidents on curved roads by lane departure. Driving a motorcycle requires subtle balancing and maneuvering. In this study, in order to clarify the influence of lane departure caused by inadequate driving maneuvers against road alignment, the authors analyzed the required curve initial operation and driving maneuvers in curves depending on the traveling speed using a kinematics simulation for motorcycle dynamics. In addition, it was analyzed how inadequate driving maneuvers for curved roads can easily cause lane departure. As a result, it shows that the steering maneuvers and the lean of motorcycle body during the curves are highly affected by the vehicle speed, and the required maneuvers increases rapidly with increasing speed. The inadequate maneuver in the curves, especially for the lean of motorcycle body and steering torque, even by 10%, may cause failure to follow the
Kuniyuki, Hiroshi, Takechi, So
Technical Paper
test rejectionSAE-PP-0945901/27/2025
test
Rickard, Christopher
Pre-Print Article
Test GV Document 2JTEST1620251 (Current)01/06/2025
test
Ground Vehicle European Prospect Committee
Technical Standard
Transportation Ecosystem and Autonomy: Vol. 2EPRCOMPV20202305/03/2024
On-road vehicles equipped with driving automation features are entering the mainstream public space. This category of vehicles is now extending to include those where a human might not be needed for operation on board. Several pilot programs are underway, and the first permits for commercial usage of vehicles without an onboard operator are being issued. However, questions like “How safe is safe enough?” and “What to do if the system fails?” persist. This is where remote operation comes in, which is an additional layer to the automated driving system where a human assists the so-called “driverless” vehicle in certain situations. Such remote-operation solutions introduce additional challenges and potential risks as the entire chain of “automated vehicle, communication network, and human operator” now needs to work together safely, effectively, and practically. And as much as there are technical questions regarding network latency, bandwidth, cybersecurity, etc., aspects like human
Beiker, Sven, Muelaner, Jody E., Razdan, Rahul
Research Book
An eleventh one for CUR-1174PC11-CUR-1174 (Current)04/02/2024
Italic
Flight Simulator Engineering and Maintenance Committee
Information Report
Soot sensor elimination with DPF substrate failure monitoring.2024-26-015301/16/2024
The automobile industry is going through one of the most challenging times, with increased competition in the market which is enforcing competitive prices of the products along with meeting the stringent emission norms. One such requirement for BS6 phase 2 emission norms is the inclusion of PM (Soot) sensor in diesel passenger cars. PM sensor detects soot leakage in case of DPF substrate failure. There is a cost factor along with extensive calibration efforts which are needed to ensure sensor works flawlessly. This paper deals with the development of an algorithm with which robust detection of DPF substrate failure is achieved. In order to achieve this, a thermodynamic model of DPF substrate was created using empirical relations between parameters like exhaust flow rate, exhaust gas temperature and soot mass content. The modeling was done in both empty (no soot) and filled (threshold soot content) substrate conditions. There were two methodologies, namely integration method and
Jain, Praveer Kirtimohan, Yadav, Omkar, Chendil, Chellapandi
Technical Paper
A New Holistic Approach for System-Level Development of Seat Features2024-26-038101/16/2024
System engineering-based approach is now ubiquitous in the automotive industry. It is a disciplined approach that ensures that targets are clearly defined and met through a structured and holistic approach. In this paper, we report an application of a systems engineering-based methodology for developing seating system features. It starts with a Business Requirement Document (BRD), which enlists the business requirements of a feature. We then developed a Logical Architecture Diagram (LAD) on a Simulink environment, which serves as an initial proposal for the design of the logic that would realize the desired functionality. As a next step, we perform Functional Failure Analysis (FFA) on the LAD to identify potential failure modes. We propose a few ways to mitigate the identified failures or modify the design so that these failures are rendered inconsequential to the end user. Based on the updated LAD, a System Requirement Document (SRD) is created, which contains all the requirements
Ghosh, Soumik, Vidhu, Nandagopal
Technical Paper
OPTIMIZATION OF OIL QUANTITY IN MANUAL TRANSMISSION AND REDUCING CHURNING LOSS2024-26-034601/16/2024
Gearbox efficiency losses are contributed by Oil seal rubbing, Synchro friction rubbing, Gear losses, bearing preload friction, windage losses, churning losses etc. Here in this experiment we have focused on quantifying and reducing the churning losses as well as verifying the lubrication requirements satisfactorily in all terrains and conditions. The paper establishes the effective way for evaluating same with over 80 trials conducted for conclusive proof. Gearboxes must work efficiently to get the job done properly and lubrication is vital to this efficiency. Lubricating oil is like the circulation system of a gearbox. If the oil levels fall too low, the gearbox will likely fail. Gearbox failure can lead to expensive repairs that could be prevented. Besides added costs due to replacement or repair, costs associated with a loss of production could be significant. These issues are why it is important to understand the consequences of having low lubricant levels. Similarly, higher oil
Lakshamanan, sundar
Technical Paper
Utilizing Computed Tomography for Cell Characterization, Quality Assessment, and Failure Analysis2024-26-018901/16/2024
This abstract presents an experimental study on using Computed Tomography (CT) scan technology for analyzing battery cell failures. Lithium-ion battery cells with known failure modes were subjected to cyclic test under different temperature and C-rates. CT scans provided high-resolution cross-sectional images of internal structures, revealing failure-related features. The advanced image processing techniques quantitatively assessed electrode morphology, active material distribution, and separator integrity. The study demonstrated CT scan's potential in non-destructive analysis, enabling a deeper understanding of failure mechanisms and informing improvements in cell design and manufacturing processes.
Singh, Sathya Prakash, Baidya, Kapil Krishna, ADHALE, Pratik
Technical Paper
Tire-Rim Impact failure prediction using mathematical model2024-26-031401/16/2024
Early design or concept phase involve decision of key Chassis & Suspension parameters finalization, in which tire size selection is one of the most important aspect. Tire size affects overall vehicle ride & handling, steering performance and styling. In addition, it will dictate the majority of suspension packaging in subsequent design phase. An improper tire size selection can lead to major design changes in later stages and cause delay in the project deliverables. Conventional method of tire size selection mainly based on load rating using Tire standards like ETRTO, JATMA etc. is sufficient for vehicle application & basic durability point of view but lacks the insight for typical tire-rim impact failure mode. Aim of the study is to develop the methodology of predicting durability failure especially kerb strike event using simplified suspension-tire mathematical model, which will help in selection of optimal tire size or its specifications in early design phase to mitigate the impact
Atal, Abhishek, Lakhera, Vivek
Technical Paper
Test Methodology Development For Rig Level Validation Of Light Weight Stabilizer Link Of EV Bus Suspension2024-26-035701/16/2024
In the modern and fast growing automotive sector, reliability & durability are two terms of utmost importance along with weight ad cost optimization. Therefore it is important to explore new technology which has less weight, low manufacturing cost and better strength. The new technology developed always seek for a quick, cost effective and reliable methodology for its design validation so that any modification can be made by identifying the failures. This paper presents the rig level test methodology to validate and to correlate the CAE derived strain levels, life cycle & failure mode of newly developed light weight stabilizer link for EV Bus suspension. Stabilizer link replaces the existing separate arrangement of anti-roll bar and parallel rods and light in weight by 30kg.This stabilizer link arrangement is having the short lever arms which are connected through torsion bar which goes under twisting moment and the short lever arms are intended to control wheel motion in longitudinal
Tangade, Atul Bandu, Babar, Sunil, Bankar, Milind Achyutrao, Mehendale, Ravindra, Dhumal, Kailas, Bhusari, Deepak
Technical Paper
Controlled Production Quantity Release Applicability Determination Method2024-26-035501/16/2024
During product development or design change, the aim is to fully validate all potential issues. On programs with significant complexity, it is difficult or impossible to fully retire all combinations of risk factors even with comprehensive analysis and testing approaches. These complex projects have the highest risk to launching with hidden defects can result in high warranty costs and erosion of customer satisfaction. This paper discusses a conservative approach called Controlled Production Quantity Release (CPQR) to manage the risks of these complex releases or changes by presenting a decision framework executed by a cross-functional team to identify those complex releases that deserve the methodical and monitored approach necessary to manage risk. The purpose of this method is to gain early concurrence with the program team with documented decision criteria rather than relying on individual opinions. This paper focus on structured approach of determining the applicability criterion
Mohammed, Zubair, Freeland, James, Soma, Nagaraju, Quadri, Danishuddin S.F.
Technical Paper
Testing and evaluation of Integrated Starter Generator system’s performance and durability characteristics in rig level using automation.2024-26-036901/16/2024
Automobiles are incorporated with advanced technologies to improve riding experience, safety, and vehicle management. Considering riding experience, major concern prevails in starting and charging system. For quick start and stop, implemented Integrated Starter Generator (ISG) in two wheelers. ISG system consists of ISG machine and ISG controller. ISG machine acts as motor during cranking and generator during charging, controlled by ISG controller. Automation kit is made with help of real sensors, actuators, and microcontroller to monitor and log the performance characteristics of ISG system during testing in rig level. Sensors continuously monitors the performance parameters and once the parameters not meeting the specification, actuators stop the testing and rise the indication. All tested data stored in cloud and taken for analysis. This automation kit served two purposes. One is eliminated test running on the failure sample for full long testing duration. Second is from logged data
K, Vishali, Patil, Pratik, Kumaran, Adm V
Technical Paper
Effect of environmental factors on the function of an Automotive Luggage Cover of a passenger vehicle – A case study2024-26-022801/16/2024
Abstract: - Automobile OEMs, universally, have always given high priority to the Luggage Area of the vehicle. Luggage Area primarily includes a Load Floor (the load bearing part), Side & Rear garnishes & the Luggage Shelf (or the Parcel Tray) for covering the luggage. The Parcel Tray makes the Luggage Area look neat and aesthetically appealing & is occasionally also used for carrying small items like files, papers, cushion, tissue box etc. The article under consideration in this paper is a Luggage Cover made from thermoplastic composite such as PP-Compounds (with Glass-fiber or Wood-powder), with rotating hinges towards the cabin side. Such types of Covers are predominantly in use in many markets including India. In the vehicle, the Luggage shelf is suspended on the Side Trims or Garnishes & has an elastomer interface with the back Door. The back door tends to be opened and closed in frequent intervals and the elastomer tends to harden with time. This leads to increased load on
Sreejith, M P, Khandelwal, Lokesh, Sandilya, Arnab, Natu, Mandar R, Ray, Amulya Kali, Handa, Rajat
Technical Paper
Effects of acoustic dissipative material in applications with acoustic leakage2025-01-011705/05/2023
In the paper, the dissipative material and other conventional acoustic materials are studied in conditions which simulates actual vehicle application with acoustic leakage. The various acoustic materials are evaluated in the lab with acoustic leakage existing in steel panel experimentally and virtually in computer simulation with the estimated Biot’s parameters of the materials. Often, the acoustic leakages exist in actual vehicle condition in pass-through or mounting faster locations. The work includes in-vehicle test results on application and show how the dissipative material works.
Yoo, Taewook, Maeda, Hirotsugu, Sawamoto, Keisuke, Anderson, Brian, Gan, KimTong, Herdtle, Thomas
Technical Paper
A Comprehensive Evaluation of PU Foam for EV NVH Performance2025-01-012005/05/2023
Low density polyurethane foam was first proposed as an alternative to expandable baffles and tapes for sealing vehicle body cavities towards the end of the last century. In spite of several inherent advantages for cavity sealing, the high equipment cost of dispensing amongst other reasons, this technology has not spread as widely as expected. With the advent of electric vehicles, there is an increased emphasis on controlling higher frequencies from motors, inverters and other components, and polyurethane foam can be a viable solution by providing more robust sealing. Polyurethane foam sealing is already being employed in the new breed of electric vehicles but its NVH advantages have not been fully studied or published in literature. Using an existing electric vehicle with conventional expandable baffles & tape sealing measures, a comprehensive evaluation of NVH performance using the closed-cell polyurethane foam solution was carried out. Testing included component level bench test on
Kavarana, Farokh, Guertin, Bill, Braun, Arnold, Hand, Joshua, Thota, Manoj
Technical Paper
Condition Monitoring of High-Speed Rotating Machinery using Digital Twins & Machine Learning Techniques2025-01-012805/05/2023
In the era of Industry 4.0, maintenance of factory equipment is changing with new maintenance system using predictive or prescriptive methods. These methods leverage condition monitoring through digital twins, AI, & machine learning techniques to obtain early signs of faults, type of faults, locations of fault etc. Bearings and Gears are one of the most common components and cracking/misalignment/rubbing/bowing are the most common failure modes in high-speed rotating machinery. In the present work, an end-to-end automated Machine Learning based condition monitoring algorithm is developed for predicting and classifying internal gear and bearing faults using external vibration sensors. A digital twin model of the entire rotating system consisting of the gears, bearings, shafts, and housing was developed as a co-simulation between MSC ADAMS and MATLAB. The gears and bearing dynamic models were developed in MATLAB and shaft and housing models were developed in MSC ADAMS flexible body. The
Rastogi, Sarthak, SINGHAL, SRIJAN, Ahirrao, Sachin, Milind, T. R.
Technical Paper
Traceability Verification with respect to DO-178 and AS 91152022-26-120005/26/2022
As many business analysts say, following Aerospace guideline DO-178 for developing aerospace software products is not cheap and it comes with a cost. That too, experts say DO-178C can increase the cost of the product above DO-178B, which already increased costs by around 20-40%. So, to keep the cost under control, it is definitely important that we need to develop the software product by following various technical methodology and processes rigorously. DO-178 relies upon significant verification (reviews, tests, and analysis) to assess product quality. However, product quality comes from a quality process, design, and implementation, not just from testing. Performing Traceability verification is one such approach to determine if the requirements are correctly and completely captured, designed, implemented and verified. In this paper we discuss the various phases of the project lifecycle where the Traceability verification needs to be performed. These Traceability verifications are a
Kathiresan, Poornima, Valiyaparambil, Praveen
Technical Paper
Design and Parametric Investigations on Various Propellers for Nature Inspired Unmanned Amphibious Vehicle2022-26-117405/26/2022
Unmanned Amphibious Vehicle (UAV) is an integrative working environments based vehicle, which doesn’t allocate the place for onboard pilots. Mostly, unmanned amphibians have been controlled through pre-provided algorithms in the predestined paths. Aerodynamic and hydrodynamic working conditions are the compositions of aforesaid integrative environments, wherein the possible lifespan affecting failure of UAV may chance to happen in a high manner. Thus, the multidisciplinary investigation on UAV and it's every component needs to be done in order to pick the suitable UAV parts for both missions executing conditions. This work deals the comprehensive computational investigations on a different number of blades equipped propellers for the proposed cum nature-inspired UAV under aerodynamic and hydrodynamic loading conditions. Three different propellers are uniquely constructed based on the aerodynamic environment reference with the guidance of analytical formulae and thereafter modeling
R, Vijayanandh, Mathaiyan, Vijayakumar, Raji, Arul Prakash, Madasamy, Senthil Kumar, Gnanasekaran, Raj Kumar
Technical Paper
Bird strike analysis on nanocomposite materials for aerospace applications2022-26-114505/26/2022
Over the years, bird strike has become a serious threat as it is inevitable and can be catastrophic. Several accidents occur due to the bird collision with wing leading edges, causing serious structural damage that may be permanent. Therefore, the failure induced by birds on the leading edge has persuaded much research interest. To heighten the impact resistance during bird strike with the leading edge of the wing, nanocomposite materials are proposed as it has improved characteristics like high surface-to-volume ratio, enhanced mechanical properties like high ductility, fracture toughness with no decrease of strength in structure. In order to achieve material constants of the nanocomposites, the finite-element method (FEM) and representative volume element (RVE) which is a micromechanical analysis approach will be considered. A comparative study will be done on different volume fractions of nanofillers impregnated with the composite material to find the optimum material properties
Neigapula, Keerthana, Anand, Sumit, Devi, Monisha, Tiwari, Anawil, Kumar, Siddharth
Technical Paper
Creation of a Virtual Framework for Control Logic Development and Validation with a Driver-In-the-Loop (DIL) Simulation2022-01-048703/29/2022
Current simulation tools can help expedite the development and validation of powertrain control systems compared to traditional methods that use actual vehicle testing. In this study, a co-simulation platform has been developed by connecting MATLAB/Simulink, IPG CarMaker, GT-Suite, and PTV Vissim to create virtual calibration and validation environment. The purpose of developing this platform is to save time and reduce cost during vehicle testing by replacing physical calibration and robustness validation with simulation-based processes. The platform enables a virtual environment that replicates the local road networks as well as randomly generated traffic patterns that an ego vehicle can interact with on the virtual road. By combining the strengths of each software listed above, the developed virtual environment can provide realistic drive scenarios for testing new vehicle control algorithms. One of the main challenges in the virtual test platform is that the driver model that creates
Fan, Shihong, Sun, Yong, Lee, Jason, Ha, Jinho, Harber, John
Technical Paper
Identifying key aspects of thermal runaway modelling for lithium-ion battery cells2022-01-087003/29/2022
Electrification and hybridization of powerplants in the transportation sector is one of the most important changes in the last few decades. Lithium-ion batteries are the main energy storage systems, but despite the maturity of this technology, it has certain contains compared to traditional internal combustion engines in the day-to-day usage. As the operating conditions of the batteries are pushed to the limits to overcome certain disadvantages relative to other conventional systems like charge and discharge times or vehicle autonomy, new concerns and safety limitations must be considered. High power rates and cooling deficiencies can produce excessive operating temperatures within the cells, leading to problems with degradation or even unchain chemical reactions that can end in thermal runaway, one of the most worrying failure modes attaining electric platforms nowadays. One of the main challenges in the ordeal of designing the system considering these effects is the crossed
Garcia, Antonio, Monsalve-Serrano, Javier, Sari, Rafael, Fogué Robles, Álvaro
Technical Paper
Development of a Built-in Type Dashboard Camera with Reliability and Usability 2022-01-012003/29/2022
Dashcam, which is considered essential parts of vehicles in Korea, are installed in most vehicles for reasons such as accidents, evidence of threatened driving of other vehicles, and insurance premiums. Aftermarket dashcam have been developed with many improvements such as higher resolution camera and LCD application, but still have problems in usability and durability. The first problem is a separate device mounted on the top of the windshield, which obstructs the driver's view and may injure the driver due to a collision impact. In addition, the connection of the power supply may cause a vehicle breakdown such as a fire due to a worker's mistake or a product defect. Secondly, in order to view the stored video, it is troublesome to remove the SD card and check it on the computer. Moreover, since the LCD is so small, it is difficult to search and play the desired video from the list in many saved files. The third problem is durability and reliability, when operating in the high
Jeong, DongHyuk
Technical Paper
An evaluation of an unhealthy part identification using a 0D-1D diesel engine simulation based Digital Twin2022-01-045703/29/2022
Commercial automotive diesel engine service and repair, post a diagnostic trouble code trigger, relies on standard troubleshooting steps laid down to identify or narrow down to a faulty engine component. This manual process is cumbersome, time-taking, costly, often leading to incorrect part replacement and most importantly usually associated with significant downtime of the vehicle. Current study aims to address these issues using a novel in-house simulation-based approach developed using a Digital Twin of the engine which is capable of conducting in-mission troubleshooting with real world vehicle/engine data. This cost-effective and computationally efficient solution quickly provides the cause of the trouble code without having to wait for the vehicle to reach the service bay. The simulation is performed with a one-dimensional fluid dynamics, detailed thermodynamics and heat transfer-based diesel engine model utilizing the GT-Power engine performance tool. The flow, combustion and
Saurabh, Shakti, Sureka, Britant
Technical Paper
Integrated Evaluation of Constant Amplitude Life Tests Towards SN Curves and Endurance Limit 2022-01-030003/29/2022
Establishing SN curves from constant amplitude life tests and locating the endurance limit are indispensable tasks in durability engineering. For both regimes, finite life and endurance limit, there are many approaches available, like linear regression or maximum likelihood. Especially on low load levels, tests may run very long and one may suspend them before failure. Especially the stair case method for evaluating the endurance limit systematically produces almost 50 percent suspended results. Hence, when data for both regimes is available, those run-outs need to be considered in a statistically proper way. If both regimes are evaluated separately it is often ambiguous if a single observations may be used for estimating the endurance limit or for the finite life re-gime. In this paper, we present an integrated approach, for simultaneous evaluation of both regimes. Every single ob-servation is mapped to one of the regimes with certain probabilities. Even more general, our model
Feth, Sascha
Technical Paper
An Efficient Machine Learning Algorithm for Valve Fault Detection 2022-01-018503/29/2022
Multi-level Miller-cycle Dynamic Skip Fire (mDSF) is a combustion engine technology that improves fuel efficiency by deciding on each cylinder-event whether to skip (deactivate) the cylinder, fire with low (Miller) charge, or fire with a high (Power) charge. In an engine with two intake and two exhaust valves, skipping the cylinder is accomplished by deactivating all valves, while firing with a reduced charge is accomplished by deactivating one of the intake valves. This new ability to modulate the charge level introduces new failure modes. The first is a failure to reactivate the single intake valve, which results in a desired high-fire having the air intake of a low-fire; the second is a failure to deactivate the single intake valve, which results in a low-fire having the air intake of a high-fire. Reliably detecting these two faults has proven challenging for classical techniques that use measured MAP and/or crank angle acceleration to identify characteristic features of the
Serrano, Joe, Ortiz-Soto, Elliott, Chen, S Kevin, Chien, Li-Chun, Joshi, Abhishek
Technical Paper
Moisture absorption behavior and hygrothermal aging life prediction for CFRP adhesive-bonded joints2022-01-038903/29/2022
Effects of moisture absorption on the strength degradation, energy absorption and failure mechanism of CFRP laminates and the adhesive-bonded joints in hygrothermal environment were investigated in this work. Experiments of accelerated moisture absorption, uniaxial tension and three-point bending were performed. SEM observations on the CFRP laminates and the fracture surfaces of the CFRP bonded joints were conducted. Strength degradation and failure mechanism induced by moisture absorption were discussed in detail. The results showed that the strength degradation in tension and in three-point bending of the CFRP laminate due to moisture absorption reached 7.4% and 17.1%, respectively. Different response of CFRP laminate and adhesive layer to the moisture determined the failure mode of the adhesive-bonded joints. Suitable match of CFRP laminate and adhesive was very important to make the failure mode of the joint under control.
Xu, Xianghe, Yu, HaiYan, Xing, Ping
Technical Paper
Evaluation of Fretting Phenomenon in Gearbox and Allied Failures2022-01-078503/29/2022
This paper takes a review of fretting phenomenon on splines of the engaging gears and corresponding splines on shaft of automotive transmission and how it leads to failure of other components in the gearbox. Fretting is a special wear process which occurs at the contact area of two mating metal surfaces when subject to minute relative oscillating motion under vibration. In automotive gearbox, which is subjected to torsional vibrations of the powertrain, the splines of engaging gears and corresponding shaft may experience fretting, especially when the subject gear pair is not engaged. The wear debris formed under fretting process when oxidizes becomes very hard and more abrasive than base metal. These oxidized wear particles when comes in mesh contact with nearby components like bearings, gears etc. may damage these parts during operation and eventually lead to failure. In this paper, a case study is presented wherein fretting has been identified as the root cause of failures of some
Mohire, Sujit, Bhandari, Kiran Kamlakar, Tendulkar, Vishveshvar, Chatterjee, Soumik
Technical Paper
Fatigue Endurance Limit of Fasteners in Automotive Application2022-01-028903/29/2022
Fastener commonly used in automotive industry plays an important role in the safety and reliability of the vehicle structural systems. In practical application, bolted joint would never undergo fully reversed loading, there always will be positive mean stress on bolt. The mean stress has little influence on the fatigue life if the maximum stress is lower than a threshold, which is the yield stress of the bolt. However, when the sum of the mean stress and the stress amplitude exceeds the yield stress, the endurance limit stress amplitude decreases fast as the mean stress increases. The purpose of this paper is to research fatigue endurance limit of fastener and establish the threshold for safe design in automotive application. In order to obtain the fatigue endurance limit at different mean stress levels, various mechanical tests were performed on M12x1.75 and M16x1.5 Class 10.9 fasteners using MTS test systems. Results show that the fatigue failure mode of bolts is different from that
Mao, Jianghui, Lin, Barry, Wu, Zhijun
Technical Paper
Prediction of Crash Performance of Adhesively Bonded Vehicle Front Rails2022-01-105103/29/2022
Adhesive bonding provides a versatile strategy for joining metallic as well as non-metallic substrates, and also offers the functionality for joining dissimilar materials. For problems of elastic behavior and small strains in vehicle unibody structures such as designing for NVH (Noise, Vibration and Harshness), adhesive bonding of sheet metal parts along flanges provides enhanced stiffening of body and improved acoustics due to sealing of openings between flanges. However, due to the brittle nature of adhesives, they remain susceptible to failure under impact loading conditions which can cause crumpling of sheet metal parts resulting in plasticity and large strains. The viability of structural adhesives as a sole or predominant mode of joining stamped sheet metal panels into closed hollow sections such as hat sections thus remains suspect and requires further investigation. The mechanical behavior of adhesives tends to be significantly different as compared to ductile and isotropic
Ramachandra, Sanketh, Deb, Dr. Anindya, Chou, Clifford
Technical Paper
The investigation of a contact and element-based approach for Cohesive zone modelling in the simulation of Delamination propagation2022-01-029203/29/2022
The CAE industry always moves towards new ways to improve the productivity, efficiency and to reduce the solution times. Conventional method of Cohesive Zone Modelling has drawback of higher computation and modelling time. Due to this problem, sometimes Engineers need to avoid simulations and rely only on some sort of approximation of crack from previous designs. This approximation can lead to either product failure or overdesign of the product. A new approach is discussed in this paper to simulate crack initiation and propagation with Cohesive Zone Modelling. Conventional method uses Cohesive zone modelling with Hex or Penta elements by assigning material with cohesive properties, which increases computation and modelling time. The new approach models Cohesive zone as contact between two bodies, thus eliminating the need to use cohesive elements which will essentially reduce the computation time as well as modelling time. This approach uses Damage model method which allows modelling
Dhangar, Vinaykumar, Hosmath, Anjaney, Salunkhe, Prashant
Technical Paper
Driveline Parking Brake Test Procedure for Medium Duty VehiclesJ2690_202110 (Current)10/28/2021
This SAE Recommended Practice establishes uniform test procedures for friction based parking brake components used in conjunction with hydraulic service braked vehicles with a gross vehicle weight rating greater than 4500 kg (10 000 lb). The components covered in this document are the primary actuation and the foundation park brake. Various peripheral devices such as application dashboard switches or indicators are not included. These test procedures include the following: a Brake Related Tests 1 Brake Functional Performance 2 Brake Dynamic Torque Performance 3 Brake Corrosion Resistance 4 Brake Endurance with Torque 5 Brake Endurance without Torque 6 Vibration Resistance 7 Brake Ultimate Static Load 8 Brake Lining Wear Adjuster Function b Actuation Related Tests 1 Mechanical Actuator Functional Performance 2 Mechanical Actuator Endurance 3 Mechanical Actuator Quick Release 4 Mechanical Actuator Ultimate Load 5 Spring Apply Actuator Functional Performance 6 Spring Apply Actuator
Truck and Bus Hydraulic Brake Committee
Recommended Practice
Improving the Slug Removal Method in Piercing Operation of Brake Components Manufacturing Process by the Introduction of Semi-Automation2021-28-022110/01/2021
This experimental study is to improve the throughput time of the backplate manufacturing process line of heavy-duty brake system components in a process line of a machine shop. The existing method of removal of the pierced slug is performed by the pneumatically supported ejection for every 5 cycles using a compressor. This process is a critical process that is a feeder for the other processes in the process line. The steps in this study include Work-study, time study, brainstorming, funneling to suggestions for improvement, failure mode effects analysis, implementation of the suggestion, and validation. The brainstorming has been conducted with the cross-function team members and the suggestions were prioritized with respect to the outcome on a scale of productivity, quality cost, safety, and handling. The obtained suggestion is: implementing a mechanical system operated by a series of linkages to eject the slug from the piercing cavity for every cycle. The time taken for the removal
B, Prabakaran, Narayan, 1Lt Harish
Technical Paper
Experimental evaluation of microstructural and mechanical properties of Abaca/epoxy composite2021-28-028610/01/2021
Natural fibre reinforced composites (NFRCs) are known to have potential structural and non-structural applications in automobile industries. The mechanical properties documented in literature have supported the potentiality of the materials in such applications. The objective of this work was to evaluate the mechanical properties of abaca/epoxy reinforced composite and understand the modes of failures from fractured surfaces. Abaca (a banana family tree) fibre processing is well-established as it is used in manufacture of garments in Asia. The composite specimens [45/0/0/45] were fabricated by hand-layup method and the mechanical tests (Tensile, Compression and Flexural) according to ASTM D standards. It was observed that, on an average, the composite failed at around 302 MPa in tensile loading, 0.083 MPa in compression load and 37.15 MPa in flexural load. Scanning electron microscope (SEM) based interpretations of the failure modes are presented alongside all test results for
Shaik, Mahaboob Subhani, Sankarasubramanian, Hariharan
Technical Paper
Evolution of Multi Axis Suspension Test Rig from Reaction Type to Inertial Type2021-26-047109/22/2021
This paper highlights the transition of multi-axis suspension test rig from fixed reacted type to semi-inertial type and the benefits derived thereof in simulation accuracies. The critical influence of ‘Mx’ and ‘Mz’ controls on simulation accuracies has been highlighted. The vital role of ‘Mz’ control in presenting the resonance of wheel pan along ‘Z’ axis and thereof arresting unwanted failures modes in spindle has been duly emphasized. Finally, the role of constraints and boundary conditions on simulation accuracies has been demonstrated by replacing the reaction frame with vehicle body.
Suryawanshi, Vishal N, Kajalkar, Atul M, Mohite, Suraj S, Bankar, Milind A, Bhusari, Deepak B
Technical Paper
Methodology To Derive RLD Based Durability Test Schedule For Gearbox Oil Seals2021-26-046109/22/2021
Oil seal leakage is one of the major failure mode in gearbox / transaxle. Oil seal failures can be due to various reasons like high temperature, insufficient lubrication, failure due to external environment, incorrect fitment etc. Major reason for oil seal failure is insufficient oil flow inside gearbox when vehicle is running on gradient for long duration. When vehicle is running in hilly region, transmission will get incline leading to oil deficiency at one half of the transmission. Oil seal in this location will not get sufficient lubrication and will run dry. Also, there will be rise in local temperature at seal lip to shaft interface leading to failure of oil seal lip. Subsequently, oil leakage from transmission will start from this location when vehicle is running in different terrain. Due to continuous seepage, oil quantity in the transmission will get reduced and may lead to gear failure or seizure of bearing. Some OEM use transmission with transparent housing for lubrication
Uttamani, Rahul, Tendulkar, Vishveshvar, Navale, Pradeep, Kumar, Ravi, bhavikatti, Gururaj
Technical Paper
MULTI-ENVIRONMENT ACCELERATED DURABILITY TEST FOR EXHAUST SYSTEM FLANGE JOINTS2021-26-047209/22/2021
Accelerated testing is vital to meet stringent project timelines and is a key consideration for developing new testing methodology. Specifically, durability testing is one of the key fields of interest to deal with all aspects. Fatigue with exposure to multiple environments is a major cause of exhaust system flange joint failure. Physical verification of increased design life expectancy, demands longer testing time, while shorter time to market is main differentiator for competitiveness. Government policy induced timeline pressures added to the need of accelerated tests. The methodology described in this paper embraces these aspects to ensure a quicker flange joint testing, with due consideration to environmental impact. Until the BSVI norms, marginal leakage through the system joints was usual and acceptable. Stringent emission norms demand ‘near-zero’ leakage from exhaust systems. The system joints essentially being the most probable leakage zones, became the focus area
Dhumal, Sagar Prakash, Suryawanshi, Sachin, Mone, Manasi
Technical Paper
Failure of Li-Ion 18650 Cylindrical Cells Subjected to Mechanical Loading and Computational Model Development2021-26-031809/22/2021
To enhance the crashworthiness of electric vehicles, designing the optimized and safer battery pack is very essential. The deformed battery cell can result in catastrophic events like thermal runaway and thus it becomes crucial to study the mechanical response of battery cell. The goal of the research is to experimentally investigate the effect of mechanical deformation on Lithium ion battery cell. The paper thoroughly studies the phenomenon of short circuiting at the time of failure. Various experiments are carried on 18650 cylindrical cells (NCA chemistry) under custom designed fume hood. The setup captures the failure modes of battery pack cell. The loading conditions have been designed considering the very possible physical conditions during crash event. The study has been done for radial compression, semicircular indentation, hemispherical indentation, flat circular indentation and case of three point bending. A detailed computation model is developed in Hypermesh to study the
Aphale, Siddharth, H, Rajesh, Dandge, Sunil, Mahajan, Rahul, Nandurdikar, Vijay, Murugkar, Milind
Technical Paper
Compliance of ISO 26262 Safety standard for Electric Power Assisted Steering System2021-26-002509/22/2021
Compliance of ISO 26262 Safety standard for Electric Power Assisted Steering System ABSTRACT This paper is an application of ISO 26262 functional safety standards for fail-safe design, development and validation of Electric Power Assisted Steering (EPAS) System. As part of safety feature to save lives, prevent injuries, and reduce economic loss due to accidents, many research methods are working to ensure the safety and reliability of emerging safety-critical electronic control systems in motor vehicles. Advanced driver assistance systems and other emerging technologies are introduced into new motor vehicles, the overall safety of these advanced electronic systems relies in part on the safety of the underlying foundation systems, such as steering systems. This paper outlines one approach of performing a Hazard Analysis and Risk Assessment (HARA) and developing a Functional Safety Concept. The approach incorporates several analysis methods, including Hazard and Operability study
Tikar, Sagar S., Ansari, Ashfaque
Technical Paper
Design and Development Methodology of Automatic Electric Start System for Power Tiller2021-26-009309/22/2021
This paper deals with designing and development methodology of Automatic Electric Start (AES) system for power tiller which has horizontal diesel engine as prime mover. Designing of AES system constitutes of designing of Starter Motor, Starter Motor Bracket, Flywheel Ring Gear, Battery, Electrical Circuit, Fan Alternator and then development these components as integrated system prototype. Unlikely tractor market, AES system are not so common in Indian power tiller market therefore, unprecedented design approach towards design of AES system on power tiller engine has been presented in this paper. An engine without AES system requires of huge amount of engine starting effort by farmer whereby farmers fatigue levels are always on higher side. AES system on power tiller has made 0 N force requirement to start engine which was approximately 92 N earlier. Design of AES system depends on analysis engine cranking torque, which is a complex process and involves calculation of moments, such as
singh, sahildeep, sakthiendran, s, kanase, kedar
Technical Paper
Development of Closed Loop Power Recirculating Type Test Rig - Higher Torque Ranges2021-26-049109/22/2021
In the past decades, many impressive progress has been made in the rig development for the gear validation. But, the challenges are to test the entire gear box for the improvement in the single gear alone to ascertain material quality or process improvement, that too with the higher torque range gear boxes, which requires huge investment and power consumption due to high capacity test rig / dynamometer. This paper deals with an experimental validation of the dynamic model for a gear pair test system, representative of a closed loop power recirculating type test rig. Being a closed loop, this system has its own uniqueness, that, it uses the low capacity prime mover, which considers the initial starting loop torque only, to cater the high power requirement in an efficient manner. The key intend of the development of this rig is to reduce the testing from system level to sub component level with low cost operation and more competence for the gears of high torque application. This also
Rajaraman, Manikandan, Srinivasan, Sriraman, Muthu kumar, Pandurangan, N, Gopi Kannan
Technical Paper
Thermo-Mechanical Fatigue and Press-Fit Loss Analysis Of Valve Seat Insert2021-26-033809/22/2021
Valve seat inserts (VSI) are installed in cylinder heads to provide a seating surface for poppet valves. Insert material is more heat and wear resistant than the base cylinder head material and hence it makes them better suited for valve seating and improved engine durability. Also using inserts permits easier repair or rebuild of cylinder heads as only the wear surfaces need to be replaced. Desirable performance characteristics are appropriate sealing, heat-transfer and minimizing valve to VSI wear and undesired outputs include valve seat dropping and cracking. With downsizing trend of diesel engines, it leads to increasing power density and therefore higher cylinder pressure and temperatures. Hence the engine components are getting exposed to more severe loadings and hence to failure modes, which were not heretofore experienced based on the warranty data. Possible identified failure modes are insert’s yielding and corresponding press-fit loss leading to either it’s cracking or drop
Ozarde, Amit Prakash, McNay, Gene
Technical Paper
Software Robustness Verification Framework (SRVF): Validating the Critical Software Module2021-26-048109/22/2021
With the advancement of inbuilt electronics and intelligent controls, automotive and other industries are looking at efficient usage of ECUs with intelligent electronic modules and more of critical functions implemented by software. Robustness of the software involved is always critical to the ECUs health, so software engineers are tasked to ensure the same by following right development and validation life cycle. Enabling the multiple decision by single software module makes verification & validation challenging, complex and time consuming. To insure the robustness of these software module, the predictable verification & validation process, which is followed by most of the industries, deals with specific standard if it is safety critical application to aid test coverage with respect to dynamic responses & function associated. Hence iterative verification & validation approach against the gaps/fixes identified during unit level, model-in-loop, hardware-in-loop & system integration test
Pandey, Vikas, Kadekodi, Pravin, Bhatarkar, Gajanan Shrawan, Manohar, Ruchita
Technical Paper
Three-way catalyst model development using physical and machine learning methods for engine control design purposes2021-01-122109/21/2021
Gasoline engine control strategies ensure a combustion control around stoichiometry. That is because the three-way catalytic converter allows CO and HC oxidation under lean operating conditions while ensuring NOx reduction for rich mixtures. In case of engine malfunction, the controller must adapt to compensate for potential torque losse and other critical attributes, potentially leading to significant deviation of the fuel-air mixture richness from stoichiometry and larger emission levels. Therefore, during development of the engine fault diagnostics the impact on the pollutant emissions must be considered. In this paper, a model-based development process is proposed. It is based on system simulation modelling techniques, where a complete exhaust line is represented in order to predict tail-pipe emissions under stoichiometric, lean and rich conditions, for engine control design purposes. Two different modelling approaches are applied and evaluated in this paper. First, a physics-based
LOUSSAIEF, Sana, Akhmetov, Yerlan, GROISIL, Melanie, Takahashi, Daisuke, Kuhara, Masaki, Isobe, Yoshiki, Mas, Peter
Technical Paper
Performance Standard for Passenger Smoke and Toxic Fumes Respiratory Protective EquipmentAS8048A (Current)09/20/2021
This SAE Aerospace Standard (AS) defines the performance requirements for equipment to be used by untrained cabin occupants for protection from toxic and irritant atmospheres while on board and during evacuation of an aircraft.
A-10 Aircraft Oxygen Equipment Committee
Technical Standard
Performance Standard for Passenger Smoke and Toxic Fumes Respiratory Protective EquipmentAS8048A-TEST-REC (Historical)09/20/2021
This SAE Aerospace Standard (AS) defines the performance requirements for equipment to be used by untrained cabin occupants for protection from toxic and irritant atmospheres while on board and during evacuation of an aircraft.
A-10 Aircraft Oxygen Equipment Committee
Technical Standard
Automotive Engineering: September 202121AUTP0909/01/2021
Weaving a new future for composites In a shift perhaps as prolific as steel to aluminum, woven plastics may finally bring the magic of composites to cost-effective mass-production. New composites target EV applications No longer a low-volume play, the latest composite materials offer EV developers new options for lightweighting, thermal management and structures. Acura TLX is Honda's new body-build benchmark All-new for 2021, Acura's midsize sport sedan gets an exclusive platform to go with its structural, materials and dynamic advancements. Body development leader Jeremy Lucas explains. Schaeffler builds an e-motor powerhouse Armed with state-of-the-art manufacturing and a history of innovation, Schaeffler Group is attacking the e-mobility space, says Daniel Sayre. Editorial EV bafflers, surprises and ironies Altair honors weight-saving innovations Finding failure inside lithium-metal batteries GM puts its new 2023 Corvette V8 on a different 'plane' SAE Standards News New ISO-SAE
Magazine Issue
Failure Modes and Effects Analysis (FEMA) & Failure Modes and Effects Summary (FEMS) Checklist - ARP4754A - AFuzionARP4754A_CK_00308/12/2021
Recommended Practice
References, Spacecraft and Spacecraft Servicing, Fluid System Components (Abbreviations, Acronyms, Definitions, Applicable Documents and Environmental Conditions)AIR4728A (Current)04/30/2021
This SAE Aerospace Information Report (AIR) presents reference information for use in preparing detailed specifications and other documents. The intent is to have a master reference document containing frequently required tabulations of information, such as the meaning of abbreviations, the spelled out wording of acronyms, the definition of terms, etc. so that such tabulations need not be repeated in recommended practice documents describing how to prepare technical documents. This document is intended to provide references in the field of fluid system components for space applications. Space applications include spacecraft, such as satellites, space stations, launch vehicles and space shuttles, and servicing equipment and components used for ground systems and launching and for servicing in space. Fluid system components include couplings, fittings, hose and tubing assemblies.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Information Report
References, Spacecraft and Spacecraft Servicing, Fluid System Components (Abbreviations, Acronyms, Definitions, Applicable Documents and Environmental Conditions)AIR4728A-TEST-REC (Historical)04/30/2021
This SAE Aerospace Information Report (AIR) presents reference information for use in preparing detailed specifications and other documents. The intent is to have a master reference document containing frequently required tabulations of information, such as the meaning of abbreviations, the spelled out wording of acronyms, the definition of terms, etc. so that such tabulations need not be repeated in recommended practice documents describing how to prepare technical documents. This document is intended to provide references in the field of fluid system components for space applications. Space applications include spacecraft, such as satellites, space stations, launch vehicles and space shuttles, and servicing equipment and components used for ground systems and launching and for servicing in space. Fluid system components include couplings, fittings, hose and tubing assemblies.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Information Report
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