Automotive Engineering Commons^™

High Performance Computing Simulations To Identify Process Parameter Designs For Profitable Titanium Machining, Mathew Kuttolamadom, Joshua Jones, Laine Mears, James Von Oehsen, Thomas Kurfess, John Ziegert

Publications

The objective of this paper was to conduct a study of the multi-level multi-variable design space in titanium machining through high performance computing (HPC) simulations that was otherwise too vast to be explored by physical experiments alone. For tool wear-based performance metrics, this resulted in a validated set of machining parameters for achieving profitable material removal rates (MRR) (optimized cost of processing and tooling) across multiple operational configurations, alloys, tool geometries, and process conditions. The approach was to include all machining-related variables and their distributions available within the software as inputs to finite-element models (FEM) of the machining process. The …

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

J. Kelly Kissock

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 …

Energy Efficient Process Heating: Insulation And Thermal Mass, Kevin Carpenter, J. Kelly Kissock

J. Kelly Kissock

Open tanks and exterior surfaces of process heating equipment lose heat to the surroundings via convection, radiation, and/or evaporation. A practical way of reducing heat loss is by insulating or covering the surfaces. This paper presents methods to quantify heat loss and energy savings from insulating hot surfaces and open tanks. The methods include radiation and evaporation losses, which are ignored by simplified methods. In addition, thermal mass, such as refractory, conveyor and racking equipment, acts as a heat sink and increases heating energy use in process heating applications. This paper presents lumped capacitance and finite-difference methods for estimating heat …

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

J. Kelly Kissock

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 …

Energy Efficient Process Heating: Managing Air Flow, Kevin Carpenter, J. Kelly Kissock

J. Kelly Kissock

Much energy is lost through excess air flow in and out of process heating equipment. Energy saving opportunities from managing air flow include minimizing combustion air, preheating combustion air, minimizing ventilation air, and reconfiguring openings to reduce leakage.

This paper identifies these opportunities and presents methods to quantify potential energy savings from implementing these energy-savings measures. Case study examples are used to demonstrate the methods and the potential energy savings.The method for calculating savings from minimizing combustion air accounts for improvement in efficiency from increased combustion temperature and decreased combustion gas mass flow rate.

The method for calculating savings from …

Optimizing Jets For Wake Control Of Ground Vehicles, Domenic Barsotti, Sandra Boetcher

Publications

A system of wake control for a ground vehicle to help promote increased fuel efficiencies of the ground vehicle by modifying an air flow wake generated during the movement of the vehicle in a forward direction. The system includes at least one slot jet configured to be located along a rear profile portion of the ground vehicle. The at least one slot jet is configured to provide a continuous flow of air at a non-zero velocity when the ground vehicle is moving in a forward direction, the non-zero velocity being at least partially directed in a rearward direction with an …

Indicators Of Assessing Vehicle Safety Status Under Platoon Conditions At Freeway, Jianan Zhou

Department of Civil and Environmental Engineering: Dissertations, Theses, and Student Research

Issue on level freeway segment (Interstate 80) in Nebraska: • High truck percentage (higher than 25%) • Different speed profile - The speed of trucks are set to 67 mph, on average. - The speed of passenger cars are 75 mph, on average. • Result platoons - Approximately 85% of vehicles are observed in platoon. - the degree of freedom to maneuver for drivers are constrained by other in-platoon vehicles. - Vehicles in platoons may face unsafe situation. Goal: Develop indicators to assess the safety status of vehicles under platoon conditions at level freeway segment.

The data were collected at …

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

David Myszka

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 …

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

David Myszka

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 …

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

Andrew P. Murray

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 …

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

Andrew P. Murray

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 …

Wire Neutralization System, Scott A. Bradley, Jason Wiitanen, Timothy B. Smigowski, John T. Niemeyer, Andrew Culkin

Michigan Tech Patents

A wire neutralizing system for use with a vehicle including a frame adapted to be hitched to a vehicle. At least one wheel supports the frame while a bottom of the wheel rolls over terrain having buried wires. The system also includes a blade movable between a stowed position in which the blade is above the bottom of the wheel and a deployed position in which the blade is below the bottom of the wheel, such that the blade plows through the terrain to disable buried wires when in the deployed position.

Built-In Bicycle Rack For Cars, Scott A. Hansberry

All Undergraduate Projects

Transporting a bicycle after riding somewhere and then needing to be pickup can be problematic. Bicycles will not fit in most vehicles without removing components. There is also the risk of damaging the inside of the vehicle. Expecting everyone to have a bike rack for their vehicle is unrealistic because the bike rack could be considered unappealing visually, take up to much space in the trunk, or limit the vehicle owner’s access to the trunk. The solution to this problem is a bike rack that mounts onto your car and then mounts your bike onto the rack. Most people don’t …

Asme Baja Rc Car Drivetrain, Walter Lackey

All Undergraduate Projects

The ASME Baja car is a student built radio controlled car, which will compete with other schools in a variety races. The drivetrain aspect of the car must smoothly transfer power from the motor to the rear wheels of the car. The drivetrain must be designed in collaboration with the other team member’s suspension system to avoid interference. The majority of the parts in the drivetrain are purchased parts intended for various applications. These parts were chosen based on their proximity to the optimal calculated values. Power flows from the electric motor through a single gear reduction, then through a …

Utilizing Ground-Based Lidar Measurements To Aid Autonomous Airdrop Systems, Martin Cacan, Edward Scheuermann, Michael Ward, Mark Costello, Nathan Slegers

Faculty Publications - Biomedical, Mechanical, and Civil Engineering

Uncertainty in atmospheric winds represents one of the primary sources of landing error in airdrop systems. In this work, a ground-based LIDAR system samples the wind field at discrete points above the target and transmits real-time data to approaching autonomous airdrop systems. In simulation and experimentation, the inclusion of a light detection and ranging (LIDAR) system showed a maximum of 40% improvement over unaided autonomous airdrop systems. Wind information nearest ground level has the largest impact on improving accuracy.

Strategically Managing Product Innovation To Create Consumer Value: An Analysis In The Context Of The Australian Electric Vehicle Market, Brendan Koehler

Theses

This thesis encompasses a body of research which looks to explore how strategic management, consumer value and product innovation interrelate. In particular, this research will evaluate such a unilateral relationship in specific reference to product innovations developed as a result of emerging and disruptive technology. Therefore, this research will be conducted in the context of the Australian electric vehicle industry. This industry was selected as it has displayed traits of an industry with companies that have a desire to incorporate electric vehicle product innovations into their portfolio from a strategic perspective; yet these product innovations have no particular consumer demand …

Model-Based Control Of Hybrid Electric Powertrains Integrated With Low Temperature Combustion Engines, Ali Soloukmofrad

Dissertations, Master's Theses and Master's Reports

Powertrain electrification including hybridizing advanced combustion engines is a viable cost-effective solution to improve fuel economy of vehicles. This will provide opportunity for narrow-range high-efficiency combustion regimes to be able to operate and consequently improve vehicle’s fuel conversion efficiency, compared to conventional hybrid electric vehicles (HEV)s. Low temperature combustion (LTC) engines offer the highest peak brake thermal efficiency reported in literature, but these engines have narrow operating range. In addition, LTC engines have ultra-low soot and nitrogen oxides (NOx) emissions, compared to conventional compression ignition and spark ignition (SI) engines. This dissertation concentrates on integrating the LTC engines (i) in …

Easily Verifiable Controller Design With Application To Automotive Powertrains, Mohammad Reza Amini

Dissertations, Master's Theses and Master's Reports

Bridging the gap between designed and implemented model-based controllers is a major challenge in the design cycle of industrial controllers. This gap is mainly created due to (i) digital implementation of controller software that introduces sampling and quantization imprecisions via analog-to-digital conversion (ADC), and (ii) uncertainties in the modeled plant’s dynamics, which directly propagate through the controller structure. The failure to identify and handle these implementation and model uncertainties results in undesirable controller performance and costly iterative loops for completing the controller verification and validation (V&V) process.

This PhD dissertation develops a novel theoretical framework to design controllers that are …

Development Of A Test Level 3 Transition Between Guardrail And Portable Concrete Barriers, Robert W. Bielenberg, David Gutierrez, Ronald K. Faller, John D. Reid, Phil Tenhulzen

Department of Civil and Environmental Engineering: Faculty Publications

Road construction often requires that work zones be created and shielded by portable concrete barriers (PCBs) to protect workers and equipment from errant vehicles as well as to prevent motorists from striking other roadside hazards. For an existing W-beam guardrail system installed adjacent to the roadway and near the work zone, guardrail sections are removed so a PCB system can be placed. A study was done to develop a crashworthy transition between W-beam guardrail and PCB systems. Design concepts were developed and refined through computer simulation with LS-DYNA. Additionally, a study of critical impact points was conducted to determine impact …

Calibrating The Robertson’S Platoon Dispersion Model On A Coordinated Corridor With Advance Warning Flashers, Zhao Li, Laurence Rilett, Ernest Tufuor

Department of Civil and Environmental Engineering: Faculty Publications

Platoon dispersion (PD) is the foundation of traffic signal coordination in an urban traffic network. PD describes the phenomenon by which vehicles depart from an upstream intersection as a platoon and begin to disperse before they arrive at the downstream intersection. Recently, advance warning flashers (AWFs) have been applied in many high-speed corridors. There is a need to update the traditional PD model to include the effect of AWFs. This paper examines the traffic flow dispersion patterns when an AWF is present and tests the hypothesis that the AWF will affect PD on a coordinated signal corridor. Platoon vehicles, which …

Development Of A High-Fidelity Model And Kalman Filter Based State Estimator For Simulation And Control Of Nox Reduction Performance Of A Scr Catalyst On A Dpf, Venkata Rajesh Chundru

Dissertations, Master's Theses and Master's Reports

Reduction of emissions and improving the fuel consumption are two prime research areas in Diesel engine development. The present after-treatment systems being used for emissions control include diesel oxidation catalyst (DOC) for NO, HC and CO oxidation along with catalyzed particulate filters for PM (particulate matter) and selective catalytic reduction (SCR) for controlling NOx emissions. Recently an after-treatment system called SCR catalyst on a DPF capable of simultaneously reducing both NOx and PM emissions has been developed in order to reduce the overall size of the after-treatment system.

The goal of this proposed research is to create a state estimator …

Effect Of Spark Advance And Fuel On Knocking Tendency Of Spark Ignited Engine, Abhay S. Joshi

Dissertations, Master's Theses and Master's Reports

Knock, in spark ignition engine is the combustion caused by the autoignition of the fuel-air mixture. It is the phenomenon that limits engine performance and thermal efficiency. Knock also has an adverse effect on emissions and fuel economy. Engine designers target engines with maximum power and torque output without compromising on fuel economy. Engine downsizing is the method generally adopted. The main goal of engine downsizing is to achieve better fuel economy while increasing the power and torque output of the engine. Better fuel economy is achieved by reducing the displaced volume which in turn means a much higher brake …

Analytical And Boundary Element Solutions Of Bulk Reacting Lined Ducts And Parallel-Baffle Silencers, Jundong Li

Theses and Dissertations--Mechanical Engineering

Lined silencers of various configurations are used to attenuate the noise from building HVAC equipment, gas turbines, and other machinery. First-mode analytical solutions are presented for sound attenuation along rectangular lined ducts, parallel-baffle silencers, and circular lined ducts. The sound absorptive lining is treated using a bulk property model. The analytical solutions entail solving a nonlinear characteristic equation in the transverse direction after the rigid-wall boundary condition is applied. The solution is compared to the boundary element solution and a local impedance analytical solution for several test cases.

Simulation Study On Effect Of Gas Charging And Egr In A Dual-Fuel Engine, Satyavenkata Naga Sai Sharath Gorthy

Dissertations, Master's Theses and Master's Reports

Natural gas combined with diesel as micro pilot has the capabilities of achieving lower NOx and soot emissions. Optimization of the combustion process in engines with natural gas and diesel micro-pilot is essential to achieve higher efficiencies and loads. Gas charging (intake air boosting) and EGR are two technologies which when implemented in the natural gas-diesel engines, provide the opportunity to achieve higher efficiencies and loads and low emissions. Simulation study is one of the approaches to investigate the extent and effects of gas charging and EGR on the performance of the engine. With the rapid improvements over the past …

An Optimal Energy Management Strategy For Hybrid Electric Vehicles, Amir Rezaei

Dissertations, Master's Theses and Master's Reports

Hybrid Electric Vehicles (HEVs) are used to overcome the short-range and long charging time problems of purely electric vehicles. HEVs have at least two power sources. Therefore, the Energy Management (EM) strategy for dividing the driver requested power between the available power sources plays an important role in achieving good HEV performance.

This work, proposes a novel real-time EM strategy for HEVs which is named ECMS-CESO. ECMS-CESO is based on the Equivalent Consumption Minimization Strategy (ECMS) and is designed to Catch Energy Saving Opportunities (CESO) while operating the vehicle. ECMS-CESO is an instantaneous optimal controller, i. e., it does not …

The Impact Of Active Aerodynamics On Motorcycles Using Computational Fluid Dynamics Simulations, Aditya Sripathi

All Graduate Theses, Dissertations, and Other Capstone Projects

Motorcycles are mostly utilized by commuters whose requirements are cheap and affordable transportation from point A to point B. Motorcycles also provide means to tour various places and have a leisure time for the majority of motorcyclists. Unfortunately, with pros also come cons such as accidents which are disabling or life-taking. According to motorcycle crash statistics produced every year, the majority of motorcycle crashes are caused due to facing unexpected obstacles in the path causing collisions due to insufficient braking time. Thus, this thesis serves as a mean to overcome this issue and provide a technological solution to the world …

Intelligent Ground Vehicle Competition, Austin R. Tyler, Chris R. Estock, Johnathan P. Johenning, Garrett W. Chonko, Allen C. Gilleland

Williams Honors College, Honors Research Projects

The Intelligent Ground Vehicle Competition (IGVC) draws teams from various universities to compete in the annual autonomous vehicle challenge at the Oakland University campus. To compete, a vehicle must be fully autonomous and can navigate a course designated by various obstacles and painted white lines. Some design challenges are motor control, navigation, environment sensing and safety. A complex navigation system will utilize several tools including a high-precision differential GPS. The vehicle’s surroundings will be mapped using a combination of Light Detection and Ranging (LiDAR) and computer-vision enabled imaging. To comply with IGVC rules, the vehicle must also follow several safety …

การพัฒนาวัสดุกันกระสุนจากวัสดุผสมอีพอกซีเสริมแรงด้วยเส้นใยชานอ้อย, นนทลี อึ่งแก้ว

Chulalongkorn University Theses and Dissertations (Chula ETD)

งานวิจัยนี้มีวัตถุประสงค์เพื่อพัฒนาวัสดุกันกระสุนจากวัสดุผสมที่ผลิตจากอีพอกซีเรซินเสริมแรงด้วยเส้นใยชานอ้อย ตามมาตรฐานที่กำหนดคือ NIJ-Type IIIA โดยทำสอบตามมาตรฐาน NIJ 0108.01 ballistic test วัสดุผสมใช้เส้นใยชานอ้อยในปริมาณ 0, 30, 50, 70 และ 90 Vol.% แผ่นวัสดุผสมถูกนำไปยึดติดกับแผ่นอะลูมิเนียมอัลลอยเกรด AA5083-H116 ที่ความหนาแตกต่างกัน และมีการวิเคราะห์ชิ้นงานทดสอบที่จัดลำดับชั้นวัสดุแตกต่างกันในการประกอบเป็นวัสดุกันกระสุน จากการทดสอบพบว่ามอดุลัสยืดหยุ่นของวัสดุผสมเพิ่มขึ้นถึง 54.32% จากการทดสอบยิงกระสุนจริงพบว่า เมื่อนำแผ่นวัสดุผสมมาไว้เป็นแผ่นหน้าของวัสดุกันกระสุนจะสามารถต้านทานการเจาะทะลุตามมาตรฐาน NIJ-Type IIIA ได้ดีกว่าเมื่อนำแผ่นอะลูมิเนียมอัลลอยเกรด AA5083-H116 มาไว้ที่ด้านหน้า

การพัฒนาวัสดุผสมชนิดใหม่เพื่อต้านทานขีปนาวุธในการใช้งานเกราะกันกระสุน, ธีระนันท์ มาลัยวงศ์

Chulalongkorn University Theses and Dissertations (Chula ETD)

การพัฒนาผนังวัสดุผสมจากยางพารามาตรฐาน STR 5L เพื่อการป้องกันกระสุน โดยทำการศึกษาเกี่ยวกับพารามิเตอร์ที่สำคัญที่มีผลต่อการป้องกันกระสุน เช่น ความหนาของวัสดุผสม, การเรียงลำดับชั้นวัสดุผสมที่เลือกใช้ในการออกแบบ และการเลือกใช้วัสดุ เป็นต้น และต้องพิจารณาถึงน้ำหนักที่มีความเหมาะสมในการใช้งาน รวมถึงต้นทุนในการผลิตจริง ซึ่งการวิเคราะห์ผลการวิจัยจะใช้ ทฤษฏีพลังงานจลน์ (Kinetic Energy) เพื่อเปรียบเทียบผลการทดลองระหว่างการจำลองการทดสอบความเร็วต่ำในห้องปฏิบัติการและการทดสอบยิงกระสุนจริงภาคสนาม ตามมาตรฐานการทดสอบ EN1 522 โดยการนำยางพารา STR 5L ที่ผ่านกระบวนการแปรรูปแล้วมาขึ้นรูปโดยการอัด โดยการเสริมแรงด้วยลวดตาข่ายเหล็ก มาทดสอบในห้องปฏิบัติการพบว่า การเสริมแรงด้วยลวดตาข่ายเหล็กทำให้วัสดุสามารถรับแรงเจาะทะลุได้เพิ่มขึ้นโดยสามารถเพิ่มขึ้นสูงสุดได้เท่ากับ 5 ชั้น ต่อความหนาชิ้นงานเท่ากับ 12 mm โดยคิดเป็นอัตราส่วนเท่ากับ 2.4 mm/Layer ซึ่งการเพิ่มขึ้นของจำนวนลวดตาข่ายเหล็กส่งผลโดยตรงกับน้ำหนักที่เพิ่มขึ้นของชิ้นงานทดสอบวัสดุผสม โดยการเพิ่มจำนวนชั้นลวดที่ 5 ชั้นมีค่าความหนาแน่นเฉลี่ยเท่ากับ 1,975.9 kg/m3 และมีค่าความหนาแน่นเพิ่มขึ้นเมื่อเทียบกับการไม่เสริมด้วยเส้นลวดตาข่ายเหล็กคิดเป็นเปอร์เซ็นต์ 6.7% และมีค่าพลังงานการแตกหักเท่ากับ 126,679.34 J/m2 มีความคลาดเคลื่อน 25% และมีค่า Ultimate Tensile Strength เท่ากับ 5.01x106 N/m2 และมีค่า Yield Strength 2% เท่ากับ 0.588x106 N/m2 และมีค่า Young's Modulus เท่ากับ 0.05 GPa เมื่อนำไปทดสอบการยิงด้วยกระสุนจริงพบว่าวัสดุผสมตามด้วยแผ่นอลูมิเนียมสามารถให้ความหนาที่ใช้ในการป้องกันกระสุนน้อยกกว่า การใช้แผ่นอลูมิเนียมประกบหน้าวัสดุผสมถึง 54%-60% ซึ่งมีขนาดความหนาและน้ำหนักที่เมื่อเปรียบเทียบกับผลิตภัณฑ์ ARMORCOR โดยมีความหนาน้อยกกว่าเมื่อคิดเป็นเปอร์เซ็นต์ 0.72% และมีความหนามากกว่าเท่ากับ 106% และมีน้ำหนักต่ำสุดน้อยกว่า 0.018 % และมีน้ำหนักสูงสุดมากว่า 132% ตามลำดับ