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Failure Analysis of Friction Weld in Rear Axle Casing 后桥壳摩擦焊失效分析
Pub Date : 2022-01-15 DOI: 10.37285/ajmt.1.1.1
G. K. Sivakumar, Ramya G Nair
In this study, Housing and Spindle failed at Friction weld (FRW) interface and sample submitted was from a Passenger vehicle after covering 18410 Kms was considered to address the repeated weld failures reported in Rear Axle Casing. The Metallurgical examinations revealed, chemical composition and hardness found satisfactory whereas Microstructure reveals presence of MnS (Manganese Sulphide) Inclusions at the friction weld interface resulting in insufficient friction weld fusion.SEM and Metallographic examinations confirmed the Orientation of MnS (Manganese sulphide) along the surface of the Spindle that was subjected to Friction welding (FRW) resulting in insufficient weld fusion. Microstructure observation of Spindle shows inclusions of Type A - Thick 2 against the allowable limits in Raw Material Type A - Thick 1. Also, the elongated MnS inclusions at the Friction weld (FRW) Interface act as initiation sites, "Stress raiser "that is more vulnerable to failure due to comparatively less tensile and impact strength than base metal similar to the effect of flake graphite’s in cast iron. Due to the anisotropy and orientation of the sulfide inclusions there is reduction in transverse ductility in reduced area and not much significant effect in longitudinal direction. Inclusion control by calcium treatment or Electro slag re-melting in spindle raw material will significantly improve the ductility and toughness of friction weldments. This paper aims to study the effect of Sulfide inclusions on weldability, mechanical properties of weld Interface and role as fracture initiation site.
在这项研究中,壳体和主轴在摩擦焊缝(FRW)界面失效,并提交了一辆乘用车在行驶了18410公里后的样品,以解决后桥套管的重复焊接失效问题。金相检查显示,化学成分和硬度令人满意,但微观结构显示摩擦焊缝界面存在MnS(硫化锰)夹杂物,导致摩擦焊缝融合不足。扫描电镜和金相检查证实了MnS(硫化锰)沿着主轴表面进行摩擦焊接(FRW),导致焊接融合不足。主轴的显微组织观察显示,A -厚2型夹杂物与A -厚1型原料的允许极限相违背。此外,摩擦焊缝(FRW)界面处伸长的MnS夹杂物作为起始点,“应力产生器”,由于相对于母材的拉伸和冲击强度较低,更容易失效,类似于铸铁中片状石墨的作用。由于硫化物包裹体的各向异性和取向,在还原区横向延展性降低,而在纵向上影响不明显。通过钙处理或电渣重熔控制主轴原料中的夹杂物,可以显著提高摩擦焊件的延展性和韧性。本文旨在研究硫化物夹杂物对焊接性能、焊缝界面力学性能及起裂部位的影响。
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引用次数: 0
Modal Analysis of Passive Engine Mount Assembly using Finite Element Analysis 被动发动机悬置总成的有限元模态分析
Pub Date : 2022-01-15 DOI: 10.37285/ajmt.1.1.10
H. V. Santhosh Kumar, K. S. Pramukh Bharadwaj, Rohith S Holla, S. Mridhul, T. Vishnu
Engine mounts play a vital role in reduction of noise and vibration. For an internal combustion engine, there exist two basic dynamic disturbances: a) the firing pulse due to the combustion of fuel in the cylinder and b) the inertia force and torque caused by the rotating and reciprocating parts. The firing pulses will cause a torque to act on the engine block about an axis parallel to the crank. The inertial forces are both parallel to the piston axis and perpendicular to the crank and piston axes. This dissertation describes the finite element approach for modal and static structural analysis of the engine mount used on an inline four-cylinder petrol engine.  A 3D model of the mount was created with the help of Solid-Edge V19 software and the same was analysed for natural frequencies and total deformation using Ansys Workbench software. Further, torsional stiffness of the mount was obtained using finite element analysis and validated using experimental testing. Viscoelastic behaviour of rubber has also been discussed with the help of a Generalized Maxwell model (GMM). GMM was chosen after reviewing all the commonly used models. Later, an in-depth analysis of transmissibility was carried out using finite element analysis approach and a 6-DOF Mathematical model approach. Random vibration analysis was carried out and the resulting RMS accelerations were compared with the ISO-2631 standard.
发动机支架在降低噪声和振动方面起着至关重要的作用。对于内燃机来说,存在两种基本的动态扰动:a)燃料在气缸内燃烧产生的燃烧脉冲和b)旋转和往复部件产生的惯性力和扭矩。发射脉冲将引起一个扭矩作用在发动机机体上的轴平行于曲柄。惯性力平行于活塞轴,垂直于曲柄轴和活塞轴。本文介绍了对直列四缸汽油发动机发动机悬置进行模态和静力结构分析的有限元方法。在Solid-Edge V19软件的帮助下创建了安装座的3D模型,并使用Ansys Workbench软件分析了该模型的固有频率和总变形。此外,通过有限元分析获得了支座的扭转刚度,并通过实验测试进行了验证。用广义麦克斯韦模型(GMM)讨论了橡胶的粘弹性特性。在审查了所有常用模型后,选择了GMM。随后,采用有限元分析方法和六自由度数学模型方法对传导率进行了深入分析。进行了随机振动分析,并与ISO-2631标准进行了比较。
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引用次数: 0
Foreword & Message 前言及留言
Pub Date : 2021-11-11 DOI: 10.37285/ajmt.1.0.0
Prof. Anil D. Sahasrabudhe
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引用次数: 0
A Systematic Approach to Evaluation of Various Cooling Strategies for EV Battery Pack Prismatic Cell using Analytical and Numerical Methods 基于解析和数值方法的电动汽车电池组柱状电池冷却策略系统评估
Pub Date : 2021-11-10 DOI: 10.37285/AJMT.1.0.9
Y. dol, Vivek Anami, Yogesh R. Jaju
Technology to maximize energy density and life of Lithium-ion batteries at a gradually reducing cost is evolving day by day. Fast charging of the battery pack has become one of the major requirements of electric vehicles. Such a requirement invariably poses certain challenges to the cells of the EV battery pack. One of them is to achieve an efficient and an optimal thermal management of the battery pack to maintain uniform operating temperature of the cells and within the manufacturers’ allowable range to ultimately increase the lifespan and reliability of the battery pack. The current work discusses the design strategies of cell cooling, heat load estimation & features of different cooling strategies. A MS Excel spreadsheet-based design tool was developed to quickly estimate the cell temperature gradient. The results from the spreadsheet-based tool, which was based on fundamental equations, correlated well with 3D CFD simulation results. The results were analysed and the cooling strategy for the battery pack was decided based on the analytical and numerical values obtained from the analysis of various cell parameters. 
在逐渐降低成本的情况下,最大限度地提高锂离子电池的能量密度和寿命的技术正在日益发展。电池组的快速充电已成为电动汽车的主要要求之一。这样的要求总是给电动汽车电池组的电池带来一定的挑战。其中之一是实现电池组的高效和最佳热管理,以保持电池的均匀工作温度,并在制造商的允许范围内,最终提高电池组的使用寿命和可靠性。本文讨论了电池冷却的设计策略、热负荷的估计以及不同冷却策略的特点。开发了基于MS Excel电子表格的设计工具,用于快速估算细胞温度梯度。基于电子表格的工具基于基本方程,其结果与三维CFD模拟结果吻合良好。根据对电池各参数的分析得到的解析值和数值,对结果进行了分析,并确定了电池组的冷却策略。
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引用次数: 0
Impact of PGM Loading in DOC on Emission in Diesel Engine Off Road Vehicle to Meet CEVIV Norms DOC中PGM加载对满足CEVIV标准的柴油机越野车排放的影响
Pub Date : 2021-11-10 DOI: 10.37285/AJMT.1.0.2
Abhijit J. Sahare
Experimental study was done for evaluation of different type of PGM loading in Diesel oxidation catalyst (DOC) for off road vehicle. The main purpose of DOC is to reduce the hydrocarbon and carbon monoxide from exhaust line and increasing the DOC outlet temperature, which used in soot oxidation in DPF and increased conversion efficiency of SCR. It is very challenging to meet the emission norm with minimum loading of DOC for low cost and durable approach for non-auto application. Test results highlights impact on emission with different PGM loading in DOC. This paper focused on the calibration of DOC model with different loading and observed that behaviour on THC and CO in exhaust system. Minimum Temperature constraint was come in NRTC rather than NRSC. With low, exhaust gas temperature white smoke observed, when unburned HCs was adsorbed on DOC. Data taken to understand thermal effect on DOC with different loading in aged condition. It observed that maximum DOC loading, conversion efficiency went up to 98% in THC after heating up. DOC loading is also responsible for conversion of NO to NO2, which is used in conversion of SCR efficiency. Detailed comparison and analysis was done to understand the impact of PGM loading in DOC for NO2 formation, exotherm, HC & CO light off temperature behaviour.
对不同类型PGM在越野车柴油氧化催化剂(DOC)中的装载性能进行了试验研究。DOC的主要目的是降低排气管道中的碳氢化合物和一氧化碳,提高DOC的出口温度,用于DPF的烟尘氧化,提高SCR的转化效率。在满足排放标准的前提下,以低成本和耐用的方式满足非汽车应用中DOC的最小负荷是非常具有挑战性的。试验结果突出了不同PGM加载对DOC排放的影响。本文重点对不同负荷下的DOC模型进行了标定,并观察了其对排气系统中THC和CO的影响。最低温度限制是在NRTC而不是NRSC中提出的。当未燃烧的hc吸附在DOC上时,废气温度低,产生白烟。采用数据了解老化条件下不同载荷对DOC的热效应。结果表明,加热后的四氢大麻酚中DOC的最大负荷、转化效率可达98%。DOC加载还负责将NO转化为NO2,用于SCR效率的转换。进行了详细的比较和分析,以了解PGM在DOC中加载对NO2形成、放热、HC和CO轻脱温度行为的影响。
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引用次数: 0
Performance of Thermal Barrier Coating on Exhaust System Component 排气系统部件热障涂层性能研究
Pub Date : 2021-11-10 DOI: 10.37285/ajmt.1.0.6
Dhanasekaran Radhakrishnan, R. R, S. Srinivasan, Libin George Alexander
Thermal management in automobiles is important to keep the passenger cabin and heat sensitive components away from thermal effects. Hence various types of insulation methods are used to reduce the thermal effects. Heatshields are the most common method of thermal insulation. They can be classified into various types based on their construction architecture and insulation materials. Some of the heat shielding systems contain fibre materials that are hazardous to health due to their carcinogenic effects and hence not recommended. With increasing space constraints in the compact vehicle architecture designs, packaging space is premium, limiting the size of heatshields. In addition, from durability aspect, heatshields alone are not adequate to withstand high temperatures during the service life of exhaust systems. Hence the role of Thermal Barrier Coating (TBC) as an alternative solution comes effective. TBC’s are ceramic coatings which can take care of extended heat loads and temperature differences. This coating not only provides thermal insulation but also improves the fatigue life of substrate material. Hence in this paper, the application of TBC on exhaust system components with respect to thermal insulation and thermo mechanical fatigue are studied. Virtual analysis and physical test are carried out to validate the results. TBC coating on exhaust component shows promising results. 
汽车的热管理对于保持客舱和热敏部件远离热效应非常重要。因此,使用各种类型的保温方法来减少热效应。隔热罩是最常见的隔热方法。根据建筑结构和保温材料的不同,它们可以分为不同的类型。一些热屏蔽系统含有纤维材料,由于其致癌作用,对健康有害,因此不建议使用。随着紧凑型车辆结构设计中空间限制的增加,封装空间是宝贵的,限制了防热罩的尺寸。此外,从耐用性方面来看,在排气系统的使用寿命期间,仅隔热罩不足以承受高温。因此,热障涂层(TBC)作为替代解决方案的作用是有效的。TBC是陶瓷涂层,可以照顾到扩展的热负荷和温差。该涂层不仅提供了隔热,而且提高了基材的疲劳寿命。因此,本文从隔热和热机械疲劳两个方面研究了TBC在排气系统部件上的应用。进行了虚拟分析和物理测试来验证结果。TBC涂层在排气部件上取得了良好的效果。
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引用次数: 0
Prognostics and Health monitoring of Lead acid battery 铅酸蓄电池的预后与健康监测
Pub Date : 2021-11-10 DOI: 10.37285/ajmt.1.0.10
Ashwin R, Dr.Suryanarayana Prasad A.N
The ever-increasing number of electrical loads in the commercial vehicle emphasizes the significance of lead acid battery used for starting and the powering of electrical systems in a commercial vehicle. In order to monitor the health of the battery, parameters SOC (State of Charge) and SOH (State of Heath) are introduced. The existing methods to calculate these parameters use impedance monitoring based approach which requires an expensive current sensor. This paper describes a smart algorithm and the experimental verification of the algorithm that uses only voltage values for predicting the failure of the battery. The voltage waveforms during a cranking event is studied by the ECU (Engine Control Unit) and the health of the battery is determined based on it. A parameter, SOH measure is obtained from the algorithm and the value of this parameter reduces with increase in life of the battery. If the value of the SOH measure reduces below a threshold, then the failure of the battery is predicted before the actual failure. The algorithm is validated with the help of real time data obtained from the vehicles. This method of calculating the SOH is resourceful and cost-effective as it exploits the data that’s already available in the ECU namely battery voltage and ambient temperature. Thus, it does not warrant an addition of sensor to the system in place.
商用车用电负荷的不断增加,凸显了铅酸蓄电池在商用车电气系统启动和供电中的重要意义。为了监测电池的健康状况,引入了SOC (State of Charge)和SOH (State of Heath)参数。现有的计算这些参数的方法是基于阻抗监测的方法,这需要昂贵的电流传感器。本文介绍了一种仅使用电压值预测电池失效的智能算法,并对该算法进行了实验验证。发动机控制单元(ECU)对发动机启动过程中的电压波形进行了研究,并据此确定了电池的健康状况。该算法得到一个参数SOH,该参数值随着电池寿命的增加而减小。如果SOH测量值降至阈值以下,则在实际故障之前预测电池故障。利用车辆实时数据对算法进行了验证。这种计算SOH的方法既灵活又经济,因为它利用了ECU中已有的数据,即电池电压和环境温度。因此,它不保证在现有系统中增加传感器。
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引用次数: 0
Light Weighting of Buses using Aluminium with Safety and Durability Considerations 考虑安全性和耐久性的铝制客车轻量化
Pub Date : 2021-11-10 DOI: 10.37285/AJMT.1.0.4
M. A. Patwardhan, P. Nirmal, R. Mahajan
Automobiles, while making living easy and convenient, have also made human life more complex and vulnerable to toxic emissions. Transport sector is huge contributor in polluting air in the entire world in the tune of around 23%.Mass transport uses buses as the medium for generalized and convenient means for commutation from one place to other. Similar pattern is observed in India for mass transportation mainly in the cities. However, commuting through buses comes with penalty of environmental pollution. City buses are large contributor in GHG emission and can be considered as prime candidates for making any kind of changes which will help in reducing environmental pollution. Immense potential lies in existing bus designs for weight optimization which has direct impact in improving fuel economy and hence will have sustainable impact in reducing carbon emissions. This paper outlines systematic approach used for development of lightweight buses using Aluminium addressing safety, durability and necessary regulatory requirements. Effective use of aluminium in development of lightweight bus structure is demonstrated in this project. While designing lightweight structure for weight optimization due care is taken for addressing prevailing regulatory norms related to AIS:052 bus body code, AIS:153 outlining safety requirements and Urban Bus Specification issued by Ministry of Road Transport and Highways specifying strength and safety requirements of bus structure. Aluminium bus designs developed shows more than 30% weight reduction compared to steel structured buses of similar class. Fuel efficiency improvement in the tune of minimum 8% and maximum 10% are observed during field level trials.
汽车在使生活变得简单方便的同时,也使人类的生活变得更加复杂,容易受到有毒物质排放的影响。交通运输部门是全球空气污染的巨大贡献者,约占23%。公共交通以公共汽车为媒介,提供从一个地方到另一个地方的通用和方便的通勤方式。在印度,主要在城市的大众交通也出现了类似的模式。然而,乘坐公共汽车通勤带来了环境污染的惩罚。城市公交车是温室气体排放的主要贡献者,可以被认为是做出任何有助于减少环境污染的改变的主要候选者。现有的客车重量优化设计潜力巨大,这对提高燃油经济性有直接影响,因此将对减少碳排放产生可持续的影响。本文概述了用于开发使用铝的轻型客车的系统方法,以解决安全性,耐久性和必要的监管要求。本项目展示了铝在客车轻量化结构开发中的有效应用。在设计轻量化结构以实现重量优化时,应注意解决与AIS:052客车车身规范、AIS:153概述安全要求和道路运输和公路部发布的城市客车规范相关的现行监管规范,其中规定了客车结构的强度和安全要求。开发的铝制客车与同类钢结构客车相比,重量减轻了30%以上。在实地试验中,燃油效率的提高幅度最小为8%,最大为10%。
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引用次数: 0
Performance Evaluation of Self-Piercing Riveted and Resistance Spot Welded Dissimilar Steel Joints 异种钢自穿铆接与电阻点焊接头性能评价
Pub Date : 2021-11-10 DOI: 10.37285/AJMT.1.0.5
T. AkhilKishoreV, B. Asati, Nikhil Shajan, K. S. Arora
Self-piercing riveting (SPR) is a mechanical joining process that has the potential to replace resistance spot welding (RSW) and is being adopted in the automotive industry.In this study, a dissimilar stack configuration widely used in the automotive industry was used. Joining was performed using self-piercing riveting and resistance spot welding processes. Welding parameters in spot welding were optimized to produce anugget with a diameter similar to the rivet shank. Tensile and fatigue attributes of these joints were assessed to evaluate the joint performance. Additionally, microstructure-property correlation was performed to evaluate the failuremode and susceptible region in the joint that can lead to crack initiation and failure.
自穿孔铆接(SPR)是一种有潜力取代电阻点焊(RSW)的机械连接工艺,正在汽车工业中得到应用。在本研究中,采用了在汽车工业中广泛使用的异种堆叠结构。采用自穿孔铆接和电阻点焊工艺进行连接。对点焊工艺参数进行了优化,得到了与铆钉柄直径相近的铆钉。对接头的拉伸和疲劳特性进行了评估,以评价接头的性能。此外,还进行了显微组织-性能相关性分析,以评估接头中可能导致裂纹萌生和破坏的破坏模式和敏感区域。
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引用次数: 4
Driving Safety through ADAS: An Indian Perspective 通过ADAS的驾驶安全:印度视角
Pub Date : 2021-11-10 DOI: 10.37285/AJMT.1.0.7
U. Karle
Analysis of the National Motor Vehicle Crash Causation Survey, conducted by the National Highway Traffic Safety Administration (NHTSA), shows that driver error is a factor in 94% of crashes. Although it is important to remember multiple factors contribute to all crashes, the largest portion of driver error issues involve the driver failing to recognize hazards, including distraction. Around 3,700 people die in traffic every day around the world, and 100,000 are injured. The automotive industry is striving to make driving safer. ADAS in India is comparatively in a nascent stage. However, it is gradually gaining pace. The government's upcoming safety regulations and consumer awareness will give further impetus to this movement. So, Advanced driver-assistance systems (ADAS) is equipping cars and drivers with advance information and technology to make them become aware of the environment and handle potential situations in better way semi-autonomously. High-quality training and test data is essential in the development and validation of ADAS systems which lay the foundation for autonomous driving technology. In addition to this, ADAS systems need to be very safe and robust, with the ability to perform in a variety of driving scenarios, and be very secure, being immune from any external cyber-attacks. In order to make ADAS systems safer, the AV will be required to drive more than a billion miles on real roads, taking tens and sometimes hundreds of years to drive those miles, considering even the most aggressive testing assumptions. Every small update to the AV will require another billion miles of testing to be approved for real world use. Moreover, the more advanced the technology becomes, the more miles will need to de driven. Real word testing plays a very crucial role in ADAS and AV development and testing. Nevertheless, relying only on real world testing will significantly slow down the development and testing of such technologies. This is where simulation comes into play. With the primary objective of road safety improvement, ADAS functionalities will definitely play a big role for automotive industry. In order to tackle Indian specific road infrastructure conditions, and thus improving the safety, a complete tool-chain for developing, deploying and validating ADAS functionalities need to be developed. The presented work shares insights of each and every aspect of this tool-chain with experimental results and real world correlations.
美国国家公路交通安全管理局(NHTSA)进行的全国机动车碰撞原因调查分析显示,驾驶员的失误是94%的撞车事故的一个因素。尽管重要的是要记住造成所有撞车事故的多种因素,但驾驶员失误问题的最大部分涉及驾驶员未能认识到危险,包括分心。全世界每天约有3700人死于交通事故,10万人受伤。汽车工业正在努力使驾驶更安全。相对而言,印度的ADAS还处于起步阶段。然而,它正在逐渐加快步伐。政府即将出台的安全法规和消费者意识将进一步推动这一运动。因此,先进驾驶辅助系统(ADAS)正在为汽车和驾驶员配备先进的信息和技术,使他们能够更好地了解环境并半自动地处理潜在的情况。高质量的训练和测试数据对于ADAS系统的开发和验证至关重要,这为自动驾驶技术奠定了基础。除此之外,ADAS系统还需要非常安全和强大,能够在各种驾驶场景中运行,并且非常安全,不受任何外部网络攻击的影响。为了使ADAS系统更加安全,自动驾驶汽车将需要在真实道路上行驶超过10亿英里,即使考虑到最激进的测试假设,也需要几十年甚至几百年的时间才能行驶这些英里。自动驾驶汽车的每一次小更新都需要另外10亿英里的测试,才能获准在现实世界中使用。此外,技术越先进,需要驾驶的里程就越多。真实世界测试在ADAS和AV的开发和测试中起着至关重要的作用。然而,仅仅依赖于真实世界的测试将大大减缓这些技术的开发和测试。这就是模拟发挥作用的地方。以改善道路安全为首要目标,ADAS功能必将在汽车行业发挥重要作用。为了解决印度特定的道路基础设施条件,从而提高安全性,需要开发一个完整的工具链,用于开发、部署和验证ADAS功能。所提出的工作与实验结果和现实世界的相关性分享了这个工具链的每个方面的见解。
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引用次数: 0
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ARAI Journal of Mobility Technology
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