Browse Topic: Finite element analysis

Items (3,397)
Based on the harmonic current injection method used to suppress the torsional vibration of the electric drive system, the selection of the phase and amplitude of the harmonic current based on vibration and noise has been explored in this paper. Through the adoption of the active harmonic current injection method, additional torque fluctuations are generated by actively injecting harmonic currents of specific amplitudes and phases, and closed-loop control is carried out to counteract the torque fluctuations of the motor body. The selection of the magnitude of the injected harmonic current is crucial and plays a vital role in the reduction of torque ripple. Incorrect harmonic currents may not achieve the optimal torque ripple suppression effect or even increase the motor torque ripple. Since the actively injected harmonic current is used to counteract the torque ripple caused by the magnetic flux linkage harmonics of the motor body, the target harmonic current command is very important
Jing, JunchaoZhang, JunzhiLiu, YiqiangHuang, WeishanDai, Zhengxing
In recent years, energy scarcity and environmental pollution have intensified globally, prompting increased research and development in new energy vehicles as countries prioritize environmental protection and energy conservation. Compared to fuel-powered vehicles, new energy vehicles have relatively larger battery volumes and weights, which can increase damage and the risk of fires and explosions in collisions. To analyze and optimize the safety performance of a specific vehicle model's battery pack, we constructed a finite element model using existing software and performed pre-processing, simulation, and analysis of modal, random vibration, and extrusion characteristics. This revealed specific damage scenarios and enabled reliability analysis under working conditions. To enhance safety and reduce mass, we parametrically modeled power pack components and optimized parameters via multi-objective genetic algorithms under three road conditions. Results indicate reduced mass and improved
Wang, Zhi
Automotive chassis components are considered as safety critical components and must meet the durability and strength requirements of customer usage. The cases such as the vehicle driving through a pothole or sliding into a curb make the design (mass efficient chassis components) challenging in terms of the physical testing and virtual simulation. Due to the cost and short vehicle development time requirement, it is impractical to conduct physical tests during the early stages of development. Therefore, virtual simulation plays the critical role in the vehicle development process. This paper focuses on virtual co-simulation of vehicle chassis components. Traditional virtual simulation of the chassis components is performed by applying the loads that are recovered from multi-body simulation (MBD) to the Finite Element (FE) models at some of the attachment locations and then apply constraints at other selected attachment locations. In this approach, the chassis components are assessed
Behera, DhirenLi, FanTasci, MineSeo, Young-JinSchulze, MartinKochucheruvil, Binu JoseYanni, TamerBhosale, KiranAluru, Phani
Vehicle restraint systems, such as seat belts and airbags, play a crucial role in managing crash energy and protecting occupants during vehicle crashes. Designing an effective restraint system for a diverse population is a complex task. This study demonstrates the practical implementation of state-of-the-art Machine Learning (ML) techniques to optimize vehicle restraint systems and improve occupant safety. An ML-based surrogate model was developed using a small Design of Experiments (DOE) dataset from finite element human body model simulations and was employed to optimize a vehicle restraint system. The performance of the ML-optimized restraint system was compared to the baseline design in a real-world crash scenario. The ML-based optimization showed potential for further enhancement in occupant safety over the baseline design, specifically for small-female occupant. The optimized design reduced the joint injury probability for small female passenger from 0.274 to 0.224 in the US NCAP
Lalwala, MiteshLin, Chin-HsuDesai, MeghaRao, Shishir
The integrated vehicle crash safety design provides longer pre-crash preparation time and design space for the in-crash occupant protection. However, the occupant’s out-of-position displacement caused by vehicle’s pre-crash emergency braking also poses challenges to the conventional restraint system. Despite the long-term promotion of integrated restraint patterns by the vehicle manufacturers, safety regulations and assessment protocols still basically focus on traditional standard crash scenarios. More integrated crash safety test scenarios and testing methods need to be developed. In this study, a sled test scenario representing a moderate rear-end collision in subsequence of emergency braking was designed and conducted. The bio-fidelity of the BioRID II ATD during the emergency braking phase is preliminarily discussed and validated through comparison with a volunteer test. The final forward out-of-position displacement of the BioRID II ATD falls within the range of volunteer
Fei, JingWang, PeifengQiu, HangLiu, YuShen, JiajieCheng, James ChihZhou, QingTan, Puyuan
Electric vehicles (EVs) have experienced significant growth, and the battery safety of EVs has drawn increased attention. However, the mechanical responses of battery during crashes have rarely been studied. Hence, the objective of this study was to understand EV battery package mechanics during side-pole crashes at different impact locations and speeds beyond regulated side-pole test with one specific speed and one location. An EV finite element (FE) model with a battery package was used. Side-pole impact simulations were conducted at four impact locations, including the baseline impact location according to side-pole impact regulation, plus three positions by moving the rigid pole 400 mm toward the back of the EV and moving the pole 400 and 800 mm toward the front of the EV. In addition, the impact velocities at 32, 50, and 80 km/h were simulated. Based on simulations, the peak relative displacement, the maximum change in gap between batteries, the maximum change in gap between the
Chen, JianBian, KeweiMao, Haojie
Neck injury is one of the most common injuries in traffic accidents, and its severity is closely related to the posture of the occupant at the time of impact. In the current era of smart vehicle, the triggered AEB and the occupant's active muscle force will cause the head and neck to be out of position which has significant affections on the occurrence and severity of neck injury responses. Therefore, it is very important to study the influences of active muscle force on neck injury responses in in frontal impact with Automatic Emergency Braking conditions. Based on the geometric characteristics of human neck muscles in the Zygote Body database, the reasonable neck muscle physical parameters were obtained firstly. Then a neck finite element model (FEM) with active muscles was developed and verified its biofidelity under various impact conditions, such as frontal, side and rear-end impacts. Finally, using the neck FEM with or without active muscle force, a comparative study was
Junpeng, XuGan, QiuyuJiang, BinhuiZhu, Feng
Triply Periodic Minimal Surface (TPMS) structures have gained significant attention in recent years due to their excellent mechanical properties, lightweight characteristics, and potential for energy absorption in various engineering applications, particularly in automotive safety. This study explores the design, manufacturing, and mechanical performance of both general and hybrid TPMS structures for energy absorption. Three types of fundamental TPMS unit cells—Primitive, Gyroid, and IWP—were modeled using implicit functions and combined to form hybrid structures. The hybrid designs were optimized by employing Sigmoid functions to achieve smooth transitions between different unit cells. The TPMS structures were fabricated using Selective Laser Melting (SLM) technology with 316L stainless steel and subjected to quasi-static compression tests. Numerical simulations were conducted using finite element methods to verify the experimental results. The findings indicate that hybrid TPMS
Liu, ZheWang, MingJieGuo, PengboLi, YouguangLian, YuehuiZhong, Gaoshuo
In this work, design optimization for the lightweight of the body frame of a commercial electric bus with the requirements of stiffness, strength and crashworthiness is presented. The technique for order preference by similarity to ideal solution (TOPSIS) is applied to calculate the components that have a great impact on the output response of the static modal model and the rear-end collision model. The thickness of the five components with the highest contribution in the two models is determined as the final design variable. Design of experiment (DOE) is carried out based on the Latin Hypercube sampling method, and then the surrogate models are fitted by the least squares regression (LSR) method based on the DOE sampling data. The error analysis of the surrogate model is carried out to determine whether it can replace the finite element (FE) model for optimization, then the optimization scheme for lightweight optimization of electric bus frame is implemented based on the algorithm of
Yang, XiujianTian, DekuanLiu, JiaqiCui, YanLin, Qiang
The electric motor is a significant source of noise in electric vehicles (EVs). Traditional hardware-based NVH optimization techniques can prove insufficient, often resulting in trade-offs between motor torque or efficiency performance. The implementation of motor control-based torque ripple cancellation (TRC) technology provides an effective and flexible solution to reduce the targeted orders. This paper presents an explanation of the mathematical theory underlying the TRC method, with a particular focus on the various current injection methods, including those that allow up to 4DOFs (degrees-of-freedom). In the case study, the injection of controlled fifth or seventh order current harmonics into a three-phase AC motor is shown to be an effective method for cancelling the most dominant sixth order torque ripple. A dedicated feedforward harmonic current generation module is developed the allows the application of harmonic current commands to a motor control system with adjustable
He, SongGong, ChengChang, LePeddi, VinodZhang, PengGSJ, Gautam
Automotive audio components must meet high quality expectations with ever-decreasing development costs. Predictive methods for the performance of sound systems in view of the optimal locations of loudspeakers in a car can help to overcome this challenge. Use of simulation methods would enable this process to be brought up front and get integrated in the vehicle design process. The main objective of this work is to develop a virtual auralization model of a vehicle interior with audio system. The application of inverse numerical acoustics [INA] to source detection in a speaker is discussed. The method is based on truncated singular value decomposition and acoustic transfer vectors The arrays of transfer functions between the acoustic pressure and surface normal velocity at response sites are known as acoustic transfer vectors. In addition to traditional nearfield pressure measurements, the approach can also include velocity data on the boundary surface to improve the confidence of the
Baladhandapani, DhanasekarThaduturu, Sai RavikiranDu, Isaac
The mechanical properties of materials play a crucial role in real life. However, methods to measure these properties are usually time-consuming and labour intensive. Small Punch Through (SPT) has non-destructive characteristics and can obtain load-displacement curves of specimens, but it cannot visually extract the mechanical properties of materials. Therefore, we designed a proprietary SPT experiment and fixture, built a finite element method (FEM) model and developed a multi-fidelity model capable of predicting the mechanical properties of steel and aluminium alloys. It makes use of multi-fidelity datasets obtained from SPT and FEM simulation experiments, and this integration allows us to support and optimize the predictive accuracy of the study, thus ensuring a comprehensive and reliable characterization of the mechanical properties of the materials. The model also takes into account variations in material thickness and can effectively predict the mechanical properties of materials
Zou, JieChen, YechaoLi, ShanshanHuayang, Xiang
The proliferation of the electric vehicle (EVs) in the US market led to an increase in the average vehicle weight due to the assembly of the larger high-voltage (HV) batteries. To comply with this weight increase and to meet stringent US regulations and Consumer Ratings requirements, Vehicle front-end rigidity (stiffness) has increased substantially. This increased stiffness in the larger vehicles (Large EV pickups/SUVs) may have a significant impact during collision with smaller vehicles. To address this issue, it is necessary to consider adopting a vehicle compatibility test like Euro NCAP MPDB (European New Car Assessment Program Moving Progressive Deformable Barrier) for the North American market as well. This study examines the influence of mass across vehicle classes and compares the structural variations for each impact class. The Euro NCAP MPDB (European New Car Assessment Program Moving Progressive Deformable Barrier) protocol referenced for this analysis. Our evaluation
Kusnoorkar, HarshaKoraddi, BasavarajGuerrero, MichaelSripada, Venu VinodTangirala, Ravi
The linear region of the side-slip mechanical properties of tires is often used in the simulation of linear monorail models for vehicles, especially in the design of active control systems. Side-slip stiffness is a key parameter in tire side-slip, and is significantly influenced by camber and load. In response to the tire industry's need for efficient acquisition of tire mechanical properties and the development of virtual prototyping technology, this paper proposes a method to address the influence mechanism of camber on side-slip in the study of tire camber side-slip prediction models. This paper analyzes the impact of camber on the linear region of tire side-slip mechanical properties at the microscopic level. It then examines the effect of camber on the side-slip condition from the perspective of tire external characteristics, combined with the tire theoretical model, to map the local characteristics of camber onto the external characteristics of tire side-slip. First, a finite
Yin, HengfengSuo, YanruWu, HaidongMin, HaitaoLiu, Dekuan
As the utilization of lithium-ion batteries in electric vehicles becomes increasingly prevalent, there has been a growing focus on the mechanical properties of lithium-ion battery cores. The current collector significantly impacts the tensile properties of the electrode and the internal fracture of the battery cell. The stripping process tends to cause additional damage to the current collector, so tensile testing is not able to obtain in-situ mechanical properties of the current collector. Therefore, nanoindentation tests are required to acquire the in situ mechanical properties of the current collector. Nanoindentation testing represents the primary methodology for the determination of the mechanical properties of thin films. The Oliver-Pharr method is the standard approach used by commercial indentation instruments for the evaluation of mechanical properties in materials. Nevertheless, this approach is constrained by the limitations imposed by the sample boundary conditions. To
Dai, RuiSun, ZhiweiPark, JeongjinXia, YongZhou, Qing
The advancement of high-performance electrification for electric vehicle (EV) development is continuously pushing the boundaries of electric motor technology. The axial flux motor (AFM) represents a promising application for high-performance EVs, offering potential advantages including up to twice the torque density and a 50% reduction in weight compared to regular IPM radial flux motors. The distinctive "pancake" configuration and high axial forces inherent to AFMs present notable NVH challenges, yet there is a lack of research exploring NVH analysis and risk assessment. In this paper, a 10-pole and 12-slot AFM motor is designed, prototyped, and tested, demonstrating the capability to deliver 320 Nm of peak torque and 140 kW of peak power. A comprehensive finite-element model is constructed, and the orthotropic stator material properties are evaluated using modal test data. The dominant axial stator modes are identified as the source of resonances in the system responses. A three
He, SongJensen, WilliamForsyth, AlexanderChang, LeZhang, PengGong, ChengYao, JianZou, YushengFedida, VincentDuan, ChengwuGSJ, Gautam
Virtual prototyping enables tires to be involved in automotive research and development (R&D) at an early stage, eliminating the trial-and-error process of physical tire samples and effectively reducing time and costs. Semi-empirical/empirical tire models are commonly used to evaluate vehicle-tire virtual mating. To parameterize these models, finite element (FE) simulations are necessary, involving combinations of sideslip, camber, and longitudinal slip under various loads. This paper identifies that when multiple inputs are combined, the FE simulation conditions become complex and numerous, presenting a significant challenge in virtual prototyping applications. Through an extensive analysis of more than ten tire prediction modeling methods and models in detail, this paper demonstrates the significant potential of tire prediction modeling in addressing this challenge. We begin with an overview of the current state of research in tire virtual prototyping, reviewing its application
Yin, HengfengSuo, YanruLu, DangXia, DanhuaMin, Haitao
With the widespread application of the Automatic Emergency Braking System (AEB) in vehicles, its impact on pedestrian safety has received increasing attention. However, after the intervention of AEB, the kinematic characteristics of pedestrian leg collisions and their corresponding biological injury responses also change. At the same time, in order to accurately evaluate the pedestrian protection performance of vehicles, the current assessment regulations generally use advanced pedestrian protection leg impactors (aPLI) and rigid leg impactors (TRL) to simulate the movement and injury conditions of pedestrian legs. Based on this, in order to explore the collision boundary conditions and changes in injury between vehicles and APLI and TRL leg impactors under the action of AEB, this paper first analyzes the current passive and active assessment conditions. Secondly, the simulation software LS-DYNA is used to build a finite element model of APLI and TRL impactor-vehicle collisions to
Ye, BinHong, ChengWan, XinmingLiu, YuCheng, JamesLong, YongchenHao, Haizhou
This paper focuses on the design optimization of a commercial electric bus body frame with steel-aluminum heterogeneous material orienting the performances of strength, crashworthiness and body lightweight. First, the finite element (FE) model of the body frame is established for static and side impact analysis, and the body frame is partitioned into several regions according to the thickness distribution of the components. The thicknesses of each region are regarded as the variables for the sensitivity analysis by combining the relative sensitivity method and the Sobol index method, and nine variables to which the performance indexes are more sensitive are selected as the final design variables for design optimization. Then the surrogate models are developed, and in order to improve the accuracy of the surrogate models, a model-constructing method called the particle swarm optimization BP neural network (PSO-BP) data regression prediction is proposed and formulated. In this method
Yang, XiujianTian, DekuanCui, YanLin, QiangSong, Yi
Shear Thickening Fluid (STF) exhibits tunable stiffness under varying loading velocities, making it an ideal candidate for energy absorption in transportation systems subjected to complex loading conditions, such as crash scenarios. Recent research highlights that integrating STF with conventional structures can significantly enhance overall energy absorption performance. In this study, we developed a novel sandwich plate by combining a newly designed bio-inspired 3D periodic structure with STF, aiming to create an advanced energy absorber. A finite element model of this system was developed to simulate the crush tests. Using this numerical model, we conducted additional impact simulations to investigate the effects of impact velocity on key structural responses, including force-displacement curve, as well as energy absorption. The contributions of both the fluid and solid components were analyzed. Our findings indicate that the integrated structure demonstrates superior performance
Zhu, FengDeb, Anindya
This study investigates the impact of various notch geometries on the outer surface of the rotor of an interior permanent magnet synchronous motor intended for traction applications, focusing on improving both its thermal and electromagnetic performances. Traditional motor cooling methods, such as water jackets or oil spray/impingement, typically target the stator and/or end windings, neglecting rotor cooling. As a result, the dissipation of the heat from the rotor is dependent on the heat transfer across the air gap surrounding the rotor, despite air’s poor thermal conductivity, which causes it to act as an insulator. Rotor notches are used to limit the higher order harmonics from air gap flux density which results in decreased torque ripple, cogging torque, noise, and vibration of the machine. While the effect of rotor notches on electromagnetic performance is analyzed, their impact on the thermal management of the motor, particularly the heat transfer coefficient in the air gap
Zajac, ArthurDe Silva, BuddhikaLee, SunMistry, JigarNasirizarandi, RezaJianu, OfeliaKar, Narayan
Triply periodic minimal surface (TPMS) structure, demonstrates significant advantages in vehicle design due to its excellent lightweight characteristics and mechanical properties. To enhance the mechanical properties of TPMS structures, this study proposes a novel hybrid TPMS structure by combining Primitive and Gyroid structures using level set equations. Following this, samples were fabricated using selective laser sintering (SLS). Finite element models for compression simulation were constructed by employing different meshing strategies to compare the accuracy and simulation efficiency. Subsequently, the mechanical properties of different configurations were comprehensively investigated through uniaxial compression testing and finite element analysis (FEA). The findings indicate a good agreement between the experimental and simulation results, demonstrating the validity and accuracy of the simulation model. For TPMS structures with a relative density of 30%, meshing with S3R
Tang, HaiyuanXu, DexingSun, XiaowangWang, XianhuiWang, LiangmoWang, Tao
This paper investigates the development of a Finite Element model of a Mixed Service Drive truck tire sized 315/80R22.5 equipped with thermal simulating properties. The physical experiments were performed at a high-speed track in Hällered, Sweden for the truck combination travelling at a constant speed of 80 km/h. For this investigation, the Gross Combination Weight is approximately 42 metric tons. In the Finite Element Analysis environment, ESI Virtual Performance Solutions, the truck tire is designed with hyperelastic Ogden solid rubber definitions. The Ogden material definition is used in this application as it is more suitable to perform thermal and wear analysis within the Finite Element environment. The Finite Element truck tire model is simulated to increase in two different temperature rates. The truck tire model simulates the thermal build-up over time for select tires on a High-Capacity transport truck combination, particularly a driven tire on the tractor. Finite element
Ly, AlfonseCollings, WilliamEl-Sayegh, ZeinabEl-Gindy, MoustafaJohansson, IngeOijer, Fredrik
Over the last two decades many improvements have been made in stock car racing driver safety. One of these is the head surround, which is rigidly secured to and an integral part of the NASCAR (National Association for Stock Car Auto Racing, LLC) seating environment and serves as an effective restraint for head protection during lateral and rear impacts. However, previous head impact material specifications were optimized for moderate to severe impacts and did not address low severity impacts that occur frequently during typical driving, such as race restart vehicle nose-to-tail contact. This study focused on developing a test methodology for comprehensive evaluation of rear head surround materials for low, moderate and severe impacts. Specifically, this study aimed to formulate a specification that maintains previous material performance during high speed impacts, while decreasing head accelerations at low speed impacts. Quasi-static and dynamic drop tower testing of sample materials
Gray, Alexandra N.Harper, Matthew G.Mukherjee, SayakPatalak, John P.Gaewsky, James
Continuing prior work, which established a simulation workflow for fatigue performance of elastomeric suspension bushings operating under a schedule of 6-channel (3 forces + 3 moments) road load histories, the present work validates Endurica-predicted fatigue performance against test bench results for a set of multi-channel, time-domain loading histories. The experimental fatigue testing program was conducted on a servo-hydraulic 3 axis test rig. The rig provided radial (cross-car), axial (for-aft), and torsional load inputs controlled via remote parameter control (rpc) playback of road load data acquisition signals from 11 different test track events. Bushings were tested and removed for inspection at intervals ranging from 1x to 5x of the test-equivalent vehicle life. Parts were sectioned and checked for cracks, for point of initiation and for crack length. No failure was observed for bushings operated to 1 nominal bushing lifetime. After 3 nominal bushing lifetimes, cracks were
Mars, WillBarbash, KevinWieczorek, MatthewPham, LiemBraddock, ScottSteiner, EthanStrumpfer, Scott
As a kind of off-road racing car, the driving condition of Baja is extremely bad. In order to allow the driver to control the vehicle well in complex working conditions, it is particularly important to provide a comfortable and convenient driving space and handling space for the driver. In this paper, firstly, RAMSIS is used to carry out the ergonomics verification of the racing car from the comfort analysis, reachable area analysis and visual field analysis, and optimize the design of the cockpit layout of the Baja racing car. Then the NVH characteristics of the Baja racing car frame are studied, and the 12-order modal results are obtained by finite element analysis and simulation. Then the natural frequency of the frame is measured by experiments, and the experimental results are verified to match the theoretical values. The research shows that the above steps can design a comfortable driving posture and operating space for the racer and provide experience for the future layout of
Liu, Silang
Using SolidWorks software's precision capabilities, an initial 3D digital model of the tire changer was constructed and then imported into Ansys for static structural analysis. By applying different meshing forms to the bow-shaped component of the tire changer and executing an exhaustive array of load simulation solutions, the total deformation and distribution of maximum principal stress of the bow-shaped component were obtained, enabling an assessment of its stress distribution and structural response under operating conditions. According to the results of the solution calculations, the total deformation and maximum principal stress distribution obtained from the hexahedral-dominated meshing method were nearly identical to those from the surface meshing method. Based on the finite element analysis results, structural optimization design was carried out on the initial 3D model of the tire changer, mainly through the reinforcement and local hollow design to achieve the increase of
Zhu, HengjiaGao, YunyiYao, YananChao, Wang
Friction heating in solid cylindrical body contact has been an interesting subject for a long time for physicists (i.e. tribologists) and application engineers. In the current environment where the industry product, such as Diesel Rotary Pump (DRP) which operates at higher speed, the temperature rise from the friction contact is of great importance to the manufacturer for thermal safety and its environment effect. In this paper, a steady-state temperature rise under friction heating is studied on a pump roller to cam ring contact within a cyclic segment of a DRP using quasi steady thermal modeling by both the analytical solution developed to the equations from friction heating and thermal conduction and colling, and the finite element analysis (FEA) method constructed with heat flux data from actual hardware test. In addition to the analytical solution and FEA results, an experimental test was conducted to measure and collect the thermal temperature data adjacent to the contact region
Pang, Michael L.Gunturu, SrinuMothes, DaveO'Brien, Michael
With the increasing prevalence of Automatic Emergency Braking Systems (AEB) in vehicles, their performance in actual collision accidents has garnered increasing attention. In the context of AEB systems, the pitch angle of a vehicle can significantly alter the nature of collisions with pedestrians. Typically, during such collisions, the pedestrian's legs are the first to come into contact with the vehicle's front structure, leading to a noticeable change in the point of impact. Thus, to investigate the differences in leg injuries to pedestrians under various pitch angles of vehicles when AEB is activated, this study employs the Total Human Model for Safety (THUMS) pedestrian finite element model, sensors were established at the leg location based on the Advanced Pedestrian Legform Impactor (APLI), and a corresponding vehicle finite element model was used for simulation, analyzing the dynamic responses of the pedestrian finite element model at different pitch angles for sedan and Sport
Hong, ChengYe, BinZhan, ZhenfeiLiu, YuWan, XinmingHao, Haizhou
Head injuries are a common cause of fatality and long-term impairment in child occupants in motor vehicle crashes. The National Highway Traffic Safety Administration (NHTSA) has developed the Large Omnidirectional Child (LODC) Anthropomorphic Test Device (ATD) where the head was designed to match pediatric biomechanical impact response targets from previous literature. The purpose of this study was to compare experimental and computational results for eight impact directions at 45-degree increments around the LODC head under two levels of impact severity: low and high, corresponding to nominal velocities of 3.08 mm/ms and 5.42 mm/ms, respectively. The experimental setup consists of the LODC head and neck assembly rigidly attached to a circular fixture plate and a hemispherical-shaped impactor 76.2 mm in diameter. The acceleration and angular velocity responses were measured and computed from the LODC finite element (FE) head CG and compared against the experimental data. Experimental
Challa, AbhishiktNoll, Scott
Utilization of fiber-reinforced composite laminates to their full potential requires consideration of angle-ply laminates in structural design. This category of laminates, in comparison with orthotropic laminates, imposes an additional degree of challenge, due to a lack of material principal axes, in determination of elastic laminate effective properties if the same has to be done experimentally. Consequentially, there is a strong inclination to resort to the usage of “CLPT” (Classical Laminated Plate Theory) for theoretically estimating the linear elastic mechanical properties including the cross-correlation coefficients coupling normal and shear effects. As an angle-ply laminate is architecturally comprised of layers of biased orthotropic laminas (based on unidirectional or woven bidirectional fibers), an essential prerequisite for the application of CLPT is an a-priori knowledge of elastic mechanical properties of a constituent lamina. It is natural to expect that the properties of
Tanaya, SushreeDeb, Anindya
The suspension Kinematics & compliance (K&C) characteristic test bench can simulate the excitation of the road to the wheels under various typical working conditions in a quasi-static manner on the bench, enabling the measurement of the K&C characteristics of the suspension system without knowing the specific suspension structure form, parameters, etc., assisting in the entire design process of the vehicle. In this paper, aiming at various geometric source errors existing in the processing and assembly process of the K&C characteristic test bench, an evaluation method based on the homogeneous transformation matrix is proposed to establish the position error of the center of the end loading disk in the series motion chain. Firstly, the mapping relationship between the position error of the end loading disk in the series mechanism kinematic chain and the assembly error is established by using the homogeneous transformation matrix. Then, the change matrix of the coordinate system from the
Sun, HaihuaDuan, YupengWu, JinglaiZhang, Yunqing
In-Mold Graining (IMG) is an innovative production technology applied to the skin wrapping of automotive interior components. In the design of automotive interior components of door panels and instrument clusters, to overcome process-related problems, such as the thinning of grain patterns and excessive reduction in thickness, simulation of the skin vacuum forming process is required. The Thermoplastic Olefin (TPO) skin material is investigated in this paper, and a viscoelastic mechanical model for this material is established. Dynamic Mechanical Analyzer (DMA) is utilized to perform scan for frequency and temperature, and the tested data is used to obtain key model parameters of the viscoelastic constitutive model. Based on the experimental data, the study explores how to calculate the relaxation time spectrum to describe the viscoelastic properties of TPO material during the vacuum forming process. Numerical simulation of the vacuum forming process of TPO material is conducted using
Chai, BingjiGuo, YimingXie, XinxingZhang, Qu
To investigate the static and dynamic mechanical properties of air springs and their influencing factors, two models were established in this paper to calculate the static and dynamic mechanical properties of air springs, including a simulation model based on the finite element method and a mathematical calculation model based on thermodynamic theory. First, a performance calculation model for rolling lobe air springs with aluminum tubes was established, which considered the thickness of the bellow and the impact of the inflation and assembly process on the state of the bellow. The static and dynamic mechanical properties of air springs were calculated using this model, including static load-bearing capacity and static/dynamic stiffness. The calculation results showed that both the static characteristics of the air spring under isothermal conditions and the dynamic characteristics under adiabatic conditions were able to be calculated accurately. However, the changes in dynamic
Wang, SiruiKang, YingziXia, ZhaoYu, ChaoLi, JianxiangShangguan, Wen-Bin
As electric vehicles (EVs) become increasingly prevalent, ensuring the safety of their battery systems is paramount. Lithium-ion batteries, present unique safety challenges due to their high energy density and the potential for failure under certain conditions. There is an extensive amount of research on pouch and cylindrical cells, however, prismatic cells have not received similar attention. This study presents an extensive series of experimental tests conducted on prismatic cells from two different manufacturers. These tests include flat punch, hemispherical punch, axial compression and three-point bending tests, all designed to assess the cells’ mechanical properties and failure behavior. A model was developed simulating the behavior of the cell under local loading scenarios. While this paper focuses primarily on testing methodologies, initial findings and an introductory FEA model, future work will incorporate these experimental results into detailed FEA models across all loading
Patanwala, HuzefaSong, YihanSahraei, Elham
The metal inert-gas (MIG) welding technique employed for aluminum alloy automotive bumpers involve a complex thermo-mechanical coupling process at elevated temperatures. Attaining a globally optimal set of model parameters continues to represent a pivotal objective in the pursuit of reliable constitutive models that can facilitate precise simulation of the welding process. In this study, a novel piecewise modified Johnson-Cook (MJ-C) constitutive model that incorporates the strain-temperature coupling has been proposed and developed. A quasi-static uniaxial tensile model of the specimen is constructed based on ABAQUS and its secondary development, with model parameters calibrated via the second-generation non-dominated sorting genetic algorithm (NSGA-II) method. A finite element simulation model for T-joint welding is subsequently established, upon which numerical simulation analyses of both the welding temperature field and post-welding deformation can be conducted. The results
Yi, XiaolongMeng, DejianGao, Yunkai
The accurate prediction and evaluation of load-deflection behavior in bump stoppers are critical for optimizing driving performance and durability in the automotive industry. Traditional methods, such as extensive experimental testing and finite element analysis (FEA), are often time-consuming and costly. This paper introduces a machine learning-based approach to efficiently evaluate load-deflection curves for bump stoppers, thereby streamlining the design and testing process. By leveraging a comprehensive dataset that includes historical test results, material properties, and geometrical dimensions, various machine learning methods, including Gradient boosting, Random forest & XG Boost were trained to predict load-deflection behavior with high accuracy. This approach reduces the reliance on extensive physical testing and simulations, significantly enhancing the design optimization process, leading to faster development cycles and more precise performance predictions. A case study is
Hazra, SandipTangadpalliwar, Sonali
CNTs play an important role in modern engineering projects, especially in engine pistons design for the next-generation of motorcycles. This work presents a comprehensive analyses proposed project using finite element method under actual operating conditions purpose performance evaluation of a motorcycle engine piston design, investigating the suitability of four distinct materials. Precise material properties adhering to linear elastic isotropic behavior were defined within the software environment and proposed advanced nanomaterial ensuring accurate representations of the proposed under the prescribed loading scenarios. The primary objective was to identify the optimal material choice for the piston, ensuring superior strength, minimal deformation, and lightweight characteristics essential for high-performance engine applications. Moreover interpreting and understanding the dynamic behavior of common and advanced engineering materials. Through a comprehensive evaluation of the
Ali, Salah H. R.Ahmed, Youssef G. A.Ali, Amr S.H.R.
This paper presents a new regression model-based method for accurate predictions of stiffness of different glass laminate constructions with a point-load bending test setup. Numerical FEA models have been developed and validated with experimental data, then used to provide training data required for the statistical model. The multi-variable regression method considered six input variables of total glass thickness, thickness ratio of glass plies as well as high-order terms. Highly asymmetrical, hybrid laminates combining a relatively thick soda-lime glass (SLG) ply joined with a relatively thin Corning® Gorilla® Glass (GG) ply were analyzed and compared to standard symmetrical SLG-SLG constructions or a monolithic SLG with the same total glass thickness. Both stiffness of the asymmetrical laminates and the improvement percentage over the standard symmetrical design can be predicted through the model with high precision.
Yu, ChaoCleary, ThomasJoubaud, Laurentkister, EvanFisher, W Keith
The primary functions of mounts include providing structural support, sound insulation, and vibration damping. Dynamic stiffness and loss angle are critical metrics for evaluating their NVH (Noise, Vibration, and Harshness) performance. This paper examines a floating decoupler hydraulic mount featuring a long decoupler membrane track. A nonlinear lumped parameter model is developed to calculate the dynamic stiffness and loss angle. The model incorporates fluid flow in the lower chamber and variations in the support reaction force of the decoupler membrane under switching conditions. Parameters of the nonlinear lumped parameter model, including rubber stiffness, equivalent piston area, and volumetric compliance of the fluid chamber, were analyzed and calculated using the finite element method. The influence of different decoupler membrane track structures on the frequency corresponding to the minimum high-frequency dynamic stiffness was investigated based on the established model. The
Li, ShenghaoZhang, ShenglanYu, ChaoTu, XiaofengShangguan, Wenbin
With the development of additive manufacturing technology, the concept of integrated design has been introduced and deeply involved in the research of body design. In this paper, by analyzing the structural characteristics of the electric vehicle body, we designed a body in white with the additive manufacturing process, and analyzed its mechanical properties through finite element method. According to the structural characteristics of the body, the integrated structure was modeled in three dimensions using CATIA. For the mechanical properties of the body, the strength and stiffness of the body structure were simulated and analyzed based on ANSYS Workbench. The results show that for the strength of the body, the maximum stress of the simulation results was compared with the permissible stress, and the maximum stress was calculated to be less than the permissible stress under each working condition. For the body stiffness, the displacement of the body deformation was used to measure, and
Xu, ChengZhang, MingWang, TaoZhang, Tang-yunCao, CanWang, Liangmo
Evaluating the structural strength and thermal performance of electric vehicle battery packs is crucial for enhancing safety and performance. In two-wheelers, the battery pack must withstand significant vibrational forces, shocks from impacts, and accidental drops, all of which can compromise the battery's structural integrity. A failure in this regard could lead to dangerous outcomes such as short circuits, fire, or even explosions, making the robustness of the battery pack crucial for both safety and performance. Conducting physical vibration, shock, and drop tests on a battery pack is one way of proving the robustness of the design, however it is time and resource consuming leading to an iterative approach of design improvement which also demands stringent safety measures and specialized equipment’s. The present work focuses on computer-aided virtual simulations at the design stage to evaluate the structural integrity of the battery pack assembly, optimize battery design, and reduce
Shinde, PranavBalachandran, KarthikGandhi, ChaitanyaMishra, SonuDeshmukh, HarishKarve, MadhuraChittur, SrikrishnaDas, Alok
As a crucial connecting component between the powertrain and the chassis, the performance of rubber mounts is directly related to the NVH (Noise, Vibration, and Harshness) characteristics of electric vehicles. This paper proposes a double-isolation rubber mount, which, compared to traditional rubber mounts, incorporates an intermediate skeleton and features inner and outer layers of “cross-ribs”. The design parameters can be simplified to: skeleton diameter, skeleton thickness, main rib width, and main rib thickness. To comprehensively evaluate its performance, a finite element analysis (FEA) model of the proposed double-isolation rubber mount was first established in Abaqus, with static stiffness and dynamic performance analyzed separately. The results indicate that, compared to traditional rubber mounts with similar static stiffness, this design effectively controls dynamic stiffness in the high-frequency range. To expand the effective vibration isolation frequency range of the
Xu, CheKang, YingziTu, XiaofengShen, Dongming
The 2026 Formula One (F1) power unit (PU) regulations introduce significant changes, particularly in the Motor Generator Unit-Kinetic (MGU-K), allowing for increased energy recovery under braking and greater energy deployment per lap. These changes are expected to lead to higher heat generation within the electric motor during the energy recovery and deployment phases. This study presents a methodology for assessing the thermal performance of the MGU-K under the 2026 regulations, with a comparative analysis against the 2024 powertrain configuration. A hybrid F1 powertrain model, coupled with rule-based control logic, was developed in GT-Drive, adhering to both FIA 2024 and 2026 regulations. Validation of the powertrain model was performed using 2023 Qualifying 3 (Q3) data. The heat loss data derived from the simulations were integrated into a hybrid thermal model, combining lumped parameter networks with finite element thermal analysis, to predict temperature increases. Based on these
Bayram, BerkeSamuel, Stephen
Impact resistance is crucial for assessing charging pile safety and reliability. This study proposes a prediction model, called GA-BP neural network, which achieved prediction errors below 5% and reduced computation time by over 95% in comparison to finite element analysis (FEA). Initially, the charging pile impact test platform is constructed, and a matching finite element simulation model is developed. The correctness of the simulation model is then verified by integrating the experimental findings. Furthermore, the Latin hypercube approach is used to create 200 sets of simulation schemes, and using the Python programming language, the impact resistance performance indicators of charging piles are automatically collected. Next, a genetic algorithm is used to optimize the initial weight and bias of the BP neural network, lastly, fine-tune the hyperparameters in the neural network to develop a prediction model for the impact resistance performance of the charging pile. The GA-BP model
Jiang, BingyunHu, PengLiu, ZhenyuYuan, PengfeiLiu, Hui
This article takes the cover of the AC charging pile as the research object and studies the process parameters of dual-color injection molding. First, the optimal Latin hypercube experimental design is carried out by using optimization software by taking the melt temperature and mold temperature of the first shot and the second shot and the holding pressure as the influencing factors. Injection simulation is carried out based on mold flow software. A high-precision neural network model RBF is constructed according to the test factors and results. Second, based on the obtained RBF prediction model, the multi-objective NSGA-II algorithm is used for optimization. The obtained optimal combination of molding process parameters is: the melt temperature of the first shot is 266.8°C, the mold temperature is 107°C, the melt temperature of the second shot is 230.3°C, the mold temperature is 59.5°C, the holding pressure of the first shot is 95 MPa, the holding pressure of the second shot is 89.9
Liu, HaoJiang, BingyunJiang, HongHu, PengCheng, Shan
Electric vehicles (EVs) represent a significant stride toward environmental sustainability, offering a multitude of benefits such as the reduction of greenhouse gas emissions and air pollution. Moreover, EVs play a pivotal role in enhancing energy efficiency and mitigating reliance on fossil fuels, which has propelled their global sales to unprecedented heights over the past decade. Therefore, choosing the right electric drive becomes crucially important. The main objective of this article is to compare various conventional and non-conventional electric drives for electric propulsion in terms of electromechanical energy conversion ratio and the thermal response under continuous [at 12 A/mm2 and 6000 rpm] and peak [at 25 A/mm2 and 4000 rpm] operating conditions. The comparative analysis encompasses torque density, power density, torque pulsation, weight, peak and running efficiencies of motor, inverter and traction drive, electromechanical efficiency, and active material cost. This
Patel, Dhruvi DhairyaFahimi, BabakBalsara, Poras T.
For the heat dissipation design of charging equipment for electric vehicles, a study is conducted on the thermal performance and its influencing factors of a specific alternating current (AC) charging device. First, based on heat dissipation theory and CFD simulation software, the corresponding finite element model is established and verified through experiments. Next, using the verified finite element model and applying the orthogonal experimental method, the factors influencing the heat dissipation performance of the AC charging pile, such as ambient temperature, output current of the AC charging pile, and surface radiation characteristics, are investigated. Finally, a prediction model for the maximum temperature of the main board is established using the response surface method (RSM), and the effects of each factor on the maximum main board temperature are analyzed, enabling rapid prediction of the heat dissipation performance of the AC charging pile. The analysis of the orthogonal
Tang, YuYan, ChongjingLu, FeifeiJiang, BingyunBao, YidongHu, Peng
This study introduces a probabilistic analysis approach to evaluate the gear tooth strength for the hypocycloid engines, which are particularly significant in internal combustion (IC) engine applications due to their unique design and critical requirements for both efficiency and durability. The research utilizes the stress–strength interference (SSI) theory within a “design for reliability” framework to develop a robust methodology for designing the internal gear mechanism required for the hypocycloid gear mechanism (HGM) engine, in accordance with American Gear Manufacturers Association (AGMA) standard gear rating practices. This approach incorporates probabilistic factors to address variations in HGM component parameters, gear material properties, and engine operational conditions. To validate the design and ensure accuracy, a finite element method (FEM)-based verification is employed, to identify potential failure points and enhance the overall reliability of the HGM engine. The
ElBahloul, Mostafa A.Aziz, ELsayed S.Chassapis, Constantin
Temperature segregation significantly affects the compaction of asphalt mixtures and the durability of the asphalt pavement layer. Uneven cooling of the mixture during transportation is a key factor contributing to temperature segregation. This study uses finite element simulations to analyze the temporal and spatial temperature evolution during the transportation of asphalt mixtures. A temperature segregation evaluation index (TSIv) is proposed to assess the significance of various factors affecting segregation. Support vector regression (SVR), random forest regression (RFR), and extreme gradient boosting (XGBoost) models are employed to predict temperature changes during transportation and optimize the predictive models. The results indicate that the proportion of areas with a temperature difference of less than 10°C is consistently the highest, followed by areas with a temperature difference greater than 25°C, and then those with temperature differences in the ranges of 10-16°C and
Cheng, HaoMa, TaoTang, FanlongFan, Jianwei
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