Browse Topic: Scale models

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Coupled Thermo-Mechanical Simulation Framework for Structural Evaluation of Battery Pack2026-26-0414To be published on 01/16/2026
With the rapid adoption of electric vehicles (EVs), ensuring the structural integrity and thermal safety of lithium-ion battery pack has become a critical priority. Battery failures resulting from mechanical abuse, thermal stress, internal pressure build up or electrical faults may lead to structural failure. To address these challenges, it is essential to understand the coupled thermal and mechanical responses of battery structure under extreme conditions. Thermo-mechanical simulation serves as a powerful tool for predictive safety assessment and design optimization, particularly in addressing thermal propagation and pressure-induced failure events. This study presents a comprehensive coupled thermo-mechanical simulation framework designed to evaluate the structural performance of EV battery enclosures under worst-case thermal and overpressure conditions. The methodology involves high-fidelity three-dimensional modeling of the battery pack enclosure, incorporating realistic material
Bhat, Sadashiv C, Sugumar, Mohanraj
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-0280To be published on 01/16/2026
This paper presents a comprehensive numerical methodology for simulating the coupled process-structure behavior of short glass fiber-reinforced, injection-molded thermoplastics. The approach integrates elastoplastic and anisotropic material characteristics using three engineering tools: Moldflow, Digimat, and ABAQUS. It accounts for fiber orientation and injection molding defects, linking to thermo-mechanical performance. This method enables accurate virtual modeling of real-time injection-molded components by transferring anisotropic data from Moldflow to ABAQUS. In this study, short fiber orientation and potential injection molding defects such as weld lines and residual stresses are discussed using Moldflow simulation. Besides, Digimat is employed as an interface tool to facilitate the transfer of Moldflow simulation results, namely fiber orientation and material behavior in the allied configurations directly into ABAQUS. This integration enables the evaluation of thermo-mechanical
T, Kalinga, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Analysis of the Structural Alignment during the System Conversion of Continuous Beam Bridges with High Piers, Long Spans and Wide Box Girders2025-99-022412/23/2025
With the rapid development of the worldwide highway transportation industry, continuous box girder bridges have many advantages, such as superior spanning capacity, reasonable force-bearing performance, and low cost, which give them significant strengths in bridge design. However, to ensure that the structural alignment of the girder meets the design and specification requirements, it is necessary to study the laws of alignment changes of cantilever structures during the construction process. This is to reasonably control the alignment of the main girder structure during construction and ensure that the alignment of the completed bridge is consistent with the design alignment. This paper takes a continuous rigid frame bridge on a certain expressway as the engineering basis. Its superstructure is a three-span prestressed concrete continuous box girder with a span of (88 + 160 + 88) m, a bridge width of 16.5 m, and a maximum pier height of 130 m. The paper analyzes the influence of each
Liu, Xingshun, Ma, Kun, Zhao, Qiang
Combustion Chamber Pressure and Temperature Analysis Based on Heat Release Rate Parameters of a Spark Ignition Engine2025-36-008212/18/2025
Internal combustion engines have been developed and widely used since the last century, and they continue to be extensively employed today. Engine development has progressed significantly, and due to the environmental impacts caused by their use, new technologies are being developed to reduce pollutant formation after the combustion process and to increase thermal efficiency. Computational modeling is a tool that has supported this development and can be categorized into three types: zero-dimensional, quasi-dimensional, and three-dimensional models. The 0D and 1D models offer a good balance between computational processing time and result uncertainty when compared to three-dimensional models. The Wiebe function is a simple analytical approach capable of describing the fuel burn rate in combustion engines. Previous studies have shown that applying this function yields results that accurately describe the apparent heat release rate in PFI engines.The present study aims to determine the
Souza Pereira, Felipe Augusto de, Araújo Moreira, Thiago Augusto de, Filho, Fernando Antônio Rodrigues
Lateral Force Analysis of Clamping Devices and Nose Landing Gear in Cornering Conditions2025-99-030612/17/2025
To further investigate the effects of the clamping mechanism’s tilt angle and the nose landing gear’s turning angle on the lateral force of the nose landing gear during turning with a towbarless tractor, as well as the changes in the lateral force difference between the inner and outer hinges, a three-dimensional model of the towbarless tractor and the aircraft was first created using SolidWorks software. The dynamic simulation of the model under different conditions was then conducted using Adams software, followed by the analysis of the simulation results. The results indicate that introducing a positive clamping angle leads to an increase in the clamping mechanism’s tilt angle and a decrease in the nose landing gear’s turning angle as the turning radius and speed increase. Consequently, the lateral force difference between the inner and outer hinges of the nose landing gear increases, ranging from 40 kN to 70 kN. To ensure the stability of the clamping device and reduce the lateral
Gao, Jianshu, Hao, Shiyu, Liu, Ziao
An Integrated Resilience Analysis Framework for Highway Tunnel Engineering Systems Using N-K-ISM Models Based on Decoupling thinking2025-99-036412/17/2025
Before Highway tunnel engineering is a complex system undergoing various evolutionary stages and characterized by multiple risk factors. The increasing interconnection and coupling of these risk factors can lead to operational accidents or disruptive events. These coupling effects pose significant challenges for project managers in effectively managing highway tunnel systems. Traditional risk-centered analysis approaches, which focus on post-event effects and causes while paying less attention to the coupling effects among risk factors, inadequately address these challenges. To fill this gap, this study examined the resilience evolution mechanism from all life cycle perspective and proposed a multi-factor and multi-stage resilience analysis framework. This integrated framework integrates the Natural Killing (N-K) model and the Interpretive Structural Model (ISM) to analyze coupling utility and implement decoupling control of resilience factors. The N-K model measures the coupling
Wang, Chunyu, An, Jingru
Analysis of Handlebar Vibration Mechanisms and Perceptual Characteristics During Push-Walking of Electric Motorcycle2025-32-002011/03/2025
Electric motorcycles produce less vibration and noise than vehicles with internal combustion engines. However, the cogging torque of electric motors can cause vibrations, particularly at low speeds. When push-walking a motorcycle at very low speeds, this cogging torque produces handlebar vibrations, resulting in discomfort for the rider. Since motorcycles are typically turned off during push-walking, it is impossible to reduce these vibrations through motor control. Thus, reducing handlebar vibrations through motor cogging torque design is required. To simulate vibration, a detailed and large-scale model that considers the characteristics of drivetrain components like belts and gears, is required. Consequently, the optimization of vibrations in the early stages of design is challenging. The ultimate goal of this study is to construct a simulation model that can predict handlebar vibration during push-walking. This report investigates the vibration transmission mechanism. Vehicle
Okamura, Tsubasa, Otaki, Ryota, Sugaya, Atsushi, Shimizu, Tsukasa
Simulation Research on Passenger Evacuation under Sudden Fire in Metro Station2025-99-005610/17/2025
In order to improve the evacuation efficiency of sudden fire in urban rail transit station, taking the National Exhibition and Convention Center Station of Tianjin Rail Transit Line 1 as the research object, a three-dimensional model of the station is established. Based on the evening peak passenger flow on October 1, 2023, the parameters were calculated and reasonably set in the Pathfinder software to simulate the evacuation process of 3316 people in the fire scene of train arrival, and the evacuation process of sudden fire in the station is simulated. The simulation results show that the station can basically ensure the safe emergency evacuation within 6 minutes under the existing conditions. The stairs, escalators, automatic gate machine and passageways in the station are identified as the evacuation bottlenecks. The total time for all station personnel to evacuate outside the metro station is 514.8 s. According to the simulation results, some suggestions on evacuation strategy and
Fu, Yanrong, Wang, Lianxia, Li, Yijuan, Liu, Yibo, Wang, Duolong
Augmenting a Thermal and Infrared Signature Simulation Tool for Use on Hybrid Electric Ground Vehicles2025-01-047909/16/2025
Thermal or infrared signature management simulations of hybrid electric ground vehicles require modeling complex heat sources not present in traditional vehicles. Fast-running multi-physics simulations are necessary for efficiently and accurately capturing the contribution of these electrical drivetrain components to vehicle thermal signature. The infrared signature and heat transfer simulation tool, “Multi-Service Electro-optic Signature” (MuSES), is being updated to address these challenges by expanding its thermal-electrical simulation capabilities, provide a coupling interface to system zero- and one-dimensional modeling tools, and model three-dimensional air flow and its convection effects. These simulation capabilities are used to compare the infrared signatures of a tactical ground vehicle with a traditional powertrain to a hybrid electric version of the same vehicle and demonstrate a reduction in contrast while operating under electrically powered conditions of silent watch and
Patterson, Steven, Edel, Zachary, Pryor, Joshua, Rynes, Pete, Tison, Nathan, Korivi, Vamshi
Correlation of NVH Model for Extended Range Generator in Electric Vehicle2025-01-007705/05/2025
Electrification in the automotive industry has been steadily rising in popularity for many years, and with any technology there is always a desire to reduce development cost by efficiently iterating designs using accurate simulation models. In the case of rotating machinery and other devices that produce vibrations, an important physical behavior to simulate is Noise Vibration and Harshness (NVH). Efficient workflow to account for NVH was established at Schaeffler for eMotor design. Quantitative prediction is difficult to achieve and is occasionally intended only for faster iterations and trend prediction. A good validated qualitative simulation model would help achieve early NVH risk assessment based on the specified requirement and provide design direction and feasibility guidance across the design process to mitigate NVH concerns. This paper seeks to provide a general approach to validate the simulation model. The correlation methods used in this paper consist of a combination of
Proben, Joel, Huang, Fatao, Pasagada, Keerti Vardhan, Hilty, Drew
Capillary Transport Analysis in Macro-Homogeneous Diffusion Media of PEM Fuel Cells2025-01-854604/01/2025
The interplay of electrochemistry, two-phase flow, and heat transfer generates complex transport phenomena within the porous materials of fuel cells that are not yet fully understood. This lack of comprehensive understanding complicates the modeling of liquid water transport, which is critical because the hydration of the polymer electrolyte membrane significantly impacts the cell performance. The liquid water transport mechanisms in porous media can be explained by capillary force, hydraulic permeation and gravity effects, as well as water condensation and evaporation. In general, the liquid water transport is mainly driven by the capillary force, while body forces, such as gravity, do not significantly affect its momentum. Due to limited experimental data on capillary pressure and saturation in gas diffusion media, the Leverett approach has been widely used for modeling liquid water transport in PEMFCs. The Leverett approach is a polynomial fitting of capillary pressure data for
Marra, Carmine, Croci, Federico, Fontanesi, Stefano, Berni, Fabio, D'Adamo, Alessandro
Robust V2X Cruise Control for Class 8 Trucks in the Presence of Traffic Lights2025-01-803304/01/2025
An implementation of a robust predictive cruise control method for class 8 trucks utilizing V2X communication with connected traffic lights is presented in this work. This method accounts for traffic signal phases with the goal of reducing energy consumption when possible while respecting safety concerns. Tightened constraints are created using a robust model predictive control (RMPC) framework in which constraints are modified so that the safety critical requirements are satisfied even in the presence of disturbances, while requiring only the expected bounds of the disturbances to be provided. In particular, variation in the actuator performance under different conditions presents a unique challenge for this application, which the approach applied in this work is well-suited to handle. The errors resulting from lower-level control and actuator performance are accounted for by treating them as bounded and additive disturbances on the states of the model used in the higher level MPC
Ellison, Evan, Ward, Jacob, Brown, Lowell, Bevly, David M.
Effectiveness of Seat’s Negative Stiffness Structure on Three Different Models of Vehicles15-18-02-001102/08/2025
The effectiveness of the negative suspension structure (NSS) in isolating the driver’s seat vibrations has been demonstrated based on the seat’s model or vehicle’s one-dimensional dynamic model. To fully assess the effectiveness and stability of the seat’s NSS (S-NSS) on different models of vehicles, the three-dimensional models of the vibratory rollers (VR), heavy trucks (HT), and passenger cars (PC) have been built to assess the effectiveness of S-NSS compared to the seat’s passive suspension (S-PC) and seat’s control suspension (S-CS). The effectiveness of S-NSS is then investigated under all operating conditions of vehicles. The investigation results indicate that under a same simulation condition, S-NSS improves the ride comfort and health of the driver better than both S-PS and S-CS on all VR, HT, and PC. However, the effectiveness of S-NSS on PC is lower than on both VR and HT while the effectiveness of S-CS on PC is better than on both VR and HT. Besides, the effectiveness of S
Su, Beibei, Wang, Qiang, Song, Fengxiang
Research on the Characteristics of an Integrated Thermoelectric Generation, Catalytic Conversion, and Noise Suppression System2025-01-706201/31/2025
In the context of global energy shortages and increasing environmental pollution, improving energy efficiency in automobiles has become a key area of research. Traditional internal combustion engines exhibit low energy conversion efficiency, with a significant portion of fuel energy wasted as exhaust heat. To address this issue, this paper proposes an integrated thermoelectric generation, catalytic conversion, and noise suppression system (ITGCMS) aimed at recovering waste heat from vehicle exhaust, while optimizing emissions and noise reduction through the combination of a catalytic converter and a muffler. A three-dimensional model was established using COMSOL software to thoroughly analyze the system's thermoelectric generation, catalytic conversion, and acoustic performance. The study found that Model B demonstrated the best thermoelectric performance, with an average surface temperature of 300.2°C and a more uniform temperature distribution across the thermoelectric modules
Wu, Ji-Xin, Su, Chu-Qi, Wang, Yi-Ping, Yuan, Xiao-Hong, Liu, Xun
Cooling Characteristics and Optimization of an Air-Cooled Battery Pack2025-01-701601/31/2025
Lithium-iron phosphate batteries are widely used in energy storage systems and electric vehicle for their favorable safety profiles and high reliability. The designing of an efficient cooling system is an effective means of ensuring normal battery operation, improving cycle life, and preventing thermal runaway. In this paper, we proposed a forced-convection air cooling structure aiming at uniform temperature distribution and reducing the maximum temperature. The initial step was constructing a heating model for a single LiFeO4 battery. A source function was derived from the experimental data, which described the variation in heating power with discharge depth. This function was then used to create a dynamic loading of the battery heating model. Subsequently, a three-dimensional model of a 7-series and 2-parallel battery pack was constructed. Seven schemes were designed on the basis of the traditional Z-shaped structure, with the position of the air inlet and outlet altered. The
Zhang, Junhong, Liu, Ting, Dai, Huwei, Lin, Jiewei
Computational Modeling of Aerodynamic Design Trends for a Production SUV Subjected to Incremental Design Changes: Roof Spoiler and Underbody Geometry15-18-01-000611/21/2024
In this work, we evaluated computational fluid dynamics (CFD) methods for predicting the design trends in flow around a mass-production luxury sport utility vehicle (SUV) subjected to incremental design changes via spoiler and underbody combinations. We compared Reynolds-averaged Navier–Stokes (RANS) using several turbulence models and a delayed detached eddy simulation (DDES) to experimental measurements from a 40% scale wind tunnel test model at matched full-scale Reynolds number. Regardless of turbulence model, RANS was unable to consistently reproduce the design trends in drag from wind tunnel data. This inability of RANS to reproduce the drag trends stemmed from inaccurate base pressure predictions for each vehicle configuration brought on by highly separated flow within the vehicle wake. When taking A-B design trends, many of these errors compounded together to form design trends that did not reflect those measured in experiments. On the other hand, DDES proved to be more
Aultman, Matthew, Disotell, Kevin, Duan, Lian, Metka, Matthew
Evaluation of an Unsteady Yaw, Gust, and Broadband Turbulence Generation System for Closed-Loop Automotive Wind Tunnels15-18-01-000510/25/2024
This study investigates the flow characteristics in the test section of a model-scale, three-quarters open-jet, closed-loop return wind tunnel equipped with a novel device featuring three subsystems to generate transient yaw, gusts, and turbulence. The effect of each subsystem on the resulting turbulent and unsteady flows is evaluated individually and simultaneously. It is demonstrated that this new turbulence generation system can generate yaw distributions with standard deviations ranging from 2.1° to 8.0°. This replicates a wide range of on-road yaw behavior. Additionally, the subsystems can activate transient yaw events and unsteady gusts. Frequency sweeping was demonstrated to fill a wide range of low-frequency spectra, which helps recreate the on-road flow spectra in wind tunnels. Unsteady gusts of more than 15% of the mean flow velocity were achieved. The active turbulence subsystem generates turbulence levels from a few percent, passively, to over 20% intensity levels actively
Cacho, Gemiel, Marques, Joshua, Van Every, David, Waudby-Smith, Peter, Hanson, Ronald
Ride Comfort Efficiency of Passenger Car’s Seat Using the Structure of Negative Stiffness with Various Dynamic Models15-18-01-000310/03/2024
Three dynamic models of a passenger car including the one-dimensional dynamic model, two-dimensional dynamic model, and three-dimensional dynamic model are built to evaluate the ride quality of the passenger car as well as the isolating performance of the SNS (structure of negative stiffness). The decrease of the root-mean-square (RMS) accelerations in the seat and car’s body shaking is the research goal. The investigation results indicate that under all working conditions including the various excitations of the road surface and various velocities of the passenger car, the seat’s acceleration with SNS is strongly ameliorated in comparison without SNS in all three models of the passenger car. Particularly, the RMS seat acceleration with SNS in one-, two-, and three-dimensional models is strongly reduced in comparison without SNS by 76.87%, 66.15%, and 70.59%, respectively. Thus, the seat’s SNS has a good effect in isolating the vertical vibration of the passenger car’s seat. However
Zhang, Lei, Li, Tao, Yang, Guixing
Modelling of Energy Scavenging from Rolling Tyres Using Contact-Separation Mode Triboelectric Nano Generators for Self Powered Electric Vehicles2024-28-005809/19/2024
Due to its affordability and environmental friendliness, triboelectric nanogenerators, or TENGs, are a promising and alluring energy harvesting technology. Here, time-dependent finite-element numerical simulations were used to study the performance of dielectric-dielectric TENGs operating in the contact-separation mode. The open-circuit voltage, short-circuit current, and ideal resistance were measured in order to assess the TENG's performance. The findings are consistent with the physical models that are now available for the short-circuit current, which show that the current increases (decreases) with the area of the TENG (the thickness of the material). The open circuit voltage differed from published models according to the area and thickness of the material; the causes for this discrepancy are provided. Because high load resistance values affect charge flow in the TENG cycle (transient state) and performance, a deeper understanding of their effects is also offered. Here, the
P, Geetha, Satyam, Satyam, Jothiprashanth, R
Modeling of Vibrational Energy Collection for Self Powered Electric Vehicles Using Soft-Contact Triboelectric Nanogenerator2024-28-006509/19/2024
In light of global warming and power issues, reducing carbon emissions through the use of renewable energy sources has become a global concern. A ubiquitous mechanical motion in daily life is vibration, and one of the hot topics in this field of study is how to capture vibrational vitality and transform it to electrical power. Vibration dynamism can be captured by utilizing tribo-electric nano generators, which operate on the principles of electrostatic induction electrification due to contacts. COMSOL software is used to simulate the interaction between the voltage between the electrodes, the transferred charge, and the electrode moving distance of a triboelectric nanogenerator. A brief description of the simulation process is provided in this work, along with a theoretical interpretation of the simulation outcome. The experimental results revealed that increasing the rpm from 10 to 1000 per second led to substantial increase in Isc from 1.35nA to 225nA, cause enhanced triboelectric
P, Geetha, Jothiprashanth, R
Multiscale and Multidomain Digital Twins for Vehicle Thermal Management Applications2024-28-011409/19/2024
Effective thermal management is crucial for vehicles, impacting both passenger comfort and safety, as well as overall energy efficiency. Electric vehicles (EVs) are particularly sensitive to thermal considerations, as customers often experience range anxiety. Improving efficiency not only benefits customers by extending vehicle range and reducing operational costs but also provides manufacturers with a competitive edge and potential revenue growth. Additionally, efficient thermal management contributes to minimizing the environmental impact of the vehicle throughout its lifespan. Digital twins have gained prominence across various industries due to their ability to accelerate development while minimizing testing costs. Some applications have transitioned to comprehensive three-dimensional models, while others employ model reduction techniques or hybrid approaches that combine different modeling methods. The discovery of unknown working mechanisms, more efficient and effective control
Palacio Torralba, Javier, Kapoor, Sangeet, Jaybhay, Sambhaji, Locks, Olaf, Kulkarni, Shridhar Diliprao, Shah, Geet
Neural-Network-Based Modeling of SCR Systems for Emission Simulation: A Comprehensive Approach2024-24-004209/18/2024
Selective Catalytic Reduction (SCR) systems are crucial for automotive emissions control, as they are essential to comply with stringent emissions regulations. Model-based SCR controls are used to minimize NOx emissions in a broad range of real-word driving scenarios, constantly adapting the urea injection to diverse load and temperature operating conditions, also accounting for different catalyst ageing status. In this framework, Neural Networks (NN) based models offer a promising alternative to reduced-order physical models or map-based controls. This study introduces a hybrid modeling approach for SCR systems, leveraging the integration of machine learning techniques with detailed physics-based models. A high fidelity 1D-CFD plant model of a SCR catalyst, previously calibrated on experimental data, was used as digital twin of the real component. A standardized simulation protocol was defined to virtually characterize the SCR thermal and chemical behavior under the full range of
Sapio, Francesco, Aglietti, Filippo, Ferreri, Paolo, Savuca, Alexandru
Multi-Scale Modeling of Selective Laser Melting Process2024-26-041506/01/2024
The Selective Laser Melting (SLM) process is employed in high-precision layer-by-layer Additive Manufacturing (AM) on powder bed and aims to fabricate high-quality structural components. To gain a comprehensive understanding of the process and its optimization, both modeling and simulation in conjunction with extensive experimental studies along with laser calibration studies have been attempted. Multiscale and multi-physics-based simulations have the potential to bring out a new level of insight into the complex interaction of laser melting, solidification, and defect formation in the SLM parts. SLM process encompasses various physical phenomena during the formation of metal parts, starting with laser beam incidence and heat generation, heat transfer, melt/fluid flow, phase transition, and microstructure solidification. To effectively model this Multiphysics problem, it is imperative to consider different scales and compatible boundary conditions in the simulations. In this paper, we
Varma, Aditya, Ganesh, Kona Veera, Roy Mahapatra, Debiprosad
A Virtual Calibration Strategy and Its Validation for Large-Scale Models of Multi-Sheet Self-Piercing Rivet Connections05-17-03-001604/29/2024
This article presents a strategy for the virtual calibration of a large-scale model representing a self-piercing rivet (SPR) connection. The connection is formed between a stack of three AA6016-T4 aluminum sheets and one SPR. The calibration process involves material characterization, a detailed riveting process simulation, virtual joint unit tests, and the final large-scale model calibration. The virtual tests were simulated by detailed solid element FE models of the joint unit. These detailed models were validated using experimental tests, namely peeling, single-lap joint, and cross-tests. The virtual parameter calibration was compared to the experimental calibration and finally applied to component test simulations. The article contains both experiments and numerical models to characterize the mechanical behavior of the SPR connection under large deformation and failure.
André, Victor, Costas, Miguel, Langseth, Magnus, Morin, David
Implementing Ordinary Differential Equation Solvers in Rust Programming Language for Modeling Vehicle Powertrain Systems2024-01-214804/09/2024
Efficient and accurate ordinary differential equation (ODE) solvers are necessary for powertrain and vehicle dynamics modeling. However, current commercial ODE solvers can be financially prohibitive, leading to a need for accessible, effective, open-source ODE solvers designed for powertrain modeling. Rust is a compiled programming language that has the potential to be used for fast and easy-to-use powertrain models, given its exceptional computational performance, robust package ecosystem, and short time required for modelers to become proficient. However, of the three commonly used (>3,000 downloads) packages in Rust with ODE solver capabilities, only one has more than four numerical methods implemented, and none are designed specifically for modeling physical systems. Therefore, the goal of the Differential Equation System Solver (DESS) was to implement accurate ODE solvers in Rust designed for the component-based problems often seen in powertrain modeling. DESS is a text-based
Steuteville, Robin, Baker, Chad
Reduced Order Modeling Technology with AI for Model-Based-Development2024-01-285004/09/2024
This paper introduces reduced-order modeling techniques with Artificial Intelligence (AI) for Model-Based Development (MBD). In vehicle development, detailed physical models are replaced by reduced-order models (ROM) to expedite simulations. With recent advancements in AI-based reduced-order modeling, it is expected that modeling work will become more efficient, leading to reduced simulation times. However, the range of simulations (Model-in-the-Loop Simulation - MILS, Hardware-in-the-Loop Simulation - HILS, bench-system) compatible with ROM is limited. To overcome this limitation, this study leverages the ONNX format (Open Neural Network Exchange), a universally supported format among machine learning frameworks, and the Functional Mock-up Interface (FMI), a standard interface format for simulation tools, to enable general-purpose embedded technology with ROM. This study employs a vehicle model in engine surge simulations to validate AI-based reduced-order modeling for MBD. In MILS
Inagaki, Takahiro, Nasu, Tadaaki, Takeshige, Minoru, Iwata, Motofumi, Nakane, Naoto
Lightweight Design of Integrated Hub and Spoke for Formula Student Racing Car2024-01-208004/09/2024
In the racing world, speed is everything, and the Formula Student cars are no different. As one of the key means to improve the speed of the car, lightweight plays an important role in the racing world. The weight reduction of unsprung metal parts can not only improve the driving speed, but also effectively optimize the dynamic of the car, so the lightweight design of unsprung parts has attracted much attention. In the traditional Formula Student racing car, the hub and spoke are two independent parts, they are fixed by four hub bolts or a central locking nut, the material of these fasteners is usually steel, so it brings a lot of weight burden. In order to achieve unsprung lightweight, a new type of wheel part design of Formula Student racing car is proposed in this paper. The hub and spoke are designed as integrated aluminum alloy parts, effectively eliminating the mass of hub bolts or central locking nuts. After proper iterative optimization, the part achieves a weight reduction of
Cui, Jiarui, Chen, Yichao
Parameter Identification of Constitute Model of Glass Fiber Reinforced Polypropylene under Adiabatic Temperature Rise Loads2024-01-235504/09/2024
To characterize the stress flow behavior of engineering plastic glass fiber reinforced polypropylene (PPGF) commonly used in automotive interior and exterior components, mechanical property is measured using a universal material testing machine and a servo-hydraulic tensile testing machine under quasi-static, high temperature, and high strain rate conditions. Stress versus strain curves of materials under different conditions are obtained. Based on the measured results, a new parameter identification method of the Johnson-Cook (J-C) constitutive model is proposed by considering the adiabatic temperature rise effect. Firstly, a material-level experiment method is carried out for glass fiber reinforced polypropylene (PPGF) materials, and the influence of wide strain rate range, and large temperature span on the material properties is studied from a macroscopic perspective. Then, the model parameters of the J-C constitutive model are identified based on the experimental data, and the
Zheng, Wei-Jun, Liu, Xiao-Ang, Shangguan, Wen-Bin, Zhang, Qu, Gu, Chen-guang
Electrification and Control of a 1:5 Scale Vehicle for Automotive Testing Methodologies2024-01-227104/09/2024
The design and testing of innovative components and control logics for future vehicular platform represents a challenging task in the automotive field. The use of scale model vehicles constitutes an interesting alternative for testing assessment by decreasing time and cost efforts with a potential benefit in terms of safety. The target of this research work is the development of a customized scale vehicle platform for verifying and validating innovative control strategies in safe conditions and with cost reduction. Consequently, the electrification of a radio-controlled 1:5 scale vehicle is carried out and a customized remote real-time controller is installed onboard. One of the main features of this commercial product is its modular characteristics that allows the modification of some component properties, such as the viscous coefficient of the shock absorbers, the stiffness of the springs and the suspension geometry. The original vehicle is equipped with a 2-stroke internal
Vella, Angelo Domenico, Biondo, Luca, Tota, Antonio, Vigliani, Alessandro
Research on Vibration Test and Dynamic Balancing of Laying Head Rotor2024-01-502502/21/2024
Wire rod is one of the important products of modern manufacturing. Laying head is widely used for wire rod coiling and storage. Rotors of laying head are typical rotating equipment in which vibration during operation is inevitable. To address the problem of achieving precise dynamic balance for the laying head rotor with complex and asymmetrical structures, a vibration test is performed on the rotor to determine its primary cause. Modal analysis is conducted on the laying head rotor using finite element analysis, with the critical speed calculated. Unbalance response analysis of the rotor is executed, coupled with the rotor structure to identify appropriate balancing planes. The rotor’s three-dimensional model is used to calculate the distribution of the unbalance amount. The balancing process effectively decreased the rotor’s eccentricity and vibration intensity with no significant increase in overall mass, meeting operational requirements. This method significantly increased
Tang, Yue
Experimental Study on Ship Squat in Intermediate Channel09-12-01-000511/09/2023
The sinking and trimming of the hull in the channel would directly affect the handling and navigation safety of the ship. In view of the ship sinking, a series of empirical formulas to estimate the subsidence have been put forward for vessel in spacious shallow water areas. However, most of the equations are based on seagoing vessels. They are not suitable for inland ships with small scales, shallow drafts, and narrow navigation width. Till now, research on ship squat in intermediate channel has not yielded more practical results. Here, a generalized physical model is used to study the sinking of 500t class ships in restricted intermediate channel under different channel widths, water depths, and speeds. The main factors affecting the squat are analyzed, the empirical relation is compared with the measured squat. The Barrass equation is modified, and the calculation relation of the settlement suitable for inland river ships is proposed. The correlation coefficient R 2 of the modified
Long, Liji, Miao, Jilun, Zhao, Wanxing, Huang, Chenglin
Calculation of Thermal Boundary Conditions for Hydrogen Internal Combustion Engines2023-01-167510/31/2023
Hydrogen has been identified as a promising decarbonization fuel in internal combustion engine (ICE) applications in many areas including heavy-duty on- and off-road, power-generation, marine, etc. Hydrogen ICEs can achieve high power density and very low tailpipe emissions. However, there are challenges; designing systems for a gaseous fuel with its own specific mixing, burn rate and combustion control needs, which can differ from legacy products. The primary pollutant of concern for Hydrogen ICEs is NOx which can be addressed by running the engine at very lean equivalence ratios and the use of Exhaust Gas Recirculation (EGR). Computation Fluid Dynamics (CFD) is a valuable tool to model the combustion characteristics under different conditions, as presented in SAE-2023-01-0197 [1], which can also be used to predict thermal loading. Being able to determine the thermal distribution and temperatures of the power cylinder components has always been critical to the design and development
Bell, David, Grimley, Peter, Hynous, Jan, Shapiro, Evgeniy, Osborne, Richard, Valenta, Lukáš
Transient Temperature Field Prediction of PMSM Based on Electromagnetic-Heat-Flow Multi-Physics Coupling and Data-Driven Fusion Modeling2023-01-703110/30/2023
With the increase of motor speed and the deterioration of operating environment, it is more difficult to predict the transient temperature field (TTF). Meanwhile, it is difficult to obtain the temperature test dataset of key nodes under various complete road conditions, so the cost of bench test or real vehicle test is high. Therefore, it is of great significance to establish a high fidelity, lightweight temperature prediction model which can be applied to real vehicle thermal management for ensuring the safe and stable operation of motor. In this paper, a physical model simulating electromagnetic-heat-flow multi-physical coupling of permanent magnet synchronous motor (PMSM) in electric drive gearbox (EDG) is established, and the correctness of the model is verified by the actual EDG bench test. Secondly, combined with the high order lumped parameter thermal network (LPTN) model derived from the multi-physics coupling model, the ten-node thermal network model of PMSM is established by
Tang, Peng, Zhao, Zhiguo, Li, Haodi
Virtual Sensors in Small Engines – Previous Successes and Promising Future Use Cases2023-01-183710/24/2023
Virtual sensing, i.e., the method of estimating quantities of interest indirectly via measurements of other quantities, has received a lot of attention in various fields: Virtual sensors have successfully been deployed in intelligent building systems, the process industry, water quality control, and combustion process monitoring. In most of these scenarios, measuring the quantities of interest is either impossible or difficult, or requires extensive modifications of the equipment under consideration – which in turn is associated with additional costs. At the same time, comprehensive data about equipment operation is collected by ever increasing deployment of inexpensive sensors that measure easily accessible quantities. Using this data to infer values of quantities which themselves are impossible to measure – i.e., virtual sensing – enables monitoring and control applications that would not be possible otherwise. In this concept paper, we provide a short overview of virtual sensing and
Ofner, Andreas Benjamin, Sjoblom, Jonas, Posch, Stefan, Neumayer, Markus, Geiger, Bernhard, Schmidt, Stephan
Digital High-Speed Photography of Cavitation in Journal Bearings2023-32-016309/29/2023
This paper presents current research comparing gaseous and vaporous cavitation in lubricant flows obtained by means of digital high-speed photography in un-precedented detail. Hydrodynamic journal bearings are compact and guarantee a nearly wear- resistant operation. These features make journal bearings the first choice for many applications. However, under particular operational conditions, e.g. a highly dynamic load, cavitation can occur which can lead to bearing failures. For the selected case of suction cavitation these conditions are characterized by high eccentricity combined with a rapid variation of the lubricating film thickness. The work at hand presents a new experimental approach to study suction cavitation in a scaled bearing model. Moreover, mechanical and fluid dynamic similarity laws are described which enable the transfer of bearing operation conditions into the model experiment and vice versa. An extensive literature research yields the parameters of operating
Reinke, Peter, Rienaecker, Adrian, Schmidt, Marcus, Beckmann, Tom
Secondary Cooling Based Thermal Management System for Electric Commercial Vehicle-An Environment Friendly Solution2023-28-000209/14/2023
Global climate change is a major concern worldwide and most refrigerants which are being used today are Hydro-fluorocarbon (HFC), which are potent green house gases. With the rising popularity of electric vehicles, there has been an increased demand for effective and efficient cooling system, not only for cabin cooling for bus but for battery pack Thermal Management Systems also. This has led to an increase in the refrigerant amount and it is even more in case of commercial electric vehicle. Alternate refrigerant with low global warming potential like R1234yf (GWP = 4), Co2 (GWP = 1), R- 152a (GWP = 124) emerged to cater this challenge; But due to their high cost, risk regarding flammability and relative performance, some researchers found secondary loop cooling system as the next possible solution. In secondary loop cooling system Water-Ethylene glycol mixture circulate inside the vehicle cabin and exchange heat with refrigerant loop, which primarily circulate in small loop outside
Sharma, Nishant, Goel, Arunkumar, Suman, Saurabh, Kushwah, Yogendra Singh
A Joint Work to Develop a Predictive 1D Modelling Approach for Heavy Duty Gaseous Fueled Engines through Experiments and 3D CFD Simulations2023-24-000708/28/2023
The present paper reports experimental and numerical research activities devoted to deeply characterize the behavior and performance of a Heavy Duty (HD) internal combustion engine fed by compressed natural gas (CNG). Current research interest in HD engines fed by gaseous fuels with low C/H ratios is related to the well-known potential of such fuels in reducing carbon dioxide emissions, combined to extremely low particulate matter emissions too. Moreover, methane, the main CNG component, can be produced through alternative processes relying on renewable sources, or in the next future replaced by methane/H2 blends. The final goal of the presented investigations is the development of a predictive 0D combustion submodel within the framework of a 1D numerical simulation platform. To this aim, an experimental campaign has been carried out on a six-cylinder HD spark ignition engine CNG engine, Euro VI d compliant, typically employed in road vehicle applications, at the test bench, in order
Fraioli, Valentina, Di Maio, Dario, Napolitano, Pierpaolo, Lanni, Davide, D'Antuono, Gabriele, Galloni, Enzo, Callu, Cyrille, Maestro, Dario
Advantages of 3d and 1d Modeling a Li-Po Battery for the Prediction of Overheating under Real Driving Conditions2023-24-016708/28/2023
1d multi-domain modeling is a powerful tool for the fast prototyping of battery packs for electric vehicles. It can help identify the optimal layout for structural and thermal aspects and then support the battery sizing process. On the other hand, its simplicity may fail whereas precise simulations are needed. For example, a catastrophic event such as the thermal runaway can be triggered by a local peak of temperature on a single cell of the battery pack and then spread to the others. For this reason, the surface temperature distribution of a battery is crucial, and 1d models provide only an average value. Conversely, 3d models can provide this information even if at higher costs, in terms of time and computational efforts. 3d models of a Li-Po battery are not common in the literature because of the high complexity of the internal structure of a cell and the availability of experimental data for validation. This paper follows a previous work where a 3d model of a Li-Po cell was
Magri, Luca, Sequino, Luigi, Ferrari, Cristian
Method for Fatigue Life Analysis in Road Implement Chassis from Power Spectral Densities2023-36-036107/25/2023
This paper presents the development of a method for the fatigue life analysis in chassis of road implements from power spectral densities, bringing a new possibility for fatigue analysis and reducing the probability of a prototype having fatigue failure. The method was executed by deploying triaxial and uniaxial accelerometers at various points on the road implement chassis, and performing finite element analysis, while it was driven on various road surfaces. Within the proposed method, three types of analyzes were performed: the operational modal analysis; harmonic and modal analysis; and fatigue life analysis. To perform the operational modal analysis, the signals were treated with low-pass and window filters and converted to the frequency domain. As a result, the modal data referring to the implement are inserted as properties of a virtual chassis model in finite elements to obtain frequency response functions through harmonic and modal analysis. A matrix of power spectral densities
Costa, Felipe Acordi, Vieceli, Alexandre, Corso, Leandro Luís, Bernardi, Rodrigo
A Comprehensive Numerical Model for Numerical Simulation of Ice Accretion and Electro-Thermal Ice Protection System in Anti-icing and De-icing Mode, with an Ice Shedding Analysis2023-01-146306/15/2023
This work presents a comprehensive numerical model for ice accretion and Ice Protection System (IPS) simulation over a 2D component, such as an airfoil. The model is based on the Myers model for ice accretion and extended to include the possibility of a heated substratum. Six different icing conditions that can occur during in-flight ice accretion with an Electro-Thermal Ice Protection System (ETIPS) activated are identified. Each condition presents one or more layers with a different water phase. Depending on the heat fluxes, there could be only liquid water, ice, or a combination of both on the substratum. The possible layers are the ice layer on the substratum, the running liquid film over ice or substratum, and the static liquid film between ice and substratum caused by ice melting. The last layer, which is always present, is the substratum. The physical model that describes the evolution of these layers is based on the Stefan problem. For each layer, one heat equation is solved
Gallia, Mariachiara, Rausa, Andrea, Martuffo, Alessandro, Guardone, Alberto
UAV Icing: Experimental Validation Data for Predicting ice Shapes at Low Reynolds Numbers2023-01-137206/15/2023
Icing is a severe hazard to aircraft and in particular to unmanned aerial vehicles (UAVs). One important activity to understand icing risks is the prediction of ice shapes with simulation tools. Nowadays, several icing computational fluid dynamic (CFD) models exist. Most of these methods have been originally developed for manned aircraft purposes at relatively high Reynolds numbers. In contrast, typical UAV applications experience Reynolds numbers an order of magnitude lower, due to the smaller airframe size and lower airspeeds. This work proposes a set of experimental ice shapes that can serve as validation data for ice prediction methods at low Reynolds numbers. Three ice shapes have been collected at different temperatures during an experimental icing wind tunnel campaign. The obtained ice shapes represent wet (glaze ice, −2 °C), mixed (−4 °C), and dry (rime ice, −10 °C) ice growth regimes. The Reynolds number is between Re=5.6…6.0×105, depending on the temperature. The ice shapes
Hann, Richard, Müller, Nicolas, Lindner, Markus, Wallisch, Joachim
Design, Characterization and Initial Testing of a Vertical Stabilizer Common Research Model for Aircraft Ground Icing Testing2023-01-143906/15/2023
Under contract to Transport Canada (TC) and with joint funding support from the Federal Aviation Administration (FAA), a vertical stabilizer common research model (VS-CRM) has been designed and built by the National Research Council of Canada (NRC). This model is a realistic, scaled representation of modern vertical stabilizer designs without being specific to a particular aircraft. The model was installed and tested in the NRC 3 m × 6 m Icing Wind Tunnel in late 2021/early 2022. Testing was led by APS Aviation Inc., with support from NRC and NASA, in order to observe the anti-icing fluids flow-off behavior with and without freezing or frozen precipitation during simulated take-off velocity profiles. The model dry-air aerodynamic properties were characterized using flow visualization tufts and boundary layer rakes. Using this data, a target baseline configuration was selected with a yaw angle equal to 0° and rudder deflection angle equal to -10°. Testing with fluids and precipitation
Clark, Catherine, Ruggi, Marco
A Three-Dimensional Level-Set Front Tracking Technique for Automatic Multi-Step Simulations of In-Flight Ice Accretion2023-01-146706/15/2023
This paper presents a novel fully-automatic remeshing procedure, based on the level-set method and Delaunay triangulation, to model three-dimensional boundary problems and generate a new conformal body-fitted mesh. The proposed methodology is applied to long-term in-flight ice accretion, which is characterized by the formation of extremely irregular ice shapes. Since ice accretion is coupled with the aerodynamic flow field, a multi-step procedure is implemented. The total icing exposure time is subdivided into smaller time steps, and at each time step a three-dimensional body-fitted mesh, suitable for the computation of the aerodynamic flow field around the updated geometry, is generated automatically. The methodology proposed can effectively deal with front intersections, as shown with a manufactured example. Numerical simulations over a NACA0012 swept wing both in rime and glaze conditions are compared with the experimentally measured ice shapes from the 1st AIAA Ice Prediction
Donizetti, Alessandro, Rausa, Andrea, Bellosta, Tommaso, Re, Barbara, Guardone, Alberto
Modelling and Simulation of Mixed Phase Ice Crystal Icing in Three-Dimensions2023-01-147506/15/2023
High altitude ice crystals have led to instances of ice accretion on stationary compressor surfaces in aeroengines. Rollback, surge and stall events are known to have been instigated through such accretions due to aerodynamic losses related to ice growth, damage and flameout due to ice shedding. The prevalence of these events has led to a change in certification requirements for icing conditions. Development of accurate numerical models allows the costs of certification and testing to be minimised. An in-house computational code was developed at the Oxford Thermofluids Institute to model glaciated and mixed-phase ice crystal icing. The Ice Crystal Icing ComputationaL Environment (ICICLE) code, comprises a frozen 2D flowfield solution, Lagrangian particle tracking, particle heat transfer and phase change and particle surface interaction modelling. In this paper the ICICLE code is developed into a 3D modelling environment, including 3D particle tracking and modelling of particle wall
Parker, Liam, McGilvray, Matthew, Gillespie, David
Design and Development of Fuel Tank for High Mobility Military Vehicle2023-28-134205/25/2023
Fuel tank is considered as safety component in the vehicle, and it has to be tested to meet the safety requirements as per AIS 095. Earlier, fuel tanks were manufactured by using Hot dipped cold rolled steel material and the weld zones are applied with Anti-corrosive coating. Few fuel tanks were reported with Corrosion problems. The root cause analysis was carried out considering the raw material, manufacturing process, transpiration, storage and usage. As an improvement, the new fuel tank is designed to eliminate the limitations of the existing fuel tank. 3D modeling was done to check space and mounting requirement in the layout and used for volume calculations. FE analysis was performed to check structural stability. Emphasis given on Interchange-ability to cater the new fuel tanks in place of old as spares requirement. The fuel tank has developed with Alumina steel material. Alumina steel is a material with the strength property of steel and corrosion resistant property of Aluminium
KUMARAN, RAJASEKAR, m, vadivelu, SG, Arun, Adepu, Rakesh, KC, satheesh
Design, Material Selection, Simulation and Manufacturing of ROPS and FOPS for Motor Grader2023-28-134805/25/2023
Motor grader is self-propelled, versatile machine widely used for road construction and maintenance in mining and construction applications. It required working in rugged terrain with uneven and slippery surfaces. Probability of rollover in motor grader is more due to the vehicle profile and high centre of gravity. In light of the above, Roll over Protective Structure (ROPS) is essential to safe guard the operator from any fatal injuries / life during the operation of the equipment at different terrain conditions. Considering DGMS (Directorate of General Mines and safety) requirements, a rugged two post Rollover Protective Structure (ROPS) was designed as per ISO 3471 criteria for ROPS and Falling object Protection Structure (FOPS) as per ISO 3449 Material selection for ROPS and FOPS is one of significant factor in design process by meeting the design criteria. It should have dual characteristic, firstly, it is expected to tough enough to withstand sudden impact forces. Secondly, it
Varadaraj, Kumar, hs, Satish Chandra
Analytical and Experimental Studies on Ride Comfort in a Combat Vehicle (CV)2023-01-111805/08/2023
Extremely uncomfortable levels of bounce and pitch vibrations are produced when a CV moves over uneven terrain. The present study was carried out to ascertain the vibrational response at the driver’s, commander’s and trooper’s seats. A 23 -degrees of freedom (DOF) lumped parameter 3-D model of a combined CV and human body was made. The vehicle had 15 DOF corresponding to the bounce, pitch and roll of the hull (sprung mass) and bounce motions of the 12 wheel stations (unsprung masses) on either side. The human body was idealized as having 8 DOF corresponding to bounce motions of the pelvis, abdomen, diaphragm, thorax, torso, back and head. The seat was also assigned a bounce DOF. The lumped masses of the body parts were distributed and connected by springs. The differential equations of motion for the linear rigid body model were formulated and the natural frequencies of different parts of the human body and the military tank were determined by eigenvalue analysis using MATLAB
Chandramohan, Sujatha, Sinha, Adheesh
Vibro-acoustic Study of a Full Vehicle Excited by an Electric Motor: Structure-borne and Air-borne Noise Comparison2023-01-111205/08/2023
This paper presents a workflow that allows noise, vibration and harshness (NVH) engineers to objectively predict the passenger compartment noise levels due to structure-borne and radiated noise arising from the motor of an electric powertrain (ePowertrain). The optimized simulation workflow enables transmission, vehicle design engineers and NVH analyst to collaborate and address potential noise concerns well before production of the ePowertrain unit and vehicle. The NVH targets can be cascaded through a series of transfer functions, linking the electromagnetic (EM) excitation from the motor to passenger compartment noise level requirements. The workflow involves the use of Romax Spectrum and Actran software. The structural modelling of the ePowertrain including the vibration response of the ePowertrain is calculated using Romax Spectrum, whilst Actran computes the acoustic radiation around the complete vehicle, and Virtual SEA then covers the calculation to interior and exterior
de Walque, Cyril, Jamaluddin, Riza
A Quasi-Dimensional Burn Rate Model for Pre-Chamber-Initiated Jet Ignition Combustion2023-01-018404/11/2023
Prospective combustion engine applications require the highest possible energy conversion efficiencies for environmental and economic sustainability. For conventional Spark-Ignition (SI) engines, the quasi-hemispherical flame propagation combustion method can only be significantly optimized in combination with high excess air dilution or increased combustion speed. However, with increasing excess air dilution, this is difficult due to decreasing flame speeds and flammability limits. Pre-Chamber (PC) initiated jet ignition combustion systems significantly shift the flammability and flame stability limits towards higher dilution areas due to high levels of introduced turbulence and a significantly increased flame area in early combustion stages, leading to considerably increased combustion speeds and high efficiencies. By now, vehicle implementations of PC-initiated combustion systems remain niche applications, especially in combination with lean mixtures. This is also due to challenges
Salerno, Francesco, Bargende, Michael, Kulzer, André, Grill, Michael, Burkardt, Patrick, Günther, Marco, Pischinger, Stefan, Villforth, Jonas
Physical-Neural Network Hybrid Modeling Method for Dynamic Characteristics of Air Springs with Auxiliary Chambers2023-01-012204/11/2023
Air springs with auxiliary chambers (ASAC) are widely used in automotive suspension systems. The introducing of the auxiliary chamber and the connecting flow passage makes the system more complex, especially in which case an additional resonance peak caused by the air inertia in a connecting pipe appears. To characterize the nonlinear dynamic characteristics, this paper proposes a novel physical-neural network hybrid modeling method for ASACs. Firstly, experiments are carried out to measure the dynamic characteristics of ASACs. Then, based on the thermodynamic principle, a nonlinear dynamic characteristic model for the ASAC is developed and a linearized process is performed to obtain a linearized physical model. Due to the amplitude dependence and frequency dependence in the dynamic characteristics of ASACs, the physical model cannot accurately characterize these nonlinearities. To compensate for the errors caused by the uncaptured frictional damping and nonlinear air resistance, a
Zheng, Yiqian, Shangguan, Wenbin
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