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Tool wear analysis on drilling process of Inconel 718 superalloy

Federal University of Sao Carlos-Pedro Cabegi Barros, Gustavo Franco Barbosa, Carlos Eiji Hirata Ventura
OSG Sulamericana-Gustavo Roberto Santos
  • Technical Paper
  • 2020-01-0034
To be published on 2020-03-10 by SAE International in United States
The inconel 718 is an alloy based on nickel of high thermal and mechanical resistance, which allows its wide application in the aerospace industry, being generally implemented in aircraft tail cone and engine components. On the other hand, these features become a recurring problem when the machining of this material is performed. For example, in the drilling process of this superalloy, the cutting tools used exhibit excessive wear due to the high temperature and pressure at the cutting edge. However, there are numerous parameters that can influence the cutting tool life, and when analyzed and well defined, determine the types of modifications needed to enable less wear, and consequently an increase of its useful life in service. Given this context and knowing that the study of tool life in the inconel 718 drilling process is extremely relevant in the aerospace sector, this paper presents a wear study in order to evaluate the behavior of different types of cutting tools used to drill the Inconel 718. It was accomplished by the combination of different cutting parameters…
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Effect of Thermal Barrier Coating on Performance and Emissions of a DI Diesel Engine

CSIR- Institute of Minerals and Materials Technology, Bhuban-Debidutta Debasish
Department of Mechanical Engineering, National Institute of-Yogeshwar Paik, Chinmaya Ranjan Sahu, Krishna Kumar Pandey, Saroj Kumar Barik, S. Murugan
  • Technical Paper
  • 2019-32-0526
To be published on 2020-01-24 by Society of Automotive Engineers of Japan in Japan
Recycling is an attractive solution to problems associated with the disposal of industrial and municipal wastes that are significantly available worldwide. Plastic in different forms is used in many applications day-to-day life. Some plastics can be converted into fuel or energy by thermal and catalytic degradation of plastic waste through pyrolysis processes. The oil obtained from pyrolysis of waste plastic can be used as an alternative fuel for CI engines. Most of the cases, it is reported by many researchers that the engine performance of a CI engine would be inferior when it is run on plastic pyrolysis oil (PPO) or its diesel blends than the diesel-fueled diesel engine operation. Reducing heat loss from engine components may improve the thermal efficiency and reduce fuel consumption of a CI engine. The heat loss can be reduced in CI engines by introducing thermal barrier coating (TBC). In this investigation, the effect of TBC on the performance and emissions of a CI engine run on PPO and its diesel blends was studied. For the investigation, a single cylinder,…
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Engine component development based on the application of non-parametric topology optimization

Robert Bosch Ltda.-RafaelAndré Morais de Souza AlmeidaFerreira, Marcos Gomes Bissolatti
  • Technical Paper
  • 2019-36-0097
Published 2020-01-13 by SAE International in United States
Topology optimization plays an important role to reach the goal of creating parts within the desired compromise of cost, time and quality. Its use reduces recursions and gives a better understanding of the product in order to design reliable and lightweight components that comply with validation criteria. This present paper explores a non-parametric topology optimization case study applied to the development of a plastic fuel rail, focusing on evaluating its dynamic response based on commercial optimization software. Results have shown that natural frequencies target could be achieved with less recursions in comparison to usual development methods without topology optimization.
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The Study of Friction Modifiers to Improve Fuel Economy for WLTP with Low and Ultra-Low Viscosity Engine Oil

ADEKA Corporation-Kenji Yamamoto, Tsuyoshi Hiramatsu, Ryo Hanamura, Yukiya Moriizumi
ADEKA Europe GmbH-Sascha Heiden
  • Technical Paper
  • 2019-01-2205
Published 2019-12-19 by SAE International in United States
Applying friction modifier (FM) in low viscosity engine oil is one well known cost effective approach for improving a fuel economy of vehicles. At first, the characteristics and mechanisms of FMs on tribological phenomena were studied with surface analysis technics. The performance of FMs was also evaluated with engine component test and motored engine test to understand the friction property of FMs in engine application. Then the effect of driving cycle, lubricant viscosity and FMs in fuel economy performance under chassis dynamo were studied.Among tested FMs, molybdenum dialkyl dithiocarbamate (MoDTC) was the most effective at boundary lubrication, which is considered significantly important friction area for WLTP, latest procedure for fuel economy test, with low and ultra-low viscosity engine oil.
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Lubricant Impact on Friction by Engine Component: A Motored Friction Tear Down Assessment of a Production 3.6L Engine

Ricardo Inc.-Stephen Cakebread
Ricardo UK Ltd-Phil Carden, Andrew de Vries
  • Technical Paper
  • 2019-01-2239
Published 2019-12-19 by SAE International in United States
Worldwide, Fuel Economy (FE) legislation increasingly influences vehicle and engine design, and drives friction reduction. The link between lubricant formulation and mechanical friction is complex and depends on engine component design and test cycle. This Motored Friction Tear Down (MFTD) study characterizes the friction within a 3.6L V6 engine under operating conditions and lubricant choices relevant to the legislated FE cycles. The high-fidelity MFTD results presented indicate that the engine is a low-friction engine tolerant of low viscosity oils. Experiments spanned four groups of engine hardware (reciprocating, crankshaft, valvetrain, oil pump), five lubricants (four candidates referenced against an SAE 0W-20) and five temperature regimes. The candidate lubricants explored the impact of base oil viscosity, viscosity modifier (VM) and friction modifier (FM) content. The results indicate that (i) a prototype SAE 0W-8 fluid generated the largest overall reduction in friction, (ii) the valvetrain group responded well to FM content, and (iii) an SAE 0W-20 with alternative VM performed remarkably well at low temperatures (-7°C to 30°C). In order to understand the significance of that engine friction…
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Multicriteria Optimization, Sensitivity Analysis, and Prediction of Bond Characteristics of Vacuum Diffusion Bonded Aero Engine Ti6Al4V Alloy Joints

SAE International Journal of Aerospace

Annamalai University, India-T. Pragatheswaran, S. Rajakumar, V. Balasubramanian, S. Kavitha
Materials Group, Gas Turbine Research Establishment (GTRE), India-Vijay Petley, Shweta Verma
  • Journal Article
  • 01-12-02-0008
Published 2019-12-13 by SAE International in United States
Joining titanium (Ti) alloys with conventional processes is difficult due to their complex structural properties and ability of phase transformation. Concerning all the difficulties, diffusion bonding is considered as an appropriate process for joining Ti alloys. Ti6Al4V, which is an α+β alloy widely used for aero engine component manufacturing, is diffusion bonded in this investigation. The diffusion bonding process parameters such as bonding temperature, bonding pressure, and holding time were optimized to achieve desired bonding characteristics such as shear strength, bonding strength, bonding ratio, and thickness ratio using response surface methodology (RSM). Empirical relationships were developed for the prediction of the bond characteristics, and sensitivity analysis was performed to determine the increment and decrement tendency of the shear strength with respect to the bonding parameters. Various criteria were applied to achieve the desired bond characteristics and their effects; optimum values and limits were evaluated through graphical and numerical optimization. The predicted and experimented results are validated and found that they are in good agreement with each other. The microstructural examination and X-ray diffraction (XRD) analysis…
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Effect of Gasoline-Ethanol Blends on GDI Engine to Reduce Cost of Vehicle Ownership

Mahindra & Mahindra, Ltd.-Kartick Ramakrishnan, Padmavathi Ramadandi, Karthikeyan N Krishnan
  • Technical Paper
  • 2019-28-2379
Published 2019-11-21 by SAE International in United States
A major challenge for combustion engine development is to optimize the engine for improved fuel economy, reduce greenhouse gases. Stringent CAFÉ and emission norms require the customer to pay higher capital on vehicles. To offset the cost of ownership- cheaper and alternative energy sources are being explored. Ethanol blend with regular Gasoline, and CNG are such alternative fuels. Reducing the consumption of Gasoline also helps India’s dependence on import of crude oil.The study was carried on turbo-charged gasoline direct injection engine. The effect of ethanol on engine and vehicle performance is estimated and simulated numerically. The work is split into three stages: first the base 1D engine performance model was calibrated to match the experimental data. In parallel, vehicle level Simulink model was built and calibrated to match the NEDC cycle performance. Second, the thermal efficiency of the ethanol blend is calculated as a linear function of theoretical Otto cycle efficiency. The engine performance for varying compression ratio & ethanol gasoline blend is studied for vehicle level using a MATLAB code. Third, 1D code was…
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Eddy Current Inspection of Circular Holes in Nonferrous Metallic Aircraft Engine Hardware

AMS K Non Destructive Methods and Processes Committee
  • Aerospace Standard
  • AS4787A
  • Current
Published 2019-10-14 by SAE International in United States
This SAE Aerospace Standard (AS) establishes minimum requirements for eddy current inspection of circular holes in nonferrous, metallic, low conductivity (less than 5% IACS) aircraft engine hardware with fasteners removed. The inspection is intended to be performed at maintenance and overhaul facilities on engine run hardware.
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Effect of Injector Cone Angle and NTP on Performance and Emissions of BS6 Engine

Mahindra Research Valley-Anbarasu Muthusamy, Vagesh Shangar Ramani, Pranav Kumar Sinha
Published 2019-10-11 by SAE International in United States
The combustion phenomenon of diesel engines has got a very major impact on the performance and exhaust emission levels. Several important factors like engine components design, combustion chamber design, Exhaust gas recirculation, exhaust after treatments systems, engine operating parameters etc. decide the quality of combustion. The role of fuel injector is crucial on achieving the desired engine performance and emissions. Efficient combustion depends on the quantity of fuel injected, penetration, atomization and optimum timing of injection. The nozzle through flow, cone angle, no of sprays and nozzle tip penetration are the factors which lead to the selection of perfect injector for a given engine. This paper focusses on the selection of the best fit injector suiting the BS6 application on evaluating the performance and emission characteristics. Injectors used were with varying cone angles and NTP. The nozzle tip protrusion of the injectors were varied by changing the sealing washer thickness. With all the above injector configurations, the performance and emission were thoroughly analysed at every level. Final confirmation of the configuration was selected based on…
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Automotive V-Ribbed Belt Drives and Test Methods

Belt Drive (Automotive) Systems Committee
  • Ground Vehicle Standard
  • J1596_201909
  • Current
Published 2019-09-24 by SAE International in United States

The following information covers engine accessory drive layout details and testing methods and includes test configurations, pulley diameters, power loads, and guidance for interpreting test data. This information has been prepared from existing literature, including standards and data supplied by both producers and users of V-ribbed belts.