Automotive Engineering Commons^™

Enhancing Bridge Resilience And Overheight Vehicle Mitigation Through Innovative Sacrificial Cushion Systems, Aly Mousaad Aly, Marc Hoffmann

Faculty Publications

Transportation departments have made significant strides in addressing the challenges posed by the increasing weights of trucks on bridges. While there is a growing awareness of overheight vehicle collisions with bridges, implementing effective countermeasures remains limited. The susceptibility of bridges to damage from such collisions is on the rise, further exacerbated by unpredictable lateral impact forces. This study employs nonlinear impact analysis to assess the response of an unprotected vehicle-girder model, yielding realistic deformation outcomes comparable to observed impacts on the US-61 bridge. Predictions for a truck traveling at 112.65 km/h indicate deformations of 0.229 m, 0.161 m, and 0.271 …

Husker Motorsports Active Drag Reduction System, Creighton Hughes, Evan Killian, Micah Busboom, Aj Johnson, Jude Steffen

Honors Theses

Formula SAE is a multifaceted competition that involves student teams designing and competing with an open-wheel style race car. There are 5 different dynamic events included in the competition. Each event requires a unique aerodynamic setup to have the best performance possible. This design project focuses on a drag reduction system (DRS) that will improve aerodynamic performance, resulting in faster lap times and increased competitiveness. Key features include a direct electronic actuation mechanism that will allow the rear wing to be adjusted during a race. The benefits of the DRS system, include increased speed, improved handling, and greater fuel efficiency …

Numerical Study Of Flow Characteristics Around A 30° Yawed Circular Cylinder At R E = 10 4, Ran Wang, Shaohong Cheng, David S.K. Ting

Mechanical, Automotive & Materials Engineering Publications

Unstable motions of bridge stay cables have been observed on site and in wind tunnel tests when a cable is yawed at certain orientations to wind. To uncover the underlying mechanisms, flow around a circular cylinder at a yaw angle of 30° has been numerically analyzed in the current study using delayed detached eddy simulation (DDES) at R e = 10 4 . A comparison with the reference normal flow case indicates the presence of a more coherent span-wise flow structure when the cylinder is yawed at 30°. The application of proper orthogonal decomposition further reveals that at this orientation, …

Thermal Modelling Of A Passive Style Net-Zero Greenhouse In Alberta: The Effect Of Ground Parameters And The Solar To Air Fraction, Oselen J. Imafidon, David S.K. Ting, Rupp Carriveau

Mechanical, Automotive & Materials Engineering Publications

Agricultural greenhouses can provide a suitable microclimate for crops to thrive under extreme weather conditions. The operations of these greenhouses are expensive due to the energy requirement of the active thermal conditioning systems required to maintain the growing environment for crop production. Engineering of these greenhouses to utilize clean renewable energy sources is critical and necessary to mitigate their carbon footprint, paving the way to a more sustainable agricultural industry. This paper presents numerical modelling of a net-zero passive solar greenhouse in Alberta, Canada with winter temperatures below freezing. The indoor microclimate of the greenhouse is modelled using the detailed …

Design And Development Of A Multi-Material, Cost-Competitive, Lightweight Mid-Size Sports Utility Vehicle’S Body-In-White, Amit M. Deshpande, Rushabh Rajesh Sadiwala, Nathan Brown, Sai Aditya Pradeep, Leon M. Headings, Ningxiner Zhao, Brad Losey, Ryan Hahnlen, Marcelo J. Dapino, Gang Li, Srikanth Pilla

Publications

Vehicle light-weighting has allowed automotive original equipment manufacturers (OEMs) to improve fuel efficiency, incorporate value-adding features without a weight penalty, and extract better performance. The typical body-in-white (BiW) accounts for up to 40% of the total vehicle mass, making it the focus of light-weighting efforts through a) conceptual redesign b) design optimization using state-of-the-art computer-aided engineering (CAE) tools, and c) use of advanced high strength steels (AHSS), aluminum, magnesium, and/or fiber-reinforced plastic (FRP) composites. However, most of these light-weighting efforts have been focused on luxury/sports vehicles, with a relatively high price range and an average production of 100,000 units/year or …

Thermoforming Process Effects On Structural Performance Of Carbon Fiber Reinforced Thermoplastic Composite Parts Through A Manufacturing To Response Pathway, Madhura Limaye, Sai Aditya Pradeep, Anmol Kothari, Sushil Savla, Akshat Agha, Srikanth Pilla, Gang Li

Publications

Thermoforming process of thermoplastic-based continuous CFRP's offer a major advantage in reducing cycle times for large-scale productions, but it can also have a significant impact on the structural performance of the parts by inducing undesirable effects. This necessitates the development of an optimal manufacturing process that minimizes the introduction of undesirable factors in the structure and thereby achieves the targeted mechanical performance. This can be done by first establishing a relationship between the manufacturing process and mechanical performance and successively optimizing it to achieve the desired targets. The current study focuses on the former part, where a manufacturing-to-response (MTR) pathway …

Solar-Powered Automated Transportation: Feasibility And Visualization, Burford J. Furman, Laxmi Ramasubramanian, Shannon Mcdonald, Ron Swenson, Jack Fogelquist, Yu Chiao, Alex Pape, Mario Cruz

Mineta Transportation Institute Publications

A solar-powered automated transportation network (ATN) connecting the North and South campuses of San José State University with three passenger stations was designed, visualized, and analyzed in terms of its energy usage, carbon offset, and cost. The study’s methodology included the use of tools and software such as ArcGIS, SketchUp, Infraworks, Sketchup, Rhinoceros, and Autodesk 3DS Max. ATN vehicle energy usage was estimated using data from the university’s Park & Ride shuttle bus operation and by modeling with SUMOPy, the advanced simulation suite for the micro-traffic simulator SUMO. The energy study showed that an extensive solar photovoltaic (PV) canopy over …

Photovoltaics- And Battery-Based Power Network As Sustainable Source Of Electric Power, Prahaladh Paniyil, Vishwas Powar, Rajendra Singh, Benjamin Hennigan, Pamela Lule, Matthew Allison, John Kimsey, Anthony Carambia, Dhruval Patel, Daniel Carrillo, Zachary Shriber, Truman Bazer, James Farnum, Kushal Jadhav, Dalton Pumputis

Publications

With the rise in the utilization of free fuel energy sources, namely solar and wind, across the globe, it has become necessary to study and implement models of a sustainable power network. This paper focuses on the design of a conceptual power network based on photovoltaics (PV) for power generation and lithium-ion batteries for storage. The power system showcases the various metrics that are involved in a grid-tied PV- and battery-based power network. It also encompasses the various design parameters and sizing considerations to design and conceptualize such a power network. The model focuses on the importance of the conservation …

The Design Of An Innovative Automotive Suspension For Formula Sae Racing Applications, Jared Darius

Senior Honors Theses

This thesis details an analytical approach to an innovative suspension system design for implementation to the Formula SAE collegiate competition. It focuses specifically on design relating to geometry, mathematical modeling, energy element relationships, and computer analysis and simulation to visualize system behavior. The bond graph approach is utilized for a quarter car model to facilitate understanding of the analytical process, then applied to a comparative analysis between two transverse half car models. The second half car model contains an additional transverse linkage with a third damper, and is compared against the baseline of the first half car model without the …

Effect Of Yaw Angle On Flow Structure And Cross-Flow Force Around A Circular Cylinder, Ran Wang, Shaohong Cheng, David S.K. Ting

Mechanical, Automotive & Materials Engineering Publications

Flow around an inclined circular cylinder at yaw angles of α = 0°, 30°, 45°, and 60° has been numerically studied using the delayed detached eddy simulation at a Reynolds number of 1.4 × 104. Periodic boundary conditions are utilized to minimize the end effect. The focus is to explore the effect of yaw angle on the flow structure and the spatial distribution of the cross-flow forces. For the normal flow case, the modulation of the span-wise averaged lift force coefficient is found to be related to the unstable shear layer. For the inclined cases, contours of the sectional lift …

Dynamic Analysis Of Vehicle Performance For Changes To Rear Axle Housing, Diane Peters, Yaomin Dong, Vimal Patel

Mechanical Engineering Presentations And Conference Materials

This paper explores the performance improvements of a 2013 Ford Mustang Shelby GT500 resulting from changes to the rear axle housing. In previous work, described in [1, 2], the rear axle housing was optimized in order to minimize its weight. It was expected that the decrease in weight would lead to improved fuel economy; in this work, the vehicle was simulated for the EPA highway drive cycle (HWFET) both before and after the optimization of the housing, in order to quantify the changes in fuel economy. It was found that the optimization of the housing did produce a modest improvement …

Development Of Iowa Dot Combination Bridge Separation Barrier With Bicycle Railing, Chaz M. Ginger

Department of Engineering Mechanics: Dissertations, Theses, and Student Research

The Iowa Department of Transportation typically builds separation barriers between vehicle and pedestrian/bicycle facilities when sidewalks or trails are present on vehicular bridges. Currently, Iowa DOT employs a combination bridge rail that utilizes a concrete parapet that previously had been successfully evaluated to National Cooperative Highway Research Program (NCHRP) Report 350 Test Level 4 (TL-4) criteria for these situations. While the parapet had been successfully evaluated, the combination bridge rail system as a whole had not been evaluated to any crash test standards. Iowa DOT desired that researchers at Midwest Roadside Safety Facility (MwRSF) design and test a combination bridge …

Fan Performance Scaling With Inlet Distortions, J. J. Defoe, E. Etemadi, D. K. Hall

Mechanical, Automotive & Materials Engineering Publications

Applications such as boundary-layer-ingesting fans, and compressors in turboprop engines require continuous operation with distorted inflow. A low-speed axial fan with incompressible flow is studied in this paper. The objectives are to (1) identify the physical mechanisms which govern the fan response to inflow distortions and (2) determine how fan performance scales as the type and severity of inlet distortion varies at the design flow coefficient. A distributed source term approach to modeling the rotor and stator blade rows is used in numerical simulations in this paper. The model does not include viscous losses so that changes in diffusion factor …

Study Of Near-Cup Droplet Breakup Of An Automative Electrostatic Rotary Bell (Esrb) Atomizer Using High-Speed Shadowgraph Imaging, Jacob E. Wilson, Stephen William Grib, Adnan Darwish Ahmad, Michael W. Renfro, Scott A. Adams, Ahmad Salaimeh

Mechanical Engineering Faculty Publications

Electrostatic Rotary bell (ESRB) atomizers are used as the dominant means of paint application by the automotive industry. They utilize the high rotational speed of a cup to induce primary atomization of a liquid along with shaping air to provide secondary atomization and transport. In order to better understand the fluid breakup mechanisms involved in this process, high-speed shadowgraph imaging was used to visualize the edge of a serrated rotary bell at speeds varying between 5000 and 12,000 RPM and with a water flow rate of 250 ccm. A multi-step image processing algorithm was developed to differentiate between ligaments and …

Active Management Assistant System For Embry-Riddle Ecocar 3 Hybrid Supervisory Control System, Matthew Nelson, Blair Cutting, Michael J. Aleardi

Student Works

The Embry-Riddle EcoCAR 3 team is developing a prototype hybrid Chevrolet Camaro utilizing a customized vehicle powertrain controller. This controller is serving to ensure system safety, vehicle operation, and consumer drivability while also incorporating advanced driving aids to achieve both the desired performance levels one expects from a Camaro as well as vehicle efficiency. This vehicle must reach the team set vehicle technical specifications of a 4.9 second 0 to 60 time while maintaining a 53 miles per gallon gasoline equivalence rating.

In order to reach the efficiency goal, the team is developing an Active Management Assistance System utilizing computer …

Investigation Of Low Reynolds Number Flow And Heat Transfer Of Louvered Surfaces, Pradeep R. Shinde

FIU Electronic Theses and Dissertations

This study focuses on the investigation of flow behavior at low Reynolds numbers by the experimental and numerical performance testing of micro-channel heat exchangers. An experimental study of the heat transfers and pressure drop of compact heat exchangers with louvered fins and flat tubes was conducted within a low air-side Reynolds number range of 20 < Re_Lp < 225. Using an existing low-speed wind tunnel, 26 sample heat exchangers of corrugated louver fin type, were tested. New correlations for Colburn j and Fanning friction f factor have been developed in terms of non-dimensional parameters. Within the investigated parameter ranges, it seems that both the j and f factors are better represented by two correlations in two flow regimes (one for Re_Lp = 20 – 80 and one for Re_Lp = 80 – 200) than a single regime correlation in the power-law format. The results support the conclusion that airflow and heat transfer at very low Reynolds numbers behaves differently from that …

Safety Of Lithium Nickel Cobalt Aluminum Oxide Battery Packs In Transit Bus Applications, Timothy Cleary, Marc Serra Bosch, Jim Kreibick, Joel Anstrom

Mineta Transportation Institute Publications

The future of mass transportation is clearly moving toward the increased efficiency and greenhouse gas reduction of hybrid and electric vehicles. With the introduction of high-power/high-energy storage devices such as lithium ion battery systems serving as a key element in the system, valid safety and security concerns emerge. This is especially true when the attractive high-specific-energy and power-chemistry lithium nickel cobalt aluminum oxide (NCA) is used. This chemistry provides great performance but presents a safety and security risk when used in large quantities, such as for a large passenger bus. If triggered, the cell can completely fuel its own fire, …

Novel Ternary Magnesium-Tin Alloys By Microalloying, Sadegh Behdad

FIU Electronic Theses and Dissertations

The objective of this research was to explore the possibility of developing novel Magnesium-Tin alloys with improved mechanical properties by micro-alloying. Magnesium is the lightest of all structural metals. It can be machined faster and with almost half the power required for aluminum. There is a limitless supply of magnesium in sea water and it can also be recycled at 5% of initial energy requirements. These properties make magnesium an ideal green alternative to replace metals and polymers in automotive, aerospace, biomedical and defense sectors. The potential weight reduction in the US automotive market alone, leads to 100 billion gallons …

A Mechanical Regenerative Brake And Launch Assist Using An Open Differential And Elastic Energy Storage, David H. Myszka, Andrew P. Murray, Kevin Giaier, Vijay Krishna Jayaprakash, Christoph Gillum

Mechanical and Aerospace Engineering Faculty Publications

Regenerative brake and launch assist (RBLA) systems are used to capture kinetic energy while a vehicle decelerates and subsequently use that stored energy to assist propulsion. Commercially available hybrid vehicles use generators, batteries and motors to electrically implement RBLA systems. Substantial increases in vehicle efficiency have been widely cited.

This paper presents the development of a mechanical RBLA that stores energy in an elastic medium. An open differential is coupled with a variable transmission to store and release energy to an axle that principally rotates in a single direction. The concept applies regenerative braking technology to conventional automobiles equipped with …

Addressing New Skills Needed For The Automotive Industry Through A Motorsports Educational Pathway, Vukica M. Jovanovic, Mileta M. Tomovic, Alok K. Verma, Nathan Luetke, Steve Branch

Engineering Technology Faculty Publications

The automotive industry has higher-skilled positions available that need engineers and engineering technologists qualified and capable to work in a high-paced, advanced manufacturing sector. Various educational programs across the country offer programs related to the motorsports area at the Associate of Science level. There are also various articu-lation agreements that enable students to continue their education to the baccalaureate level. These programs try to fill in the gap related to the skills shortage in systems and new design methods and processes. The main strength of such educational pathways is that students, who are trained to work as technicians with an …

Development Of Nhtsa’S Side Impact Test Procedure For Child Restraint Systems Using A Deceleration Sled : Part 2, Janet Brelin-Fornari, Sheryl Janca

Mechanical Engineering Grants

This report presents the results of the continued research and development of child seat side impact tests using the deceleration sled at Kettering University’s Crash Safety Center. The objective of this test series was to gain further insight into the sensitivity of the side impact test fixture response. Test variations included speed of impact, weight of the fixture, and impact characteristics. Additionally, 20 child restraint system (CRS) specific tests were conducted using a fixed set of test parameters.

Development Of Nhtsa’S Side Impact Test Procedure For Child Restraint Systems Using A Deceleration Sled : Part 1, Janet Brelin-Fornari, Sheryl Janca

Mechanical Engineering Grants

This report presents the results of the research and development of the child seat side impact tests performed at Kettering University’s Crash Safety Center for NHTSA. The tests were conducted using a deceleration sled. The objective of this testing was to obtain data for the development of a side impact test procedure for child restraint systems.

Development Of A Spring-Based Automotive Starter, David H. Myszka, Jonathan Lauden, Patrick Joyce, Andrew P. Murray, Christoph Gillum

Mechanical and Aerospace Engineering Faculty Publications

Automotive starting systems require substantial amounts of mechanical energy in a short period of time. Lead-acid batteries have historically provided that energy through a starter motor. Springs have been identified as an alternative energy storage medium and are well suited to engine-starting applications due to their ability to rapidly deliver substantial mechanical power and their long service life. This paper presents the development of a conceptual, spring-based starter. The focus of the study was to determine whether a spring of acceptable size could provide the required torque and rotational speed to start an automotive engine. Engine testing was performed on …

Loading Path Determination For Tube Hydroforming Process Of Automotive Component Using Apdl, E. Masoumi Khalil Abad, Amir Ghazanfari, R. Hashemi

Faculty Publications, Mechanical Engineering

In this study, an extended stress-based forming limit diagram (FLD) for prediction of necking based on the Marciniak and Kucznski (M-K) model is represented and applied in tube hydroforming. The bulge forming of a straight tube is simulated by finite element method and verified with published experimental data. This adaptive simulation technique is based on the ability to detect the onset and growth of defects (e.g., bursting and wrinkling) and to promptly readjust the loading paths. Thus, a suitable load path is determined by applying Adaptive Simulation Method in ANSYS Parametric Design Language (APDL).

Crash Safety In The Introductory Physics Lab, Daniel Ludwigsen, Janet Brelin-Fornari, Joseph Neal

Mechanical Engineering Presentations And Conference Materials

Crash Safety in the Introductory Physics Lab Abstract In the field of vehicle occupant protection and crash safety, the Deceleration Sled offers researchers a controlled, repeatable, and relatively cost-effective means to test interior parts such as safety restraint systems. The sled can accelerate a 2000 lb payload to achieve a speed of 40 mph before a hydraulically controlled deceleration models the deformation of the vehicle structure during a crash. Understanding the dynamics of the sled and interpreting test results incorporates many of the core concepts of a first course in introductory physics. This application of physics principles is the inspiration …

Understanding Industrial Energy Use Through Lean Energy Analysis, Brian Abels, Franc Server, J. Kelly Kissock, Dawit Ayele

Mechanical and Aerospace Engineering Faculty Publications

Due to rising energy costs and global climate change, many industries seek to improve their energy efficiency. This paper describes a three-step method to analyze utility billing, weather, and production data to understand a company’s energy performance over time. The method uses regression modeling of utility billing data against weather and production data. The regression models are then driven with typical weather and production data to calculate the ‘normal annual consumption’, NAC. These steps are repeated on sequential sets of 12 months of data to generate a series of ‘sliding’ NACs and regression coefficients. The method can quantify successful energy …

Measuring Progress With Normalized Energy Intensity, Nathan Lammers, J. Kelly Kissock, Brian Abels, Franc Server

Mechanical and Aerospace Engineering Faculty Publications

Energy standard ISO 50001 will require industries to quantify improvement in energy intensity to qualify for certification. This paper describes a four-step method to analyze utility billing, weather, and production data to quantify a company's normalized energy intensity over time. The method uses 3-pararameter change-point regression modeling of utility billing data against weather and production data to derive energy signature equations. The energy signature equation is driven by typical weather and production data to calculate the 'normal annual consumption', NAC, and divided by typical production to calculate 'normalized energy intensity' NEI. These steps are repeated on sequential sets of 12 …

Improving Compressed Air Energy Efficiency In Automotive Plants: Practical Examples And Implementation, Nasr Alkadi, J. Kelly Kissock

Mechanical and Aerospace Engineering Faculty Publications

The automotive industry is the largest industry in the United States in terms of the dollar value of production [1]. U.S. automakers face tremendous pressure from foreign competitors, which have an increasing manufacturing presence in this country. The Big Three North American Original Equipment Manufacturers (OEMs)-General Motors, Ford, and Chrysler-are reacting to declining sales figures and economic strain by working more efficiently and seeking out opportunities to reduce production costs without negatively affecting the production volume or the quality of the product. Successful, cost-effective investment and implementation of the energy efficiency technologies and practices meet the challenge of maintaining the …

Optimizing Compressed Air Storage For Energy Efficiency, Brian Abels, J. Kelly Kissock

Mechanical and Aerospace Engineering Faculty Publications

Compressed air storage is an important, but often misunderstood, component of compressed air systems. This paper discusses methods to properly size compressed air storage in load-unload systems to avoid short cycling and reduce system energy use. First, key equations relating storage, pressure, and compressed air flow are derived using fundamental thermodynamic relations. Next, these relations are used to calculate the relation between volume of storage and cycle time in load-unload compressors. It is shown that cycle time is minimized when compressed air demand is 50% of compressor capacity. The effect of pressure drop between compressor system and storage on cycle …

Simulation And Thermodynamic Analysis Of Extended Expansion On A Concept Rotary Engine Including Its Effects On Fuel Efficiency, Denis Allemant Andre, Matthew James Jensen, Gerald Micklow, James Brenner, Helgevon Helldorff

Mechanical and Civil Engineering Faculty Publications

This paper describes a novel method for extended expansion in a rotary combustion engine running ordinary gasoline. The engine consists of a toroidal-shaped piston that rotates around a drum to expand and evacuate the hot gas. There are several problems with today’s internal combustion (IC) engines. Current IC engines do not always have the necessary internal volume to extract the maximum work possible, and since the whole process of compression, combustion, and expansion happen within the same space, excess heat builds up and increases emissions of nitric oxides and nitrogen dioxide. The proposed solution is to redesign the IC engine …