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Design & analysis of 2 point aluminum upper control arm in modular multi link rear suspension system

ZF India Pvt Ltd.-Mayur Shamkant Kulkarni
  • Technical Paper
  • 2019-28-2564
To be published on 2019-11-21 by SAE International in United States
In current automobile market, due to the need of meeting future CO2 limits and emission standards, demand for hybrid systems is on the rise. In general, the requirements of modern automobile architecture demands modular chassis structure to develop vehicle variants using minimum platforms. The multi-link modular suspension system provides ideal solution to achieve these targets. To match ideal stiffness characteristics of system with minimum weight, aluminum links are proving a good alternative to conventional steel forged or stamped linkages. Design of current 2-point link (Upper Control Arm) is based on elasto-kinematic model developed using standard load cases from multi body dynamics. CAD system used is CATIA V5 to design upper control arm for rear suspension. This arm connects steering knuckle & rear sub frame. For Finite Element Analysis we used Hyperworks CAE tool to analyze design under all load cased & further optimization is done to resolve highly stressed zones. An optimized solution presented with a balance of ideal stiffness & strength. A CAD model developed with aluminum forged alloy (6082 - T6) is compared…
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High Durable PU Metallic Monocoat system for tractor sheet metal application.

Mahindra & Mahindra, Ltd.-Rahul Lalwani, Sudhir Sawant, Yogesh keskar, Nitin Pagar
Mahindra Research Valley-Vinay Kumar
  • Technical Paper
  • 2019-28-2541
To be published on 2019-11-21 by SAE International in United States
In sheet metal painting for various applications like Tractor, Automobile, most attractive coating is metallic paints and it is widely applied using 3 coats 2 bake or 3 coat 1 bake technology. Both options, results in high energy consumption, higher production throughput time & lower productivity in manufacturing process. During various brainstorming & sustainable initiatives, paint application process was identified for alternative thinking to reduce burden on environment & save energy. Various other industry benchmarking & field performance requirement studies helped us identify the critical to quality parameters. We worked jointly with supplier to develop mono-coat system without compromising the performance & aesthetical properties. This results in achieving better productivity, elimination of two paint layers, substantial reduction in volatile organic content, elimination of one baking cycle and energy saving. Metallic mono-coat formulated using strong polyurethane resins & latest technology pre-coated aluminum pigment for achieving metallic effect in finish. With new resin technology further, reduction of baking temperature is possible & reduce further energy consumption. The proposed technology is fully validated on component and ready. Proposed…
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Design of Light Weight Footstep Using Continuous Glass Fiber Reinforced Plastics

Mahindra & Mahindra, Ltd.-Praveen Kumar, Vivek KV Shenoy, Ashish Kumar Sahu, Srivatsa Sriperumbudur, Anton Kumanan, K V Balaji
Published 2019-10-11 by SAE International in United States
Utility or Off-road vehicles are characterized with their higher ground clearances. Higher ground clearance of vehicle requires the vehicle to have footsteps for easy entry and exit of passengers from the vehicle. A typical foot step construction consists of structural steel brackets with an Aluminum or plastic top panel. Conventional steel construction is heavier to meet weight bearing capacity and durability requirements. Our objective of this work is to explore lightweight materials which can meet these performance requirements with a lighter construction. We chose to study the continuous glass fiber reinforced plastic as an alternative to the metal construction.
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A Parametric Study on Electro Thermally Actuated Novel Compliant Microgripper

NIT-Kishor Bharadwaj, Thillaigovindan Ramesh
VIT-Renold Elsen
Published 2019-10-11 by SAE International in United States
At Micron-level actuation, thermal gripper provides greater forces when compared with electrostatic mode of actuation. To accomplish larger translations at minimal voltages, the Electro thermal actuation is applied. The mechanism of selective non-uniform Joule heating; which helps in thermal expansion of the design owing to restraints. The gripper proposed in this work is analyzed using FEA and is fabricated using Aluminum and stainless steel to achieve quicker response. The in-plane displacement, strain, stress, current density and temperature have been predicted for different magnitudes of current-voltage combination that the gripper sustains. It was found that, micro gripper performs well under 1v giving 60 μm displacement. Parametric sweep was carried out using commercially available FEA software package; COMSOL Multiphysics, to study and asses the outcome of various parameters on the performance of the gripper. It has been observed that the displacement increases with the increase in applied voltage.
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Experimental Investigation on Turning Characteristics of TiC/MoS2 Nanoparticles Reinforced Al7075 Using TiN Coated Cutting Tool

Sri Sairam Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan, Devendiran Sundararajan, Budireddy Uday Kumar, Dhulipalla Anvesh, Varupula Akhil
Published 2019-10-11 by SAE International in United States
In recent years, aluminum metal matrix composites (Al-MMC) are found as a potential material for numerous applications owing to its excellent tribological and mechanical properties. In this work, the machining characteristics of aluminum alloy (Al7075) reinforced with TiC/MoS2 having nanoparticle has been studied. The samples of aluminum metal matrix composites by varying TiC in 0, 2 and 4 and MoS2 in 0 and 2 of the percentage weight of aluminum alloy (Composite 1(Al7075), Composite 2 (Al7075/2TiC/2MoS2) and composite 3 (Al7075/4TiC/2MoS2), respectively) are fabricated by the stir-casing method. The turning characteristics of the developed metal matrix composites are studied at various parameters such as cutting velocity (30 m/min, 60 m/min and 90 m/min), cutting depth (0.5 mm, 1.0 mm and 1.5 mm) and composites (1, 2 and 3) using TiN coated cutting tool by dry turning at 0.05 mm/rev feed rate. The turning characteristics of the prepared samples are compared each other under L20 orthogonal array on CNC turning machine. The significant findings in the present study are: hardness of base aluminum alloy is found to…
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The new gas tank: Constellium readies its first OEM EV battery tray

Automotive Engineering: October 2019

Paul Seredynski
  • Magazine Article
  • 19AUTP10_04
Published 2019-10-01 by SAE International in United States

Global Tier-1 aluminum specialist Constellium's first OEM EV battery enclosure is a far cry, engineering-wise, from the century-old fuel tank.

The “gas tank” is about to get a lot more sophisticated. Electric vehicle (EV) battery trays are highly-engineered components that barely existed a few years ago but play a wide role in an EV's safety, rigidity and weight - and therefore efficiency. They also need to be watertight. The enclosures typically reside within an EV's wheelbase and often serve double duty as the vehicle's underbelly, housing the complement of batteries, control and monitoring electronics along with cooling and high-voltage circuits.

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Manufacturing Process for Aluminum Alloys

  • Magazine Article
  • TBMG-35274
Published 2019-10-01 by Tech Briefs Media Group in United States

An advanced manufacturing process was developed to produce nano-structured rods and tubes directly from high-performance aluminum alloy powder in a single step. Using a Solid Phase Processing approach, researchers eliminated several steps that are required during conventional extrusion processing of aluminum alloy powders and achieved a significant increase in product ductility (how far a material can stretch before it breaks).

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Aluminum Alloy, Hand Forgings 7.5Zn - 1.6Cu - 1.5Mg - 0.12Zr (7085-T7452) Solution Heat Treated, Compression Stress-Relieved, and Overaged

AMS D Nonferrous Alloys Committee
  • Aerospace Material Specification
  • AMS4414
  • Current
Published 2019-09-19 by SAE International in United States
This specification covers an aluminum alloy in the form of hand forgings 12 inches (305 mm) and under in nominal thickness and of forging stock.
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Study on Application Methods to Mitigate Galvanic Corrosion between Wheel Bearing and Aluminum Knuckle

Iljin Global-Sewoong Kim, Seonho Lee, Hyounsoo Park
Published 2019-09-15 by SAE International in United States
The substitution of aluminum for steel is an effective weight reduction solution where the application permits it; aluminum knuckles have been widely used for this reason. However, when an aluminum knuckle is assembled with the steel outer-ring of a wheel bearing without any means for galvanic corrosion prevention, the aluminum knuckle may severely corrode. Galvanic corrosion products can make it difficult to remove a wheel bearing from the aluminum knuckle during vehicle maintenance. Prevention of this problem is the focus of this paper. In this study, several concepts were examined to prevent or mitigate galvanic corrosion between a wheel bearing and its mating aluminum knuckle. One set of concepts involves using surface treated metal sleeves (using ferritic nitro-carburizing or a special coating). The sleeves were then inserted onto the outer-ring diameters of the wheel bearings prior to assembly into the steering knuckle. Another set of concepts that were investigated involves the application of thin coatings having high anti-corrosion properties. The coatings were applied directly to the bearing outer-ring knuckle piloting surfaces and bearing knuckle mounting…
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Acceleration Resistant HiK Heat Spreader

Aerospace & Defense Technology: September 2019

  • Magazine Article
  • 19AERP09_04
Published 2019-09-01 by SAE International in United States

As electronic technologies advance in defense and aerospace applications, heat fluxes are becoming larger and more centralized[1,2]. In order to meet the performance specifications of new technologies, thermal solutions must also advance. The push for more capable thermal technologies is evident with the U.S. Air Force Research Laboratory (AFRL) signing an agreement with private companies and contractors for the development of innovative vapor cooling technologies capable of handling high heat fluxes[2].

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