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Comparative Study of ANN and ANFIS Prediction Models For Turning Process in Different Cooling and Lubricating Conditions

SAE International Journal of Materials and Manufacturing

Faculty of Mechanical Engineering-Branislav Sredanovic, Djordje Cica
  • Journal Article
  • 2015-01-9082
Published 2015-05-01 by SAE International in United States
The most efficient way to reduce friction and heat generation at the cutting zone is to use advanced cooling and lubricating techniques. In this paper, an experimental study was performed to investigate the capabilities of conventional, minimal quantity lubrication (MQL) and high pressure cooling (HPC) in the turning operations. Process parameters (feed, cutting speed and depth of cut) are used as inputs to the developed artificial neural network (ANN) and the adaptive networks based fuzzy inference systems (ANFIS) model for prediction of cutting forces, tool life and surface roughness. Results obtained by the models have been compared for their prediction capability with the experimentally determined values and very good agreement with experimental results was observed.
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Implementing the Hybrid Lean-Agile Manufacturing System Strategically in Automotive Sector

SAE International Journal of Materials and Manufacturing

Salah A. Elmoselhy
  • Journal Article
  • 2015-01-9083
Published 2015-05-01 by SAE International in United States
In order to strike a balance between cost and availability, the present study presents the strategic implementation of the hybrid lean-agile manufacturing system. The proposed implementation is based on literature review and statistical analysis. The study presents short term and long term proposed plans for implementing this newly developed system in a sustainable way. It shows how the strategic facet of the hybrid lean-agile manufacturing system addresses the key manufacturing competitive dimensions. The paper presents as well a cost-benefit analysis in comparison with the lean manufacturing system and agile manufacturing system based on the net present value. The study shows that the expectedly most efficient among the manufacturing systems is the Hybrid Lean-Agile Manufacturing System with normalized comparative improvement of about 58% and 42%, respectively. The study concludes through a statistical sample that about one third of the variation in successfully dealing with the sources of competitive advantage in automotive sector can be explained by adopting the strategic facet of the hybrid lean-agile manufacturing system. The study is limited to the automotive manufacturing sector. The…
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Thermal and Structural Analysis of Functionally Graded NiCrAlY/YSZ/Al2O3 Coated Piston

SAE International Journal of Materials and Manufacturing

Srivathsan Puzhuthivakkam Rengarajan, Vignesh Natarajan, Harikrishnan Kanagasabesan
College Of Engineering Chennai-Terrin P Babu
  • Journal Article
  • 2015-01-9081
Published 2015-05-01 by SAE International in United States
Functionally Graded Thermal Barrier Coatings (FG-TBC) increases the performance of high temperature components in gasoline engines by decreasing the thermal conductivity and increasing the unburned charge oxidation in the flame quenching area with the increase in temperature near the entrance of the crevice volume between the piston and the liner during the compression and the early part of the expansion strokes.In this study, a 3-D finite element steady state thermal and structural analysis are carried out on both uncoated and functionally graded NiCrAlY/YSZ/Al2O3 coated gasoline engine piston using a commercial code, namely ANSYS. The effects of coating on the thermo mechanical behaviours of the piston are investigated. It has been shown that the maximum surface temperature of the ceramic coated piston is improved approximately by 7% for the Al-Si alloy. The application of TBC enhances the Von Mises stress withstanding capacity approximately by 15% than the uncoated piston due to maximum temperature difference and difference in thermal expansion coefficients within the ceramic layers.
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Application of the Fourier Amplitude Sensitivity Test (FAST) to Analyze Thermal Performance of Vehicle Underbody Components

SAE International Journal of Materials and Manufacturing

Univ of Windsor-Ashley Lehman, Vesselin Stoilov, Andrzej Sobiesiak
  • Journal Article
  • 2015-01-0438
Published 2015-04-14 by SAE International in United States
This paper describes the application of the Fourier Amplitude Sensitivity Test (FAST) method [1] to investigate the effect of uncertainty in design parameters on the thermal system performance of vehicle underbody components. The results from this study will pinpoint the design parameters which offer the greatest opportunity for improvement of thermal system performance and reliability. In turn, this method can save engineering time and resources.An analytical model was developed for a vehicle underbody system consisting of a muffler, heat shield, and spare tire tub. The output from this model was defined as the temperature of the spare tire tub. The majority of the input parameters in this model deviate from their nominal values due to environmental factors, wear and ageing, and/or variation in the manufacturing process. Using MATLAB software package, the model was simulated with input parameters which were simultaneously and sinusoidally varied at distinct frequencies over their respective uncertainty ranges.Finally, the Fourier transform was applied to the output of the model to convert the response into the frequency domain to allow the amplitude of…
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A Data Mining-Based Strategy for Direct Multidisciplinary Optimization

SAE International Journal of Materials and Manufacturing

Ford Motor Co-Hongyi Xu, Ching-Hung Chuang, Ren-Jye Yang
  • Journal Article
  • 2015-01-0479
Published 2015-04-14 by SAE International in United States
One of the major challenges in multiobjective, multidisciplinary design optimization (MDO) is the long computational time required in evaluating the new designs' performances. To shorten the cycle time of product design, a data mining-based strategy is developed to improve the efficiency of heuristic optimization algorithms. Based on the historical information of the optimization process, clustering and classification techniques are employed to identify and eliminate the low quality and repetitive designs before operating the time-consuming design evaluations. The proposed method improves design performances within the same computation budget. Two case studies, one mathematical benchmark problem and one vehicle side impact design problem, are conducted as demonstration.
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Effect of Water Absorption on Tensile and Fatigue Behaviors of Two Short Glass Fiber Reinforced Thermoplastics

SAE International Journal of Materials and Manufacturing

GM-Abolhassan Khosrovaneh
University of Toledo-Seyyedvahid Mortazavian, Ali Fatemi
  • Journal Article
  • 2015-01-0546
Published 2015-04-14 by SAE International in United States
An experimental study was conducted to evaluate the effect of water absorption on tensile and fatigue behaviors of an impact-modified short glass fiber polyamide-6 and a short glass fiber polybutylene terephthalate. Specimens were prepared in the longitudinal and transverse directions with respect to the injection mold flow direction and immersed in water. Kinetics of water absorption was studied and found to follow the Fick's law. Tensile tests were performed at room temperature with specimens in the longitudinal and transverse directions and with various degrees of water absorption. Mathematical relations were developed to represent tensile properties as a function of water content. Load-controlled tension-tension fatigue tests were conducted in both longitudinal and transverse directions and correlations between tensile and fatigue strengths were obtained. Specimen fracture surfaces were also microscopically studied and mechanisms of tensile and fatigue failures were identified.
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A Study into the Mechanical Behavior of Adhesively-Bonded Jute Fiber-Reinforced Composite

SAE International Journal of Materials and Manufacturing

Indian Institute of Science-Anshul Mittal, Anindya Deb
Wayne State Univ-Clifford Chou
  • Journal Article
  • 2015-01-0729
Published 2015-04-14 by SAE International in United States
Rapid progress in the interdisciplinary field of automotive engineering and the pressing need for an environmental friendly alternative to metal and synthetic fiber-reinforced composites for vehicle structure have triggered recent research in the field of natural fiber-based composites. Their potential advantages are attributed to their light weight, low cost and biodegradability. However, their usage in present day automotive systems is restricted due a lower magnitude range of mechanical properties and limited study in this area. In contrast to mechanical joints, the adhesively bonded joints aid in reducing stress concentration, joining of dissimilar materials, corrosion prevention, weight reduction and a smoother finish. Thus, in the present study, failure load, and mean shear stress of single lap shear and double lap shear joints as a function of joint overlap length, are evaluated using a two part epoxy adhesive made by Huntsman. Initially, the specimens are tested according to the reference test methods specified in ASTM D5868 and ASTM D3528 standards, and the overlap length is then varied to determine the failure load and the mean shear strength…
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Transient Dip Paint Simulation of Entire Car Bodies within One Day

SAE International Journal of Materials and Manufacturing

Caelynx-Hans Steiner
Engineering Center Steyr GmbH & Co. KG-Martin Schifko, Daniela Fellhofer, Xinghua Song, Kevin Verma
  • Journal Article
  • 2015-01-0731
Published 2015-04-14 by SAE International in United States
The development of entire car bodies benefits from simulations, especially if they are performed at an early stage of development. Simulations lower the costs for required car body modifications. This paper focuses on dip painting simulation and describes the simulation process by detecting badly painted areas and liquid carry overs. A new hydrodynamic method has been benchmarked to CFD and real-life results. Results will be shown together with case examples. The solver is similar to, and as accurate as, standard CFD solvers; it is faster in its computation speed by a factor of at least 1000. The electrophoretic deposition (ELPO) of an entire car body can be simulated overnight with ALSIM. How is this possible? This paper points out the reason for all of this.
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Very High Cycle Fatigue of Cast Aluminum Alloys under Variable Humidity Levels

SAE International Journal of Materials and Manufacturing

Ford Motor Co-Xuming Su, Carlos Engler-Pinto
Nanjing Univ. of Aero. & Astro-Wenkai Li, Haitao Cui, Weidong Wen
  • Journal Article
  • 2015-01-0556
Published 2015-04-14 by SAE International in United States
Ultrasonic fatigue tests (testing frequency around 20 kHz) have been conducted on four different cast aluminum alloys each with a distinct composition, heat treatment, and microstructure. Tests were performed in dry air, laboratory air and submerged in water. For some alloys, the ultrasonic fatigue lives were dramatically affected by the environment humidity. The effects of different factors like material composition, yield strength, secondary dendrite arm spacing and porosity were investigated; it was concluded that the material strength may be the key factor influencing the environmental humidity effect in ultrasonic fatigue testing. Further investigation on the effect of chemical composition, especially copper content, is needed.
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Physical Properties of Leather-Feeling Coatings for Automotive Interior

SAE International Journal of Materials and Manufacturing

Hyundai Mobis-Woo Jeong Oh
Samwha Paint-Se yoon Pang
  • Journal Article
  • 2015-01-0735
Published 2015-04-14 by SAE International in United States
The performance of the car, as well as the emotional quality is an important factor as the product and the importance of automotive interior materials is getting increasing. With expandable microspheres at a constant temperature, leather -feeling surface can be implemented and it could express not 2-dimensional feeling but 3-dimensional feeling (bushed or suede-like feeling). For the automotive parts, leather-feeling coatings similar to feeling of leather could was developed and could correspond to emotional quality of consumer.
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