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Unsettled Technology Domains in Aerospace Additive Manufacturing Concerning Safety, Airworthiness, and Certification

Muelaner Engineering, Ltd.-Jody Muelaner
  • Research Report
  • EPR2019008
To be published on 2019-12-20 by SAE International in United States
Additive manufacturing (AM) is currently being used to produce many certified aerospace components. However, significant advantages of AM are not exploited due to unresolved issues associated with process control, feedstock materials, surface finish, inspection, and cost. Components subject to fatigue must undergo surface finish improvements to enable inspection. This adds cost and limits the use of topology optimization. Continued development of process models is also required to enable optimization and understand the potential for defects in thin walled and slender sections. Costs are high for powder-fed processes due to material costs, machine costs, and low deposition rates. Cost for wire-fed processes are high due to the extensive post-process machining required. In addition, these processes are limited to low-complexity features. Incremental improvements in all of these areas are being made but a step change could potentially be achieved by hybrid processes, which use wire feedstock to deposit the bulk of the part and powder for fine detail. NOTE: SAE EDGE™ Research Reports are intended to identify and illuminate key issues in emerging, but still unsettled, technologies…
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Control Strategy for Hybrid Electric Vehicle Based on Online Driving Pattern Classification

SAE International Journal of Alternative Powertrains

University of Alabama, USA-Zhengyu Yao, Hwan-Sik Yoon
  • Journal Article
  • 08-08-02-0006
Published 2019-12-04 by SAE International in United States
Hybrid Electric Vehicles (HEVs) are gaining popularity these days mainly due to their high fuel economy. While conventional HEV controllers can be classified into rule-based control and optimization-based control, most of the production vehicles employ rule-based control due to their reliability. However, once the rule is optimized for a given driving pattern, it is not necessarily optimal for other driving patterns. In order to further improve fuel economy for HEVs, this article investigates the feasibility of optimizing control algorithm for different driving patterns so that the vehicle maintains a high level of optimality regardless of the driving patterns. For this purpose, a two-level supervisory control algorithm is developed where the top-level algorithm classifies the current driving pattern to select optimal control parameters, and the lower level algorithm controls the vehicle power flow using the selected control parameters in a similar way to conventional supervisory controllers. To study the effectiveness of the proposed algorithm, a HEV model with a rule-based control algorithm is modified such that the control parameters are optimized for different driving patterns, and…
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A Machine Learning based Multi-objective Multidisciplinary Design Optimization (MMDO) for Lightweighting the Automotive Structures

Mahindra and Mahindra, Ltd.-Ranga Srinivas Gunti
  • Technical Paper
  • 2019-28-2424
Published 2019-11-21 by SAE International in United States
The present work involves Machine Learning (ML) based Multi-objective Multidisciplinary Design Optimization (MMDO) for lightweighting the automotive structures. The challenge in deployment of MMDO algorithms in solving real-world automotive structural design problems is the enormous time involved in solving full vehicle finite element models that involve large number of design variables and multiple performance constraints pertaining to vehicle dynamics, durability, crash and NVH domains. With the availability of powerful workstations and using the advanced Computer Aided Engineering (CAE) tools, it has become possible to generate huge sets of simulation data pertaining to multiple domains. In the present work, lightweigting of the vehicle structure is achieved, considered the vehicular hardpoint locations and the gages of the vehicle structures as the design variables and performance parameters pertaining to vehicle dynamics, structural durability, front-end intrusions during an IIHS offset impact test and the modal frequencies of few critical structural members as the constraint variables. Artificial Neural Networks (ANN) based algorithms were used for developing the predictive models of various performance parameters. The predictive models were then used to…
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Optimization of vehicle side panel to improve crashworthiness.

Kichumon Haldus
  • Technical Paper
  • 2019-28-2573
Published 2019-11-21 by SAE International in United States
The front of a car, though susceptible to the biggest impacts in terms of magnitude, has space and additional reinforcement to incorporate various safety measures. The rear has considerable amount of space to contain a proper crash box. The side of the car, though, doesn’t have this flexibility in design, the main limiting parameter being space. Any intrusion into the passenger cabin can result in serious injury or even death. The objective of this work is to improve the crashworthiness of a vehicle’s side so as to reduce intrusion into the passenger cabin. The work is focused on optimizing the door and B pillar. The optimized side panel is compared with the baseline model as per standard. ANSYS solver is used for the simulation. The optimized design applied to the door and B pillar will significantly improve crashworthiness of the vehicle side panel as a whole.
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Design optimization for Engine mount

Prateek Sharma
VE Commercial Vehicles, Ltd.-Mahendra Parwal
  • Technical Paper
  • 2019-28-2540
Published 2019-11-21 by SAE International in United States
The mounting of an engine plays important role in controlling the vibration transmissibility, alignment of transmission unit within specific limit. Design of any mounting system mainly depends on stiffness, allowed deformation and transmissibility of force, natural frequency and size w.r.t space constraints etc. This paper helps to study the behavior of engine mount with different layer of rubber with defer stiffness. Firstly the design of front engine mount with single rubber layer according to space constraint in vehicle and then analysis is done to determine the deformation and various results using CAE technique. As per the results, design is modified with varying layer of rubber pad and again analysis is done with same boundary condition followed by improved results.
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Design improvements in advanced automotive batteries using AI

International Centre For Automotive Tech.-Devesh Pareek Sachin
  • Technical Paper
  • 2019-28-2505
Published 2019-11-21 by SAE International in United States
Introduction: The advent of electric mobility is changing the conventional mobility techniques and with this comes challenges to improve the performance of battery to optimize power consumption in electric vehicles. Objective: This paper would focus on the optimization of battery performance incoherent with vehicle power consumption behavior in terms of efficiency using decision-making ability based on given input signals
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Light-Weighting of Additive Manufactured Automotive Fixtures through Topology Optimization Techniques

General Motors Technical Center India-Abhijith Naik, T Sujan, Suraj Desai, Saravanakumar Shanmugam
  • Technical Paper
  • 2019-28-2544
Published 2019-11-21 by SAE International in United States
Rapidly enhancing engineering techniques to manufacture components in quick turnaround time have gained importance in recent times. Manufacturing strategies like Additive Manufacturing (AM) are a key enabler for achieving them. Unlike traditional manufacturing techniques like injection molding, casting etc.; AM unites advanced materials, machines, and software which will be critical for the fourth industrial revolution known as Industry 4.0. Successful application of AM involves a specific combination and understanding of these three key elements. In this paper the AM approach used is Fused Deposition Modelling (FDM). Since material costs contribute to 60% of the overall FDM costs, it becomes a necessity to optimize the parts. This paper reports the case studies of 3D-printed Automotive Fixtures which utilize computational methods (CAE), topology optimization and FDM constrains (build directions) to manufacture the part. These methodologies were used to validate the current operating conditions, optimize the design, increase the stiffness of the original part and reduce the material costs. The newly optimized designs were verified successfully passing the Finite Element Analysis tests. The components have been printed and…
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SmartPlay Studio: A Connected Infotainment Development

Maruti Suzuki India, Ltd.-Pankaj Kumar Bharti, Shashi Kant Roy, Surendra Raghuwanshi, Satish Pandey, Ritesh Khandelwal, Tarun Aggarwal, Satish Kumar Pandey
  • Technical Paper
  • 2019-28-2440
Published 2019-11-21 by SAE International in United States
Infotainment has always been an important aspect of life which has made its way to car design. The cars today are much more advanced compared to their predecessors. The in-vehicle Infotainment advancements have followed the consumer electronics market in terms of technologies such as Touchscreen; App based Navigation, Voice Assistant and other multimedia services. This trend is going to expand further as smartphones have revolutionized the Infotainment domain with awareness and accessibility to customers. The Infotainment system in the cars are expected to be connected not only to the cloud but various vehicle controllers to display host of information & controls at customer`s fingertips. To design a system that supports connectivity to both cloud and vehicle is challenging in terms of cost and design for the OEMs.With focus on Indian market condition and global trends, this paper analyzes the customer expectation for Connected Infotainment system. It also explains the methodology adopted by Maruti Suzuki India Limited to: (i) Provide a seamless Connected Infotainment system (Smartplay Studio) for its model line-up (ii) Leveraging Smartphone Linkage technologies…
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Mass Optimized Hood Design for Conflicting Performances

General Motors Technical Center-Santosh Swamy, Shivakumar Chidanandappa
University of Agder, Norway-Gulshan Noorsumar
  • Technical Paper
  • 2019-28-2546
Published 2019-11-21 by SAE International in United States
Passenger vehicles have stringent safety regulations for pedestrian protection to meet child and adult head impact requirements to minimize injuries. These pedestrian safety requirements often conflict with stiffness and durability performance criteria, which pose a challenge for most automotive OEMs. There is a growing need for performance balancing to meet both these loadcases. This paper uses Multi-Disciplinary Optimization (MDO) approach involving shape variables to achieve optimized performance for stiffness, durability and pedestrian safety.The current study describes an approach that helps reduce time and efforts needed to resolve performance issues between both stiffness/durability and Pedestrian safety requirements. This approach not only helps find a feasible cross-functional solution but also provides an opportunity to reduce the overall development cycle time and mass whenever possible. It also demonstrates the importance of shapes and dimensions of slots on the inner panel as variables. The slots on inner panel and palm reinforcement are observed to be most sensitive, whereas thicknesses of inner panel, palm and latch reinforcement are the most sensitive size variables. It also involves using a reduced content…
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IMPROVE NVH CHARACTERISTICS OF ENGINE OIL PAN BY OPTIMIZATION & LIGHT WEIGHING WITH DEEP LEARNING PROCESS

Altair Engineering-Srinivas Tangudu, Padmaja Durgam
Altair Engineering India Pvt , Ltd.-Muralidhar Gumma
  • Technical Paper
  • 2019-28-2552
Published 2019-11-21 by SAE International in United States
Recent Years “NVH” is gaining lots of attention as the perception of vehicle quality by a consumer is closely aligned to NVH Characteristics. Demand on Vehicle Light weighting to compliance the environmental norms with powerful engines challenging the “Vehicle NVH”, powertrain induced noise will be continued to be a primary factor for all IC engine vehicles. Component level NVH refinement is necessary to control the overall NVH characteristics of vehicle with lighter Vehicle goal. Current Paper works starts with physical testing the Engine oil pan of the most popular vehicle and build an equivalent simulation model by reverse engineering the design and match similar performance trend in simulation model. After building baseline simulation model, conduct shape, topology, gauge and material optimization to improve weight and performance of Oilpan. In addition to the Simulation DVPS to study the complete NVH characteristics oil pan models, a deep Learning model developed with power of GPUs to disrupt oil pan design methodology as well as optimizing the weight, Performance and cost . Every design engineer would like to optimize…