Browse Topic: CAD, CAM, and CAE

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Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions2024-32-003804/18/2025
The arc welding process is essential for motorcycle frames, which are difficult to form in one piece because of their complex shapes, because a single frame has dozens of joints. Many of the damaged parts of the frames under development are from welds. Predicting the strength of welds with high reliability is important to ensure that development proceeds without any rework. In developing frames, CAE is utilized to build up strength before prototyping. Detailed weld shapes are not applicable to FE models of frames because weld shapes vary widely depending on welding conditions. Even if CAE is performed on such an FE model and the evaluation criteria are satisfied, the model may fail in the actual vehicle, possibly due to the difference between CAE and actual weld bead geometry. Therefore, we decided to study the extent to which the stresses in the joint vary with the variation of the weld bead geometry. Morphing, a FE modeling method and design of experiment method, was utilized to
Hada, Yusuke, Sugita, Hisayuki
Technical Paper
test rejectionSAE-PP-0945901/27/2025
test
Rickard, Christopher
Pre-Print Article
Arinc Automation Document - Standard Characteristic - PageCount less than 45KJH003 (Current)12/19/2024
Arinc Automation Document - Standard Characteristic - PageCount less than 45
Aviation Maintenance Committee
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Airlines Electronic Engineering Committee
Draft
Automation Title for Group Code D21: Updated in Authoring: 5/03/24PC-Auto-1714611830430 (Current)05/02/2024
Automation Abstract for Group Code D21. Updated in Authoring: 5/03/24
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Automation Title for Group Code D22PC-Auto-1713447343633 (Current)04/18/2024
Automation Abstract for Group Code D22
Airlines Electronic Engineering Committee
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Automation Title for Group Code D21PC-CUR-1232 (Current)04/18/2024
Automation Abstract for Group Code D21
Airlines Electronic Engineering Committee
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Automation Title for Group Code D21PC-Auto-1713447321320 (Current)04/18/2024
Automation Abstract for Group Code D21
Airlines Electronic Engineering Committee
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An eleventh one for CUR-1174PC11-CUR-1174 (Current)04/02/2024
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Flight Simulator Engineering and Maintenance Committee
Information Report
A sixth one for CUR-1174PC6-CUR-1174 (Current)03/26/2024
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testing tasksSAE-PP-0922503/21/2024
3rd task
Mutagaana, Festo
Pre-Print Article
Method Of Improving Slam Durability Fatigue Of Vehicle Liftgate Subsystem For Fast-Track Vehicle Development Cycle2024-26-030201/16/2024
ABSTRACT With reference to existing literature, most OEMs are working on reducing product development time by around ~20%, to achieve seamless integration to digital ecosystem and focusing on new features catering to dynamic customer needs. The Systems Engineering approach focuses on functions & systems rather than components. In this approach, designers (Computer Aided Design) / analysts (Computer Aided Engineering) need to understand program requirements early to enable seamless integration. This approach also reduces the number of iterative loops between cross functions thereby reducing the development cycle. In this paper, we have taken a common challenge faced by Closures (Liftgate) engineering to meet slam durability fatigue life, replicating customer normal and abusive closing behavior. For modern vehicles, with faster vehicle development process, major challenges are balancing mass with improved structural and durability performance while also considering design changes with
Subramanian, Vijayasarathy, Evans, Jon, Schoenow, James, Arikatti, Karegowda
Technical Paper
Dual-Motor-BEV Controls Optimization2024-26-024301/16/2024
In this paper we will discuss different techniques of controls optimization for a dual motor BEV model and look at the most optimal solution with an objective to minimize motor losses or maximize efficiency. In a dual motor model, torque split ratio plays a vital role in deciding the operating points for each motor and hence the losses or inefficiency in the system. It is important to find the optimal torque split ratio to improve range and performance. Four techniques covered in this paper includes ECMS (Equivalent Consumption Minimization Strategy, DP (Dynamic Programming), DOE (Design of Experiment) and Empirical relation-based approach. ECMS is a local optimization technique whereas DP is global optimization technique. DOE was used to perform a full factorial analysis with an eventual goal of creating a map which relates TSR (Torque Split Ratio) to the operating points in the form of vehicle acceleration and vehicle speed. A quadratic empirical relation between vehicle acceleration
Chopra, Ujjwal
Technical Paper
Lightweighting of Two-Wheeler Frame with CAE - Multi Domain Optimization (MDO)2024-26-026101/16/2024
Lightweighting in the automotive industry without the use of finite element methodologies is now inconceivable. With the development and enhancement of various CAE tools available in the market, CAE-driven optimization has become part of the product development cycle. Using a variety of CAE techniques in a lightweight optimization process can significantly reduce product development lead time with good results. Traditional light weighting can be done through different iterative approaches with different manual inputs from cross-domain teams, which is usually time consuming and leads to repeated analyses, etc. The current method describes the case of a multi-domain optimization (MDO) approach involving E-Motorcycle frame weight reduction while taking into account various important cross-domain load cases using CAE methodologies. For frame optimization, the most important loads - stiffness, durability/strength (Normal & Abusive), and NVH (Modes & Vibration) - were taken into account, as
S, Vishnu, kakanur, Ashok, U PE, Manjunatha, Bhat, Sachin, POOJARY, KIRAN, V N, Kishor
Technical Paper
The Impact of Uncertainty Quantification and Sensitivity Analysis in CAE Simulation based Regulatory Compliance2024-26-029401/16/2024
Computer aided engineering (CAE) is a routinely used technology for the design and testing of road vehicles, including the simulation of their response to an impact. To increase automotive industry competitiveness by reducing physical test based type approval and to improve road safety, recent initiatives have been taken by both industry and public authorities to promote the use of virtual testing through numerical simulation as an alternative way to check regulatory compliance. [1] To ensure acceptance of this alternative method, accuracy of the simulation models and procedures needs to be assured and rated independently of the modelling process, software tools, and computing platform. Similarly, it is also imperative to understand the uncertainties emerging out of different component design parameters and analyze their sensitivity towards producing deviations in the reported results as per the requirements of the regulatory standard. Simulations are however deterministic in nature
Deshpande, Saurabh, Mahajan, Rahul, Jones, Gavin
Technical Paper
Simulation of Crimping Process for Electrical Contacts to ensure Structural Integrity of Crimped Joint under Static Loads2024-26-029101/16/2024
The use of electrical contacts in aerospace applications is crucial, particularly in connectors that transmit signal and power. Crimping is a widely preferred method for joining electrical contacts, as it provides a durable connection and can be easily formed. This process involves applying mechanical load to the contact, inducing permanent deformation in the barrel and wire to create a reliable joint with sufficient wire retention force. This study utilizes commercially available Abaqus software to simulate the crimping process using an explicit solver. The methodology developed for this study correlates FEA and testing for critical quality parameters such as structural integrity, mechanical strength, and joint filling percentage. A four-indenter crimping tool CAD model is utilized to form the permanent joint at the barrel-wire contact interfaces, with displacement boundary conditions applied to the jaws of the tool in accordance with MIL-C-22520/1B standard. The study identifies the
Aher, Ravi, More, Sandip Raghunath, Demarthon, Simon
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
An experimental approach to investigate the FEAD cover failure & its design optimization.2024-26-037101/16/2024
In automotive Front End Accessory Drives (FEAD), the crankshaft supplies power to accessories like alternators, pumps, etc. FEAD undergoes forced vibration due to crankshaft excitation, dynamic tension fluctuations can cause the belt to slip on the accessory pulleys. By considering the criticality of the system, when engine mounting is longitudinally to the vehicle which makes it directly exposed to the air flow containing foreign particles which may cause the damage to the FEAD system and deteriorate the intended functionality. FEAD cover is introduced in the system to enhance belt-pully system functionality by restricting the entry of foreign particles during engine operation. This paper contains study of FEAD cover failure and provide the stepwise approach to capture such issue during novel model development for 4 cylinder naturally aspirated engine during engine bench testing. Failure mechanism was studied using various methodology such as CAE and G-Load measurement to identify the
PATEL, HARDIK MANUBHAI, KUMAR, NITISH, Chand, Subhash, Gupta, Vineet
Technical Paper
Reduction of carbon footprint using Additive Inspired design in Tractor Hydraulic systems2024-26-007001/16/2024
Tractor usage is growing due to introduction of wide range of implements and applications. Tractor plays a major role in Agri and Construction applications. Due to the environmental factors, restrictions are set on the tractor emissions. This brings new challenge in the tactor industry to reduce the carbon footprint. By reducing the weight of the tractor, Co2 emissions can be reduced. Many of the components in the Hydraulic systems are made of metal casting. Conventional casting process involves preparation of die & mold, material removal at unwanted regions, machining in the final stage to get the desired final product. Contrary to conventional manufacturing process, Additive Manufacturing process is a transformative approach to industrial production that enables creation of lighter and stronger parts. The process involves creation of 3D component by adding material layer by layer. The advantage of this method is the minimum wastage of raw material and possibility of integrated
Dumpa, Mahendra Reddy, Perumal, Solairaj, K, Bheshma, Gomes, Maxson, Magendran, G, Redkar, Dinesh, Londhe, Abhijit
Technical Paper
Brake Noise CAE Enhancement with the Synergy between Design of Experiments and Machine Learning2025-01-012405/05/2023
The digitalization of industrial systems has led to increased data availability. Machine learning (ML) methodologies are now commonly used for data analysis in industrial contexts. Not all contexts have abundant data; sometimes data collection can be scarce or expensive. DOE is a technique that provides an informative dataset for ML analysis when data are limited. It involves systematically designing experiments to collect relevant data points with regression models. Disc brake noise is a challenging problem in vehicle noise, vibration, and harshness (NVH). Different noise events occur under various operating conditions and across frequencies (1-16 kHz). To enhance computer-aided engineering (CAE) techniques for brake noise, ML is used to generate additional data. Sequential experimentation in DOE aligns well with ML’s ability to continuously learn and improve as more data become available. DOE is applied in CAE to collect data for training ML models. ML helps find patterns in high
Song, Gavin, Venugopal, Narayana, Vlademar, Michael
Technical Paper
Performance Improvement on Electric BUS A/C Through CAE & CFD Simulation2022-28-043411/09/2022
Light weight, structural integrity, dynamic behavior, selection of material, performance, electrical energy consumption evaluation are very challenging areas while designing electrical vehicle AC components. Structural integrity and dynamic behavior of the component predicted by conducting dynamic analysis of the assembly under standard load conditions. Selection of material is another challenging part which been decided out based on the analysis result. Achieving the required cooling capacity with less compressor power is also another challenging area which been achieved by proper design changes on condenser and evaporator side. For this CFD analysis been performed on the unit. In this paper, durability analysis of the unit been carried out to check the strength of the unit as per the std and CFD analysis carried out to check the air flow on the condenser side and design modification to improve the air flow to meet the cooling capacity. On dynamic analysis, modal frequency and
Parayil, Paulson, Goel, Arunkumar, Singh, Shobit Kumar, Sen, Somnath
Technical Paper
EXPERIMENTAL SETUP FOR VISUALIZATION OF PLASMA PROPELLED THRUSTERS2022-26-121805/26/2022
Plasma propelled propulsion thrusters(PPPT) is an advance propulsion system for deep space missions ,conventionally chemical propelled thrusters(CPT) are used to carry out space missions. High efficiency and high exhaust velocity will give a plasma propulsion a upper hand, in this project we are creating an visualization setup to visualize the flow of plasma under various electromagnetic fluctuation .plasma is created with the help of high voltage which is induced in a propellent gas (argon) in a ionization chamber . Thus the electron voltage required for argon to ionize is 15.76 Ev . The plasma created in the chamber will be propelled outward with the help of electromagnetic force even know as plasma fluttering technique. Different magnetic intensity will be applied to the vacuum chamber so as to observe the change in plasma because of the change in magnetic field intensity . The plasma will be captured using definition camera . The vacuum chamber is designed using design software's
bali, Rahuljeet singh, KALYAN, 1Lt REPUDI
Technical Paper
Design of Entomopter for Target Killing2022-26-121205/26/2022
Entomopter is a small aircraft or a micro-aerial vehicle which flies using the ‘wing-flapping’ aerodynamics of an insect. In this paper, an entomopter has been designed for real-life applications to reduce the manual risks involved in military bases and defence sector using a dragonfly as a bio-mimic which fits into the ecosystem. The entomopters are capable enough to kill the target by injecting the serum through the legs/ by destroying military base using explosives. The entomopter used in this paper is a bio-mimic of a dragonfly which comprises a set of injecting legs and a couple of sets of supporting legs. The injecting legs are supported by a miniature storage system to store the serum/poison within the legs. Catia V5 21 has been used to design the entire dragonfly entomopter. Thus, the opponent never knows that a small insect like a dragonfly can be capable enough to kill him with a poison or even destroy the whole military base.
N, Swarna Lakshmi
Technical Paper
Analysis of Aerodynamic Composites & Advanced Materials Using Modeling & Simulation for Blended/Hybrid Wing Body Designs2022-26-113605/26/2022
In the Era of 21st Century, accurate precision, performance and advancement of surface of high speed Aerospace Vehicle is essentially necessary with the type of material, selection of wing type, determination of dimensioning and performance factors with the proper propulsion analysis. For certain critical applications the characterization of any hybrid design of any high speed vehicle is necessary especially in its full trajectory which requires number of various or spontaneous Computational Fluid Dynamics (CFD) calculations with different analytical factors. Performing the detailed CFD calculations, design factors using CATIA V5, MATLAB, Solid works & ANSYS for different flow conditions and geometries. We observed that performance factor of our given design model gave efficient and long endurance varying the coefficient scale of heat transfer during the steady flight time maintaining the difference in temperature of our hybrid design model and it's skin temperature. We used our simple
Kaushik, Ishan, Saini, Sandeep
Technical Paper
Automotive Turbocharger rotor optimization using Machine Learning Technique 2022-01-024503/29/2022
Turbochargers are widely employed in in both, diesel and gasoline engine vehicles to boost the power output while retaining the fuel economy. From structural point of view, key component of an automotive turbocharger is rotor and primarily consists of compressor wheel, turbine wheel, shaft and bearing. Typically, design & development of turbocharger rotor is done using Computer Aided Engineering(CAE) and the dynamic characteristics are evaluated using Multibody dynamic (MBD) analysis. The current MBD approach solves the fluid-structure interaction problem by modelling oil film in the journal bearing in conjunction with modal transient analysis of the shaft. This process is quite complex and demands huge computational resources with simulations running for days. Over the period of last few years, lot of such simulations were conducted for different turbocharger applications and a huge database is created. Taking advantage of the availability of data, a deep learning-based approach is
Shrivastava, Sandeep, Sinha, Ankur, Ray, Sudipto, Du, Isaac, Begin, Louis
Technical Paper
U-Bolt Pre-Load and Torque capacity determination using Non-Linear CAE Analysis2022-01-092103/29/2022
This paper present a method of using CAE to determine the pre-load and torque applied to a U-Bolt rear suspension. By this process it is possible to determine the minimum Torque and the correct pre-load in the U-Bolt element and assuring the correct fastening of the components avoiding over stress in the Bar elements.
Martinez Laurent, Juan Carlos, Carrasco, Marco
Technical Paper
Simultaneous free-size, gauge, and composite optimization for automotive chassis design: A practical case study with CFRP crossmember 2022-01-094303/29/2022
Rising gas prices and increasingly stringent vehicle emissions standards have pushed automakers to increase fuel economy. Mass reduction is the most practical method to increase fuel economy of a vehicle. New materials and CAE technology allow for lightweight automotive components to be designed and manufactured, which outperform traditional component designs. Topology optimization and other design optimization techniques are widely used by designers to create lightweight structural automotive parts. Other design optimization techniques include free-size, gauge, and size optimization. These optimization techniques are typically used in sequence or independently during the design process. Performing various types of design optimization simultaneously is only practical in certain cases, where different parts of the structure have different manufacturing constraints. This paper presents a case where this simultaneous optimization approach is used to redesign an automotive front
Jalayer, Shayan, Dossett, Wesley, Krsikapa, Daniel, Lee, Young Min, Ko, Kwang Un, Huh, Mong Young, Choi, Byeung Hyeun, Ku, Ja Won, Lee, Keon Chul, Kim, Il Yong
Technical Paper
PREDICTION OF OPTIMIZED DESIGN UNDER DYNAMIC LOADS USING ML2022-01-094903/29/2022
The stamped components play important roles in supporting many sub-systems within engine and transmission assembly. In few cases, the stamped components will not meet the design criteria whereas, due to overdesign in few other components, there will be opportunities to reduce the mass. Hence in CAE simulations, it would require to perform multiple iterations to enhance the component design by varying multiple design parameters (such as thickness, bend radius, material, etc.,) as per allowable limit. The conventional process of design enhancements will follow unidirectional parametric changes, though it helps in meeting the design criteria, it would be very difficult to produce the best optimized design within the limited time span. With the aid of Altair-HyperMorph technics, multiple design parameters can be controlled simultaneously, and DOE analyses are performed using Altair-HyperStudy to extract simulated results corresponding to the pre-defined design parameters. These DOE results
S, Siddesh, Nayak, Swarnendu Bikash, Freiman, David
Technical Paper
CAE driven light weighting of automotive hood using multiple loadcase optimization 2022-01-095503/29/2022
In the automotive industry the requirement for low emissions has led to the demand for lightweight vehicle structures. Light weighting can be achieved through different iterative approaches but is usually time consuming. Current paper highlights deployment of the multi-objective optimization approach for light weighting. This work involves developing a process for multi-objective optimization (MOO) for vehicle durability system, in this case Hood. The main goal is to minimize the weight of a Hood assembly by meeting strength and stiffness targets. The design variable considered in the study is thickness of the panels. Design constraints were set for Stress and Stiffness based on DVP requirement. Optimization workflow is setup in modeFRONTIER with design objective as minimizing weight of hood. Using the Design of Experiments (DOE) data response surfaces are generated using different algorithms for prediction of the structural performance parameters such as displacement, modal frequency
Kangde, Suhas
Technical Paper
DFSS Optimization of Vehicle IIHS Small Overlap Rigid Barrier (SORB) Impact Performance Using a Simplified Spring-Mass CAE Model2022-01-093503/29/2022
In the modern practice of the vehicle crashworthy design development and its impact performance validation, virtual full vehicle crash models have been widely and successfully utilized as the analysis tool by many safety CAE engineers. Recently, a typical full-vehicle front impact model has grown in size up to over 3 million finite elements to enable analysis of highly localized and transient responses of vehicle structure deformation under the impulsive loads. This full vehicle model takes 10 ~15 computer hours per run even on a fast Massively Parallel Process(MPP) server. The CPU time will increase if the full-vehicle model is applied for analysis of the offset-barrier events in which the test vehicle receives barrier impact loading for a longer duration. Furthermore, for a design optimization task running a large DOE variation matrix, the total turn-around time including CPU hours taken for the DOE model iterations could rise significantly depending on the number of the control
Park, Sae U., Hor, Hassan, Rajagopalan, Rajkumar, Kleinhoffer, Stacey, Westra, Michael
Technical Paper
Parametric Tool to Design Excavator Digging Bucket2022-01-092003/29/2022
A parametric tool is developed to design general purpose and medium duty digging buckets for excavator. This is an excel based tool linked with CREO using VB API Toolkit feature of CREO. Critical parameters in determining lift ratio (such as vehicle tonnage, OEM bucket details, OEM maximum lift at full reach etc.) are defined as input parameters in the excel. Formulae set in this excel are used to calculate lift ratio which is used to determine if this newly developed bucket can be used with specified vehicle tonnage. It will auto generate 3D CAD model and 2D print in PDF format. This tool will also help to standardize the design process. Further, the developed 3D model is analysed in ANSYS to check if stresses induced in bucket due to its working conditions are less than the material limit thereby assessing the robustness of design. Thus, it will help to reduce turn around time for design iterations.
Kumar, Mukesh
Technical Paper
Development of a CAE Modeling Technique for Heavy Duty Cargo Weight using a DFSS Methodology2022-01-092503/29/2022
Cargo box is one of the indispensable structures of a pickup truck which makes it capable of transporting heavy cargo weights. This heavy cargo weight plays an important role in durability performance of the box structure when subjected to road load inputs. Finite element representation for huge cargo weights is always challenging, especially in a linear model under dynamic proving ground road load durability analysis using a superposition approach. Any gap in virtual modeling technique can lead to absurd cargo box modes and hence durability results. With the original computer aided engineering (CAE) approach, durability results could not correlate much with physical testing results. It was crucial to have the right and robust CAE modeling technique to represent the heavy weight to provide the right torsional mode of the cargo box and good durability results. As there were multiple variables owing to heavy cargo weight, Design for Six Sigma (DFSS) methodology was used to develop a
Pankaj, Ananta Vijaya, Nazir, Fazil, Zhang, Weidong, Guo, Mingchao
Technical Paper
Design and Optimization of an Electric Car Chassis and Body using Structural Analysis and CFD 2022-01-033903/29/2022
The transition from traditional gasoline-powered automobiles to electric vehicles (EVs) has taken time, two major challenges of engine- powered vehicles are greenhouse gas emissions and fuel economy. Electric cars require less maintenance. A lot of money can be saved while also helping the environment. In today's world, working with lightweight materials have emerged as a key area for improvement in the automotive industry. The most efficient method for increasing power output is to reduce the weight of vehicle components. Composite materials have benefited greatly from research and development because they are stronger, more recyclable, and easier to integrate into vehicles. The primary goal of this research is to design the body and chassis frame of a two-seater electric car. A CFD analysis was performed to determine the drag coefficient of the body along with structural analysis to obtain the frontal impact and torsional rigidity of the chassis to develop an effective electric car
Aiyan, Mohammed, Raghav S, Sanjay, Sagar, S Sumanth
Technical Paper
Design Optimization of Bicycle Wheel Hub Assembly for Automotive Applications2022-01-030503/29/2022
The diminutive rolling resistance and wheel bearing drag characteristics of a bicycle wheel assembly makes it a lucrative choice of component in numerous 3-wheeled (3W) and 4-wheeled (4W) automotive applications. However, when a bicycle wheel is subjected to the loads encountered in such applications, complications pertaining to strength, durability and, performance are encountered. Since a bicycle wheel is intended to be arrested at either end of its axle, cantilever loading of the component as practiced in automotive applications diminishes the ability of the spindle to withstand longitudinal, and vertical forces encountered. Furthermore, while cornering on a bicycle, the maneuver of leaning in a corner significantly reduces the lateral stiffness requirement of the hub flanges. Therefore generic hub assemblies are designed without accounting for the action of lateral forces that are experienced at the hub with the wheel held vertical. Since most bicycle wheel assemblies are designed
Chakraborty, Apurva, R, Shreyas, Kanhai, Palash
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
Laser Interferometry to Investigate the Strain and Stress State of Details and Units of Heat Engines03-15-04-002310/08/2021
The article is devoted to laser interferometry technology for investigating the strain and stress state (SSS) of heat engine details and units. It is an efficient alternative to traditional technologies based on using strain gauges. It has been shown that the use of traditional technologies to experimentally investigate the SSS of heat engine complex details when using the strain gauges requires a significant amount of research and time. Thus, deploying physical effects previously not used for solving similar problems is a perspective research direction that includes laser interferometry technology. The article deals with its use to experimentally investigate the SSS of complex details, such as a crankcase block of an internal combustion engine (ICE). Laser interferometry research is based on the use of holographic interferometry, speckle photography, electronic speckle pattern interferometry, and modern methods of computer simulation. The article goes on to say that to achieve the aim
Kesariiskyi, Oleksandr G., Marchenko, Andrii, Gritsuk, Igor, Mateichyk, Vasyl, Pylyov, Volodymyr, Kravchenko, Serhii
Journal Article
The design process for a formula student car brake disc2021-28-025210/01/2021
In today's world with fast-growing mobility, everything is becoming more compact day by day with ever-increasing technological advances. This paper deals with the design of a disc brake rotor considering the requirement of the student formula team. In this paper, different design iterations shall be realized to have maximum heat flux distribution and at the same time maintain the structural rigidity of the rotor so that it can withstand the torque requirement of an SAE vehicle especially the acceleration test. Solidworks was used for design modeling while Optistruct and Hypermesh were used to perform the CAE Analysis for the brake rotor. In this paper, we will explain various design iterations and how design can be optimized with extensive use of CAE tools by performing structural and thermal analysis, etc. The analytical results from the CAE simulation will help us to determine the slots and hole pattern on the rotor face as well as material selection for the rotor. The numerical
KUMAR, NAVNEET, Pandey, Anurag
Technical Paper
A Detailed Concept Selection Strategy for Rear Suspension Design Entailing Comparison of H-Arm and Trailing-arm Geometries for ATV Application.2021-28-024510/01/2021
Choice of suspension geometry is an integral part of an ATV design. It directly affects the ride comfort and vehicle-dynamic characteristics, the most prominent one being the unsprung mass. In the rear, teams often face the decision to select either a Trailing-Arm suspension design or an H-Arm design. Teams must take into account their existing parameters to rightly decide which geometry will suit their application. In this paper, a concept selection strategy is proposed. This strategy combines the conventional way of analyzing mechanical systems and machines with product design aspects. We analyze several characteristics of the geometry and assign a criteria weight to each of these. These criteria include the cost to manufacture, unsprung mass, load handling capacity, acceleration gain ratio during bumps, ease of manufacturing, and ergonomics of the design. Further, using concept selection methods such as weighted decision matrix and analytical hierarchy process, we arrive at the
Gandhi, Om, Nagar, Tanay
Technical Paper
Optimization of Spring-Damper orientation in Double-Wishbone type Suspension geometry using Genetic Algorithm in Python2021-28-025610/01/2021
The orientation of the spring-damper system in a suspension geometry is a critical but hidden factor in vehicle performance characteristics. Spring and damper mounting characteristics are the significant factors to ensure proper contact of the tire with the ground, maintain ride height, minimize forces on spring, smooth ride, and driver comfort, as varying stiffness for spring orientation will affect the acceleration gain due to road excitation. Determining the spring orientation is conventionally a long and iterative process that involves lots of computational simulations and analytical expressions that should align with the practical vehicle constraints. Due to numerous possible orientations, the designer would randomly pick the orientation and do the simulation, which reduces the solution's reliability and the better solutions remain unexplored. This paper proposes a new methodology to optimize spring damper orientation in a suspension geometry using a genetic algorithm in Python
Madhan, Pratik, Gandhi, Om
Technical Paper
CAE Performance Prediction Using Machi Learning Model Based on Historical Data2021-26-040109/22/2021
Machine Learning applications are developed to disrupt product design methodology across all industries. Every design engineer would like to optimize his design at the concept stage only considering a few critical and essential load cases. The major challenge for the design engineer has not much simulation expertise required to prepare the CAE model, apply material properties, load case, solve and post-process to understand the CAE performance. Even, when the engineer has CAE expertise, it will take a considerable amount of time to prepare the CAE model, solve and post-process it. The objective of this work to predict the simulation results (stress/strain/ displacement/modal frequencies/fatigue life etc.) for a new design using a machine learning predictive model built based on historical simulation data, without going through traditional CAE simulation workflow. This also helps the engineer to understand the effect of each geometry/thickness/material parameter change influencing the
Tangudu, Srinivas Patro, Rongali, Praveen
Technical Paper
Continuous Fiber Reinforced Composite Container for N1 category of Vehicles2021-26-025109/22/2021
The small commercial vehicle business is driven by demand in logistic, last mile transportation and white goods market. And to cater these businesses operational and safety needs, they require closed container on vehicle. As of now, very few OEM's provide regulatory certified container vehicle because of constrains to meet inertia class of the vehicle. The paper focuses on design of a durable and extremely reliable container, made of the low-cost economy class glass fiber & core material. The present work provides the means to design the composite container for the N1 category of the vehicle. The weight of after-market metal container ranges between 300-350 Kgs for this category of vehicle, which affects the overall Fuel Economy and Emission of the vehicle. A detailed CAE analysis is done to design composite container suitable to meet inertia class targets and to achieve weight reduction of 30-40% as compared to metal container. The design is validated and optimised using Inertia
Khandekar, Dhiraj Baburao, Ankur, Manjeet Singh
Technical Paper
Virtual simulation method to predict farm tractor durability load cycles for proving ground tests2021-26-009709/22/2021
Agriculture machinery industries have always relied on conventional product development process such as laboratory tests, accelerated durability track tests and field tests. Now a days the competitive nature seen in industry concerns need to enhance product quality, time to market and development cost. Utilization of computer aided engineering (CAE) methods not only provide solution but also could play key role in tractor development process. The objective is to assess the performance of virtual simulation model of mid segment farm tractor using Multibody System Model (MBS) for predicting the durability loads on virtual proving ground test tracks. Multibody simulation software MSC ADAMS is used to develop a virtual tractor model. Durability test tracks and simulation is carried out as per company testing standards. Data measurement is done using Wheel force Transducer (WFT) to study front and rear spindle forces and moments to evaluate the virtual model performance. Spindle vertical
Subbaiyan, Prasanna Balaji, N, Balaramakrishna, Londhe, Abhijit, Redkar, Dinesh, Arun, G
Technical Paper
Digital Road Load Data Acquisition Methodology for Automotive Durability Analysis2021-26-034409/22/2021
Durability is an important indicator to measure the automobile quality and reliability. Automotive industry is striving to develop products having excellent performance to weight ratios and along with high safety standards. A successful product should have adequate robustness during normal customer operation and the ability to withstand high impact events without impairment of function or safety relevant damage. Road Load Data Acquisition (RLDA) along with efficient design and validation processes are, among others, critical factors for success in the automotive industry. Physical RLDA is expensive and time consuming, the prototype vehicles being costly and only available at a later stage in the vehicle development cycle. Component failures occurring on the proto test vehicles can prove to be a major setback, delaying the product launch by months. In order to overcome above challenge this paper presents an innovative methodology to carry out Digital RLDA. The methodology consists of
Avhad, Anish, Iqbal, Shoaib
Technical Paper
Virtual Platform Development for New Control Logic Concept Test and Validation2021-01-114309/21/2021
As computer-aided engineering software tools advance, more simulation-based processes are utilized to reduce development time and cost. Traditionally, during the development of a new control algorithm dyno or on-road testing is necessary to validate a new function, however, physical testing is both costly and time consuming. This study introduces a co-simulation platform and discusses its use as an improved method of powertrain control logic development. The simulation platform consists of a dynamic vehicle model, virtual road network and simulated traffic objects. Engineers can utilize Matlab/Simulink along with other programs such as PTV Vissim, Tass Prescan, and AVL Cruise to create an integrated platform capable of testing and validating new control strategies. The structure and configuration of this virtual platform is explained in this paper, and an example use case is demonstrated. A driver model was developed to simulate realistic vehicle inputs. Validation of this new driver
Fan, Shihong, Lee, Jason, Sun, Yong, Ha, Jinho, Harber, John
Technical Paper
Study on the Influence of Mass Flow Rate over a National Advisory Committee for Aeronautics 6321 Airfoil Using Improved Blowing and Suction System for Effective Boundary Layer Control01-14-02-001108/06/2021
The numerical analysis of the three-dimensional (3D) flow over a National Advisory Committee for Aeronautics (NACA) 6321 airfoil to evaluate the mass flow rate by using a novel method Improved Blowing and Suction System (IBSS) to control the boundary layer is presented in this study. Analysis is performed based on 3D Reynolds-Averaged Navier-Stokes (RANS) equation with a K-omega SST solver. The aerodynamic performance of the NACA 6321 is analyzed at a Mach number of 0.10 with three different mass flow rates, namely, 0.08 kg/s, 0.10 kg/s, and 0.12 kg/s. From the study, it is seen that when the mass flow rate decreased, the aerodynamics performance also reduced, and the aerodynamic performance improved with the increase in mass flow rate. Results also show that a mass flow rate of 0.10 kg/s improved the stalling angle of attack (AoA) by 60% and coefficient of lift (CL) by 50%, enabling optimum efficiency of the aircraft wing in all aspects compared to the baseline airfoil model. The mass
Karuppiah, Balaji, Wessley, Jims John
Journal Article
Experimental Analysis of the Influence of Body Stiffness on Dynamic Suspension Kinematics and Compliance Characteristics and Dynamic Body Behavior10-05-04-003207/14/2021
Many disciplines of the current vehicle development process are still based on subjective scoring of prototypes, especially in the field of vehicle dynamics. To further reduce the need for hardware and to discover possible weaknesses early in the development process and therefore reduce costs, suitable simulative methods are required. The influence of body and chassis stiffness on vehicle dynamics is not fully understood and requires further research to implement reliable simulative methods. The development of methods requires an understanding and objective depiction of the physical chain. The influences of stiffening beams at the front of a vehicle on the static and dynamic response of wheels and body are observed by using static and dynamic suspension kinematics and a compliance test rig setup. This response is assessed by acceleration sensors, strain gauges, and optical measurement of wheel positions. Static load cases show that minor differences are caused by varying the vehicle’s
Derrix, Daniel, Deubel, Clemens, Kubenz, Jan, Prokop, Günther
Journal Article
Experimental Analysis of the Influence of Body Stiffness on Dynamic Suspension Kinematics and Compliance Characteristics and Dynamic Body Behavior10-05-04-0032-TEST-REC07/14/2021
Many disciplines of the current vehicle development process are still based on subjective scoring of prototypes, especially in the field of vehicle dynamics. To further reduce the need for hardware and to discover possible weaknesses early in the development process and therefore reduce costs, suitable simulative methods are required. The influence of body and chassis stiffness on vehicle dynamics is not fully understood and requires further research to implement reliable simulative methods. The development of methods requires an understanding and objective depiction of the physical chain. The influences of stiffening beams at the front of a vehicle on the static and dynamic response of wheels and body are observed by using static and dynamic suspension kinematics and a compliance test rig setup. This response is assessed by acceleration sensors, strain gauges, and optical measurement of wheel positions. Static load cases show that minor differences are caused by varying the vehicle’s
Derrix, Daniel, Deubel, Clemens, Kubenz, Jan, Prokop, Günther
Journal Article
Analytical Methods for Aircraft Seat Design and EvaluationARP5765B (Current)03/30/2021
This SAE Aerospace Recommended Practice (ARP) defines a means of assessing the credibility of computer models of aircraft seating systems used to simulate dynamic impact conditions set forth in Title 14, Code of Federal Regulations (14 CFR) Parts 23.562, 25.562, 27.562, and 29.562. The ARP is applicable to lumped mass and detailed finite element seat models. This includes specifications and performance criteria for aviation specific virtual anthropomorphic test devices (v-ATDs). This document provides a recommended methodology to evaluate the degree of correlation between a seat model and dynamic impact tests. This ARP also provides best practices for testing and modeling designed to support the implementation of analytical models of aircraft seat systems. Supporting information within this document includes procedures for the quantitative comparison of test and simulation results, as well as test summaries for data generated to support the development of v-ATDs and a sample v-ATD
Aircraft SEAT Committee
Recommended Practice
Analytical Methods for Aircraft Seat Design and EvaluationARP5765B-TEST-REC (Historical)03/30/2021
This SAE Aerospace Recommended Practice (ARP) defines a means of assessing the credibility of computer models of aircraft seating systems used to simulate dynamic impact conditions set forth in Title 14, Code of Federal Regulations (14 CFR) Parts 23.562, 25.562, 27.562, and 29.562. The ARP is applicable to lumped mass and detailed finite element seat models. This includes specifications and performance criteria for aviation specific virtual anthropomorphic test devices (v-ATDs). This document provides a recommended methodology to evaluate the degree of correlation between a seat model and dynamic impact tests. This ARP also provides best practices for testing and modeling designed to support the implementation of analytical models of aircraft seat systems. Supporting information within this document includes procedures for the quantitative comparison of test and simulation results, as well as test summaries for data generated to support the development of v-ATDs and a sample v-ATD
Aircraft SEAT Committee
Recommended Practice
Preliminary Structural Design of a Fowler Flap High-lifting Device2020-36-002803/26/2021
The design of high lift device has great importance in development of transport aircraft, for both manufacturers and operators. With this motivation, a preliminary structural design of a 4-bar mechanism as an actuator of a single-slotted Fowler flap was developed. Fundamental concepts about the subject, such as overlap, gap and Fowler motion, was presented. Aiming the aerodynamic requirements, the mechanism was synthesized in order to reach three critical points: cruise, landing and take-off. For landing and take-off conditions, the loads were estimated and applied on the flaps to evaluate and to size the linkage system. The kinematics and kinetics of the movement was studied by two methods: analytical and numerical by multibody simulation. In order to refine the sizing, a finite element analysis was employed to determine the margins of safety and to drive optimization studies. Thus, with static and fatigue analysis performed and safety margins calculated, the topological optimization
Lima, D. Z., Aguiar, J. B., Ferreira, W. G.
Technical Paper
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