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MOLD IN COLOR DIAMOND WHITE ASA MATERIAL FOR AUTOMOTIVE EXTERIOR APPLICATION

Mahindra & Mahindra Ltd-Karthik Govindaraj, K V Balaji, Murukesan Vimalathithan, Gandhi Samir, Ladhe Rajesh
  • Technical Paper
  • 2019-28-2562
To be published on 2019-11-21 by SAE International in United States
In this paper, mold in color diamond white ASA material has been explored for front bumper grill, fender arch extension and hinge cover applications. Other than aesthetic requirements, these parts have precise fitment requirement under sun load condition in real world usage profile. Structural durability of the design was validated by virtual engineering. Part design and material combinations with better tooling design iterations were analysed by using mold flow analysis. Complete product performances were validated for predefined key test metrics such as structural durability, thermal aging, cold impact, scratch resistance, and weathering criteria. This part met required specification. This mold in color ASA material-based parts has various benefits such as environmentally friendly manufacturing by eliminating environmental issues of coating, easily recycled, and faster part production because intended color achieved in one step during molding. Also, it lowers overall production energy footprint, less scrap with no secondary painting, and lower final part cost by eliminating secondary operations.
 

Realtime Tuning and optimization of EV traction motors with controllers on E-motor testbench

A R A I-Manoj Desai
Automotive Research Association of India-Monishram Venkataram
  • Technical Paper
  • 2019-28-2478
To be published on 2019-11-21 by SAE International in United States
The need for dedicated development of indigenous electric power-train is becoming much essential in the recent times with upcoming trends and policies. Hence, The validation and optimization of the newly developed electric power-train becomes much crucial in order to ensure smooth real world operation. This can be only possible in E-motor test benches with dedicated equipment for thorough evaluation. Also, there are no practical limitations to check the peak characteristics in a controlled laboratory environment. Initially, the motor is setup by mechanically coupling with the dynamo-meter and the controller in the open loop method with constant parameters to check steady state operability without load or external parameters that affect the torque production and speed of the drive. Then progresses to closed loop method incorporating the feedback control and external parameters including torque loading at the shaft from the dynamo-meter. The output torque is primarily estimated from phase currents and forms as the feedback to alter the input to the drives. In closed loop control, the electric power train is run with either speed control or…
 

Analysis of Accelerator Hardware for Real-Time Processing in Autonomous Vehicles and Data Centers.

Wayne State University-Kyle W. Brown
  • Technical Paper
  • 2019-01-2615
To be published on 2019-10-22 by SAE International in United States
The development of Autonomous Vehicles (AV) has become a popular subject in academia and industry. Companies and cities are quickly realizing the opportunities that AVs can generate from Mobility as a Service to traffic safety. The challenges for the infrastructure to incorporate AVs as a viable transportation source are immense, beginning with an outdated infrastructure. Historically, the transportation infrastructure has been fraught with challenges from underfunding, economics, and misappropriations. With the current infrastructure unable to support many of the services required by a fully connected network, a transformation will be necessary to meet growing mobility needs. The role of accelerating technology in data centers are key for production operations among industry leaders such as Amazon and Microsoft. The same accelerating technology that has successfully impacted data centers will play the same role in much smaller Edge data centers for Smart-City design in the transportation infrastructure. The Edge data centers will be tasked with processing, latency, and tasking, caching and offloading (TCO) of millions of connected vehicles simultaneously. With the recent upgrade of 5G from 4G…
 

Calculation of Drag Torque Losses by Component of a Transfer Case

Magna Powertrain of America, Inc.-Ricardo Rivera Rodriguez, Carlos Martinez
  • Technical Paper
  • 2019-01-2605
To be published on 2019-10-22 by SAE International in United States
In recent decades, fuel economy has become a key indicator of an automaker social responsibility and a market differentiation factor, and ultimately it is regulated by government agencies such as EPA through CO2 emissions compliance tests. The light pick-up truck and SUV production share has been increasing in the last few years, being the 4-wheel drive capability one of the main features that the customers look for. Within the 4-wheel drive system, the transfer case has a significant impact to both torque transfer efficiency and parasitic losses. The scope of this paper is to better understand the parasitic losses of a transfer case by the quantification of its individual drag losses by component. At product development phase, one measurement of interest is the system level spin loss which has a target value defined by the automakers, and contribution by component is often neglected if the system has the expected performance. This study summarizes the tests performed on a 2-speed chain driven transfer case, where as a first step, a baseline spin loss measurement was taken,…
 

Development of Methodology to Determine Toe Geometry of any Vehicle at its Early Design Stage for Optimum Tyre Life

Mahindra & Mahindra, Ltd.-Nitin Kumar Khanna, Karthik Senthi, Vignesh Natarajan
  • Technical Paper
  • 2019-28-0105
To be published on 2019-10-11 by SAE International in United States
Toe setting, or the Vehicle geometry is one of the major wheel alignment parameters which directly effects handling of a vehicle. Correct toe setting ensures desired dynamic behavior of an automobile like straight line stability, cornering behavior, handling and tire durability. Incorrect setting of toe during design stage significantly deteriorates tire durability and leads to uneven tire wear. Within the current scenario in the Automotive Industry, the toe setting is majorly an iterative or a trial and error process which is both time consuming and involves higher development cost as there may be instances where 2 to 3 sets of iterations are needed before specification is finalized for production. Therefore, determining optimum toe setting at an early stage of a product development will not only save significant development time but it will also benefit in reducing product validation time and cost. Through this paper, an attempt has been made to develop a methodology for deciding toe setting for any vehicle as a First Time Right (FTR) approach to cut down on conventional, expensive & time-consuming…
 

Thumb Design and Optimization for Backhoe Loader

John Deere C&F-Kurtis Langner
John Deere India Pvt. Ltd.-Sandeep Dhotre, Surya Pratap Ponnana, Amit Ghate
  • Technical Paper
  • 2019-28-0109
To be published on 2019-10-11 by SAE International in United States
Product Engineering organizations are committed to provide solutions with right quality and value to customers. Value improvement and efficient product improvement are key considerations for product engineering. In this paper, Author outlines the summary of Thumb Design and Optimization for Backhoe Loader. This project goal was to come up with own thumb design. The Backhoe thumb attachment was previously a Proprietary Design of the supplier which had two major limitations, limited opportunity of design improvements for resolving customer issues and higher total cost. The paper covers details about overcoming these limitations. In Backhoe loaders, for multiple variants of machines, four different thumbs are used. Small and mid-backhoe machine classes use 4-tine and 2-tine thumb depending upon customer applications. The design team targeted an external customer requirement of a more compact design and internal requirement of accelerating design improvement cycle time. To overcome these concerns, along with few more constraints, a full study of new thumb design was conducted. Key constraints included compatibility to current design, maintain tip forces, and optimize for a compact design. The…
 

Experimental Investigation of High Speed Turning Of ASTM A510 Alloy in Micro Turning Process Parameters and Its Validation through Ranking Algorithm

SRM Institute Of Science And Technology-Sundar Singh Sivam Sundarlingam Paramasivam, Durai Kumaran, Krishnaswamy Saravanan, Raj Rajendran
Tishk International University-Ganesh Babu Loganathan
  • Technical Paper
  • 2019-28-0071
To be published on 2019-10-11 by SAE International in United States
There is a growing demand for industrial products with increased number of functions and of reduced dimensions and part features in sub millimeter scale in parts and Assembly. Micro-machining is the most basic technology for the production of such miniature parts and components. In this study, a number of turning operations were performed in micro conditions i.e. Micro Process parameters to achieve the best response for the benefits of industries at very high Spindle Speed (3000,3500,4000 Rpm), Feed ( 20,40,80 µm/s), Depth of Cut (0.2,0.4,0.8 µm) and Tool Nose Radius ( 0.4.0.8,1.2 mm ). At a wide range of Input Process Variables, the variations in Surface Quality, Material Removal Rate, Energy Consumption and Tool wear were investigated. After completion of Experimental to develop optimization strategy for given set of input parameter combination for better response using combined Taguchi and Grey Relational Analysis (GRA). So this Model would be beneficial for manufacturing a micro parts for better maximum product accuracy and improve the productivity
 

Improvement of Mechanical Properties, and Optimization of Process Parameters of AISI 1050 Spheriodized Annealed steel by Ranking Algorithm

SRM Institute of Science and Technology-Durai Kumaran, Sundar Singh Sivam Sundarlingam Paramasivam, Krishnaswamy Saravanan, Raj Rajendran
Tishk International University-Ganesh Babu Loganathan
  • Technical Paper
  • 2019-28-0143
To be published on 2019-10-11 by SAE International in United States
AISI 1050 is used in the production of landing gear, actuators and other aerospace components but their application is limited due to machinability of the material. In any metal cutting operation the features of tools, input work materials, machine parameter settings will influence the process efficiency and output quality characteristics. A significant improvement in process efficiency may be obtained by process parameter optimization that identifies and determines the regions of critical process control factors leading to desired outputs or responses with acceptable variations ensuring a lower cost of manufacturing. This experimental study elucidates the problems and machinability issues like failure of tools and accuracy are found while machining and less output in machining. In the present study of spherodizing heat treatment of AISI 1050 was investigated during the turning operation in CNC lathe, under the consideration of several turning process parameters. The microstructures of the as-received, and heated specimens were investigated by Optical Microscopy (OM). A correlation between various process parameters on the desired response namely surface finish, roundness Material Removal Rate (MRR), power consumption…
 

Automation of Sorting and Kitting from Cutting Tables

Broetje-Automation GmbH-Erik Berg
  • Technical Paper
  • 2019-01-1899
To be published on 2019-09-16 by SAE International in United States
Within the current part production of carbon fiber parts a lot of manual work is included for sorting and kitting of automatic cut plies. This is required due to the high raw material costs and enables a good utilization of the materials. Automation of this non-value adding process will be a big benefit for the part production. The high variety of shapes and the different materials to be processed are complex boundary conditions, which are to be overcome. Broetje is in development of handling systems and automation solutions, which are used for a high variety of materials as well as for a high variety of shapes. These systems are meant to be an add-on for existing cutting tables as well as for fully integrated production systems with downstream automation equipment like draping hoods. Mayor challenges to overcome are safe gripping capabilities, detection of #non-cut fibers, high variety of shapes, complex logistic management. These challenges are addressed with Broetje’s ASK Solution. This paper will focus on the innovative automated sorting and kitting solution invented by Broetje-Automation.
 

New Technologies for Airframe Structural Assemblies

LISI Aerospace-Mehdi Dahane
  • Technical Paper
  • 2019-01-1915
To be published on 2019-09-16 by SAE International in United States
With air traffic demand constantly increasing and several years of aircraft production in their backlog, major aircraft manufacturers are now shifting their focus toward improving assembly process efficiency. One of the most promising solutions, known as “One Side Assembly”, aims to perform the whole assembly sequence from one side of the structure (drilling, temporary fastener installation and removal, blind fastener installation, assembly control) and with a high level of integrated automation. Investments in robotic equipment, automation engineering and innovation are very active and automation capabilities have already increased a lot in the aerospace industry. As an example, drilling operations for large dimensions airframe are clearly moving from manual to automated. However, despite more and more clever and sophisticated robotics, the use of historical fasteners with two side installation method remains a strong limitation to innovative automated assembly sequences. A blind fastener which can provide the same mechanical characteristics than current structural fasteners, while providing automation friendly features and meeting cost objectives is a real “must have” for assembly process efficiency improvements. It is also full…