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Frame Structure Durability Development Methodology for Various Design Phases

FCA Engineereing India Pvt., Ltd.-Raghavendra Byali, Venkatesh Naik
FCA US LLC-Chandra Thandhayuthapani, Barry Lin, Jianghui Mao
  • Technical Paper
  • 2020-01-0196
To be published on 2020-04-14 by SAE International in United States
It is a challenging task to find an optimal design concept for a truck frame structure given the complexity of loading conditions, vehicle configurations, packaging and other requirements. In addition, there is a great emphasis on light weight frame design to meet stringent emission standards. This paper provides a framework for fast and efficient development of a frame structure through various design phases, keeping durability in perspective while utilizing various weight reduction techniques. In this approach frame weight and stiffness are optimized to meet strength and durability performance requirements.Fast evaluation of different frame configurations during the concept phase (I) was made possible by using DFSS (Design for Six Sigma) based system synthesis techniques. This resulted in a very efficient frame ladder concept selection process. Frame gauge optimization during the subsequent development phase (II) utilizing a newly developed damage based approach greatly reduced the number of design iterations relative to a typical stress based approach. In the light weighting phase (III) that followed, a method was established to effectively locate and optimize lightening holes using fatigue…
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New Seven Speed DCT transaxle and effect of angular positioning of shaft in layout.

Satyam-Venture Engineering Services-Muralidhar Bhat
  • Technical Paper
  • 2020-01-0429
To be published on 2020-04-14 by SAE International in United States
This paper presents about new concept developed on 7 speed DCT transaxle for transverse application and a torque capacity of 200 Nm to 360 Nm. How current 6 speed DCT can modified to 7 speed with packaging benefit is discussed. In this paper, discussions are focused about torque carrying parts of transaxle only. Here only single countershaft is used giving lot of packaging advantage and at first glance layout looks like four speed layout, but it is compact layout. Further in this paper effect of angular position of shaft in layout is discussed.. Position of shafts in transaxle layout effects the stress, bending moment and displacement induced in shaft. Detailed study on effect of change in angle with respect to Bending moment, Stress in shaft, Cylindrical roller bearing (CRB) and Deep Groove Ball Bearing (DGBB) Bearing reaction force analysis, life calculations are computed.
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Virtual Verification of Light Reflection for Cluster and Side Mirror in Real Time Scenario

VE Commercial Vehicles Ltd.-Manas Bhatnagar, Jyotiranjan Biswal, Saurabh Sharma
  • Technical Paper
  • 2020-01-0568
To be published on 2020-04-14 by SAE International in United States
In the very automobile world trends are changing at a very fast pace, due to continuous expectation changes by user and new regulatory requirements demand from government authorities with a very stringent timeline.In the current scenario, manufacturer has to wait for mock up for concept selection and physical proto build to conclude open points of design verification. This complete process takes more than a year to enhance the design maturity for further builds.In VECV we have created Cluster design standard to meet different level of cluster illumination & reflection at virtual level. We are defining the cluster light illumination based on our rigorous study on cluster reflection impact on side glass, windscreen and mirror. Accordingly we have packaged our mirror to minimize the impact of cluster reflection on mirror visibility.With the help of virtual verification of cluster and Side mirror inter co-relation of packaging, we significantly reduced the time loss and save huge cost required for developing proto build. Different options of mirror and cluster can be verified in quick session. With the help of…
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Titanium Alloy Welding Wire, 6Al - 4V, Extra Low Interstitial, Environment Controlled Packaging

AMS G Titanium and Refractory Metals Committee
  • Aerospace Material Specification
  • AMS4956H
  • Current
Published 2020-04-02 by SAE International in United States

This specification covers a titanium alloy in the form of wire for welding filler metal.

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Validation Testing of Lithium Battery Performance-Based Packaging for Use in Air Transportation (SAE G-27)

National Research Council Canada-Khalid Fatih, Manuel Hernandez
Transport Canada-Ian Whittal, Kiran Shoib
  • Technical Paper
  • 2020-01-0042
Published 2020-03-10 by SAE International in United States
The SAE G-27 committee was tasked by ICAO to develop a performance-based packaging standard for lithium batteries transported as cargo on aircraft. The standard details test criteria to qualify packages of lithium batteries & cells for transportation as cargo on-board passenger aircraft. Lithium batteries and cells have been prohibited from shipment as cargo on passenger aircraft since 2016.This paper summarizes the results of the tests conducted by Transport Canada and National Research Council Canada to support the development of this standard with evidence-based recommendations. It includes a description of the test specimens, the test set up, instrumentation used, and test procedures following the standard as drafted to date.The study considered several lithium-ion battery and cell chemistries that were tested under various proposed testing scenarios in the draft standard. The aim was to assess the feasibility of proposed tests, and to determine whether the tests are able to accurately capture hazards which may arise from a catastrophic battery or a cell failure within the package. Laboratory results were also simulated with Computational Fluid Dynamics software for…
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Self-Cleaning, Non-Stick Coating

  • Magazine Article
  • TBMG-36200
Published 2020-03-01 by Tech Briefs Media Group in United States

Researchers have developed a self-cleaning surface that can repel all forms of dangerous bacteria. The new plastic surface — a treated form of conventional transparent wrap — can be shrink-wrapped onto door handles, railings, IV stands, and other surfaces that can be magnets for bacteria such as MRSA and C. difficile. The treated material is also ideal for food packaging, where it could stop the accidental transfer of bacteria such as E. coli, salmonella, and listeria from raw chicken, meat, and other foods.

new

Layered Composite Insulation

  • Magazine Article
  • TBMG-36163
Published 2020-03-01 by Tech Briefs Media Group in United States

NASA's Layered Composite Insulation (LCI) technology is an easy-to-use system that can benefit multiple industries that depend on regulation of low temperatures in equipment and products. The technology combines a unique layered cryogenic insulation system with specific manufacturing, packaging, wrapping, and rolling methods.

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DC Resistivity vs RF Impedance of EMI Gaskets

AE-4 Electromagnetic Compatibility (EMC) Committee
  • Aerospace Standard
  • AIR1404
  • Current
Published 2020-01-30 by SAE International in United States
This AIR discusses the DC resistivity property of EMI gaskets.
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O-Ring Machined from AMS3617 Material

A-6C2 Seals Committee
  • Aerospace Standard
  • AS9772A
  • Current
Published 2020-01-13 by SAE International in United States
This standard establishes the dimensional and visual quality requirements, lot requirements, and packaging and labeling requirements for O-rings machined from AMS3617 polyamide material. It shall be used for procurement purposes.
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Development of a test rig to evaluate the performance of Front-End Accessory Drive systems

VIBROACUSTICA-Celso Kenzo Takemori, Diego Wilian da Silva, Edmar Baars
ZEN S.A. Indústria Metalúrgica-Alvaro Canto Michelotti, Lucas Figueiro Berto, Pedro Palma Pastorelli, Andre Francioso Ferreira
  • Technical Paper
  • 2019-36-0296
Published 2020-01-13 by SAE International in United States
The increased adoption of downsized engines along with higher electrical demand is generating a challenge to the Front-End Accessory Drive (FEAD) system functioning and validation. One alternative to speed up the validation of potential design solutions is the in-vehicle experimental tests approach. Nevertheless, experimental data collection during in-vehicle FEAD evaluation imposes some challenges due to, for instance, packaging space constraints and sample rate required to capture the dynamic events during vehicle operation, among others. In order to overcome this limitation, the objective of this research is focused in the development of a customized test rig that emulates FEAD layout of an actual automobile in a simulated operating condition. This equipment could contribute in research studies focusing in critical performance parameters, allowing complete data acquisition and evaluation of potential design trade-offs that could maximize overall performance of the system, as the test rig could also allow the study of the impact of different layouts or operational configurations in the overall system efficiency. Therefore, the test rig design intent is to have a configurable layout that can…
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