Automotive Engineering Commons^™

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, …

Coupled Thermal Mechanical Analysis Methodology For Thermal Performance Evaluation And Failure Mode Identification Of Thermal Barrier Coatings For Heavy Duty Diesel Engines, Sean Moser

All Dissertations

Consumer demand and government regulation, as well as the Department of Energy’s SuperTruck program has motivated extraordinary effort to maximize the heavy-duty diesel engine’s thermal efficiency. Thermal barrier coatings (TBCs) provide an avenue for increasing the thermal efficiency of the mixing controlled combustion (MCC) process through the reduction of heat transfer losses. The myriad of previous studies presents conflicting conclusions, both in the merit of TBCs for cycle improvement, and also for coating durability and potential adverse effects from coating failure. While the most recent studies with thin thermal barrier coatings (~100-250 µm) have shown a majority of positive cycle …

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 …

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.

Evaporator Modeling And An Optimal Control Strategy Development Of An Organic Rankine Cycle Waste Heat Recovery System For A Heavy Duty Diesel Engine Application, Dhruvang Rathod

All Dissertations

The Organic Rankine Cycle (ORC) has proven to be a promising technology for Waste Heat Recovery (WHR) systems in heavy duty diesel engine applications. However, due to the highly transient heat source, controlling the working fluid flow through the ORC system and maximizing the heat recovery is a challenge for real time application. To that end, this research resulted in the following main developments.

The first new development is in the area of heat exchanger modeling. The heat exchanger is a key component within the WHR system and it governs the dynamics of the complete ORC system. The heat exchanger …

(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 …

Polymer Injection Forming: A New Age Technology For Manufacturing Polymer-Metal Hybrids, Saeed Farahani

All Dissertations

Due to global competition, manufacturing firms in high-wage countries must target innovation in production processes and technologies that allow the mass manufacturing of customized products through highly efficient processes. Motivated by the concept of the integrative production systems, 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 using a single tooling, machinery, and operating system. During this process, the sheet metal blank inside the injection mold is deformed by means of tool movement and/or by pressure of the polymer melt. As the melt cools, the …

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.

Design, Synthesis And Sustainable Applications Of Animal Protein-Based Thermoset Polymers And Covalent Organic Frameworks, Xiaoyan Yu

All Dissertations

Extensive research has been undertaken in recent times on finding suitable, alternative, non-feed and non-fertilizer applications for proteinaceous materials in the animal rendering industry. In this regard, use of such proteins to derive plastics, especially thermoplastics and derived composites, has emerged as a potentially acceptable choice. However, the widespread use of such proteins for aforementioned applications is limited by their poor mechanical properties, high moisture absorption and their inherent odor. In this study, we have engineered, for the first time, high-strength, toughened thermoset polymers from proteinaceous materials obtained from the rendering industry so that they can be employed in high …

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 …

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 …

Supervisory Control Optimization For A Series Hybrid Electric Vehicle With Consideration Of Battery Thermal Management And Aging, Xueyu Zhang

All Dissertations

This dissertation integrates battery thermal management and aging into the supervisory control optimization for a heavy-duty series hybrid electric vehicle (HEV). The framework for multi-objective optimization relies on novel implementation of the Dynamic Programing algorithm, and predictive models of critical phenomena. Electrochemistry based battery aging model is integrated into the framework to assesses the battery aging rate by considering instantaneous lithium ion (Li+) surface concentration rather than average concentration. This creates a large state-action space. Therefore, the computational effort required to solve a Deterministic or Stochastic Dynamic Programming becomes prohibitively intense, and a neuro-dynamic programming approach is proposed to remove …

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 …

A Study On General Assembly Line Balancing Modeling Methods And Techniques, Bryan Pearce

All Dissertations

The borders of the assembly line balancing problem, as classically drawn, are as clear as any other operations research topic in production planning, with well-defined sets of assumptions, parameters, and objective functions. In application, however, these borders are frequently transgressed. Many of these deviations are internal to the assembly line balancing problem itself, arising from any of a wide array of physical or technological features in modern assembly lines. Other issues are founded in the tight coupling of assembly line balancing with external production planning and management problems, as assembly lines are at the intersection of multiple related problems in …

Understanding The Automotive Pedal Usage And Foot Movement Characteristics Of Older Drivers, Yubin Xi

All Dissertations

The purpose of this study was to understand the pedal usage characteristics of older drivers in various driving tasks using an instrumented vehicle. This study stemmed from the prevalence of the pedal application errors (PAEs) and the older drivers’overrepresentation in crashes caused by PAEs.

With the population increasing and becoming older, it is estimated that in 2020 there will be 40 million drivers over the age of 65 in the United States. Compared with their younger counterparts, older drivers are facing declining cognitive and physical abilities, such as impaired vision, slower reaction time and diminishing range of limb motion. Because …

A Laminated Ring On Elastic Foundation Model With Application To Analysis Of Tire-Road Contact, Chunjian Wang

All Dissertations

A deformable Ring on Elastic Foundation (REF) model has been widely used for modeling rotating structures such as gears, bearings and tires. This dissertation extends the existing work with three main contributions focusing on applications to tires: 1) The elastic foundation is endowed with unilateral stiffness, which leads to a nonlinear deformation dependent stiffness typical of some non-pneumatic tires; 2) The model of the deformable ring is extended from simple Timoshenko rings to a laminated orthotropic ring model, with bending, shear stiffness and extensibility in the internal layer, and transverse stiffness in the external layer; 3) Facilitated by the laminated …

Measurement Of Older And Younger Drivers' Selected Seat Position Within Their Personal Vehicles To Influence Recommended Practices For Meeting Safety Needs Of Drivers, Shayne Kelly Mcconomy

All Dissertations

The objective of this research was to measure and understand the preferred seat position and posture of older drivers and younger drivers within their personal vehicles to influence recommended practices for meeting the safety needs of all drivers.Currently, the United States is experiencing an ageing population, whereby in 2020 nearly 40 million people over the age of 65 will be licensed drivers. In addition, crash reports show that older drivers are over represented in vehicle fatality statistics, once adjusted for vehicle miles traveled. The increased fatality rate of older drivers has been attributed to a combination of increased fragility of …

A Study Of The Effects Of Manufacturing Complexity On Product Quality In Mixed-Model Automotive Assembly, Kavit Ravindra Antani

All Dissertations

The objective of this research is to test the hypothesis that manufacturing complexity can reliably predict product quality in mixed-model automotive assembly.

Originally, assembly lines were developed for cost efficient mass-production of standardized products. Today, in order to respond to diversified customer needs, companies have to allow for an individualization of their products, leading to the development of the Flexible Manufacturing Systems (FMS). Assembly line balancing problems (ALBP) consist of assigning the total workload for manufacturing a product to stations of an assembly line as typically applied in the automotive industry. Precedence relationships among tasks are required to conduct partly …

Impact-Acoustic Evaluation Method Of Internal Crack In Rubber Composite Structure, Qin Shen

All Dissertations

The main objective of this work is to investigate the impact acoustic method as a means of nondestructive testing (NDT) for internal cracks in a rubber composite structure, such as that found in a tire. As demonstrated in this dissertation, this approach is an effective and economical alternative to the current NDT methods for tires casing integrity inspection. There are two separate aspects of the impact acoustic signals considered in this work: the impact force signal and the resultant acoustic signal. First, a contact dynamics model is developed based on the Hertz’s impact theory and modified for rubber composite materials. …

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 …

Warning! Engineers In Training: Introducing Middle School Students To Industrial Engineering, Its Usefulness, And Its Applications, M. Grubb, A. Berger, D. Browning, M. Mayorga, Laine Mears

Publications

The McCants Middle School Pre-engineering class is designed to teach engineering skills to students with a predisposition for and interest in math and science. This team’s initiative is to use Industrial Engineering tools to enhance the existing pre-engineering course curriculum. The purpose of this study is to make middle school students better aware of an engineer’s thought process as it pertains to effectively planning and working on projects, and to measure the impact of our influence. Through this study, we want to improve the overall quality of the student’s projects and ultimately increase the retention and quantity of students interested …

Open-Loop Velocity Planning To Mitigate The Stiction Effect In Pushing Positioning, Laine Mears, Thomas Kurfess

Publications

No abstract provided.

Quality And Inspection Of Machining Operations: Review Of Condition Monitoring And Cmm Inspection Techniques 2000 To Present, John T. Roth, Laine Mears, Dragan Djurdjanovic, Xiaping Yang, Thomas Kurfess

Publications

In order to consistently produce quality parts, many aspects of the manufacturing process must be carefully monitored, controlled, and measured. The methods and techniques by which to accomplish these tasks has been the focus of numerous studies in recent years. With the rapid advances in computing technology, the complexity and overhead that can be feasibly incorporated in any developed technique has dramatically improved. Thus, techniques that would have been impractical for implementation just a few years ago can now be realistically applied.

This rapid growth has resulted in a wealth of new capabilities for improving part and process quality and …