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

  • 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…

A Mathematical Approach to Determine Die Wear during Forging Process and Validation by Experimental Technique

Dr P K Ajeet Babu-Ajeet Babu P K
  • Technical Paper
  • 2019-28-2563
To be published on 2019-11-21 by SAE International in United States
The automotive industry is constantly trying to develop cost effective, high strength and lightweight components to meet the emission and safety norms while remaining competitive in the market. Forging process plays an important role to produce most of the structural components in a vehicle. Precision forging technology is used to produce components with little or no flash leading to elimination of machining process after forging. The load acting on the dies during net or near net forging is very high and leads to wear in the die. In order to have a good die it is important that die wear which is an inevitable phenomenon in a bulk metal forming processes is predicted mathematically. In this study a review on the vast number of studies done in the area of wear and various predictive models is carried out. The various models available for abrasive wear such as Archard, Felder-Montagut and IFUM model and for adhesive wear such as Holms model has been studied and implemented in commercial FE Code by developing FORTRAN subroutine and wear…

Orbital Forming of Automotive Wheel Bearings

Orbitform-Jake Sponsler
  • Technical Paper
  • 2019-01-2133
To be published on 2019-09-15 by SAE International in United States
Orbital forming is considered an optimal assembly process for many designs of automotive wheel bearing assemblies. More specifically, this process involves forming the spindle over the inner race of the wheel bearing to retain the inner ring and to maintain bearing preload. The unique forming properties and precise controls allow orbital forming to produce an ideal finished retention feature and form for these types of bearings. This paper discusses the specific benefits of orbital forming of automotive wheel bearings. Forming basics, the physics behind the benefits of orbital forming, as well as pre-form lip geometry and other part design considerations are presented. Advanced machine control methodologies and historical machine process improvements are also reviewed concluding with next steps in process control and in-machine quality assurance.

Superfinishing of HVOF Applied Tungsten Carbide Coatings

AMS B Finishes Processes and Fluids Committee
  • Aerospace Material Specification
  • AMS2452
  • Current
Published 2019-07-15 by SAE International in United States
This specification covers requirements for the superfinishing of High Velocity Oxygen/Fuel (HVOF) applied tungsten carbide thermal spray coatings.
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Machining Capabilities Enhance Space-Related Programs

  • Magazine Article
  • TBMG-34736
Published 2019-07-01 by Tech Briefs Media Group in United States

Insaco Quakertown, PA


Machining Titanium Aero-Frames

  • Magazine Article
  • TBMG-34543
Published 2019-06-01 by Tech Briefs Media Group in United States

The rise of titanium for aerospace applications has been well documented in recent years. Equally, the challenges associated with the efficient, productive and high-quality machining of this popular material, have also been a topic of debate and scrutiny. Of course, every machine shop wants optimized performance from its cutters when milling titanium, but this can prove less than straightforward without the right technology and know-how in place. Today, however, thanks to a breakthrough in this area, things are beginning to change.


Landing Gear Common Repair

A-5B Gears, Struts and Couplings Committee
  • Aerospace Standard
  • AIR5885A
  • Current
Published 2019-04-11 by SAE International in United States
This document outlines the most common repairs used on landing gear components. It is not the intention of this AIR to replace overhaul/component maintenance or technical order manuals, but it can serve as a guide into their preparation. Refer to the applicable component drawings and specifications for surface finish, thickness, and repair processing requirements. This document may also be used as a guide to develop an MRB (Material Review Board) plan. The repairs in this document apply to components made of metallic alloys. These repairs are intended for new manufactured components and overhauled components, including original equipment manufacturer (OEM)/depot and in-service repairs. The extent of repair allowed for new components as opposed to in-service components is left to the cognizant engineering authorities. Reference could be made to this document when justifying repairs on landing gears. For repairs outside the scope of this document, a detailed justification is necessary. Landing gear repair is often a combination of several repair types defined herein. It must be understood that all the repairs listed in this document are not…
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Dynamic Modeling of CNC Drive Systems: Comparison of Two Models

University of Detroit-Mostafa Mehrabi
Published 2019-04-02 by SAE International in United States
Accurate positioning and precision of CNC machines are directly affected by performance of their mechanical drive system and control unit (CNC feeddrive system). This is more important in contouring operations where axes motion is synchronized by interpolators and errors are accumulative. This research work is focused on study of dynamics of the feeddrive unit. In this regard, a detailed dynamic model is developed in state-space format that is used to study its response properties. A parametric study of the system is carried out by studying shifts in eigenvalue loci when a parameter is changed. The results are used in further simplifying this model to a reduced order system which is simpler in structure and more appropriate for control applications. A comparison is made between these models and the merits of each individual model are presented.
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A Comparison of the Mechanical Performance of AA6061-T6 Extrusions Subjected to Axial Crushing and Axial Cutting

University of Windsor-John A. Magliaro, William Altenhof
Published 2019-04-02 by SAE International in United States
Conventional axially loaded energy absorbers dissipate kinetic energy through progressive folding. The significant fluctuations in load and high risk of transition to global bending are drawbacks that engineers have attempted to mitigate through several methods. A novel energy dissipation mechanism, referred to as axial cutting, utilizes thin-walled extrusions and a strengthened cutting tool to absorb energy in an axial impact. Compared to progressive folding, this can be achieved with minimal fluctuations in load during the deformation process. Based upon estimates from finite element models, a series of test cases were postulated where, for 8 and 10-bladed cutting scenarios, greater total energy absorption could be achieved through axial cutting than with progressive folding of geometrically similar extrusions. The specimens were AA6061 extrusions having T6 temper conditions that possessed 63.5 mm outer diameters and 1.5 mm wall thicknesses. All tests were performed quasi-statically using a universal MTS testing machine at a crushing rate of 50 mm/min. The axially cut extrusions displayed an average of 22.8 % more energy absorption than their respective axially crushed test specimens with…
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Drawing Interpretation and Standard Machining Practices, Couplings, Fittings and Hose Ends, Fluid Systems

G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
  • Aerospace Standard
  • ARP4296B
  • Current
Published 2019-03-26 by SAE International in United States

This SAE Aerospace Recommended Practice (ARP) is intended to interpret and clarify engineering drawing requirements relating to the manufacture and inspection of fluid system couplings, tube fittings, and hose ends. Because it is impractical to define every minute detail of the part on the face of the drawing, this document describes interpretations of dimensioning of general machining features and otherwise undefined tolerances that fall under the heading of "good shop practice". This document serves as a supplement to engineering drawings when referenced on applicable documents.