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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…

Development of a Graphical User Interface (GUI) Based Tool for Vehicle Dynamics Evaluation

Mahindra & Mahindra Ltd-Saravanan Muthiah
Mahindra & Mahindra, Ltd.-Divyanshu Joshi
  • Technical Paper
  • 2019-28-2397
To be published on 2019-11-21 by SAE International in United States
Title Development of a Graphical User Interface (GUI) Based Tool for Vehicle Dynamics Evaluation Authors Mr. Shubham Kedia, Dr. Divyanshu Joshi, Dr. Muthiah Saravanan Mahindra Research Valley, Mahindra & Mahindra, Chennai Objective Objective metrics for evaluation of major vehicle dynamics performance attributes i.e. ride, handling and steering are required to compare, validate and optimize dynamic behavior of vehicles. Some of these objective metrics are recommended and defined by ISO and SAE, which involve data processing, statistical analysis and complex mathematical operations on acquired data, through simulations or experimental testing. Due to the complexity of operations and volume of data, evaluation is often time consuming and tedious. Process automation using existing tools such as MS Excel, nCode, Siemens LMS, etc. includes several limitations and challenges, which make it cumbersome to implement. In the current work, a GUI based post-processing tool is developed for automated evaluation of ride, handling and steering performance. Methodology This work is about development of a centralized platform for quantification, visualization and comparison of ride, handling and steering performance metrics from testing and…

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 (,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

Advanced Exergy Analysis of an Air Craft Gas Turbine Engine at Different Power Loading Operations.

GIFT, Bhubaneshwar-Alok Kumar Mohapatra
VIT Universtity Vellore-Tapano Hotta
  • Technical Paper
  • 2019-01-1863
To be published on 2019-09-16 by SAE International in United States
The innovations in aircraft propulsion have been identified as the key parameter towards the progress in transportation. Continuous advancement in the performance and efficiency of propulsion has enabled aircraft to travel over larger distances with higher speed. Aviation is also responsible for approximately 2% of total greenhouse gases emission and is expected to grow around 3% by 2050. The present study aims to use the exergetic analysis of a turboprop engine which should be helpful in designing of such engines and also helps these engine users to regulate and select the operation modes. A gas turbine with film air cooling of turbine blades has been proposed to be the turboprop engine. The engine is analyzed on exergy point of view at different power loading operation modes and the performance is studied. Selected exergetic measures under consideration are Exergy Efficiency, Fuel Exergy Depletion Ratio, Relative Exergy Consumption Ratio, Exergetic Improvement potential and Productivity Lack ratio. The total fuel exergy depletion ratio of the turboprop engine is estimated to be around 44%. . Also, among the identified…

Improving Competitiveness of Additive Manufacturing Aerospace Serial Parts

LISI Aerospace-Maxime Gas, Alexis Rene-Corail, Sebastien Eyrignoux, Guillaume Iker, Stephane Sudre
  • Technical Paper
  • 2019-01-1900
To be published on 2019-09-16 by SAE International in United States
The interest of selective laser melting technology for aerospace parts is very high due to their high complexity and their freedom of design which allow functions integration. However, the competitiveness of Laser Beam Melting (LBM) machines for aerospace industry is limited by two major road blocks. On the one hand, basic parametric set sold with LBM machines are more oriented to historical qualification than productivity rates. For instance, the ongoing qualification on EOS M290 by AIRBUS COMMERCIAL AIRCRAFT only enables us to produce a hundred pieces per machine per year. On the other hand, wasted times between two consecutive manufacturing batches are significant and are impacting the yearly output of the machines. The present project focuses on two activities, focusing on the largest available machines, XLINE2000R and M400, in order to maximize the amount of pieces per build. The first one was the improvement of parametric set productivity, to reduce production time, while keeping material and mechanical properties. We focused on main aerospace materials: titanium alloys, aluminum alloys (Scalmalloy®) and nickel-chromium-based superalloys. The second one…

Data connectivity in HARSH ENVIRONMENTS

SAE Truck & Off-Highway Engineering: August 2019

Christian Manko
  • Magazine Article
  • 19TOFHP08_03
Published 2019-08-01 by SAE International in United States

Ensuring high-speed data transmission requires OEM designers to think more about components, placement and the impact of environmental conditions early in design.

Technology advances are increasingly bringing a new level of connectivity to industrial and commercial vehicles. Customers are demanding functionality that automates or enhances operational tasks to increase driver productivity and safety and, in many cases, also brings down total cost of ownership.

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Capturing the Impact of Fuel Octane Number on Modern Gasoline Vehicles with Octane Indices

SAE International Journal of Fuels and Lubricants

Argonne National Laboratory, USA-Forrest Jehlik, Henning Lohse-Busch, Simeon Iliev
Illinois Institute of Technology, USA-Carrie Hall
  • Journal Article
  • 04-12-02-0005
Published 2019-05-09 by SAE International in United States
The need for high efficiency automotive engines has led to more complex air handling and fuel injection systems, higher compression ratios, more advanced combustion and aftertreatment systems, and the use of fuels with higher octane ratings. Higher octane number fuels have a lower propensity to knock. This work studies the influence of changing fuel octane rating on two modern production gasoline vehicles, one with a naturally aspirated, port injected engine and the other with a turbocharged, direct injected engine, using fuels with four different octane number grades (with 85, 87, 91, and 93 anti-knock indices) and operated over a variety of driving cycles and temperature conditions. Unlike previous studies, this effort develops and demonstrates a methodology that isolates fuel effects on fuel consumption and provides a clear view of the octane impact on existing vehicles. While fuel octane rating can also impact factors such as the allowable compression ratio and gear shifting strategies, this study examines fuel consumption changes that are solely attributable to octane rating on production vehicles. The developed approach uses results from…
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A Guide to Collaborative Robot Safety

  • Magazine Article
  • TBMG-34385
Published 2019-05-01 by Tech Briefs Media Group in United States

The ability of collaborative robots to share tasks with humans and flexibly adapt to new requirements can provide high returns on investment in a wide variety of industrial applications. Manufacturers employ these robots to reap the benefits of integrated safety features that allow them to work with or close by humans and boost productivity for a wide variety of repetitive tasks.


Integrating a Proactive Quality Control Concept into Machining Operation of a Crankshaft Manufacturing Process

FCA US LLC-Loda Bazzi
Published 2019-04-02 by SAE International in United States
Competition in the manufacturing industry is ever increasingly intense. Manufacturing organizations that want to grow and prosper must embrace a discipline of constant improvement. Their engineering departments are tasked with improving existing manufacturing processes in terms of quality and throughput, which is vital to competing on a global scale. Manufacturers strive to utilize technologies to extract efficiencies from their existing processes. Reducing scrap and rework is the paramount goal in increasing a processes’ efficiency. The foundation of this study is to analyze a production line to determine the quality status throughout the manufacturing process. The intention is to react to process instability before the production becomes non-compliant (scrap/rework) which will significantly improve productivity.By incorporating the proposed technology into the production process, the desired achievement will be to spot process variables at the earliest stages so that counter measures can be taken to stabilize the process before production drifts into non-compliance. Furthermore, the technology will communicate with machining operations to initiate counter measures such as program offsets, tool changes and wheel dressings. The main goal of…
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Evaluation of Ecosystem for Design Assessment and Verification by BAJA Dynamometer Capstone Team at the University of Nebraska

Imagars LLC; Portland State University-Baldur Steingrimsson
Portland State University-Bao Phan, Sung Yi
Published 2019-04-02 by SAE International in United States
This paper summarizes the outcome of an evaluation by capstone design teams from the Department of Mechanical and Materials Engineering at the University of Nebraska-Lincoln, of the Ecosystem for Design Assessment and Verification. The Ecosystem is a design decision support tool whose main goal is to identify design oversights, defined in terms of deviations from the design process or unfulfilled design requirements, early in the design process, guide designers through the design process, and teach proper design techniques. It is capable of automatically assessing students’ design work against ABET compliant learning outcomes. The Ecosystem offers many additional features found useful by capstone design teams, such as automatic generation of formatted project reports as well as interfaces to tools for team communications (Google Drive, Dropbox or OneDrive) or development (e.g., SolidWorks, CATIA, NX Unigraphics or AutoCAD).The Ecosystem was recently evaluated by a capstone team working on an automated straw flattening machine and again during a following semester by a team designing a dynamometer used for measuring the engine power of a BAJA race car.The paper draws…
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