Browse Topic: Materials

Items (79,427)
Find
Development and Validation of a Reduced Order Model Incorporating a Semi-Empirical Degradation Model for Pouch Type LiFePO 4 /Graphite Cells2017-01-121804/23/2025
We propose a reduced order model (ROM) for LFP/graphite cells derived from the electrochemical thermal principles that considers degradation effects and validated against experimental data obtained from a large format pouch type LFP/graphite cell whose nominal capacity is 20Ah. The characteristics of the two-phase transition and path dependence were taken into account in the ROM using a shrinking-core model with a moving interface that presents lithium rich and deficient phase. Different currents (0.1/1/3/4C) were applied to fresh cells at different ambient temperatures (25/35/45°C). Comparison between simulated results of the ROM and the collected experimental data shows a good match. The path dependence was also analyzed experimentally. For degradation model, side reaction is treated as the predominant cause of degradation of cells, which are affected by the operating conditions, such as temperature and SOC cycling range. At every 30 or 40 cycles, the capacity and impedance of five
ZHAO, XINCHEN, Bi, Yalan, Choe, Song-Yul
Journal Article
Basic Science and Art of Aircraft Wreckage ReconstructionR-48004/23/2025
Basic Science and Art of Aircraft Wreckage Reconstruction is a unique title which addresses important aspects of investigating crashes, who does this kind of work, and how a healthy attitude and open mind are required to properly perform investigations. It also discusses what to expect from the on-scene part of the investigation, and the fundamental approaches to common types of wreckage reconstruction. Written by Don Knutson, a veteran of this industry, Basic Science and Art of Aircraft Wreckage Reconstruction is intended for the practitioner, student, or those who are simply curious about how aircraft wreckage is reconstructed. Full references are provided in the various chapters for additional reading and research. Many examples of aircraft crash scenarios and circumstances are presented in a "generic" form but relate to actual investigations, which should prove as a useful investigative resource whether you are an apprentice or an experience professional with a government aviation
Knutson, Donald F.
Reference
Fatigue Analysis of Motorcycle Rear Swing Arm on Different Road Surfaces2024-32-004604/18/2025
The rear swing arm, a crucial motorcycle component, connects the frame and wheel, absorbing the vehicle’s load and various road impacts. Over time, these forces can damage the swing arm, highlighting the need for robust design to ensure safety. Identifying potential vulnerabilities through simulation reduces the risk of failure during the design phase. This study performs a detailed fatigue analysis of the swing arm across different road conditions. Data for this research were collected from real-vehicle experiments and simulation analyses, ensuring accuracy by comparing against actual performance. Following CNS 15819-5 standards, road surfaces such as poorly maintained, bumpy, and uneven roads were tested. Using Motion View, a comprehensive multi-body dynamic model was created for thorough fatigue analysis. The results identified the most stress-prone areas on the swing arm, with maximum stress recorded at 109.6N on poorly maintained roads, 218.3N on bumpy surfaces, and 104.8N on
Chiou, Yi-Hau, Hwang, Hsiu-Ying, Huang, Liang-Yu
Technical Paper
Detailed Approach for Pre-Chamber Heat Release Analysis for the HSASI Pre-Chamber Spark Plug Using a Pressure Sensor Glow Plug2024-32-006304/18/2025
The hot surface-assisted spark ignition (HSASI) pre-chamber spark plug, which was developed at the Karlsruhe University of Applied Sciences, increases the dilution limit with excess air and the tolerance to residual gas in the pre-chamber compared to a conventional passive pre-chamber spark plug. In this study, the conventional glow plug which is integrated in the pre-chamber of the HSASI pre-chamber spark plug was replaced by a pressure sensor glow plug (PSG) from BERU. This allows for a detailed combustion analysis in the pre-chamber. The signal of the PSG was validated with a piezoelectric cylinder pressure sensor and a method to analyse the pre-chamber heat release was introduced. Experimental investigations were carried out on a single-cylinder gasoline engine. A series of operating points diluted with excess air and a variation in load were conducted. The gas flow rate through the orifices of the pre-chamber was calculated from the pressure difference between the pre-chamber and
Holzberger, Sascha, Kettner, Maurice, Kirchberger, Roland
Technical Paper
Operating Characteristics of an Automotive Adjustable-Field Permanent Magnet Motors with 3D Magnetic Paths and Asymmetric Magnet Arrangement2024-32-002704/18/2025
This paper describes a three-dimensional structure of an adjustable field magnetization permanent magnet (PM) motor and a high-power density rotor structure with asymmetric permanent magnet arrangement for both high torque and high efficiency operation in the high speed and low torque range. 3D-FEA has confirmed that it is possible to achieve both high torque density and adjustable field magnetization. Load testing using the prototype proposed motor confirmed that high motor efficiency can be achieved even during high-speed operation.
Hiyoshi, Yutaro, Doi, Kotaro, Noguchi, Toshihiko
Technical Paper
bp w revbestPractice204/08/2025
sfg
Best Practice
Mechanical Property Analysis of Triply Periodic Minimal Surface Structure with a Novel Hybrid Structure2025-01-821504/03/2025
Abstract Triply periodic minimal surface (TPMS) structure, demonstrates significant advantages in vehicle design due to its excellent lightweight characteristics and mechanical properties. To enhance the mechanical properties of TPMS structures, this study proposes a novel hybrid TPMS structure by combining Primitive and Gyroid structures using level set equations. Following this, samples were fabricated using selective laser sintering (SLS). Finite element models for compression simulation were constructed by employing different meshing strategies to compare the accuracy and simulation efficiency. Subsequently, the mechanical properties of different configurations were comprehensively investigated through uniaxial compression testing and finite element analysis (FEA). The findings indicate a good agreement between the experimental and simulation results, demonstrating the validity and accuracy of the simulation model. For TPMS structures with a relative density of 30%, meshing with
Tang, Haiyuan, Xu, Dexing, Sun, Xiaowang, Wang, Xianhui, Wang, Liangmo, Wang, Tao
Technical Paper
JMS BP initial productjms_bp_104/01/2025
JMS BP initial product
AESQ Steering Group
Best Practice
A review of warm forming for steels: History, Methodology and Emerging trends2025-01-881404/01/2025
Many manufacturing techniques and process modifications have been implemented over the years to improve the formability of sheet metals. Warm forming of sheet metals is one such established method. However, it is more commonly and successfully applied to aluminum grades. The reevaluation of less-used metal forming technologies, such as warm forming and sheet hydroforming for steel, is a response to the challenges posed by competitive processes like large castings and the geometry requirements of new BEV parts. By understanding the effects of elevated temperatures (below recrystallization temperatures) on different steel grades and the impact of various heating methodologies, the industry can adapt and optimize these proven techniques for modern applications. This paper is a comprehensive summary of the effect of elevated temperatures on various grades of steel. Different heating techniques, their cycle times and effects on final forming feasibility is contrasted. The effect of
Kella, Caroline, Wormald, Tom, Gatts, Joshua
Technical Paper
TitlebestPractice103/31/2025
Scope
Best Practice
Characterization and Aluminum Recovery from Chemical Milling Sludge in Aerospace Industry2025-01-501603/21/2025
The chemical milling process used in the aerospace industry generates substantial metallic residue in the etching bath, referred to as chemical milling sludge (CMS). The direct disposal of CMS into the environment leads to ecological deterioration and economic losses. This study focused on the recovery of aluminum from the aerospace industry CMS, aiming to mitigate environmental harm and enhance resource efficiency. The energy-dispersive X-ray (EDX) analysis revealed that the aluminum content in extracted CMS increased significantly to 95.86%, compared to 28.98% in non-extracted sludge. The XRD analysis of the CMS extracted samples also revealed the presence of increased Al2O3. The surface morphology study suggested the irregularly shaped particles with large chunks, and fine granules were observed on CMS. The yield of Al2O3 was observed to be 35.9% (wt) prior to the calcination process followed by 12.1% (wt) after calcination. The phytotoxicity study indicated that the CMS inhibited
Prasad, Jag, Sonwani, Ravi Kumar
Technical Paper
automation test jms - titleSAE-PP-0946501/31/2025
automation test jms - abstact
Rickard, Christopher
Pre-Print Article
Performance Analysis of Graphene-Coated Heat Pipe Heat Exchangers for Automobile Exhaust Cooling and Purification2025-01-500601/23/2025
This research investigates the development of a heat pipe heat exchanger coated with graphene for cooling and purification of automobile exhausts. The heat exchanger directly affects the performance of the engine because proper heat dissipation and transfer can improve engine performance, reduce fuel consumption, and decrease the emission. Moreover, this effect is much more noticeable on coated heat pipes because of the enhanced thermal conductivity and mechanical properties of the graphene films. A heat null emitted by internal combustion engines was used in the experimental setup to test the thermal performance, cooling efficiency, and purification efficiency of the newly designed in-house exhaust simulation system where the new heat pipes were inserted. The results of the experiment show that the heat pipes have very high thermal performance as the efficiency of the heat pipes was calculated to be around 85%. Furthermore, the temperature decrease over the surfaces of the heat
Karthigairajan, M., Seeniappan, Kaliappan, Balaji, N., Natrayan, L., Sheik, Salman Basha, Ravi, D.
Technical Paper
Analyses of Cold Thermal Energy Storage Systems Using Eutectic Mixtures of Inorganic Hydrated Salts as Phase Change Materials2025-01-500301/23/2025
Cold thermal energy storage using phase changing materials is being researched to find freezing and thawing points. The use of inorganic hydrated salts, a type of phase changing material (PCM) used in cold energy storage systems without the use of existing renewable energy systems, allows for a longer cooling effect and saves energy. A high volumetric storage density and relatively high thermal conductivity make hydrated salts suitable materials for thermal energy storage. They can be used only as inorganic mixtures or else they can also be used as eutectic mixtures, which involve mixtures of inorganic–inorganic salts or simply a combination of two or more inorganic salts. This research deals with eutectic mixtures, which are 4% KNO3 + 96% H2O, 4% NaHCO3 + 96% H2O, and 2% KNO3 + 2% NaHCO3 + 96% H2O. Three different novel eutectic mixtures were examined and found a suitable mixture for a cold thermal energy system. An efficient phase change approach involving 2% KNO3 + 2% NaHCO3 + 96
Vasanthkumar, P., Santhoshkumar, A., Gopika, P., Murali, M., Meera, C.
Technical Paper
testing author affiliationsSAE-PP-0945801/10/2025
test
SintzADMIn, Jeneane, Gatts, Joshua, GattsCurator, Josh, GattsCurator2, Josh, GattsCurator2, Josh
Pre-Print Article
NASA’s Inspection Technology for Spacecraft Tests Quality of Seacraft HullsTBMG-5222312/05/2024
Shipbuilders didn’t have the option of fiberglass when the nonprofit American Bureau of Shipping (ABS) was established 160 years ago to help safeguard life and property on the seas. Fortunately, technology to help better ensure the safety of ocean vessels has also come a long way in that time, in part because people have become a spacefaring species.
Magazine Article
DEVCOM CBC Innovates and Integrates through Autonomous TechnologiesTBMG-5212912/01/2024
The U.S. Army Combat Capabilities Development Command Chemical Biological Center (DEVCOM CBC) is paving the way and helping the Army transform into a multi-domain force through its modernization and priority research efforts that are linked to the National Defense Strategy and nation’s goals. CBC continues to lead in the development of innovative defense technology, including autonomous chem-bio defense solutions designed to enhance accuracy and safety to the warfighter.
Magazine Article
Aviation Safety Expert Unites Industry to Safeguard Aviation Supply ChainTBMG-5212812/01/2024
In the summer of 2023, a receiving clerk in the procurement department of TAP Air Portugal, a Lisbon-based airline, made a curious discovery: A $65 engine part that should have appeared brandnew showed signs of significant wear. The clerk checked the documentation from the London-based parts supplier and noticed that the submitted documentation was also suspicious.
Magazine Article
New Battery Cathode Material Could Revolutionize EV Market and Energy StorageTBMG-5214212/01/2024
A multi-institutional research team led by Hailong Chen, an Associate Professor with appointments in the George W. Woodruff School of Mechanical Engineering and the School of Materials Science and Engineering, has developed a new, low-cost cathode that could radically improve lithium-ion batteries (LIBs) — potentially transforming the electric vehicle (EV) market and large-scale energy storage systems.
Magazine Article
High-Efficiency Hollow-Core Fiber Optic CableTBMG-5216112/01/2024
Researchers have designed a six-hole micro-structure antiresonant air-core fiber (AR-HCF) with a large core diameter of 78 μm. The researchers say it is the first time that 2.79 μm high energy pulsed laser has been transmitted with good efficiency at room temperature.
Magazine Article
Maximizing the Potential of TPU Extrusion in Medical Tubing ApplicationsTBMG-5216412/01/2024
Whether for vascular catheters or implantable devices, medical tubing must meet tough standards for flexibility, strength, and biocompatibility. That’s why more manufacturers are turning to thermoplastic polyurethanes (TPUs) that strike the ideal balance between these key properties, making them an excellent choice for high-performance medical tubing. Unlocking the best that TPUs have to offer means optimizing the extrusion process. This article looks at why TPUs are a top pick, the common obstacles in extrusion, and the ways manufacturers can fine-tune their process to get the most out of different grades.
Magazine Article
Crafting Safe, Long-Cyclable Lithium Metal Batteries for High TemperaturesTBMG-5213912/01/2024
Existing commercial battery technologies, which use liquid electrolytes and carbonaceous anodes, have certain drawbacks such as safety concerns, limited lifespan, and inadequate power density particularly at high temperatures. This has prompted researchers to search for solid electrolytes that are safe and compatible with lithium metal anodes, which are known for their high theoretical specific power capacity.
Magazine Article
4D Printing of Shape Memory PolymersTBMG-5219112/01/2024
Researchers have successfully demonstrated the four-dimensional (4D) printing of shape memory polymers in submicron dimensions that are comparable to the wavelength of visible light. 4D printing enables 3D-printed structures to change their configurations over time and is used in a variety of fields such as soft robotics, flexible electronics, and medical devices.
Magazine Article
Scientists Fuse Simulations and Machine Learning to Accelerate Novel Additively Manufactured MaterialsTBMG-5212712/01/2024
Researchers at the Johns Hopkins Applied Physics Laboratory (APL) in Laurel, Maryland, have demonstrated a novel approach for applying machine learning to predict microstructures produced by a widely used additive manufacturing technique. Their approach promises to dramatically reduce the time and cost of developing materials with tailored physical properties and will soon be implemented on a NASA-funded effort focused on creation of a digital twin.
Magazine Article
Bio-Ink for 3D PrintingTBMG-5218912/01/2024
Biomedical engineers have developed a “bio-ink” for 3D-printed materials that could serve as scaffolds for growing human tissues to repair or replace damaged ones in the body. Bioengineered tissues show promise in regenerative, precision, and personalized medicine; product development; and basic research, especially with the advent of 3D printing of biomaterials that could serve as scaffolds or temporary structures to grow tissues.
Magazine Article
The Sky’s the Limit... Except for FuelLIFTOFF202411/08/2024
Oxygen and Petrol
A-10 Aircraft Oxygen Equipment Committee
Technical Standard
testing exclusion rulesSAE-PP-0945111/05/2024
testing
SintzADMIn, Jeneane
Pre-Print Article
Influences of Lubricant Viscosity and Metallic Content on Diesel Soot Oxidation Reactivity2024-01-508408/23/2024
This study examined the effects of lubricant viscosity and metallic content on the oxidation reactivity of diesel particles. In the first part, the factors affecting thermogravimetric analysis (TGA) experiments was discussed and confirmed. The influences of initial soot mass, heating rate, and airflow rate on soot oxidation rate and experimental reproducibility were investigated to develop an optimized TGA method. On the basis of these experiments, an initial soot mass of 2.0 mg, airflow rate of 4.8 L/h, and heating rate of 2.5°C/h were used for all subsequent TGA tests. It could be found that the TGA experiments had high repeatability, and the differences were less than 0.1%. In the second part, a four-cylinder diesel engine was lubricated with seven kinds of lubricant with different viscosity and metallic content by the use of viscosity index improver (VII), antioxidant and corrosion inhibitor (ACI), and ashless dispersant (AD). Particle samples were subjected to TGA to test their
Meng, Hao, Yang, He, Zhang, Weili, Xing, Jianqiang, Xu, Yan, Wang, Yajun
Technical Paper
Regression Test 08/22/24 - Tatsiana twrtwtwSAE-PP-0944808/22/2024
QA Test
Mutagaana, Festo
Pre-Print Article
Hard Anodic Coating on Aluminum and Aluminum AlloysAMS2469K (Historical)04/09/2024
This specification establishes the requirements for a hard anodic coating on aluminum and aluminum alloys.
AMS B Finishes Processes and Fluids Committee
Material Specification
Liquid Runway Deicing/Anti-icing ProductAMS1435E (Current)03/12/2024
This specification covers runway deicing and anti-icing products in the form of a liquid. Unless otherwise stated, all specifications referenced herein are latest (current) revision.
G-12RDP Runway Deicing Product Committee
Material Specification
Liquid Runway Deicing/Anti-icing ProductAMS1435E-TEST-REC (Current)03/12/2024
This specification covers runway deicing and anti-icing products in the form of a liquid. Unless otherwise stated, all specifications referenced herein are latest (current) revision.
G-12RDP Runway Deicing Product Committee
Material Specification
Iron and Steel Castings Engineering GuideB-ASM-05502/28/2024
This engineering guide, an accompanying guide to Aluminum Castings Engineering Guide (ASM International, 2018), explains the interactions of product design (for function and manufacturability), materials engineering (for the best choice of alloy and microstructure), and process engineering practices (to achieve the properties and integrity of a component at the most comprehensive cost).
Reference
Schey’s Tribology in Metalworking: Friction, Lubrication, and WearB-ASM-05702/28/2024
Schey’s Tribology in Metalworking—Friction, Lubrication, and Wear is an update to the seminal text Tribology in Metalworking by John Schey, originally published by ASM International in 1983. The 1983 first edition served as a recognized essential resource for researchers in the fields of manufacturing tribology and metal forming for many decades. This 2023 update preserves the essential information in that first edition but provides a thorough update, including a description of the significant advances in tribological research and detailed information for every metal forming process.
Book
Dynamic Mechanical and Thermal Properties of Polymer-Coated Jute Fibers for Enhanced Automotive Parts2024-01-501902/12/2024
Automobile parts often require materials that offer high strength and durability. With the continuous push for environmentally friendly solutions, natural fibers such as jute have emerged as a potential alternative for synthetic fibers in automobile components. In this study, we aim to enhance the properties of jute fibers by coating them with different polymers and assessing their suitability for automotive applications. We treated jute fibers with various polymers—low-density polyethylene, polyester, and araldite epoxy. The performance of these treated fibers was compared using fiber tensile experimentation, differential calorimetry, and dynamic mechanical evaluation. Our findings reveal that the treated jute fibers exhibit a tensile strength of 598 MPa. However, when coated with polymers, there’s a variance in strength: polyethylene (263 MPa), polyester (191 MPa), and epoxy (281 MPa). Among these, epoxy-coated fibers displayed the least tensile strength, while polyethylene-coated
Natrayan, L., Kaliappan, Seeniappan, Balaji, N., Mahesh, V.
Technical Paper
Enhancing Microstructural Characteristics and Mechanical Properties in Friction Stir Welding of Thick Magnesium Alloy Plates through Optimization2024-01-501402/06/2024
This research explores friction stir welding (FSW) to examine the mechanical characteristics and microstructure of thick plates manufactured from the Mg-8Al-0.5Zn alloy. Applying the FSW procedure to warm-form an Mg-8Al-0.5Zn alloy for the differential case covering the gears in the car’s automotive technology. Weld quality was significantly improved after using response surface methodology (RSM) to examine various welding parameters and find the best configurations. Improved grain refinement and phase distribution in the weld zone were found in the microstructural study of 11.5 mm thick magnesium alloy plates using RSM-optimized parameters. By dynamic recrystallization, the grain size was reduced to 16 μm, which is fifteen times smaller than the original material, thanks to the good results of single-pass FSW welding. Welding results showing high-quality characteristics such as tensile strength (161.8 MPa), elongation (27.83%), and joint efficiency (98.96%) were achieved using the
Sabari, K., Muniappan, A., Singh, Mandeep
Technical Paper
Aircraft Cockpit Window Improvements Enabled by High-Strength Tempered Glass01-17-02-001201/25/2024
This research was initiated with the goal of developing a significantly stronger aircraft transparency design that would reduce transparency failures from bird strikes. The objective of this research is to demonstrate the fact that incorporating high-strength tempered glass into cockpit window constructions for commercial aircraft can produce enhanced safety protection from bird strikes and weight savings. Thermal glass tempering technology was developed that advances the state of the art for high-strength tempered glass, producing 28 to 36% higher tempered strength.As part of this research, glass probability of failure prediction methodology was introduced for determining the performance of transparencies from simulated bird impact loading. Data used in the failure calculation include the total performance strength of highly tempered glass derived from the basic strength of the glass, the temper level, the time duration of the load, and the area under load.A high-strength transparency
Lampman, DeWitt
Journal Article
Retain Newness of Commercial vehicle: Lining and Paneling2024-26-018801/16/2024
Commercial vehicle are exposed to harsh environment conditions like dust, mud, wind, rain, extreme sun and winter throughout. Apart from white goods and other conventional loading these vehicles also used in applications which involve Handling of Dirty Loads, Construction Raw materials, Mining Industry etc. which leads to fast deterioration of Interiors. Also, in most cases drivers are not the owners. Hence due to high cost of Cleaning at dealerships and low Product maintenance awareness amongst Commercial Vehicle Users, on Road Washing & Cleaning by riverside is common practice which leads to early deterioration of Interior trims. This paper deals with the retention of newness of soft trim parts such as headliner and wall trims. Causes of product deterioration and attributes which influence newness like product appeal, NVH, perceived quality, environmental impact, geometry retention over time etc. have been discussed in detail. Material properties and design considerations for
Shah, Kapil, Apte, Sanjay, Navsariwala, Prashant, Kumar, Sunil, Komar, Sanju, ghodageri, santosh, SURENDRAN, SHIJU
Technical Paper
A Simulation methodology to design the AVAS system to meet safety regulations and create the expected perception for the vulnerable road user2024-26-023001/16/2024
"Designing an effective AVAS system, not only to meet safety regulations, but also to create the expected perception for the vulnerable road user, relies on knowledge of the acoustic transfer function between the sound actuator and the receiver. It is preferable that the acoustic transfer function be as constant as possible to allow transferring the sound designed by the car OEM to ensure the safety of vulnerable road users while conveying the proper brand image. In this paper three different methodologies for the acoustic transfer function calculations are presented and compared in terms of accuracy and calculation time: classic Boundary Element method, H-Matrix BEM accelerated method and Ray tracing method. An example of binaural listening experience at different certification positions in the modeled simulated space is also presented."
Calloni, Massimiliano, Hadjit, Rabah, Salvekar, Pinak, Musser, Chadwyck
Technical Paper
Reduction of Gearbox noise by optimizing Gear micro geometry2024-26-023401/16/2024
Vehicle noise level has to be maintained within the limit specified by Pass By Noise (PBN) standards to meet the regulatory requirements. Gearboxes and engines are the main sources of noise in a vehicle, owing to the mechanical and physical processes involved. The noise problem in transmission system is characterized by high amplitude acoustic signals, and the gear mesh noise can be indirectly estimated using the Transmission error parameter. Transmission error is defined as the difference between the actual position of the output gear and the position it would occupy if the gear drive were perfect, which can be attributed to various factors such as tooth profile errors, misalignment, and tooth deflections. A six-speed manual transmission commercial vehicle is observed to exhibit higher noise levels during the vehicle PBN test. The gearbox is modelled in Romax gearbox simulation software and the transmission error value is identified to be high. The micro geometry parameters lead
G R, Santosh Kumar, Ks, Dhianeshwar, Basim, K Mohammed
Technical Paper
Quantitative Criteria for Correlating Simulation-based Fatigue Life Predictions with Test Outcomes2024-26-030601/16/2024
Fatigue life of a component is influenced by lot of factors like material, manufacturing & geometric variations and due to this there is a huge scatter in both test & predicted life through simulations. There are different methods available to account for these variations while predicting fatigue life. However, whenever a fatigue simulation engineer tries to correlate predictions with test outcomes, he/she will face a challenge as to: How to account for scatter in test? How to compare predicted life through simulations with test data? How much difference between test outcome and predictions is acceptable? To address these challenges, authors have suggested two approaches in this paper - 1. Deterministic correlation and 2. Probabilistic correlation. This paper suggests a set of criteria under both these approaches to conclude confidently that the prediction model is able to match the test outcomes. Also, the paper highlights the kind of measurements that needs to be done and the
Dasamaneni, Vinod Kumar, Gawture, Majnoo M
Technical Paper
A Detailed Study to Evaluate Sporty Sound Character of Passenger Cars2024-26-020701/16/2024
Sound design is becoming increasingly important for vehicle manufacturers. ‘Sportiness’ of a car is one of the important criteria to consider while designing a car for passionate customers and those who love aggressive driving. Automobile manufacturers are identifying a typical sound for their cars as a ‘key product specification’ to attract particular market. This study focused on identifying frequency ranges and order content through a detailed study of subjective feelings based on physiological acoustics. A benchmark study of various different sport vehicles has been done to measure and record sound samples; these samples were further analysed based on sound quality parameters. Subjective evaluations were carried out by NVH experts to determine their concept of sportiness. Frequency ranges and order noise quantity were confirmed by correlations between subjective and objective evaluations under various customer drive patterns. Relations of the dominant exhaust firing order and its
Sadekar, Umesh Audumbar, Titave, Uttam, ZALAKI, NITIN, Naidu, Sudhakara, Vardhanan K, Aravindha Vishnu
Technical Paper
Challenges for Indian Road Traffic with Sound Alert Devices on Electric Vehicles2024-26-021101/16/2024
Challenges for Indian Road Traffic with Sound Alert Devices on Electric Vehicles For safety towards pedestrians and other road-vehicles, sound alert systems (horns) have been in use since development of Automobiles. On the same line but with special purpose of preventing a Driver to sleep in a running vehicle, a Driver Monitoring System [DMS] is recently developed. For Electric Vehicles which are very quiet during starting and driving till 20 km/hr, Acoustic Vehicle Alert System (AVAS) is deployed in Europe and likely to be implemented in India soon. For all these Alert Devices, there are Standard Regulations across the world: ECE R-28 for Horns and ECE R-138 for AVAS. They, however, define only lower and upper dBA limits of the sound radiated by them. For DMS, no such regulation exists till today. With this, there has been a long time debate on what an optimal dBA level should be there, for all road-users as well as for vehicle- users inside the cabin. It would be adequate, on one
A, Milind Ambardekar
Technical Paper
Effect of Busbar Design on the Thermal Performance of Battery Packs2024-26-013501/16/2024
Li-ion batteries face challenges which is not usually present with other chemistries is cell balancing. If a high imbalance occurs within a parallel circuit, possibly because of the poor cell -grading or due to temperature localization, the other cells will charge the unbalanced cell and it may be possible that the imbalance never completely fades away and the other cells also end up unbalanced, One of the key solutions to maintaining cell balance is to ensure that all cells within a battery pack are kept at a uniform temperature. This requires careful thermal management, which can be achieved through a combination of conduction and convection circuits. In this paper, a 1D-3D simulation study has been performed on a 12 V 4s4p pack by varying the thickness of HV busbars and temperature localization effects and temperature uniformity has been observed. The holder has 16 cells with a 4*4 grid pattern, each cell has a diameter of 18 mm and a length of 65mm. The cells are connected in
Jagtap, Aditya, Khan, Faiz, Shah, Harsh, Malani, Shekhar
Technical Paper
Multi-parameter Optimization of 400V e-Compressor Motor using Magnet Sizing and Flux Barrier Topology using JMAG Simulation2024-26-028001/16/2024
Permanent Magnet Synchronous Motor (PMSM) for 400V Compressor uses a rare earth magnet (NdFeB). Rare earth magnets have the advantage of high torque, high power density and high efficiency, however, pose a challenge of increased motor cost.. The requirement is to use less quantity of magnet in the motor design, which should serve the purpose of providing the needed starting torque at the worst case operating temperature scenario (-40 deg C). The objective of the present work is to design a PMSM with optimal design of magnets and to evaluate its performance. Also, to generate an efficiency map for the optimized PMSM compressor capable of achieving an efficiency of 92% at the rated operating point.The PMSM should be covering all the peak and continuous operating regions within the specified limit of peak line current consumption. JMAG Designer® is used to parameterize the rotor, stator and coil profile and to perform the efficiency analysis at speed priority mode. The JMAG tool helped to
Gurudevan, Vinothini, KHANCHOUL, Mohamed, Elumalai, Ilakya
Technical Paper
Application of Coated Metallic Bipolar Plate for Proton Exchange Membrane (PEM) Fuel Cell2024-26-017201/16/2024
In the current era of green energy adoption for reaching the zero-carbon target, the mobility sector is extensively working together to use hydrogen as a major source of energy, especially in vehicles with long range requirements. For this, Proton Exchange Membrane Fuel Cells (PEMFC) are employed to convert the chemical energy of hydrogen back into electricity. Acceptability of PEMFC in the automotive field mostly depends on system efficiency, durability & cost of the FC stack. In PEMFC, the bipolar plate (BPP) is a critical component of the system, which realizes the transport of gases to the electrodes, evacuates reactant product water and ensures electrical current collection. In some applications, graphite is used as material for bipolar plates due to good chemical stability and corrosion resistance, whereas it is also a rather brittle material with some manufacturing challenges. In mobile applications, metallic bipolar plates are widely used, as they allow for a significantly
Sheikh, Shabbir, Reum PhD, Mathias, Wegener PhD, Moritz, Bagcivan PhD, Nazlim, Weber, Joachim, Schulz PhD, Edgar, Stumpf PhD, Jan Martin
Technical Paper
Unique Optimization Approach of Axle Component and it’s Weld Life Improvement2024-26-031601/16/2024
Axles are a prominent part of automotive design. Along with a power transmission and differential system, axles support a vehicle’s weight and road-load reactions. Axles carry different attachments such as brakes and suspensions using brackets. Welds play an important role in design and longevity of bracket assemblies. Welds can be susceptible to fractures caused by intrusions akin to cracks and/or discontinuities, compounded by stress concentration due to weld profile and welding processes. Additionally, the simultaneous optimization of both brackets and welds remains a challenge with limited available methods. While topography or shape optimization techniques can enhance bracket robustness by minimizing compliance as the objective, this approach might inadvertently elevate the likelihood of weld fracture if weld dimensions are not concurrently updated. In this endeavor, compliance is used to improve weld life without affecting bracket robustness by using the Vertex Morphing
Wagh, Pranav, Sutar, Mohan, Nilangekar, Abhijit
Technical Paper
Evaluation of interface microstructure and bonding strength for dissimilar rotary friction welding of E46 and AA6061-T62024-26-019501/16/2024
Nowadays, friction welding is recognised as a highly productive and economic joining process for similar as well as dissimilar welding of automobile and aerospace components. Friction welding is the viable solution to offset the challenges of dissimilar fusion welding due to varying thermal and physical properties as well as limited mutual solubility. The main objective of this study is to evaluate the interface microstructure and interface bonding strength for dissimilar rotary friction welding of 3.15 mm E46 disc and 45 mm AA6061-T6 bar at different friction time and forging pressure. The direct drive rotary friction welding of E46 and AA6061-T6 is performed at combinations of two different friction time (4 sec and 7 sec) and forging pressure (108 MPa and 125 MPa). Mechanical bonding strength at the interface is evaluated based on the push-off and multi-step shear strength. Further, fractography of failed samples is carried out to understand the failure mechanism of welded joints
Chudasama, Gautam, Kalyankar PhD, Vivek, Chauhan, Shiv
Technical Paper
A UNIVERSAL STEERING GROMMET DESIGN APPROACH TO ENHANCE THE PASSENGER CABIN NVH PERFORMANCE2024-26-020201/16/2024
As a car OEM, we continuously strive to set the bar for competitors with every product. Consumer travel experiences are enhanced by increasing passenger cabin silence. There is only one steering system opening in the firewall panel, which is used for allowing intermediate shaft's fitment on the pinion shaft of the steering gear. The steering grommet is the sole component that covers the firewall cut-out without disrupting steering operations, which has a substantial impact on the NVH performance of the vehicle. It is typically used in cars to eliminate engine noise and dust entering to passenger compartment. The part is assembled inside the vehicle where the steering intermediate shaft passing through BIW firewall panel. We use a bearing, plastic bush, or direct rubber interference design in the steering grommet to accommodate the rotational input the driver provides to turn the automobile. However, occasionally noise may be produced due to uneven bearing or plastic bush loading or a
J, Sadhish, Vijayarangan, Deepak
Technical Paper
Methodology for jury evaluation and target setting for passenger vehicle operational sound quality2024-26-022701/16/2024
In automotive market, with competitive car prices, build quality of a car will be a major distinguishing factor. Consumer's need for acoustic comfort has evolved from the removal of annoying noises to perceived sound quality. Operational sounds from electromechanical systems like sunroof system, window regulator, door lock system, HVAC etc. directly interact with users' senses. The perceived acoustics comfort of these sounds are direct indicators of vehicle character and can influence customer's buying decision. With the reduction in product development time and stringent cost constraints, a proper structured target setting methodology to benchmark & evaluate these operational sounds is crucial. In this paper, such a target setting methodology is proposed and discussed for operational sound quality evaluation. Electromechanical noises from various vehicles are measured using binaural head measurement system. Using Simultaneous Categorical Scaling method, jury evaluation is performed
Somasundharam, Sundaralingam, Manoj K, Mridul, RAJ, GAURAV, Mohammed, Riyazuddin, R, Prasath
Technical Paper
Items per page:
1 – 50 of 79427