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Development of a hybrid power unit for Formula SAE application: ICE CFD-1D optimization and vehicle lap simulation

UNIMORE-Enrico Mattarelli, Carlo Alberto Rinaldini, Francesco Scrignoli
Universita di Modena e Reggio Emilia-Valerio Mangeruga
  • Technical Paper
  • 2019-24-0200
To be published on 2019-08-15 by SAE International in United States
The paper reviews the CFD optimization of a motorcycle engine, modified for the installation in a hybrid powertrain of a Formula SAE car. In a parallel paper [Development of a hybrid power unit for Formula SAE application: packaging optimization and thermo-mechanical design of the electric motor case], the choice of the donor engine (Ducati 959 “Panigale”) is thoroughly discussed, along with all the hardware modifications oriented to minimize the new powertrain dimensions, weight and cost, and guarantee the mechanical reliability. In the current paper, the attention is focused on two main topics: 1) CFD-1D tuning of the modified Internal Combustion Engine (ICE), in order to comply with the Formula SAE regulations, as well as to maximize the power output; 2) Simulation of the vehicle in racing conditions, comparison between a conventional and a hybrid powertrain
 
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Uncertainty of the Ice Particles Median Mass Diameters Retrieved from the HAIC-HIWC Dataset: A Study of the Influence of the Mass Retrieval Method

Delphine Leroy
Airbus-Alice Grandin, Fabien Dezitter
Published 2019-06-10 by SAE International in United States
In response to the ice crystal icing hazard identified twenty years ago, aviation industry, regulation authorities, and research centers joined forces into the HAIC-HIWC international collaboration launched in 2012. Two flight campaigns were conducted in the high ice water content areas of tropical mesoscale convective systems in order to characterize this environment conducive to ice crystal icing. Statistics on cloud microphysical properties, such as Ice Water Content (IWC) or Mass Median Diameter (MMD), derived from the dataset of in situ measurements are now being used to support icing certification rulemaking and anti-icing systems design (engine and air data probe) activities. This technical paper focuses on methodological aspects of the derivation of MMD. MMD are estimated from PSD and IWC using a multistep process in which the mass retrieval method is a critical step. Complementary to previous studies reporting on MMD values calculated from the HAIC-HIWC dataset, this paper deals with the uncertainty in MMD by comparing two different approaches for the retrieval of the mass-size (m-D) relationship. The analysis encompasses the data collected in the…
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Process Regulations and Mechanism of WEDM of Combustor Material

SAE International Journal of Aerospace

National Institute of Technology, Kurukshetra, India-Bhupinder Singh, Joy Prakash Misra
  • Journal Article
  • 01-12-01-0004
Published 2019-06-07 by SAE International in United States
This study discusses the experimental investigation on WEDM of combustor material (i.e., nimonic 263). Experimentation has been executed by varying pulse-on time (Ton), pulse-off time (Toff), peak current (Ip), and spark gap voltage (Sv). Material removal rate (MRR), surface roughness (SR), and wire wear rate (WWR) are employed as process performance characteristics. Experiments are designed as per the box-Behnken design technique. Parametric optimization has also been performed using response surface methodology. Besides this, field-emission scanning electron microscope (FE-SEM) and an optical microscope are utilized to characterize WEDMed and worn-out wire surfaces. It is observed that both surfaces contain micro-cracks, craters, spherical droplets, and a lump of debris. Furthermore, the mechanism of recast layer formation has been critically evaluated to apprehend a better understanding of the technique. The key features of the experimental procedure are also highlighted.
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Mitigation of Community Noise from a Vacuum Excavator Using Simulations

Charles Machine Works-Vernon Stellman, Craig Clevenger, Jeff Smith
Dassault Systemes Simulia Corp.-Rahul Sanal, Karthik Mahadevan Muthuraman, Robert Powell
Published 2019-06-05 by SAE International in United States
Off-highway equipment operates in residential communities and must meet their radiated noise targets to be compliant with noise regulations and to be competitive in the marketplace. Traditional find and fix noise testing of late-stage prototype designs may cause launch delays, with intense time pressures that often result in missed opportunities to create excellent products with good value. Accurate simulation of noise from these machines allows noise targets to be assessed at each stage of product development, giving engineers time to develop low noise products without adding excessive manufacturing cost. Simulation of an early prototype of a new vacuum excavator showed excessive levels of radiated noise in two different frequency ranges. Further investigation of the simulation results of these two spectrum ranges indicated different noise mechanisms producing the excessive noise levels. An acoustic resonance was excited in the exhaust flow downstream of a silencer by highly vortical flow through a ninety-degree elbow. Broadband flow noise was also being generated downstream of this silencer, in a higher frequency range. Solutions to the two separate noise issues were…
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Broadband Membrane-Type Acoustic Metamaterial Structures with Polymorphic Anti-Resonance Modes

Gissing Tech. Co., Ltd.-Qianqian Zhang, Xiujie Tian, Yuying Jiang, Wei Huang, Keda Zhu
Xi’an Jiaotong University-Guojian Zhou, Jiu Hui Wu
Published 2019-06-05 by SAE International in United States
The researches indicate that rational design of membrane-type acoustic metamaterial (MAM) can make it have a high sound transmission loss (STL) at the anti-resonant frequency. Based on the principle of local resonance of acoustic metamaterials, this paper studied the coupling interactions between sound field and vibration modes, and designed four lightweight MAM structural units with different distributed harmonic oscillators, and then the anti-resonant behaviors of different units within the low frequency were gradually analyzed. The regulation mechanism of continuous polymorphic anti-resonance modes on broadening STL bandwidth was further revealed, and the STL characteristics have been verified within the low-frequency range by numerical simulation and experiments. The results show that the design of a single cross-shaped resonator can increase the diversity of anti-resonance modes and eliminate the node-circular-type resonance mode, then ensure the wider STL bandwidth. Furthermore, four metal platelets set symmetrically between the swing arms based on the unit above increase the local anti-resonance modes of the new unit, which greatly expand the STL bandwidth by shifting its upper limit to the right. In addition,…
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COMPOUND, ALKALINE RUST REMOVER Aircraft Turbine Engine Components

AMS J Aircraft Maintenance Chemicals and Materials Committee
  • Aerospace Material Specification
  • AMS1379A
  • Current
Published 2019-06-03 by SAE International in United States
This specification covers an alkaline rust remover compound in the form of a liquid concentrate or a water-soluble powder for dilution with water.
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Getting driverless trucks onto roadways

SAE Truck & Off-Highway Engineering: June 2019

based on exclusive interview with TuSimple's Chuck Price-Terry Costlow
  • Magazine Article
  • 19TOFHP06_03
Published 2019-06-01 by SAE International in United States

Autonomous developers at TuSimple address many technical issues, but they also must consider regulations and operating modes.

The developers who are creating autonomous systems have plenty of complex technical questions that must be analyzed and solved, but their challenges don't stop there. Design teams also have to plan for the use cases of driverless vehicles, even going so far as to plan for what might happen if the vehicle has to sacrifice itself to avoid a serious accident.

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Unique hybrids required

SAE Truck & Off-Highway Engineering: June 2019

based on exclusive interview with Perkins' Oliver Lythgoe-Ryan Gehm
  • Magazine Article
  • 19TOFHP06_02
Published 2019-06-01 by SAE International in United States

Power systems expert at Perkins stresses that on-highway electric solutions cannot be directly applied to the more-rugged and varied applications in off-highway.

Hybrid powertrains still account for a small portion of the off-highway vehicle market-less than 1%, according to Oliver Lythgoe, product marketing executive at Perkins-but interest is most certainly intensifying. Engine makers cannot delay R&D activities in this area, lest they be left behind.

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Steel, Sheet and Strip 0.25 Carbon, Maximum Hard Temper

AMS E Carbon and Low Alloy Steels Committee
  • Aerospace Material Specification
  • AMS5045K
  • Current
Published 2019-04-25 by SAE International in United States
This specification covers a carbon steel in the form of sheet and strip.
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Filler Metal, Aluminum Brazing 12Si

AMS D Nonferrous Alloys Committee
  • Aerospace Material Specification
  • AMS4185F
  • Current
Published 2019-04-11 by SAE International in United States
This specification covers an aluminum alloy in the form of wire, sheet, foil, pig, grains, shot, and chips.
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