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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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Development of low cost closed crankcase ventilation with oil mist separation system on light duty diesel engine.

Tata Technologies Ltd-Vishal Kailas Walhekar, Sujit Gavade, Gaurav Soni, Aashish Bhargava
  • Technical Paper
  • 2019-28-2578
To be published on 2019-11-21 by SAE International in United States
Currently automotive industry is facing bi-fold challenge of reduction in Greenhouse gases emissions as well as low operating cost. On one hand Emission regulations are getting more and more stringent on other hand there is major focus no customer value proposition. Engine blow by gases are one of the source of Greenhouse gases emission from engine. Blow by gases not only consist of unburn hydrocarbons but also carry large amount of oil. If oil is not separated from these gases, it will led to major oil consumption and hence increase total operating cost of Vehicle. In this paper, effort has been taken to develop a low cost closed crank case ventilation with oil mist separation system on diesel engine. For cost effective solution, two different design and configuration of oil mist separation system has been developed Further, engine with two different above said configuration has been tested for blow by gasses and oil consumption measurement on Engine test bed and vehicle to understand the behavior in real environment. Further results has been compare for both…
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Turbocharger Thermal Transfer Model Initialization: Quasi-Adiabatic Map Calculation

Ecole Centrale De Nantes-Guillaume Goumy, Pierre Marty, Pascal Chesse, Nicolas Perrot, Rémi Dubouil, Georges Salameh
  • Technical Paper
  • 2019-24-0232
To be published on 2019-10-07 by SAE International in United States
To comply with the evermore stringent polluting emission regulation, such as Euro 6c and its new homologation WTLP cycle, the use of turbocharger has been widely adopted amongst modern IC Engines, either in Diesel or Gasoline ones. It has also leaded to a large variety of implementation as single / two stage(s) or even parallel functioning. In the meantime, car manufacturer intend to decrease development cost and time by using more and more simulation over experimental measurements. However usual turbocharger model have not followed this trend of modernity and are still map based from turbocharger manufacturer data. While the heating part of the standard cycle becomes a major issue and simulation accuracy is the keystone of the new development strategies , turbocharger models have not followed this trend of modernity. They are still map based from turbocharger manufacturer data, measured in hot conditions, as this is usually the only available entry data. To improve their accuracy, new turbocharger model needs to take into account the thermal transfer. Different models have been offered to solve this…
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Environmental and Health Impact of Electric and Hydrogen Light Vehicles: The Case of an Italian Small City

University of Roma Tor Vergata-Luca Andreassi, Giacomo Falcucci
University of Tuscia-Andrea Luigi Facci, Stefano Ubertini
  • Technical Paper
  • 2019-24-0250
To be published on 2019-10-07 by SAE International in United States
As the emission regulations get more and more stringent, the electric and fuel cell electric vehicles have attracted growing attention by automakers, governments, and consumers. In fact, electric and fuel cell vehicles coupled with low-carbon electricity sources offer the potential for reducing greenhouse gas emissions and exposure to tailpipe emissions from personal transportation. In particular, Pedal Assisted Bicycles (PAB) popularity is rising in urban areas due to their low energy consumption and environmental impact. In fact, they are zero emission vehicles with low noise emissions, as well. These positive characteristics could be even improved by coupling a PAB with a fuel cell based power generation system, thus increasing the vehicle autonomy without influencing their emissions and consumption performances. In this paper, four types of vehicles are compared from an environmental and accessibility point of view: conventional car, bus, electric PAB, and hydrogen fuel cell PAB. For such vehicles, the respective utilization stages are considered, i.e. without considering the manufacturing process. The analysis has been carried out comparing different vehicles performance along different routes of an…
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Lightweight Wheel Bearing with Dissimilar Materials for Vehicle

Hyundai Motor Group-Jaehee Lee
Iljin Global-Inha Lee, Seonho Lee, Heechan Shim, Jungyang Park
Published 2019-09-15 by SAE International in United States
Limited fossil fuel resources, air pollution, and global warming all drive strengthening of fuel economy and vehicle emission standards globally. Much R&D continues to be dedicated to improve fuel efficiency of automobiles and to reduce exhaust gasses. These include improvement of engine/driveline performance for higher efficiency, development of alternative energy, and minimization of air resistance through aerodynamic design optimization. OEM weight reduction-focused research has extended into chassis components (steering knuckle, brakes, control arms, etc.) in sequence from body-in-white(BIW). Wheel bearings, one of the core components of a driveline and part of a vehicle’s unsprung mass, are also being required to reduce weight. Conventionally, wheel bearings have achieved “lightweighting” primarily through design optimization methods. They have been highly optimized today using steel based materials. Opportunities for further mass optimization are increasingly limited and so the focus of this study is integration of lighter-materials into steel bearing components for weight savings. Both aluminum and CFRP were considered in the study for partial integration into the steel hub flange which interfaces directly with the wheel. The application of…
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Development of a Low Friction High Performance Wheel Bearing Seal

ILJIN USA Corporation-Seungpyo Lee
Iljin Bearing GmbH-Reinhold Mahr
Published 2019-09-15 by SAE International in United States
The ever tightening of fuel economy and greenhouse gas emissions standards globally continues to challenge bearing companies toward lower torque, lower mass products. This paper focuses on improving fuel efficiency by considering the torque of automotive wheel bearing seals. This study establishes the level of drag torque reduction achieved through the structural design of the bearing seals. Wheel bearing seals are a critical component that must pass stringent torque, water exclusion, and other critical OEM and supplier performance specifications. They are designed as non-serviceable and must maintain full performance through the life of the vehicle.As a result of the application of specialized structural design, the drag torque, per the study, is reduced by more than 50% compared to existing bearing specifications. Electric vehicle companies are also seeking low friction wheel bearing solutions to further reduce CO2 (indirect or wheel-to-wheel) emissions. This research findings can assist the OEM’s in meeting the rigid emissions and fuel economy standards through drag reduction in the wheel bearings.
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Analysis of Emissions in the European Driving Cycle of Used Light-Duty Vehicles Imported to Europe from North America

State Road Transport Research Institute, Ukraine-Oleksiy Klymenko, Viktor Ustymenko, Kostiantyn Kolobov, Sergiy Rychok, Mykola Hora, Nila Naumenko
  • Journal Article
  • 13-01-01-0001
Published 2019-09-13 by SAE International in United States
This study analyzes the distribution of exhaust mass pollutants emission obtained in 1,157 tests in the European driving cycle of used light-duty vehicles (LDVs). At the time of production, the tested vehicles complied with the Federal environmental requirements of the United States (USA) and were imported to Europe from North America. They included 1,109 passenger cars (PCs) and 48 light-duty trucks (LDTs), equipped with gasoline engines. In general, for measured emissions of carbon monoxide (CO), nonmethane hydrocarbons (NMHC), nitrogen oxides (NOx), and particulate matter (PM): 25% of test results for PCs do not exceed the T2B5 limits of the US Federal Standard; 43% of test results for PCs do not exceed the thresholds, designated for on-board diagnostic system (OBD) proper functioning; 45% of test results for PCs do not exceed the European Union (EU)’s former standard “Euro-5” norms. The automotive manufacturers of the PCs group represented various legislative and engineering approaches in Europe (Volkswagen, VW), Japan (Mazda), and North America (Ford) that are reflected in the emissions analysis results. In particular, the stricter CO limits…
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Injection Pattern Investigation for Gasoline Partially Premixed Combustion Analysis

Magneti Marelli SpA - Powertrain-Federico Stola, Matteo De Cesare
University of Bologna-Vittorio Ravaglioli, Giacomo Silvagni, Fabrizio Ponti
Published 2019-09-09 by SAE International in United States
Nowadays, compression-ignited engines are considered the most efficient and reliable technology for automotive applications. However, mainly due to the current emission regulations, that require increasingly stringent reductions of NOx and particulate matter, the use of diesel-like fuels is becoming a critical issue. For this reason, a large amount of research and experimentation is being carried out to investigate innovative combustion techniques suitable to simultaneously mitigate the production of NOx and soot, while improving engine efficiency.In this scenario, the combined use of compression-ignited engines and gasoline-like fuels proved to be very promising, especially in case the fuel is directly-injected in the combustion chamber at high pressure. The presented study analyzes the combustion process produced by the direct injection of small amounts of gasoline in a compression-ignited light-duty engine. The engine under investigation has been modified to guarantee a stable engine operation over its whole operating range, that is achieved controlling boost pressure and temperature, together with the design of the injection pattern.Experimental tests have been performed to highlight the impact of several control variables on the…
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A Novel 1D Co-Simulation Framework for the Prediction of Tailpipe Emissions under Different IC Engine Operating Conditions

Aristotle University of Thessaloniki-Grigorios Koltsakis, Zissis Samaras
EMPA-Panayotis Dimopoulos Eggenschwiler, Viola Papetti, Jakub Rojewski, Patrik Soltic
Published 2019-09-09 by SAE International in United States
The accurate prediction of pollutant emissions generated by IC engines is a key aspect to guarantee the respect of the emission regulation legislation. This paper describes the approach followed by the authors to achieve a strict numerical coupling of two different 1D modeling tools in a co-simulation environment, aiming at a reliable calculation of engine-out and tailpipe emissions. The main idea is to allow an accurate 1D simulation of the unsteady flows and wave motion inside the intake and exhaust systems, without resorting to an over-simplified geometrical discretization, and to rely on advanced thermodynamic combustion models and kinetic sub-models for the calculation of cylinder-out emissions. A specific fluid dynamic approach is then used to track the chemical composition along the exhaust duct-system, in order to evaluate the conversion efficiency of after-treatment devices, such as TWC, GPF, DPF, DOC, SCR and so on. This co-simulation environment is validated against a real engine configuration which was instrumented and tested at EMPA labs. A 4-cylinder SI, turbocharged, CNG engine is investigated at different loads and revolution speeds, to…
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Experimental Test on the Feasibility of Passive Regeneration in a Catalytic DPF at the Exhaust of a Light-Duty Diesel Engine

Universita Degli Studi Di Salerno-Bruno Rossomando, Ivan Arsie, Eugenio Meloni, Vincenzo Palma, Cesare Pianese
  • Technical Paper
  • 2019-24-0045
Published 2019-09-09 by SAE International in United States
Diesel engines are attractive thanks to good performance in terms of fuel consumption, drivability, power output and efficiency. Nevertheless in the last years, increasing restrictions have been imposed to particulate emissions, concerning both mass (PM) and number (PN). Different technologies have been proposed to meet emissions standards and the wall-flow Diesel Particulate Filter (DPF) is currently the most common after-treatment system used to trap PM from the exhaust gases. This technology exhibits good features such that it can be regenerated to remove any accumulation of PM. However, this process involves oxidation of the filtered PM at a high temperature through after and post fuel injection strategies, which results in an increase of fuel consumption and may lead to physical damages of the filter in the long term.This work deals with the experimental testing of a catalytic silicon carbide (SiC) wall flow DPF, aiming at decreasing the soot oxidation temperature. The catalyst (CuFe2O4) was deposited on the filter by means of an optimized procedure based on a preliminary controlled chemical erosion of the SiC porous structure.…
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