Browse Topic: Engine mounts

Items (666)

Development of System Level Testing Method for Passenger Car Engine Mounts

2024-26-032401/16/2024

Engine mount is an integral part of any Internal Combustion engine. It is the medium which isolates the vibrations coming from engine being transferred to the chassis or body of vehicle. Engine or power plant is the main source of unbalanced vibrations. The major role of an engine mount is to minimize those vibration levels, improve ride comfort and increase the life of an engine and its accessories. Most of the OEM’s are validating the engine mounts in virtual environment as FEA analysis software. In this paper detailed procedure of testing of Engine mount at system level is presented. This work determines the development of test procedure for passenger car engine mounts in the Laboratory by using Multi-axial environment which also explains the details of truly Multi-axial test rig development, Drive file creation and Durability Testing with the maintained vehicle conditions by simulating the field conditions in the laboratory. Results of simulation and durability also enclosed. This

Tormal, Uday Bapurao

Refined Driveline Isolation in Bus Vehicles

2024-26-020501/16/2024

Bus vehicles required isolated NVH performance at the mounting of the Engine, Propeller shaft, AC Compressor, etc. within a relative package envelope. This paper demonstrates the most predominant NVH case in Bus vehicles in which aggregates are mounted on the chassis Frame and its attachment point stiffness and mobility in multi directions are studied. The same was evaluated analytically and tested so as to cater to NVH issues in vehicles. Also, it contains the details of the systematic approach used with the help of digital software by creating the analytical model so as to resolve issues of multi-direction high mobility and relatively low stiffness at the attachment points. This evaluated model can be used across similar application vehicles so to avoid multi-iteration design and development costs. Digital Analysis indicates a good correlation with the tests for specific loading conditions. Multiple solutions were studied that were confirmed in the analysis. The most cost-effective

Dhadiwal, Nishant Surendra, Pathak, Rahul, Bijwe, Vilas, Gore, Pandurang

Design optimization of Engine Mount bracket to reduce various gear noises in the passenger car cabin

2024-26-020801/16/2024

With the advancement of regulatory norms in the automobile industry, there is challenging to meet performance efficiency targets, especially with a lightweight platform, while providing a superior driving experience to customers. The shift towards weight optimization makes the vehicle structure more susceptible to transfer a diverse range of noise and vibrations through the body. Although most undesirable noises perceived inside the cabin can be reduced by superior technology engine mounts and NVH packaging, all such solutions lead to cost addition. Intelligent considerations in part design can be used to supplement predictable transfer paths to quell unwanted vibrations. One such case is of the gear whine noise in certain rpm bands caused by inherent gear meshing frequency coinciding with the natural frequency of an engine mounting bracket. This paper demonstrates two methodologies to counter such a phenomenon, either through engine mount bracket natural frequency optimization or

Ghosh, Chiranjit, Agrawal, Adheesh, Karmakar, Sudipto, Srivastava, Shubham, Khan, Aamir

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

Evaluating Powertrain Mount Decoupling: Insights from Simulation, Experimental Results, and Analytical Calculations

2025-01-002205/05/2023

This study presents a thorough examination of engine mount decoupling by integrating virtual simulations, physical testing, and analytical calculations. Engine mounts are crucial for isolating vibrations and enhancing vehicle comfort and performance, making their dynamic behavior vital for effective design. In our approach, we employ multi-body dynamics (MBD) simulations to model the interactions within engine mounts. By adjusting the bush stiffness parameters in the MBD framework, we can predict decoupling frequencies and analyze kinetic energy distribution. The bush stiffness values used in simulations are then applied in physical testing, ensuring consistency in the results for decoupling frequencies and kinetic energy distribution. This alignment between virtual and empirical data significantly enhances the reliability of our findings. Moreover, we conduct analytical calculations that correspond with the results from both the simulations and physical tests. This comprehensive

Shende, Kalyani, Shingavi, Shreyas, Rane, Vishesh, Hingade, Nikhil

Hybrid RLDA methodology for passenger car engine mount applications

2025-01-009505/05/2023

In the development of engine mounting systems for passenger cars, accurately capturing dynamic loads during real-world driving conditions is crucial for optimizing performance, durability, and NVH (Noise, Vibration, and Harshness) characteristics. This paper introduces an innovative approach that integrates load cell and strain gauge technologies for Road Load Data (RLD) acquisition, specifically designed for engine mounting applications. By combining load cells and strain gauges, this method offers a comprehensive solution for measuring both direct forces and the resulting strains on engine mounts, providing a more detailed understanding of the load profiles. Load cells capture the overall forces exerted on the engine mounts, while strategically placed strain gauges measure local deformations and stress distributions within the mounts. This dual-method approach enables precise correlation of force and strain data, enhancing the accuracy of load calculations under various driving

Hazra, Sandip, Khan, Arkadip Amitava, Mohare, Gourishkumar

Designing Rubber Flaps for Resonance Management: High-Frequency Tuning in Electric Vehicles Using AI/ML Approaches

2025-01-012505/05/2023

High-frequency whine noise in electric vehicles (EVs) poses a significant challenge, affecting customer perception and the overall vehicle experience. One primary source of this undesirable noise is the interaction between motor pole resonance and the resonance of the engine mount rubber. This paper presents an innovative method for predicting and tuning the frequency response of engine mounts by precisely adjusting the dimensions of rubber flaps, specifically their length and width. The proposed solution employs a dual approach: fine-tuning rubber flap dimensions and utilizing machine learning (ML) techniques. An ML model, trained on historical data, predicts how varying flap dimensions impact frequency response, providing a data-driven foundation for optimization. This prediction capability is enhanced by a Python program that automates the optimization process using a linear combination formula, efficiently addressing resonance issues. By integrating ML insights with the linear

Hazra, Sandip, Khan, Arkadip

Crash Performance Improvement: The Impact of Engine Mount Crash Plates on Achieving a 5-Star Safety Rating

2025-01-008505/05/2023

Electric vehicles (EVs) differ from internal combustion engine (ICE) vehicles in that they lack a conventional engine and feature an electric drive unit, leading to distinct dynamic behaviours in the powertrain. Additionally, the arrangement of auxiliary components in EVs often differs from that in traditional ICE vehicles, which can sometimes significantly impact safety ratings. This paper examines a case study of a critical failure during a crash test, where displacement of an engine mount arm caused substantial structural intrusion and reduced the vehicle's safety rating. To address this issue and enhance crashworthiness, a "crash plate" was designed and integrated into the mount system. This solution effectively constrained the mount arm's movement during impact, preventing the intrusion observed in previous tests. The paper provides a detailed analysis of the crash plate's dimensions and its relationship to the engine mount, demonstrating its potential for broader application in

Hazra, Sandip, Khan, Arkadip, Mohare, Gourishkumar

A new approach to check the heath of engine mounting & suspension bolted joints

2022-01-076403/29/2022

The torque required to tighten any threaded joint is different from the necessary torque to untighten threaded bolt or nut, and it is not observed or widely known since this is a regular and straightforward operation. Typically the torque needed to untighten a newly tightened clamp is around 10% to 30% less than the torque to stretch it further. During tightening a threaded bolt, a significant amount of torque required to overcome friction in the threads and under the nut face. The proportion of the torque used to overcome frictional resistance depends upon the friction value. When we tighten a joint with a coefficient of friction of 0.12, only about approximately 14% of the torque required to stretch the fastener producing the clamp load with 86% of the torque is lost overcoming friction. The torque needed to pull the bolt always acts in the untightening direction, resulted in untightening torque lags behind the tightening torque. Sufficient preload has to be there in the bolted joint

Deshmukh, Sagar

Saddle type structure design for electric vehicle

2022-01-087603/29/2022

Abstract: Electric vehicle are likely to gain market share in near future as technology is getting evolved and cost of ownership is also reducing. Focus on pure electric vehicle is need of an hour and vehicle manufacturers are investing heavily on future trends. Conventional vehicle has BIW front end which is used to protect from crash. With recent development in vehicle architecture, it is learned that secondary load path can be created with help of saddle structure to and there can be huge weight saving in BIW front end which still can meet safety norms. Saddle structure is also helping to have idealistic engine mount locations in vehicle. A & B mount can be packaged exactly on TRA (Torque Roll Axis) to get the best NVH performance. With saddle type structure all three mount can be weight carrying member and easy to handle high torque. This paper explains how saddle type structure is beneficial for crash point view and engine mounting system best performance, Keywords: - Engine

Deshmukh, Sagar

Engine vibration-dampening (reduction) through split engine mounting arm for passenger vehicle.

2022-01-024403/29/2022

Automotive industry is focusing on NVH reduction and customer comfort for passenger vehicle. Structural optimization is an one of the effective tool to obtain an optimum design to achieve NVH reduction. For an internal combustion engine, there exist two basic dynamic disturbances: a) the firing pulse due to the explosion of the fuel in the cylinder and b) the inertia force and torque caused by the rotating and reciprocating parts (piston, connecting rod and crank). The usage of engine mounts is the best solution for dampening the effect of vibrations and transmitting forces between the engine and the automotive body structure. In this paper, application of structural optimization in the design of a engine mount has been carried out. Effort has been taken to develop engine-mounting arm with two different designs solution. Further, engine with two different configuration has been tested at Engine test bed and vehicle level to understand the behavior in real environment. Further results

Gavade, Sujit Vithoba, Gangurde, Prashant, Bhargava, Aashish, Walhekar, Vishal, Mishra, Abhishek, Sawant, Yogesh

Fatigue Life Prediction and Correlation of Engine Mount Elastomer Bush using A Crack Growth Approach

2022-01-092403/29/2022

Abstract: In passenger car, suspension link bushings, engine and transmission mount bushings and bump-stops are made of elastomer material, to maximize the durability and comfort. Thus, deformation behavior of rubber and its durability is important for product design and development. In virtual engineering, simulating rubber fatigue is a complex exercise, as it needs right modeling strategy and coupon testing based material data. Principal stretch based Ogden model is used to characterize the hyper elastic behavior of rubber. Fatigue crack growth approach used here for the fatigue analysis. Engine torque strut mount is used to control the engine and transmission fore aft motion and it is connected between body and Power Train (PT) system. Powertrain events are predominant for damage contribution of mount failure. So, it is important to predict fatigue life of mount elastomer bush. The objective of this work is to find the fatigue life of the elastomer bush for PT loads. Virtual

Elango, C., Pandi, Sathish Kumar, Mahadule, Roshan N, ZARRIN-GHALAMI, Touhid

Multi-axial road simulation for Component level validation of engine mount structure and elastomer

2021-26-045209/22/2021

Today, reducing the vehicle development time is a very crucial task. In the early development stages, the limited time and vehicle prototypes are available for validation. In such scenarios, durability validation of different design iterations of critical components like engine mounts, with respect to the real road usage is a challenge. Road simulation testing in a laboratory is a reliable approach to fatigue and durability tests for the evaluation of platforms, components and subassemblies. Durability evaluation of engine mount is, generally, performed either at assembly level, using multi-axial road simulation approach or at component level, using uniaxial sinusoidal load testing. The new testing approach here allows testing of engine mounts at component level using road simulation approach by applying multiaxial loads or deflections as per the real road usage conditions. This testing approach enables fast, accurate and highly repeatable reproduction of desired motions, providing the

Kuwar, Virendra S, Shinde, Vikram V, Pawar, Prashant R, Mohare, Gourishkumar, Hazra, Sandip

Bus NVH refinement: A Journey towards Comfortable Future

2021-26-027209/22/2021

The future of bus transit in new millennium is promising. This optimism is based on an anticipated long-term slowdown in growth of suburbs and revitalization of central cities. It reflects and escalates the public concern with traffic congestion, sprawl and pollution. This calls for double the use of public transport to address above issues. It calls for changing the mind-set of society towards public transports like buses, coaches etc. This could happen if bus design ensures right comfort, safety & TCO by ensuring refined bus transport. Hence, it is responsibility of OEMs to provide the new generation buses and coaches, which will ensure the public demands of comforts in terms of NVH refinement. This paper covers the innovative approach used to convert the existing bus NVH refinement to next level as a short-term solution and with the intention of articulating NVH strategies for new generation bus development. This work explains combined experimental and simulation approach deployed

Doshi, Sohin, Taware, Girish, Kalsule, Dhanaji, Bijwe, Vilas, Naidu, Sudhakara

Development of Systematic Technique for Design of Electric Motor Mounting System in EV/ HEV Application

2021-26-016509/22/2021

Last decade has been era of environmental awareness. Various programs have launched for making devices and appliances eco-friendly. This initiative has lead automobile industry toward hybridization and now total electrification of vehicles. As electric motor is being added to automobile as a prime mover, due to high frequency vibrations along with higher torque electric motor needs to be isolated properly & carefully as this vibration can damage other automobile parts. Dynamic response of electric motor is different from response of IC engines, so use of engine mounting design method may not be suitable for designing mounting system for electric motor. First, both 4- point and 3- point mounting system are considered for analytical and experimental investigation of force and displacement transmissibility. Position and orientation of elastomeric mounts plays important role in design of mounting system for electric motor. Mounts used in passive vibration isolation are made up of

Kumar, Ravindra, Dhanawade, Tushar

Digital Road Load Data Acquisition Methodology for Automotive Durability Analysis

2021-26-034409/22/2021

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

Engine mounted Oil cooler 3D CFD CHT Analysis for predicting Thermal Performance

2021-26-035109/22/2021

This paper describes steady state, computationally rigorous, three-dimensional conjugate heat transfer 3D CFD analysis of an engine mounted oil cooler. Thermal performance of an oil cooler is very significant from engine oil consumption, bearings performance etc. In an engine water jacket, coolant flows around and through the oil cooler making the flow three dimensional. Therefore, demanding the need of a 3D CFD analysis for capturing all the flow and heat transfer aspects and thereby accurate prediction of thermal performance. An oil cooler contains intricate turbulators in flow paths and have dimensions varying from as small as 0.25 mm to as large as 300 mm, therefore making the meshing and solution a formidable task. In current work an oil cooler with all the intricate details is modelled in a commercial CFD code. Objective is to develop a solution approach which can predict thermal performance of an oil cooler in an accurate way. An engineering practice with guidelines for geometry

Tawar, Ranjit Ramchandra, Brasmer, Susan, Bedekar, Sanjeev

Effect of engine mount stiffness on joint integrity and durability of mounts.

2021-26-051409/22/2021

Powertrain mounts location and stiffness in vehicle plays very important role in improving vehicle noise and vibration which is caused by engine firing forces and road disturbances. Once locations are finalized based on initial calculation and packaging, then it is very much critical to play with mount stiffness to achieve required NVH level in vehicle. This paper describes the effect of mount stiffness on the bolted joint integrity. Stiffness fine tuning is done to improve vehicle level NVH and various iteration are done with change in stiffness values of A, B and C mounts. When stiffness specs are finalized it is recommended to do aquire road load data on the finalized stiffness mount and check for bolted joint integrity since load signature is varying significantly on mount w.r.t stiffness change. If we change mount stiffness value from 128N/mm to 98N/mm then loads on that particular mount is getting increased from 4500N to 6500N in one of the track testing. This paper clearly

Deshmukh, Sagar, Hazra, Sandip, Soundarrajan, Hariprasad

Development of an Intake Valve Deposit Test with a GM LE9 2.4L Engine

2021-01-118609/21/2021

The U.S. Environmental Protection Agency (EPA) certifies gasoline deposit control additives for intake valve deposit (IVD) control by means of ASTM D5500, a vehicle test using a1985 BMW 318i vehicle equipped with a 1.8L I-4 port fuel injected engine. Concerns with the age of the test fleet, its relevance in the market today, and the availability of replacement parts led the American Chemistry Council’s (ACC) Fuel Additive Task Group (FATG) to begin a program to develop a replacement test. General Motors suggested developing a replacement test using a 2.4L LE9 test engine mounted on a dynamometer and committed to support the engine until 2030. Southwest Research Institute (SwRI®) was contracted to run the development program in four Phases. In Phase I, the engine test stand was configured and a test fuel was selected. In Phase II, a series of tests were run to identify a cycle that would build an acceptable level of deposits on un-additized base fuel. In Phase III, the resultant test

Shoffner, Brent, Cloud, Brandon, Kulinowski, Alexander, Hayden, Thomas, Stevens, Colleen

Characterization and Comparison of Steady-Flow Techniques Used for Engine Airflow Development

2021-01-115109/21/2021

This paper compares bulk impulse-torque and 2D planar PIV steady flow-field measurements created by an engine cylinder head and intake system model using a steady-flow bench and evaluates operational aspects of the steady-flow test system. The model included a full-sized intake manifold and cylinder head section from a Chrysler 2.4L PFI four-valve per cylinder engine mounted to an optical cylinder. Two test system operational aspects were evaluated: (1) upstream versus downstream engine location relative to the flowbench (operational modes corresponding to flow bench pulling or pushing through the system), (2) PIV seeding particulate choice. Several dry and oil fog particulates were assessed however, of the options tested, only laboratory grade glass and consumer grade talc allowed long enough operation for practical data acquisition. Tests were performed over lift-over-diameter (L/D) ratios spanning from 0.1 to 0.3. The results indicate that for the setup evaluated, the flowbench

Voris, Alex R., Puzinauskas, Paulius

Virtual Analysis of Engine Mount Stiffness Tuning for Better NVH Performance

2021-01-102608/31/2021

If we see from the past and now competition in automotive industry increased tremendously and every car manufacturer are bringing up there innovations into the market and giving a lot of options to the customers to choose and the customer experience as well as satisfaction has become one of the main driver of success for the company. In today’s world of automotive design virtual analysis is playing a crucial role in the design and development. There are software’s that are available in market to simulate practical conditions digitally. Here we are mainly focused on effect of change in engine mount stiffness on acceleration at driver seat rail point using ADAMS. Which facilitates reduction of design of experiments and finalizing optimized stiffness values for engine mounts for engine idle vibration refinement point of view. ADAMS is mechanical system analysis software where we can simulate the dynamic behavior and distribution of loads throughout the system. In this paper we are going

Deshmukh, Sagar, Hazra, Sandip

Engine Flywheel Housing and Mating Transmission Housing Flanges

J617_202009-TEST-REC (Historical)09/29/2020

This SAE Standard specifies the major dimensions and tolerances for Engine Flywheel Housings and the Mating Transmission Housing Flanges. It also locates the crankshaft flange face or the transmission pilot bore (or pilot bearing bore) stop face in relation to housing SAE flange face. This document is not intended to cover the design of the flywheel housing face mating with the engine crankcase rear face or the design of housing walls and ribs. Housing strength analysis and the selection of housing materials are also excluded. This document applies to any internal combustion engine which can utilize SAE No. 6 through SAE No. 00 size flywheel housing for mounting a transmission.

Automatic Transmission and Transaxle Committee

Engine Flywheel Housing and Mating Transmission Housing Flanges

J617_202009 (Current)

09/29/2020

Automatic Transmission and Transaxle Committee

Design, Analysis and Optimization of Engine Mounting Bracket for SAE Supra Car Using Finite Element Analysis

2020-28-037409/25/2020

The power train components of vehicles are firmly attached to the Engine mounting bracket. It plays very important role in performance of vehicle and its comfortable ride. As SAE India Supra car was high performance vehicle, the mounting brackets undergo high static and dynamic loading conditions due to that Huge amount of vibrations were produced. By careful designing and analysis of engine mounting bracket we can mitigate the vibration produced in the vehicle. The current paper discusses the modelling of bracket in Catia, Static and Modal Analysis of bracket was carried out in FEAST Software. Optimization of bracket is carried out in hyper mesh Software for weight reduction. A Formula Student car is required to be highly manoeuvrable and quick with high rates of acceleration and deceleration. Hence the mounting of the engine should be well constrained and the mount brackets need to be light-weight and designed to safely bear the inertial loads and maximize vibration transmission. FEA

Mekalke, Girish

Simulating and Optimizing the Dynamic Chassis Forces of the Audi e-tron

2020-01-152106/03/2020

With battery electric vehicles (BEV), due to the absence of the combustion process, the rolling noise comes even more into play. The BEV technology also leads to different concepts of how to mount the electric engine in the car. Commonly, also applied with the Audi e-tron, the rear engine is mounted on a subframe, which again is connected to the body structure. This concept leads to a better insulation in the high frequency range, yet it bears some problems in designing the mounts for ride comfort (up to 20Hz) or body boom (up to 70Hz). Commonly engine mounts are laid-out based on driving comfort (up to 20Hz). The current paper presents a new method to find an optimal mount design (concerning the stiffness) in order to reduce the dynamic chassis forces which are transferred to the body up to 100Hz. This directly comes along with a reduction of the sound pressure level for the ‘body boom’ phenomena. Here we use multibody simulation along with a sophisticated tire model in the time

Uhlar, Stefan

An FxLMS Controller for Active Control Engine Mount with Experimental Secondary Path Identification

2020-01-042404/14/2020

Active engine mounts (AEMs) notably contribute to ensuring superior performance of vehicle’s noise, vibration, and harshness. This paper incorporates a filtered-x-least-mean-squares (FxLMS) controller into the active control engine mount system to attenuate the transmitted force to the body. To avoid the error caused by substituting the load cell for acceleration transducer, the FIR model of the secondary path was obtained by experiment. Finally, a hardware-in-the-loop testing system is built to verify the performance of the active engine mount. It can be observed from the test results that the vibration is reduced notably after control, which demonstrates the effectiveness of the active engine mount and the controller in vibration attenuation.

Guo, Rong, Zhou, Ziwei, Chen, Hao

Develop the Methodology to Predict the Engine Mount Loads from Road Load Data Using MSC ADAMS and FEMFAT Virtual Iteration

2020-01-140104/14/2020

Design of powertrain mounting bracket is always a challenge in achieving good NVH characteristics and durability with less weight. For this activity engine mount load is necessary to optimize the weight to meet durability and NVH targets. This paper introduces a new method to calculate engine mount loads from chassis accelerations. The method starts by measuring chassis acceleration near engine mount location, then reproducing the same chassis acceleration in Multi Axis Shaker Table (MAST), and finally extracting the load in engine mount using testing (using load cell). The MAST test actuator displacement input is imported into ADAMS and engine mount loads are extracted. The extracted loads are correlated with physical test results. The correlation includes load time history and peak-to-peak load range. It is recommended to implement this method in early vehicle design phases. Implementing engine mount bracket weight optimization is desirable in early design stages. To avoid MAST

Anthonysamy, Baskar, N, Balaramakrishna, Londhe, Abhijit

Engine mount design & failure analysis in commercial vehicle and a correlation between virtual & physical validation.

2020-01-049104/14/2020

Vehicle life and performance is affected by many factors when in use. The most influential being the vibrations generated especially when the vehicle is in motion. These vibrations are directly experienced by the driver, whose performance goes down, if under continuous influence of these vibrations. This increases the fatigue and greatly reduces the return on investment done by the customer. There are two major sources of vibrations, the engine and the road on which the vehicle moves. To prevent such issues engine mounts are used in vehicles, which may seem simple but perform a critical role, of providing comfort to the driver. Therefore it becomes important that thoroughly designed and examined mounts are being used in the vehicle. This paper focuses on the parameters and methodology to be followed for design and validation of an engine mount used in heavy duty vehicles. Case study has been presented to show the failure cases in an engine mount, especially the separation of rubber and

Dev, Arushi, Parwal, Mahendra, Dev, Arushi, Parwal, Mahendra

Elastomeric Component Fatigue Analysis: Rubber Fatigue Methodology and Correlation between Crack Initiation and Crack Growth

2020-01-019304/14/2020

Many elastomeric components in automotive industry applications are subjected to dynamic service loads. Fatigue must be a consideration in the design of these components. The two approaches in rubber fatigue analysis discussed in this study are the conventional crack initiation approach, based on continuum mechanics parameters versus life, and the crack growth approach, based on fracture mechanics parameters. These methodologies were utilized and illustrated for a passenger vehicle engine mount here. Temperature effects are not considered since testing was performed at ambient room temperature and with a low frequency, typically less than 5 Hz. This promising methodology for fatigue life prediction, discussed in this paper, is a critical plane approach based on crack energy density. Rainflow cycle counting method and Miner’s damage rule are used for load cycle characterization and damage accumulation respectively. A fracture mechanics approach is implemented based on specimen crack

Zarrin-Ghalami, Touhid, Datta, Sandip, Bodombo Keinti, Robert, Chandrashekar, Ravish

Sweating the details OF C8 DEVELOPMENT

20AUTP04_0304/01/2020

How GM's Corvette engineers tackled challenges in the move to a mid-engine architecture. Shifting 500 lb (227 kg) of engine mass rearward by 7.5 feet (2.3 m) and moving 300 lb (136 kg) of transmission components aft by almost three feet transformed the 2020 Chevrolet Corvette Stingray into a budding supercar. General Motors' motive behind adopting a mid-engine layout for the eighth-generation (C8) Corvette was to improve acceleration, braking and handling via substantially increased rear-tire loading. While numerous test-drive reviews and ‘Of the Year’ trophies mark that mission accomplished, there are lessons behind the hoopla: how GM engineers solved problems they encountered reinventing America's sports car. “Porsche was our primary benchmark, especially in reference to their PDK dual-clutch automatic transmission's overall dynamics,” revealed executive chief engineer Tadge Juechter, in an interview with SAE's Automotive Engineering. He said GM also purchased a Ferrari 458 for

Sherman, Don

More sting for the STINGRAY

19AUTP11_0211/01/2019

GM Propulsion engineers elevate the evergreen small-block V8 to new heights for its mid-engine Corvette mission. Instead of heaving decades of small-block V8 expertise out the window, GM Propulsion engineers led by chief engineer Jordan Lee leveraged past success to create a new-for-2020 V8. Known as the LT2, the 6.2-L V8 gives Chevy's all-new, eighth-generation 2020 Corvette more power (the most yet in the base Stingray), stirring response, and competitive fuel efficiency compared with the outgoing C7. And the small-block, with its single camshaft in block and two valves per cylinder, remains unmatched versus its rivals in three key metrics: bill of material, package efficiency, and the power-per-dollar quotient. It's the payoff for 65 years of continuously refining (and never giving up on) a brilliant original design.

Sherman, Don

The Challenge of Replacing Hard Chrome

TBMG-3535910/01/2019

The Challenge of Replacing Hard Chrome

19AERP10_0310/01/2019

The search for a suitable replacement for hard chrome on aerospace components has been a key supply chain priority for aircraft manufacturers. This is because of the documented health risks to workers and the impact on the environment from exposure to hexavalent chromium, a carcinogen that occurs during the chrome plating process and is the most toxic form of chromium. As a result, chromium is a highly regulated chemical in major markets worldwide. In the European Union, hexavalent chromium falls under the domain of the EU regulation, REACH (Registration, Evaluation, Authorization and Restriction of Chemicals), which establishes guidelines for the safe use of chemicals throughout the supply chain. Chromium is also closely regulated in the United States by OSHA.

Test Method for Measuring Performance of Engine Cooling Fans

J1339_201909 (Current)09/30/2019

This SAE Recommended Practice is intended for use in testing and evaluating the approximate performance of engine-driven cooling fans. This performance would include flow, pressure, and power. This flow and pressure information is used to estimate the engine cooling performance. This power consumption is used to estimate net engine power per SAE J1349. The procedure also provides a general description of equipment necessary to measure the approximate fan performance. The test conditions in the procedure generally will not match those of the installation for which cooling and fuel consumption information is desired. The performance of a given fan depends on the geometric details of the installation, including the shroud and its clearance. These details should be duplicated in the test setup if accurate performance measurement is expected. The performance at a given air density and speed also depends on the volumetric flow rate, or the pressure rise across the fan, since these two

Cooling Systems Standards Committee

Engineering the 2020 CHEVROLET CORVETTE

19AUTP09_0109/01/2019

The eighth-gen (C8) Corvette is a creative mix of novel and traditional technical solutions unleashed at a shockingly low base price. Two days before the 50th anniversary of astronaut Neil Armstrong's leap for mankind and 10 years after General Motors emerged from bankruptcy, the camouflage was finally ripped from the eighth-generation (C8) 2020 Chevrolet Corvette. As widely anticipated, C8 now flaunts a mid-engine layout that ostensibly puts it on equal terms with the world's most venerated supercars. After six decades of experimentation and concept-car teasing, GM acknowledged that the new Stingray will enter production before year's end. The truly shocking announcement is a base price of $59,995 including destination, only $3,000 more than today's front-engine C7. Along with moving the cockpit forward 16.5 inches (419 mm) to facilitate shifting the engine rearward, the new Corvette is an innovative mix of novel and traditional engineering solutions.

Sherman, Don

Optimization Approach to Passive Engine Mounting System for Reducing Automotive Vibrations

2019-01-507507/08/2019

Improvised noise, vibration, and harshness (NVH) performance of vehicle implies better comfort for passengers. Apart from road inputs, engine vibration is one of the major contributors to interior vibrations in automotive. The aim of this paper is to optimize specifications and locations of engine mounts to reduce vehicle vibration without affecting engine performance and to provide better ride comfort. This paper also includes the challenges involved in the analysis of engine vibration on critical conditions such as movement on the road surface or braking action. Therefore, a fully numerical simulation expands to a four-cylinder engine by considering piston side force. In this model, the mass distribution in the connecting rod and crankshaft, outside of the center pin, and friction between the cylinder and piston have been considered. Furthermore, simulation analysis is implemented for an engine in vehicle movement with constant speed on the road class B roughness and braking

Abedi, Reza, Shamekhia, Amir H., Rahi, Abbas

New Method for Decoupling the Powertrain Roll Mode to Improve Idle Vibration

2019-01-158806/05/2019

Modern engines have high torque outputs and have low RPM due to increased demand for fuel efficiency. Vibrations caused by such engines have to be mitigated. Decoupling the roll mode from the remaining five rigid body modes results in a response which is predominantly about the torque roll axis (TRA) and helps reduce vibrations. Therefore, placing the mounts on the TRA early in the design phase is crucial. Best NVH performance can be obtained by optimizing the powertrain mount parameters viz; Position, Orientation and Stiffness. Many times, packaging restricts the mounts to be placed about the TRA resulting in degradation in NVH performance. Assuming that the line through the engine mount (Body side) centers is the desired TRA, we propose a novel method of shifting the TRA by adding mass modifying the powertrain inertia such that the new TRA is parallel to and on top to the desired TRA. This in turn will decouple the roll mode and reduce vibrations. This problem is formulated as an

Haider, Syed F., Abbas, Ahmad, Sturla, Francisco

A Lumped Parameter Model Concerning the Amplitude-Dependent Characteristics for the Hydraulic Engine Mount with a Suspended Decoupler

2019-01-093604/02/2019

This paper presents a novel lumped parameter model(LPM) and its parameter identification method for the hydraulic engine mount(HEM) with a suspended decoupler. In the new model the decoupler membrane’s variable stiffness caused by being contact with the metallic cage is considered. Therefore, the decoupler membrane in the model can be taken as a spring. As a result, two parameters of the decoupler’s variable stiffness and the equivalent piston area are added. Then the finite element method is employed to analyze the suspended decoupler membrane’s variable stiffness characteristics under the contact state with the metallic cage. A piecewise polynomial is used to fit the decoupler membrane’s variable stiffness. To guarantee the symmetry of the stiffness, the polynomial only keeps the odd power coefficients. The other lumped parameters of the HEM, such as the elastic stiffness and equivalent piston area of the rubber spring, volumetric compliance of the fluid chamber, the fluid inertia

Zhou, Dawei, Zuo, Shuguang, Wu, Xudong

Interior Sound Quality Refinement Base on Mechanism Study of Crankshaft Impact Noise

2019-01-077204/02/2019

A rumbling noise is audible in a vehicle passenger compartment during acceleration. Mechanism detail of the rumbling noise is studied. A series of preliminary transfer path experiments investigation on chassis dynamometer shows that the interior rumbling noise is mainly induced by abnormal crankshaft impact at particular crank angle. Spectrum analysis indicates that high level half order harmonic components significantly affects the rumbling noise. Multi-body dynamics model of the powertrain is developed to further investigate the root cause of the abnormal crankshaft impact. Experiment results are used to verify the numeric model. High deviation of main bearing forces at the crank angle 0° to 180° after the Fire Top Dead Center of the no.l cylinder is considered to fundamentally induces the high level half order components. The force ripple coupled with the crankshaft resonance induces the crankshaft rumbling. Sensitivities analysis of various bearing seat structure, crankshaft

Su, Zhangming, Chen, Hanshuang, Yang, Qi, Kong, Dandan, Xing, Weizhe, Xu, Yanghui, Cao, Xuelu

Development of Parametric Tool to Design Base Frame for Cummins Marine Application Engine

2019-01-079804/02/2019

A spread sheet based parametric tool is developed to design the base frame for a marine generator-set. Factors such as engine details, generator details, anti-vibration mount (AVM) etc., that determine the design of the base frame, are set as parameters in the spreadsheet. The spreadsheet has formulae to calculate channel specifications, and AVM deflections. It is linked to channel standards database and selects the optimal channel based on calculations. Similarly, the tool provides guidance in selection of AVM from supplier catalogues, helps to predict number of anti-vibration mounts required and their location on base frame. This spread sheet is integrated with a generic base frame 3D model and 2D print in “Creo 3d modelling software” (Creo), which is auto-updated based on calculated parameters in the spreadsheet. Using this tool, the user can generate a 3D-model and 2D print. This tool helps to standardize the design process and reduces design turnaround time considerably. The

Kumar, Mukesh, Rajasekhar, Neeraja, Pokharkar, Prachi, Mahanta, Bibhu, Saha, Rohit

Prediction of Seat Rail and Steering Wheel Vibration at Idle Using Crank Drive and 16-DOF ADAMS Model

2019-26-018101/09/2019

Due to the recent trend in auto industry to opt for higher power engines, causes increase in vibrations levels in the passenger’s compartment. This requires a better and comprehensive model to analyze vibrations from engine to seat and steering wheel much before the proto stage of development in the design stage itself. For this purpose, modelling is done in ADAMS multi dynamics and assuming the 16 degrees of freedom of the vehicle. Further, a crank drive model is developed to simulate engine excitation forces comprising unbalanced inertia forces and torque fluctuations and their effects seat rail and steering wheel vibration is derived. This tool is an attempt to predict such vibrations caused and assist in design enhancement and streamline the procedure.

Hazra, Sandip

Design Optimization of Engine Mount De-Coupler for Cabin Noise Refinement in Passenger Vehicle

2019-26-019901/09/2019

Quieter cabins are indispensable in today’s evolving automobile industry. The effective isolation of vehicle noise and vibrations are essential to achieve the above. Since, low frequency powertrain induced NVH has been one of the major contributors affecting noise and vibration levels inside the passenger cabin. Thus, use of hydraulic mounts is a natural choice for all major OEMs. The objective of this study is to optimize the design of the hydraulic mount de-coupler unit, to reduce the abnormal noise felt inside the cabin. This condition was observed when the vehicle was driven at 20~30 km/h over undulated road surface, found very often in Indian drive conditions. Due to lack of accuracy and repeatability errors during NVH data acquisition in actual driving condition, the above road profile was captured and subsequently simulated in an acoustically treated BSR (Buzz, Squeak and Rattle) four poster simulator. Problem investigation and countermeasure validation were also performed in

Verma, Pallavi, Chatterjee, Joydeep, Bhadani, Priyesh, Ghosh, Chiranjit

Reverse Thrust

AIR6064 (Current)05/07/2018

Propulsion measurements and thrust methods presented in the current published versions of AIR1703 and AIR5450 place a primary focus on the engine reactionary force (thrust) acting to propel an aircraft in the forward direction. In contrast, this document addresses the use of the engine reactionary force in the opposite direction (reverse thrust) to supplement aircraft deceleration. This document’s application spans commercial and military transport turbofan engine applications for various engine and reverse thrust configurations. The discussion and examples primarily focus on separate flow exhaust turbofan engines. Piston and turboprop variable-pitch propeller blade applications are not covered. Although reverse thrust has been utilized for in-flight deceleration, primarily for short takeoff and landing aircraft and military fighter applications, this application of reverse thrust is only covered in a cursory manner.

E-33 In Flight Propulsion Measurement Committee

Challenges of Hydraulic Engine Mount Development for NVH Refinement

2018-01-068104/03/2018

NVH refinement of passenger vehicle is essential to customer acceptance for premium or even mid-size segment passenger cars. Hydraulic engine mount is becoming common for these segments to reduce engine bounce, idle shake and noise transfer to passenger cabin. Modern layout of hydraulic mount with integrated engine-bracket and smaller size insulator has made it cost-effective to use due to reduction of cost gap from conventional elastomeric mounts. However the downsizing and complex internal structure may create some new types of noises in passenger cabin which are very difficult to identify in initial development stage. Main purpose of hydraulic mount is to provide high damping at low-frequency range (6~15 Hz) and to isolate noise transfer from combustion engine to passenger cabin within wide frequency range (15~600 Hz).This paper emphasizes on challenges and problems related to hydraulic mount development. Tuning of Hydraulic mount is required to avoid cavitation noise at low

Ghosh, Chiranjit, Parmar, Aashish, Chatterjee, Joydeep

Frequency Domain Fatigue Analysis of Exhaust Systems

2018-01-139604/03/2018

Today in the automotive industry, there is a continual reduction in available development time. There is also an urgent need to reduce cost and weight, to adapt to customer and legislation which drives to an increase in design complexity. These challenges are sometimes made harder by the late availability of hardware and this creates the need to extend and continually improve the established CAE methods which are used to develop automotive parts. This holds especially true in the field of exhaust systems and their components, which experience loads from various sources like temperature, engine or road. In the field of road excitation the use of dynamic transient simulation and subsequent damage calculation is state of the art in terms of simulations methodology. Nevertheless the problems of this method are the long calculation times and large scratch data requirements as well as the necessary precise knowledge of the test track profile, which is generally not available in early project

Leisten, Philippe, Bishop, Neil, Spieth, Arnulf

Effect of Thermal Management on Engine Performance

2018-01-022404/03/2018

The effect of engine coolant and oil temperature on the performance was experimentally evaluated on a Navistar 12.4 Liter engine. The engine speed and load selected for evaluation represented the engine conditions typically found during a Class-8 truck’s cruising operation. In order to study the effect of oil and coolant temperature in isolation, the production coolant-cooled oil-cooler was replaced with a separate oil and coolant conditioning system. The piston and liner surface temperature was also logged at select locations to provide solid temperature response to coolant and oil temperature changes. The engine tests showed that oil temperature variation had greater impact on the engine performance compared to the coolant temperature. This performance improvement came primarily from the lower combustion heat rejection and reduced friction at moderate engine loads. At higher engine loads the performance improvement was largely due to lowered heat rejection. Engine operation at

Rajkumar, M., Vojtech, Ryan, Cigler, James

WHAT WE'RE DRIVING

18AUTP02_1502/01/2018

It isn't every carmaker that introduces its new model with a session on a tight and slippery test track. But when it's a 1955-kg (4090-lb) sedan with 450 kW (603 hp) and 850 N·m (627 lb·ft) available at the shove of a foot, it is a useful education. That's what Mercedes-Benz offers its U.K. buyers of the new Mercedes-AMG E 63 S 4Matic+.

Aircraft Engine Exhaust Nozzle System for Jet Noise Reduction

TBMG-2767710/01/2017

A system of nozzles and pylons that redistributes jet exhaust noise sources upstream to reduce jet noise has been developed. Certain aircraft configurations install the propulsion engines above the wing or tail surfaces, or above the fuselage, or in some cases above the structure that is a blend of the wing and body or hybrid wing body aircraft. In these aircraft configurations, reducing noise propagation to the community below is possible by using the aircraft as an acoustic shield for the sources associated with the engine. The more difficult engine noises to be shielded are from the jet exhaust because they are typically distributed downstream, the equivalent of several engine nozzle diameters. This innovation redistributes jet exhaust upstream to reduce noise.

Aircraft Turbine Engine Pneumatic Component Contaminated Air Endurance Test

ARP4014A (Current)09/05/2017

This SAE Aerospace Recommended Practice (ARP) describes a method of conducting an endurance test using contaminated air when the applicable specification requires non-recirculation of the contaminants. The objective of the test is to determine the resistance of the engine mounted components to wear or damage caused by the contaminated air. The method described herein calls for non-recirculation of the contaminants and is intended to provide a uniform distribution of the contaminant at the inlet to the Unit Under Test (UUT). The UUT may require the use of a hydraulic fluid for actuation of components within the test unit. Contamination of the test hydraulic fluid is not part of this recommended practice. If contaminated hydraulic fluid is required by the applicable test specification, refer to MAP749.

AC-9 Aircraft Environmental Systems Committee

A Systematic Approach Towards Engine Mounting System Vibration Isolation Performance Validation in Commercial Vehicles

2017-28-192807/10/2017

Engine mounts and mounting brackets play a critical role in determining NVH performance of a vehicle. A lot of work has been done in the area of virtual simulation using FE models to study engine mounting system performance and its impact on vehicle level performance. An overall approach towards engine mounting system validation at vehicle level is also very critical to validate simulation results in a prototype based on which further refinement work will be carried. In this paper a detailed procedure for engine mount and mounting bracket physical validation at vehicle level is presented. Various tests to be performed at vehicle level to quantify engine mount and mounting bracket performance parameters is discussed in detail along with measurement procedures and techniques. Test results are interpreted and its impact on overall performance is also explained. These test results will help design engineers to further improve engineering parameters of mounts and mounting brackets. An

Channamaneni, Rajesh Babu, Kannan, P, Padavala, Prasad

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