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Thermal Challenges in Automotive Exhaust System through Heat Shield Insulation

Sharda Motor industries limited ( R&D )-Rajadurai S
  • Technical Paper
  • 2019-28-2539
To be published on 2019-11-21 by SAE International in United States
While advanced automotive system assemblies contribute greater value to automotive safety, reliability, emission/noise performance and comfort, they are also generating higher temperatures that can reduce the functionality and reliability of thesystem over time. Thermal management and insulation are extremely important and highly demanding in BSVI, RDE and Non-IC engine operating vehicles. Passenger vehicle and Commercial vehicle exhaust systems are facing multiple challenges such as packaging constraints, weight reduction andthermalmanagement requirements.Frugal engineering is mandatory to develop heat shield in the exhaust system with minimum heat loss. The focus of the paper is to design, develop and validate heat shield products with different variables such as design gap, insulation material, sheet metal thickness and manufacturing processes. 1D and 3D computational simulations are performed with different gaps from 3 mm to 14 mm are considered. Heat protection of about 75% is achieved ( from 614°C to 140°C) using different insulation materials. Sheet metal thicknesses from 0.15 mm to 1 mm with different manufacturing processes are used in the wrap around, closed and open type protections. Computational simulation and…

High Durable PU Metallic Monocoat system for tractor sheet metal application.

Mahindra & Mahindra Kandivali-SUDHIR SAWANT
Mahindra & Mahindra Ltd-Yogesh keskar, Nitin pagar
  • 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…


Automotive Manufacturer-Jayanthan Balasubramanian
Mahindra Engineering-Rahul Lalwani
  • Technical Paper
  • 2019-28-2561
To be published on 2019-11-21 by SAE International in United States
TITLE: MITIGATION FOR EDGE CORROSION PROTECTION FOR AUTOMOTIVE BODIES. Keyword: Edge corrosion, Edge protection, Rust on edges, Corrosion mitigation. Objective: A major challenge to automotive industry is to protect the vehicle from corrosion in varying environment with respect to different service conditions. One of the main types of corrosion that affects aesthetic look is edge corrosion on sheet metal. Mostly edge is acting as starting point of corrosion due to unprotected metal exposed to environment. A special attention to be given to exposed edges to protect from rust formation. Methodology: To mitigate corrosion in visible area, various solution proposed in manufacturing process, material usage, sealer application, BIW design. Samples were prepared as per design of experiments with respect to manufacturing process condition and subjected for testing. Results: Proposed solutions were validated in manufacturing process line and reports are discussed. Improvements observed in controlled lab testing were furnished with observations and recommendations. Limitation of this study: On high volume passenger and commercial segment, corrosion mitigations are linked with high cost impact where high-end corrosion protection like…

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…

Mechanical and corrosion behaviour of 7075 aluminium matrix composite reinforced with TiC and Al2O3

Vellore Institute of Technology-Subham Jaiswal, Govindasamy Rajamurugan, Prabu Krishnasamy, Yashwardhan Shaswat, Mishra Kaushik
  • Technical Paper
  • 2019-28-0094
To be published on 2019-10-11 by SAE International in United States
Various research regarding new methods of fabrication and modifications of Aluminium alloy to improve the existing properties are going on. The wide application of aluminium in aerospace and automobile Industry, demands improved mechanical properties with little to zero increment in weight. This work is based on the fabrication of hybrid metal matrix composites of 7075 aluminium alloy with the addition of TiC (Titanium Carbide) and Al2O3(Aluminium Oxide) reinforcements is fabricated using stir casting technique. Weight percentage of 5%, Al2O3 8% and Tic 12%, Tic 15% and Al2O3 10%. Samples are prepared for each mass distribution . Varying weight fraction samples are prepared to have a proper comparative study of the mechanical properties. In the fabrication we gradually increased the weight of TiC and Al2O3 as we progressed with the experiment.. The objective is to have a clear idea of mechanical properties variation with variation in reinforcement. Hardness tests is done using optical Brinell Hardness Testing machine . A proper characterisation of the samples was attained by using advanced electron microscopes. Tensile properties of the samples…

Investigation of Dry sliding Wear behavior of AA8011 reinforced with Zirconium Oxide and Aluminium Oxide Hybrid Composites processed through Multi direction forging

Sri Krishna College of Engg. and Tech.-Sathishkumar Kuppuraj, Soundararajan Ranganathan, Sathishkumar Aruchamy, Shanthosh Gopal
  • Technical Paper
  • 2019-28-0057
To be published on 2019-10-11 by SAE International in United States
The present work focused on fabricating hybrid composites of AA8011 with reinforcement particles of Zr2O3 and Al2O3 was taken equal (5wt%) weight percentage respectively. The hybrid composites were casted in square shape (50x50x50 mm size) under the optimal stir casted process parametric condition, further it was taken for forging process. The prepared three samples were induced for uni-direction (x), bi- direction (x and y) and multi direction (x,y and z) forging route and the response of micro hardness of 68,81 and 96 VHN were obtained due to microstructural phase changes with uniform distribution of particles in the matrix. Further the forged hybrid composites were investigated for tribological tests under dry sliding condition in a Pin-on-Disc tribometer apparatus by varying the load of 5,10,15,20 N and by adjusting the sliding speed as 200, 450 and 800 rpm respectively. The outcomes uncovered all the samples that the wear rate increments with increase in load and coefficient of friction shows decrement at most extreme load conditions. Wear rate increases with increase in sliding speed and coefficient of friction…

Critical wear assessment of AA8011/Hybrid metal matrix composites with surface amendment using Friction Stir process

Sri Krishna College of Engg. and Tech.-Soundararajan Ranganathan, Shri Vignesh Ramachandran, Ramprakash Palanivelu, Saravanakumar Ramasamy
  • Technical Paper
  • 2019-28-0096
To be published on 2019-10-11 by SAE International in United States
Friction Stir Process (FSP) was used for surface modification of steel, titanium, aluminum and magnesium based alloy has been considerably reviewed during the last decade. FSP can improve surface properties such as abrasion resistance, hardness, strength, ductility, corrosion resistance, fatigue life and formability without affecting the bulk properties of the material. The aluminum alloy having low ductility and softness characteristics are restricted because of their poor tribological properties. Preliminary studies reveal that, an ideal circumstance is to improve the aluminum alloy material life cycles by the way of strengthening the surface layer which can be modified through reinforcing nano particles through FSP. By the way, this experiment was carried out to obtain three set of samples like virgin AA8011, AA8011 with shape memory alloy and AA8011 along with shape memory alloy and silicon nitride during FSP under optimal process parametric condition. The improved distributions of nanoparticles were obtained after each FSP pass and progress in mechanical properties was observed. On the other hand to assess the tribological performance of prepared hard surface, three samples were…

Stress and Model Analysis of Upper and Lower Bolster Components of Molten Steel Transfer Vehicle

Vellore Institute of Technology-Darla Siva Prasad, Chooriyaparambil Damodaran Naiju, Posam Naveen Kumar
  • Technical Paper
  • 2019-28-0119
To be published on 2019-10-11 by SAE International in United States
The transportation of hot metal from blast furnaces to melting shops is carried out by molten steel transfer vehicle such as Torpedo ladle car in the steel plants. In need to design Torpedo ladle car within size limitation, capacity requirement and withstanding the impact, static, thermal shock and abrasion conditions, structural analysis is essential for validation. In this paper, stress and model analysis for upper and lower bolsters of Torpedo Ladle Car is carried out. The components are modelled in CAD and analysed using finite element method using software with the required boundary conditions. The results of structural analysis of bolster components are presented and discussed.

Tensile and Fatigue behavior of shallow cryogenically treated En19 alloy steel

BSACIST-Loganathan Sekar, Tamil Arasan
SRM Institute of Science and Technology-Rajendran Raj
  • Technical Paper
  • 2019-28-0100
To be published on 2019-10-11 by SAE International in United States
Wear, tensile and axial fatigue tests were conducted on shallow cryogenically treated En19 medium carbon alloy steel to investigate its mechanical behavior. The test samples are conventionally heat treated then oil quenched at 34 ˚C. Followed by the samples were kept under shallow cryogenic treatment to -80˚C for 12 hours using liquid nitrogen. Then the samples were tempered in a muffle furnace to relieve the induced residual stresses. Wear, Tensile and axial fatigue test was carried out on both treated and non-treated samples to measure its wear resistance, tensile strength and fatigue behavior respectively. Microscopic examination also done using scanning electron microscope to compare the effect of shallow cryogenic treatment on its microstructure. The results exposed that there is a reduction in the tensile strength and fatigue life of shallow cryogenically treated samples over base metal and improved wear resistance.

Corrosion characteristics on friction stir welding of dissimilar AA2014/AA6061 alloy for automobile application.

Bannari Amman Institute of Technology-Sadhasivam Deepankumar, Anbalagan Ramakrishnan, Dinesh Dhanabalan
Vellore Institute of Technology-Govindasamy Rajamurugan, Prabu Krishnasamy
  • Technical Paper
  • 2019-28-0063
To be published on 2019-10-11 by SAE International in United States
Friction Stir Welding (FSW) is a widely used solid state welding process in which its heats metal to below recrystallization temperature. FSW mostly avoids welding defects like hot cracking and porosity which are mainly in conventional welding techniques due to alloy’s higher heat dissipating nature and low re-crystallization temperature. In this process combining mechanical work and deformation heating to get high defect free welding joints. Aluminium Alloys 2014 and 6061 are generally used in a wide range of applications such as an automobile, shipbuilding and aerospace due to their high corrosion resistance, lightweight and good mechanical properties. In the present work, aluminium alloys of AA6061 and AA2014 were effectively welded by friction stir welding technique. The mechanical and Corrosion behaviour of the welded joints were investigated at different welding parameters.