Engineering Commons^™

Metal Organic Framework Modifications Of Structural Fibers, Marwan Al-Haik

Publications

A reinforced carbon composite can include a carbon sub­strate and a metal organic framework bonded to the carbon substrate. For example, a reinforced carbon composite can include a first layer, a second layer, and a resin adhered to the first layer and the second layer. The first layer can include a carbon substrate and a metal organic framework bonded to the carbon substrate. The second layer can include a carbon substrate and a metal organic framework bonded to the carbon substrate.

On The Measurement Of Nakazima Testing Based Out-Of-Plane Forming Limit Curves Using 2d Digital Image Correlation, Akshat Agha, Fadi Abu-Farha

Publications

The strain compensation method for measuring in-plane forming limit curves (FLCs) using 2D digital image correlation developed previously [A method of measuring in-plane forming limit curves using 2D Digital Image Correlation, SAE Int. J. Mater. Manf., 2023] was modified and extended to more versatile and popular out-of-plane FLCs. The current study introduces a straightforward strain compensation technique for measuring Nakazima testing based out-of-plane FLCs utilizing an affordable single-camera (2D) DIC system. In this study, forming tests are performed on two automotive-grade sheet metal alloys: DP980 steel and a 6xxx series aluminum alloy using the Nakazima test method. The experiments are …

Composites 4.0: Enabling The Modernization Of Legacy Manufacturing Assets In South Carolina, Amit Makarand Deshpande, Gayatri Keskar, Sai Aditya Pradeep, Saeed Farahani, Srikanth Pilla

Publications

Composites 4.0 is the implementation of Industry 4.0 concepts to plastics and composites manufacturing with the goal to overcome the complexities associated with these materials. Due to very complex process-structure-property relationships associated with plastics and composites, a wide range of process parameters need to be tracked and monitored. Furthermore, these parameters are often affected by the tool and machinery, human intervention and variability and should thus, be monitored by integrating intelligence and connectivity in manufacturing systems. Retrofitting legacy manufacturing systems with modern sensing and control systems is emerging as one of the more cost-effective approaches as it circumvents the substantial …

Thermoplastics Foams: An Automotive Perspective, Sai Aditya Pradeep, Srishti Shukla, Nathaniel Brown, Srikanth Pilla

Publications

The automotive industry has witnessed a massive shift in terms of materials used, ranging from being a metallic heavyweight in the 1950s to employing a hybrid sandwich of multiple material systems. This apparent shift can be attributed to achieving improvements in performance, safety and fuel efficiency, along with responding to the various environmental regulations imposed by different governments. The recent advocacy of Corporate Average Fuel Economy (CAFE) standard of 54.5 MPG by 2025 by the US Environmental Protection Agency (EPA) to reduce greenhouse gas (GHG) emissions [1] has spurred the sector at large towards the use of lightweight materials.

Metal Organic Framework Modifications Of Structural Fibers, Marwan Al-Haik

Publications

A reinforced carbon composite can include a carbon sub­strate and a metal organic framework bonded to the carbon substrate. For example, a reinforced carbon composite can include a first layer, a second layer, and a resin adhered to the first layer and the second layer. The first layer can include a carbon substrate and a metal organic framework bonded to the carbon substrate. The second layer can include a carbon substrate and a metal organic framework bonded to the carbon substrate.

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 …

Numerical Implementation And Validation Of A Viscoelastic-Plastic Material Model For Predicting Curing Induced Residual Stresses In Adhesive Bonded Joints, Akshat Agha, Fadi Abu-Farha

Publications

One of the main challenges in the joining of multi-material components is the assessment of the nature and magnitude of the residual stresses developing in the adhesive bond during the heat curing manufacturing process. Numerical modeling of these residual stresses can provide insights for making informed decisions related to (i) material substrate properties; (ii) adhesive properties i.e., low, medium, or high stiffness; (iii) bondline geometry i.e., bondline width and bead thickness; (iv) curing cycle characteristics; and (v) fixation design i.e., type, spacing, the number of joints. This work presents a cure history-dependent viscoelastic-plastic material description for the modeling of adhesive …

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 …

Advanced Anti-Buckling Device Coupled With Real-Time Digital Image Correlation For Complex Cyclic Tension-Compression Testing Of Lightweight Materials, Akshat Agha, Fadi Abu-Farha

Publications

In sheet metal forming and stamping operations, modeling the behavior of sheet metal alloys for springback prediction is known to be very challenging, not only because of the complex models needed to account for kinematic hardening (such as the Yoshida-Uemori Model) but more importantly because of the experimental limitations of our ability to perform the complex tests needed to calibrate such models. For instance, reliable monotonic uniaxial compression tests and then cyclic tension-followed-by-compression tests are essential for characterizing the response of the material under those loading conditions, providing quantitative evaluation of the Bauschinger Effect and tension/compression asymmetry in the material, …

Assessment Of Conventional And Air-Jet Wheel Deflectors For Drag Reduction Of The Drivaer Model, Sandra K. S. Boetcher, Kaloki L. Nabutola

Publications

Aerodynamic drag is a large resistance force to vehicle motion, particularly at highway speeds. Conventional wheel deflectors were designed to reduce the wheel drag and, consequently, the overall vehicle drag; however, they may actually be detrimental to vehicle aerodynamics in modern designs. In the present study, computational fluid dynamics simulations were conducted on the notchback DrivAer model—a simplified, yet realistic, open-source vehicle model that incorporates features of a modern passenger vehicle. Conventional and air-jet wheel deflectors upstream of the front wheels were introduced to assess the effect of underbody-flow deflection on the vehicle drag. Conventional wheel-deflector designs with varying heights …

Viscoelastic Model To Capture Residual Stresses In Heat Cured Dissimilar Adhesive Bonded Joints, Akshat Agha, Fadi Abu-Farha

Publications

The thermal loading during the curing process of an adhesive-bonded joint induces residual stresses in the joint, thereby affecting its performance. The problem becomes worse in the case of a multi-material joint involving varying coefficients of thermal expansion (CTE) for different parts. A novel approach was developed to model the properties of automotive grade structural adhesives during the heat curing process. The material model was divided into two components: curing kinetics model and viscoelastic mechanical model. The models were calibrated using experimental data from Differential Scanning Calorimetry (DSC) and Dynamic Mechanical Analysis (DMA) tests performed on an epoxy-based single-component adhesive. …

Experimental Methods To Capture Curing Induced Effects In Adhesive Bonded Joints, Akshat Agha, Fadi Abu-Farha

Publications

The rapidly increasing use of structural adhesives, especially in the joining of automotive body structures has motivated various investigations of the effects of adhesive curing process on joints. The automotive-grade structural adhesives require heat curing, which, in the meantime, performs thermal loading on the substrates and causes undesirable effects in the joint. For example, the curing process results in complex residual stresses in the adhesive bond which are detrimental to the performance of the adhesive bond and thereby the automobile body structure, particularly the crashworthiness. To thoroughly evaluate such effects, this paper consists of two parts. The first part presents …

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 …

Performance Testing Of Aero-Naut Camfolding Propellers, Or D. Dantsker, Robert W. Deters, Marco Caccamo, Michael S. Selig

Publications

The increase in popularity of unmanned aerial vehicles (UAVs) has been driven by their use in civilian, education, government, and military applications. However, limited on-board energy storage significantly limits flight time and ultimately usability. The propulsion system plays a critical part in the overall energy consumption of the UAV; therefore, it is necessary to determine the most optimal combination of possible propulsion system components for a given mission profile, i.e. propellers, motors, and electronic speed controllers (ESC). Hundreds of options are available for the different components with little performance specifications available for most of them. By examining a variety of …

Integration Concept Of Injection, Forming And Foaming: A Practical Approach To Manufacture Hybrid Structures, Saeed Farahani, Sai Aditya Pradeep, Srikanth Pilla

Publications

Motivated by the concept of the integrative production systems, the hybrid process of polymer injection molding and sheet metal forming, known as polymer injection forming (PIF), has been introduced to manufacture sheet metal-polymer components in a single operation. Despite the wide potential application of this technology, its implementation in actual industrial production has been hindered due to several challenges; a thick layer of polymer where there is deep deformation, non-uniform deformation due to pressure loss and the opposite phenomena of shrinkage and springback. To mitigate these practical issues, the novel idea of integrating supercritical fluid (Sc.F.) technology with the PIF …

Transformative And Disruptive Role Of Local Direct Current Power Networks In Power And Transportation Sectors, Prahaladh Paniyil, Rajendra Singh, Amir A. Asif, Vishwas Powar, Guneet Bedi, John Kimsey

Publications

The power sector is about to undergo a major disruptive transformation. In this paper, we have discussed the best possible energy solution for addressing the challenges of climate change and eradication of energy poverty. This paper focusses on the decentralized power generation, storage and distribution through photovoltaics and lithium batteries. It encompasses the need for local direct current (DC) power through the factors driving this change. The importance of local DC power in the transportation sector is also established. Finally, we conclude with data bolstering our argument towards the paradigm shift in the power network.

Guest Editorial Special Issue On Toward Securing Internet Of Connected Vehicles (Iov) From Virtual Vehicle Hijacking, Yue Cao, Houbing Song, Omprakash Kaiwartya, Sinem Coleri Ergen, Jaime Lloret, Naveed Ahmad

Publications

Today’s vehicles are no longer stand-alone transportation means, due to the advancements on vehicle-tovehicle (V2V) and vehicle-to-infrastructure (V2I) communications enabled to access the Internet via recent technologies in mobile communications, including WiFi, Bluetooth, 4G, and even 5G networks. The Internet of vehicles was aimed toward sustainable developments in transportation by enhancing safety and efficiency. The sensor-enabled intelligent automation of vehicles’ mechanical operations enhances safety in on-road traveling, and cooperative traffic information sharing in vehicular networks improves traveling efficiency.

(Invited) Emerging Role Of Silicon Carbide And Gallium Nitride Based Power Electronics In Power And Transportation Sectors, Prahaladh Paniyil, Rajendra Singh

Publications

Free fuel-based energy sources (solar and wind) are pointing towards a future in which sustainable energy is affordable, abundant and deployed with high energy efficiency. Driven by advancements in the technology of lithium batteries and the availability of low-cost sustainable clean electric power, the electrification of transportation is going through fundamental disruptive transformation. Without any doubt, both power and transportation sectors will provide phenomenal growth of power electronics in the 21st century. Recently, both SiC and GaN are drawing the attention as potential replacement of Si-based power electronics. These may open some new markets where Si based power electronics cannot …

Does Length Of Ride, Gender Or Nationality Affect Willingness To Ride In A Driverless Ambulance?, Stephen Rice, Scott R. Winter, Rian Mehta, Joseph R. Keebler, Bradley S. Baugh, Emily C. Anania, Mattie N. Milner

Publications

Due to the frequent lack of ambulances and personnel, the purpose of this study was to examine consumers’ willingness-to-ride in an ambulance that was either driven by a human driver or completely automated (with no human driver) based on the gender of the participant and their nationality, either Indian or American. A two-study experimental design was utilized using over 1,000 participants. In Study 1, the length of the ride and the type of driver were manipulated while in Study 2, the length of the ride was manipulated across genders and nationality. Study 2 also collected affect measures to complete a …

Cure History Dependent Viscoelastic Modeling Of Adhesively Bonded Joints Using Mat_277 In Ls-Dyna®, Akshat Agha, Fadi Abu-Farha, Rakan Alturk, Tim Welters, Georges Romanos

Publications

The effects of Coefficient of Thermal Expansion (CTE) mismatch in multi-material adhesive joints, induced during the manufacturing process, are expected to hinder the peak performance of the adhesive in the service life of the vehicle. With a goal to estimate these effects, this paper attempts to model the curing phenomenon of an adhesive and predict its mechanical properties using MAT_277 material model available in LS-DYNA, which serves as a good starting point towards modeling the cure history dependent viscoelastic behavior of adhesives. The adhesive is used to join two substrates of dissimilar metals and tested to capture the relative displacement …

A Complementary Cyber-Human Systems Framework For Industry 4.0 Cyber-Physical Systems, Matthew Krugh, Laine Mears

Publications

Humans are a vital element to automotive manufacturing; however, skilled production personnel have largely been designated as data receivers in Cyber-Physical Systems (CPS) of Industry 4.0. A renewed focus on the human worker who completes significant portions of manual value-added content in automotive assembly through Cyber-Human Systems (CHS) is allowing humans to perform their jobs more safely, efficiently, and supporting enhanced control and quality monitoring of manual manufacturing tasks. There is a need for a unified complementary framework of CHS and CPS to guide the implementation of future smart manufacturing systems.

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 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 …

Obstacle Filtering Alogrithm For Control Of An Autonomous Road Vehicle In Public Highway Traffic, Qian Wang, Beshah Ayalew

Publications

This paper presents an obstacle filtering algorithm that mimics human driver-like grouping of objects within a model predictive control scheme for an autonomous road vehicle. In the algorithm, a time to collision criteria is first used as risk assessment indicator to filter the potentially dangerous obstacle object vehicles in the proximity of the autonomously controlled vehicle. Then, the filtered object vehicles with overlapping elliptical collision areas put into groups. A hyper elliptical boundary is regenerated to define an extended collision area for the group. To minimize conservatism, the parameters for the tightest hyper ellipse are determined by solving an optimization …

Energy Consumption Modeling And Analyses In Automotive Manufacturing Plant, Lujia Feng, Laine Mears

Publications

Manufacturing plants energy consumption accounts for a large share in world energy usage. Energy consumption modeling and analyses are widely studied to understand how and where the energy is used inside of the plants. However, a systematic energy modeling approach is seldom studied to describe the holistic energy in the plants. Especially using layers of models to share information and guide the next step modeling is rarely studied. In this paper, a manufacturing system temporal and organizational framework was used to guide the systematic energy modeling approach. Various levels of models were established and tested in an automotive manufacturing plant …

Energy, Economy, And Environment Analysis And Optimization On Manufacturing Plant Energy Supply System, Lujia Feng, Laine Mears, Cleveland Beaufort, Joerg Schulte

Publications

Increasing attention has recently been drawn to energy consumption in manufacturing plants. Facing the challenges from reducing emissions coupled with rising raw material prices and energy costs, manufacturers are trying to balance the energy usage strategy among the total energy consumption, economy, and environment, which can be self-conflicting at times. In this paper, energy systems in manufacturing environments are reviewed, and the current status of onsite energy system and renewable energy usage are discussed. Single objective and multicriteria optimization approaches are effectively formulated for making the best use of energy delivered to the production processes. Energy supply operation suggestions based …

Differential Effects Of Refractive Blur On Day And Nighttime Driving Performance, Joanne M. Wood, Michael J. Collins, Alex Chaparro, Ralph Marszalek, Trent Carberry, Philippe Lacherez, Byoung Sun Chu

Publications

PURPOSE. To investigate the effect of different levels of refractive blur on real-world driving performance measured under day and nighttime conditions.

METHODS. Participants included 12 visually normal, young adults (mean age = 25.+- 5.2 years) who drove an instrumented research vehicle around a 4 km closed road circuit with three different levels of binocular spherical refractive blur (+0.50 diopter sphere [DS], +1.00 DS, +2.00 DS) compared with a baseline condition. The subjects wore optimal spherocylinder correction and the additional blur lenses were mounted in modified fullfield goggles; the order of testing of the blur conditions was randomized. Driving …

Effect Of Machining Feed On Surface Roughness In Cutting 6061 Aluminum, Mathew Kuttolamadom, Sina Hamzehlouia, Laine Mears

Publications

The general manufacturing objective during the fabrication of automotive components, particularly through machining, can be stated as the striving to achieve predefined product quality characteristics within equipment, cost and time constraints. The current state of the economy and the consequent market pressure has forced vehicle manufacturers to simultaneously reduce operating expenses along with further improving product quality. This paper examines the achievability of surface roughness specifications within efforts to reduce automotive component manufacture cycle time, particularly by changing cutting feeds. First, the background and attractiveness of aluminum as a lightweight automotive material is discussed. Following this, the methodologies employed for …

Investigation Of The Machining Of Titanium Components For Lightweight Vehicles, Laine Mears, Mathew A. Kuttolamadom, Joshua J. Jones, Thomas R. Kurfess, Aditya S. Choragudi

Publications

Due to titanium’s excellent strength-to-weight ratio and high corrosion resistance, titanium and its alloys have great potential to reduce energy usage in vehicles through a reduction in vehicle mass. The mass of a road vehicle is directly related to its energy consumption through inertial requirements and tire rolling resistance losses. However, when considering the manufacture of titanium automotive components, the machinability is poor, thus increasing processing cost through a trade-off between extended cycle time (labor cost) or increased tool wear (tooling cost). This fact has classified titanium as a “difficult-to-machine” material and consequently, titanium has been traditionally used for application …

Volumetric Flank Wear Characterization For Titanium Milling Insert Tools, Uli Burger, Mathew Kuttolamadom, April Bryan, Laine Mears, Thomas Kurfess

Publications

Machining wear models are useful for the prediction of tool life and the estimation of machining productivity. Existing wear models relate the cutting parameters of feed, speed, and depth of cut to tool wear. The tool wear is often reported as changes in flank width or crater depth. However, these one-dimensional wear measurements do not fully characterize the tool condition when tools wear by other types of wear such as notching, chipping, and adhesion. This is especially true when machining difficult-to-machine materials such as titanium. This paper proposes another approach for characterizing tool wear. It is based on taking measurements …