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Passenger "Sleeper Bus" Structure, an Optimization Study using Finite Element Analysis

JCBL, Ltd.-Yaseen Khan
JCBL,Ltd.-Priyanka Bhola
  • Technical Paper
  • 2019-28-2537
To be published on 2019-11-21 by SAE International in United States
ABSTRACT Sleeper buses are increasingly used as connectivity between cities and remote areas with sleeping comfort for passengers. During the normal operation, the bus body is subjected to several loads, external loads from the road (i.e. crossing over a speed bump, breaking & cornering). Moreover, there is a substantial possibility that these loads may lead to a structural failure. Hence, it is necessary to determine stresses occurred in the bus body to ensure its integrity under these driving scenarios. During the accident, rollover/front/rear/side impact, energy absorbing capacity of bus body structure is crucial for safety of passengers. The objective of this study is to reduce weight of bus structure while maintaining cost & safety as constraint. 3D Model prepared in NX and finite element model created in hypermesh ,LS-dyna/optistruct used as solver and post processing done in hyperview. In this study, fully loaded bus with passengers as well as maximum language mass, considered. The present study is based on the finite element analysis and design optimization of passenger sleeper bus. Number of iterations in stiffness…

Rapid Prototyping and Implementation of traction motor drive for E- Mobility

Altair Engineering India Pvt Ltd-Sreeram Mohan
Altair Engineering India Pvt , Ltd.-Srikanth R
  • Technical Paper
  • 2019-28-2472
To be published on 2019-11-21 by SAE International in United States
Objective / Question: Is it possible to extend the envelope of simulation driven design and its advantages to development of complex dynamic systems viz. traction motor drives? The objective that then follows is how to enable OEM/Tier-1s to reduce wastes in the process of traction motor controller design, development, optimization and implementation. Motor control design to validation process is time consuming and tricky! Additionally, the requirement of software knowledge to write code to implement drive engineer's control ideas. The challenges here are - to name a few - algorithm for real time, addressing memory constraints, debugging, comprehending mathematical overflows, portability & BOM cost. These introduces wastes in parameters like time, cost, performance, efficiency and reliability. Methodology: Developing a new traction motor controller for E Mobility takes 18 - 24 months typically. 2 distinct activities take place in a loop. One is the motor drive engineer who has good understanding of the motor, requirement demands on the motor & digital control of the motor and the second is the software engineer who has a good understanding…

Electrification System Modeling with Machine/Deep Learning for Virtual Drive Quality Prediction

General Motors Technical Center India-Brijesh Borkar, John Bosco Maria Francis, Pankaj Arora
  • Technical Paper
  • 2019-28-2418
To be published on 2019-11-21 by SAE International in United States
A virtual 'model' is generally a mathematical surrogate of a physical system and when well correlated, serves as a basis for understanding the physical system in part or in entirety. Drive Quality defines a driver's 'experience' of a blend of controlled responses to an applied input. The 'experience' encompasses physical, biological and bio-chemical perception of vehicular motion by the human body. In the automotive domain, many physical modeling tools are used to model the sub-components and its integration at the system level. Physical Modeling requires high domain expertise and is not only time consuming but is also very 'compute-resource' intensive. In the path to achieving 'vDQP (Virtual Drive Quality Prediction)' goal, one of the requirements is to establish 'well-correlated' virtual environments of high fidelity with respect to standard test maneuvers. This helps in advancing many developmental activities from a Controls and Calibration aspect. Recently, machine/deep learning have proven to be very effective in pattern recognition, classification tasks and human-level control to model highly nonlinear real world systems. This paper investigates the effectiveness of deep learning…

Assessment of Numerical Cold Flow Testing of Gas Turbine Combustor through an Integrated Approach using Rapid Prototyping and Water Tunnel

Indian Institute of Technology Madras-Ssheshan Pugazhendhi
SRM Institute of Science and Technology-Sundararaj Senthilkumar
  • Technical Paper
  • 2019-28-0051
To be published on 2019-10-11 by SAE International in United States
In the present work, it is aimed at developing an integrated approach for combustor modeling involving rapid prototyping and water tunnel testing to assess the cold flow numerical simulations; the physical model will be subjected to cold flow visualization and parametric studies and CFD analysis to demonstrate its capability for undergoing rigorous cold flow testing. A straight through annular combustor is chosen for the present study because of it has low pressure drop, less weight and used widely in modern day aviation engines. Numerical Analysis has been performed using ANSYS-FLUENT. Three dimensional RANS equations are solved using k-ɛ model for the Reynolds numbers ranging from 0.64 x 10^5- 1.5 x 10^5 based on the annulus diameter. Post processing the results is done in terms of jet penetration, formation of re-circulation zone, effective mixing, flow split and pressure drop for different cases. Physical combustor models are fabricated using Rapid prototyping with Poly Lactic Acid material and approximated 2D combustor model is used for capturing important flow patterns using high speed camera in 2D water tunnel, and…

Damage Analysis of Composite Laminates

GITAM School of Technology-Palaniammal Rajamani, Nathi Venu Kumar
  • Technical Paper
  • 2019-28-0092
To be published on 2019-10-11 by SAE International in United States
The favourable mechanical properties of Composite materials are excellent stiffness/weight and strength/weight ratios, easy formability and corrosion resistance. The application of composites in structural components is still limited by the difficulty in predicting their service lives. The objective of this research paper is to develop and evaluate damage initiation or delamination onset and growth in a C-C composite 8 layered pre-preg material 3D laminate model (dimension 25x3.4x85mm and ply thickness 1mm) under various loading conditions for two cases, one without crack and another with crack using ANSYS Autodyne tool subjected to a uni-axial load of 40N at the free end. Mapped quadrilaterals mesh is generated with 2610 nodes and 1792 elements. Cohesive Zone Model (CZM) formulations are more powerful than Fracture Mechanics approaches because they allow the prediction of both initiation and crack propagation. The composite laminate plate is thus bent due to Poisson effect, and crack opens up due to the heavy normal stress at the crack interface and the strain energy variation is uniform in length direction for pre-preg model. The bonding ply…

Modeling tracked vehicle to determine undercarriage performance

John Deere India Pvt. Ltd.-Goutam Shriyan, Vikas Vithal Kshirsagar
  • Technical Paper
  • 2019-28-0116
To be published on 2019-10-11 by SAE International in United States
In tracked vehicles, the undercarriage frame components such as track shoes, sprocket, idler, rollers and their configuration plays an important role while transferring the loads from the ground to the main frame. In order to understand the loads coming on the upper frame, it is important to model the undercarriage components. This paper presents the methodology for modeling undercarriage tracked frame dynamics. A 3D model of tracked vehicle was developed using commercial available Multi-Body Dynamics tool and validated against test results. The contact parameters between ground and track shoes was determined by varying their values within a defined range based on empirical data available. The undercarriage performance was measured by determining the power required by the hydrostatic drivetrain motor. The contact friction between the sprocket and the track shoe is important to properly transfer the motion from the sprocket to track chain. This value is determined by measuring the power required in the test and adjusting the friction value accordingly in the model. This model can be used to determine the loads on the undercarriage…

Design and Implementation of Digital Twin for Predicting Failures in Automobiles using Machine Learning Algorithms

VIT Universtity-Kalivaradhan Ramesh Babu
Vellore Institute of Technology-Ponnuraman Balakrishnan, Chooriyaparambil Damodaran Naiju, Muthaiyan Madiajagan
  • Technical Paper
  • 2019-28-0159
To be published on 2019-10-11 by SAE International in United States
The drastic technological advancements in designing autonomous vehicles and connected cars lead to substantial progression in the commercial values of automobile industries. However, these advancements force the Original Equipment Manufacturers (OEMs) to shift from feedback-based reactive business analysis to operational-data based predictive analysis thereby enhancing both the customer satisfaction as well as business opportunities. The operational data is nothing but the parameters obtained from several parts of an automobile during its operation such as, temperature in radiator, viscosity of the engine oil and force applied over the brake disk. These operational data are gathered using several sensors implanted in different parts of an automobile and are continuously transmitted to backend computers to develop Digital Twin, which is a virtual model of the physical automobile. Later, the gathered operational data are analysed using data mining algorithms to predict the failures of an automobile well in advance, better insights into performance of an automobile thereby recommending alternative design choices and remote service management of failures by a professional technician. This research work primarily focuses towards the creation…

Advanced Assembly Solutions for the Airbus RACER Joined-Wing Configuration

University of Nottingham-David Bainbridge, Konstantinos Bacharoudis, Andrea Cini, Alison Turner, Atanas Popov, Svetan Ratchev
  • Technical Paper
  • 2019-01-1884
To be published on 2019-09-16 by SAE International in United States
The Rapid And Cost Effective Rotorcraft (RACER) is being developed by Airbus Helicopters (ABH) to demonstrate a new Vertical Take-Off and Landing configuration to fill the mobility gap between conventional helicopters and aeroplanes. RACER is a compound rotorcraft featuring wings and multiple rotors. The wing arrangement suggested by ABH is defined as a staggered bi-plane joined configuration with an upper and a lower straight wing, either side of the fuselage, connected at their outboard extent to form a triangular structure. The ASTRAL consortium, consisting of the University of Nottingham and GE Aviation Systems, are responsible for the design, manufacture and assembly of the wings. Producing an optimised strategy to assemble a joined-wing configuration for a passenger carrying rotorcraft is challenging and novel. The objective of this work concerns all aspects of assembling the joined-wing structure. The joined-wing and fuselage structures will be produced independently and mated together during the final RACER assembly. A multi-stage process will deliver the joined-wing assembly and ensure it will fit to the fuselage. Producing the individual wing structures requires a…

Landing Gear Integration into Aircraft Structure in Early Design Stage

Bauhaus Luftfahrt EV-Ulrich Kling, Mirko Hornung
  • Technical Paper
  • 2019-01-1890
To be published on 2019-09-16 by SAE International in United States
The demanded development towards various emission reduction goals set up by several institutions forces the aerospace industry to think about new technologies and alternative aircraft configurations. With these alternative aircraft concepts, the landing gear layout is also affected. Turbofan engines with very high bypass ratios could increase the diameter of the nacelles extensively. In this case, mounting the engines above the wing could be a possible arrangement to avoid an exceedingly long landing gear. Thus, the landing gear could be shortened and eventually mounted at the fuselage instead of the wings. Other technologies such as high aspect ratio wings have an influence on the landing gear integration as well. To assess the difference, especially in weight, between the conventional landing gear configuration and alternative layouts a method is developed based on preliminary structural designs of the different aircraft components, namely landing gear, wing and fuselage. Simplified parametric finite element structural models for the different components are introduced. These models are used to investigate different aircraft configurations with special regard on the landing gear integration. The…

Probabilistic Method for Assessing the Stability of Multi-Axle Vehicle When Braking

Kharkiv Gymnasium № 39-Tetyana Abramova
Kharkov National Auto and Highway University-Mikhail Podrigalo, Dmytro Klets, Dmytrii Abramov
  • Technical Paper
  • 2019-01-2146
To be published on 2019-09-15 by SAE International in United States
The stability of the vehicle when braking is one of the most important operational properties that determine traffic safety. This article proposes a probabilistic method for estimating the sustainability of multi-axle vehicles based on the model of normal distribution of the stability coefficient values. The solution to the problem of stability of a multi-axle vehicle during braking is connected with the determination of the dynamic distribution of normal road reactions between the axles. To assess the stability of the vehicle is used as an indicator of the stability factor representing the ratio of the stabilizing moment to moment, the perturbing skid. When the values of the stability coefficient is greater than or equal to unity, the movement is stable, and otherwise it is unstable. For a multi-axle vehicle, determining the dynamic normal road reactions on the axles is possible after disclosing the static uncertainty of the physical model of the car, which is a multi-support beam. The solution to this problem involves the use of the "three sigma" rule. The maximum possible value of the…