Browse Topic: Pipes and ducts

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Multi-stage Packaging and Routing Optimization for Automotive Component Layout, Wire Harness and Duct Route Design2026-01-0507To be published on 04/07/2026
Modern vehicle design involves complex considerations and tradeoffs between system integration and layout which have a direct impact on performance, efficiency, and cost. The placement of equipment including control boards, motors, and fans as well as the routing of ducts and wire harnesses poses a time-consuming and intricate problem for design engineers. This paper presents an automated methodology to determine the optimal component packaging configuration, duct routing, and wire harnessing layout to maximize component packing density and minimize the total routing length. A two-stage optimization framework has been developed where the first stage packages the components within the design space with considerations for space utilization, component overlap, proximity relationships, point-to-point accessibility, and component mounting. The second stage implements a custom A-star path-finding algorithm and gradient based optimization to determine the optimal route layout between port
LeFrancois, Richard, Kim, Il Yong
FITTING, ELBOW, 90°, PIPE, INTERNAL THREADAS4856B (Current)1/31/2026
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Human Detection Capacity of Vehicle Front Sonar Sensors in Light and Small Passenger Cars and Minivan2025-22-00091/22/2026
Sonar sensor systems have been developed to prevent collisions between vehicles and surrounding objects by employing ultrasonic sensors mounted at the front of the vehicle. These systems warn drivers when nearby obstacles are detected. However, relatively few studies have examined the capacity of sonar to detect humans. This study aims to clarify the human detection capacity of front sonar sensors installed in two light passenger cars (LPC-I and LPC-II), one small passenger car (SPC), and one minivan (MNV). The LPC-I, SPC, and MNV were equipped with center and corner sensors, whereas the LPC-II had only corner sensors. Three volunteers—a child, an adult female, and an adult male—participated in the study. Human detectability was assessed using the “maximum detection distance ratio,” defined as the ratio of the maximum detection distance for a volunteer to that for a standard pipe. The results showed that both the center and corner sensors consistently detected front- and side-facing
Matsui, Yasuhiro, Oikawa, Shoko
Effect of Pipe Bending by Rotary Tube Bending Process on Durability of Frame Structure2026-26-03701/16/2026
Automobile frames, particularly trellis frame structures, are engineered for superior dynamic performance, with stiffness being a paramount consideration1. These frames frequently utilize welded tubes, a manufacturing process made more complex by the necessity of bending tubes to precise angles to meet packaging and assembly requirements2. This bending, however, induces residual stresses that can substantially compromise the frame's durability3. This investigation employs a detailed finite element simulation to analyse the structural deformation and residual stresses that arise during the bending of Cold Electric Welded (CEW) annealed round pipes4. A comprehensive 3D mechanical model, incorporating realistic tooling and contact interactions, was developed to accurately simulate shape change, ovality, and wall thickness redistribution during the bending process5. CEW pipes, unlike their Electric Resistance Welded (ERW) counterparts, possess minimal initial forming stresses, and the
Rajwani, Ishwar, Khare, Saharash
A Novel Approach to Optimal Strain Gauge Placement for Structural Assessment: Integrating Looping Configurations with Calibration Techniques2026-26-05511/16/2026
Addressing the challenge of optimal strain gauge placement on complex structural joints and pipes, this research introduces a novel methodology combining strategic gauge configurations with numerical optimization techniques. Traditional methods often struggle to accurately capture combined loading states and real-world complexities, leading to measurement errors and flawed structural assessments [9]. For intricate joints, a looping strain gauge configuration is proposed to comprehensively capture both bending and torsional effects, preventing the bypassing of applied loads. A calibration technique is used to create strain distribution matrices and access structural behavior under different loading conditions. Optimization algorithms are then applied to identify gauge placements that yield well-conditioned matrices, minimizing measurement errors and enhancing data reliability. This approach offers a cost-effective solution by reducing the number of gauges required for accurate stress
Shingate, Uttam, Yadav, Dnyaneshwar, Deshpande, Onkar
Investigation of Fatigue Failure Mechanisms in High-Pressure Hydraulic Pipes of Power Steering Systems2026-26-05421/16/2026
The high-pressure steering hose in a hydraulic steering system carries pressurized hydraulic fluid from the power steering pump to the steering gear (or steering rack). Its main function is to transmit the force generated by the pump so that the hydraulic pressure assists the driver in turning the wheels more easily. The high-pressure hydraulic pipeline in the power steering system is a vital component for ensuring optimal performance. During warranty analysis, leakage incidents were observed at the customer end within the warranty period. The primary factors contributing to these failures include pipe material thickness, material composition, mechanical properties, and engine-induced vibrations. This study investigates fatigue-related failures through detailed material characterization and Computer-Aided Engineering (CAE) based on real world usage road load data collected. The objective is to identify the root causes by examining the influence of varying pipe thickness on fatigue life
Survade, Lalit, Koulage, Dasharath Baliram, Biswas, Kaushik
Advancing Vehicle-Level AC Thermal Management System Performance2025-28-043410/30/2025
Modern mobility solutions increasingly rely on HVAC systems due to growing transport demands, traffic congestion, and harsh environmental conditions. These systems, comprising a compressor, evaporator, condenser, and thermal expansion valve, require adequate airflow for optimal performance. Insufficient airflow, caused by factors like undersized ducts, improper fan settings, clogged filters, or high static pressures from duct restrictions, significantly hinders cooling capacity. The objective of this study is to develop a predictive model for passenger vehicle AC system performance under controlled environmental conditions. Discrepancies between predicted and desired performance will trigger a structured problem-solving process involving iterative testing, root cause analysis, and the development of corrective measures. The improvements will be focused on the vehicle-level HVAC design, adhering to customer specifications. This research will also establish an experimental validation
Meena, Avadhesh Kumar, Agarwal, Roopak, Sharma, Kamal, Kishore, Kamal
Ultra-Thin Cooling Solution for Mobile Devices Unlocks Slimmer, High-Performance TechnologyTBMG-5391810/1/2025
Scientists from Nagoya University in Japan have developed an innovative cooling device — an ultra-thin loop heat pipe — that significantly improves heat control for electronic components in smartphones and tablets. This breakthrough successfully manages heat levels generated during intensive smartphone usage, potentially enabling the development of even thinner mobile devices capable of running demanding applications without overheating or impeding performance.
Effect of Pressure Losses and Reynolds Number on Active Grille Shutter Characteristics and Its Prediction2025-01-50599/10/2025
In the present article it is investigated why active grille shutters (AGS) can have very different aerodynamic characteristics, ranging from progressive to strongly degressive, and which factors influence them. For this purpose, the authority concept known from the field of heating, ventilation, and air-conditioning (HVAC) is referred to. According to this theory, the control characteristics of dampers depend primarily on the ratio of the pressure losses at the fully open damper to the pressure losses of the rest of the system. The adaptation of the concept to the automotive field shows that, in addition to the pressure losses, the geometry of the cooling air ducting plays a decisive role in motor vehicles. The effect of driving speed and fan operation on the characteristic curves is also being investigated. In addition, authority theory can also be used to derive the conditions under which the opening characteristic curve of an AGS provides a good prediction of the real characteristic
Wolf, Thomas
Aerospace & Defense Technology: August 202525AERP088/7/2025
Are Military Avionics Systems Ready for Artificial Intelligence? Reclaiming Readiness: Advancing US Defense Through Scalable Additive Manufacturing When Innovation Outpaces Infrastructure: R&D's New Reality in Aerospace Confidence Through Testing: How to Design a Practical Structural Test Program The Tug-of-War Between Speed and Strength How to strike a balance between cable performance and resilience. 101st Combat Aviation Brigade Makes History with First MUOS Connectivity in a Helicopter New Laser Technique Revolutionizes Ultra-High Ceramic Manufacturing for Spacecraft Researchers have demonstrated a new technique that uses lasers to create ceramics that can withstand ultra-high temperatures, with applications ranging from nuclear power technologies to spacecraft and jet exhaust systems. A Twist in Topology Optimization Leads to High-Performing Heat Exchanger Researchers used an innovative approach to the geometry and design of pipes that flow hot and cold fluids through heat
Investigation of Expansion Characteristics of Convergent–Divergent Nozzles with a Variable Geometry Sudden Expanded Duct01-18-02-00107/9/2025
In recent years, there has been a significant rise in research focused on estimating the base pressure (Pb) characteristics of convergent–divergent nozzles with sudden expansion regions. This study explores the use of geometrical parameters as a control strategy for nozzles experiencing abrupt expansion at supersonic Mach numbers within an axisymmetric duct. It focuses on four distinct novel expansion duct configurations: square nozzle (SN), step square nozzle (SSN), curved nozzle (CN), and double curved nozzle (DCN). In this work, the high-speed compressible flow investigation is carried out numerically using control volume method on the nozzle with a fixed area ratio (AR) and L/D nozzle. Standard k-ε turbulence model is used in the analysis to access the recirculation region formed near the nozzle walls. The recirculation zone directly influences the Pb and shock cell. For NPR range from 2 to 10, SSN and CN shows an increase in Pb, which further increases the thrust and decreases the
Raj, R. Jini, Kumar, P. Deepak, Panchksharayya, D. V., Kousik Kumaar, R., Praveen, N.
Commercial Vehicle’s Exhaust Front Pipe Reliability Improvement through Virtual Simulation and Experimental Validation2025-01-02096/16/2025
The exhaust front pipe is a critical structural component in commercial vehicles, ensuring the leak-proof flow of exhaust gases into the exhaust after-treatment system while withstanding engine and frame vibrations. To isolate these vibrations, the front pipe is equipped with a flex connector capable of enduring various displacements at frequencies between 8-25 Hz. The position of the flex connector relative to the engine crank axis significantly impacts its structural reliability over its service life. This paper compares the existing design, which features a horizontally positioned flex connector, with a modified design that positions the flex connector vertically and changes the material from SS-304 to SS-321. Finite element analysis was conducted using Nastran software. The fatigue life of the existing flex connector design is approximately 1015 cycles. In contrast, the improved design demonstrates a fatigue life of 1727 cycles, representing a 70% increase in durability compared to
Chandel, Kushal, Paroche, Sonu, Namdev, Akhilesh, Jain, Shailendra, Patil, Keyur
Robotic System for Infrastructure ReconnaissanceTBMG-532306/1/2025
Innovators at NASA Johnson Space Center have developed a robotic system whose primary structural platform, or “orb,” can be injected into a pipe network and perform reconnaissance of piping infrastructure and other interior volumes. When deployed, this technology uses throttled fluid flow from a companion device for passive propulsion. A tethered line facilitates directional control by the orb’s operator, allowing it to navigate through various piping configurations, including 90° junctions.
GPU-Accelerated Aeroacoustic Simulations of HVAC Duct Configurations2025-01-01335/5/2025
Large eddy simulations (LES) of two HVAC duct configurations at different vent blade angles are performed with the GPU-accelerated low-Mach (Helmholtz) solver for comparison with aeroacoustics measurements conducted at Toyota Motor Europe facilities. The sound pressure level (SPL) at four near-field experimental microphones are predicted both directly in the simulation by recording the LES pressure time history at the microphone locations, and through the use of a frequency-domain Ffowcs Williams-Hawking (FW-H) formulation. The A-weighted 1/3 octave band delta SPL between the two vent blades angle configurations is also computed and compared to experimental data. Overall, the simulations capture the experimental trend of increased radiated noise with the rotated vent blades, and both LES and FW-H spectra show good agreement with the measurements over most of the frequency range of interest, up to 5,000Hz. For the present O(30) million cell mesh and relatively long noise data collection
Besem-Cordova, Fanny M., Dieu, Donavan, Wang, Kan, Brès, Guillaume A., Delacroix, Antoine
Evaluation of Hybrid Aeroacoustics Models for HVAC Duct Noise Predictions2025-01-50325/1/2025
This study evaluates the effectiveness of two hybrid computational aeroacoustic methods—Lighthill wave model and perturbed convective wave model—in simulating HVAC duct noise in the automotive industry. Using component-level acoustic testing of a Ford HVAC duct, simulations were conducted at varying airflow rates to assess the accuracy of both models in predicting duct noise. The Lighthill wave model, suitable for noise analysis in regions outside turbulent flow areas, showed a good correlation with experimental data, especially in the frequency range of 100 Hz–5000 Hz, but sometimes struggled with pseudo-noise effects at low frequencies near turbulent regions. The perturbed convective wave model, which is suitable for noise analysis anywhere in the flow domain, underpredicted sound pressure levels at low frequencies as well. Both models underpredicted high-frequency noise (>5 kHz) due to insufficient mesh and time-step sizes. Despite these limitations, the Lighthill wave model
Nam, Jee-Whan, Mendel, Marc, Golberg, Igor
Automatic Generation of HVAC Ducting System Designs Using Topology and Shape Optimization2025-01-86564/1/2025
In this paper, the topology and shape optimization of a vehicle Heating, Ventilation, and Air Conditioning (HVAC) system is presented. The CFD and optimization methodologies are implemented within AcuSolve™ software. The topology optimization algorithm computes the geometry, where the design domain is parameterized with a field of porosity design variables which indicates the material, fluid or solid, throughout the domain. The optimization is performed using the continuous adjoint approach by the Galerkin Least Squares solver on which the AcuSolve™ solver is based. The design is further improved by using shape optimization. To optimize the geometrical shape, a combination of smooth perturbations, in terms of so called morph shapes, are used to deform the geometrical shape in the optimization algorithm. To this end, a parameterization of the design space is done using a moderate number of design variables, each associated with a morph shape. The two optimization phases are connected by
Papadimitriou, Dimitrios, Sandboge, Robert
Numerical Analysis of Capillary Performance of Various Lattice Structures for Vapor Chamber Application2025-28-00622/7/2025
Additive manufacturing has made it possible for the design of increasingly complex structures that require precise manufacturing. This may be particularly beneficial for heat pipe and vapor chamber design – particularly for the wick structure, a very important component. This study uses numerical simulation to analyze three different types of lattice structures of increasing complexity, in terms of their capillary performance. This is one of the most important parameters which determine the wick efficacy. Simple cubic, Column and Octet lattice models are computationally designed and CFD is used to simulate capillary action in a pipe of 0.4 mm inner radius for 2 milliseconds, after validation of the numerical model with existing experimental results. It is found that the Octet lattice (with the most complex inner structure) has the greatest capillary rise in the same amount of time. The rate of rise is not uniform for any structure, but is highest for Octet. This study demonstrates the
Sundararaj, Senthilkumar, Hudge, Ajay, Basuroy, Suhashini, Kang, Shung-Wen
Temperature Reduction of Servo Oil Used in Steering System Using Pulsating Heat Pipe2025-28-01042/7/2025
There are various steering technologies are available in market nowadays. Hydraulic Power Steering (HPS) is one of them. As hydraulic name is linked to it the temperature role comes to play. While doing hard cornering the hydraulic oil used to assist the working in steering system get over heated, due to which oil loses its viscosity became one of the major causes of hard steer in trucks. Also, due to limited space the large heat exchanger cannot be used there. So, objective of this Thesis is to examine an effective solution which can be compact in design and at the same time should be effective to solve this problem. After going through literature analysis, we finalize that the Principal of Pulsating Heat Pipe could be a possible solution. So, for that we design different model based on previous research work in Creo and simulate them in Star CCM+ to finalize the optimality.
Saikrishna, VNL, P, Rudresha, Yadav, Satyendra, B, Ruthvika, Vishwasa, Viditha
Design and Performance Optimization of Automotive Thermoelectric Generator System Integrated with Heat Pipes2025-01-70601/31/2025
In the field of static power generation, thermoelectric technology has become an important solution for utilizing automotive exhaust waste heat. This study presents a new design for a heat exchanger integrated with heat pipes, aimed at augmenting the installation area of thermoelectric modules and improving the hot end temperature by high heat transfer rate. Moreover, the number of heat pipes in each region is optimized to reduce the temperature gradient along the direction of exhaust flow and maximize overall output performance. A comprehensive numerical model of the thermoelectric generator system is developed to conduct the performance prediction and parameter optimization. The results reveal that the integration of heat pipes substantially boosts the performance of the automotive thermoelectric generator system, characterized by enhanced heat transfer, increased power output, and improved conversion efficiency. And the optimization yields an optimal configuration with 5 heat pipes
Zhao, JinFu, Ding, Renkai, Chen, Jie, Wang, Ruochen, Luo, Ding
Automatic Hose Cutting Machine for Small Scale Industries2024-01-521712/10/2024
The goal of this work is to increase the accuracy and efficiency of hose cutting operations in small scale industries is by designing and building an automatic hose-cutting equipment. The device uses a computer-controlled system to autonomously cut pipes of various sizes and lengths. By means of a stepper motor-driven, rapidly spinning blade, the cutting process is accomplished. Additionally, the machine has sensors that measure the hose's length and modify the cutting position as necessary. Premium components and materials are used in the machine's construction; these are chosen for their performance and longevity. The device is able to boost cut precision and raise industry production all around from 100% to 190% efficient system thereby decreasing labor and time needed for hose cutting operations.
Feroz Ali, L., Manikandan, R., Madhankumar, S., Sri Hari, P., Suriya Prakash, T., Vishnu Doss, G.
Development of a Method to Model Flexible Hose in FE Linear Dynamics Simulations2024-28-025412/5/2024
Linear dynamics simulations are performed on engine components to ensure structural integrity under dynamic loading. The finite element model of the engine assembly must be prepared accurately to avoid under or over design of the engine components. Flexible hoses are present at pipe routings and modeling them in simulations is a challenge because the stiffness of the composite is not known. The hose under study in this paper is a rubber composite with a knitted reinforcement layer. A multiscale modelling approach is presented to characterize the hose stiffness. A representative volume element geometry i.e., unit cell representation of the composite, consisting of the knitted yarn and surrounding rubber is used to establish orthotropic elastic properties at microscale, by performing finite element homogenization using the ANSYS material designer module. The homogenized properties are assigned to the macroscale hose geometry to perform modal analysis simulation in free-free and fixed
Ashodiya, Jay Virendra, Jayachandran, Janarthanan, Santhosh, B
Design Optimization of Air Duct for Noise Reduction Using Gaussian Process Regression Algorithm2024-28-004210/17/2024
In the context of Battery Electric Vehicles (BEVs), airborne noise from Heating, Ventilation and Air Conditioning (HVAC) ducts becomes a prominent concern in the view of passenger comfort. The automotive industry traditionally leverages Computational Fluid Dynamic (CFD) simulation to refine HVAC duct design and physical testing to validate acoustic performance. Optimization of the duct geometry using CFD simulation is a time-consuming process as various design configurations of the duct have to be studied for best acoustic performance. To address this issue effectively, the proposed a novel methodology uses Gaussian Process Regression (GPR) to minimize duct noise. Present solution demonstrates the power of machine learning (ML) algorithms in selecting the optimal duct configuration to minimize noise. Utilizing both real test data and CFD results, GPR achieves remarkable accuracy in design validation, especially for HVAC air ducts. The adoption of GPR-based ML algorithms significantly
Althi, Tirupathi Rao, Manuel, Naveen, K, Manu
Numerical Investigation on Performance Based Methodology for Developing Vane Design of AC Duct2024-28-000410/17/2024
Airflow directionality in a vehicle cabin is one of the concerns of car owners, researchers, and vehicle manufacturers. After exposed/parked in hot ambient condition for a long time, HVAC system normally takes few minutes to cool down and reach an acceptable cabin temperature for the passenger comfort. To ensure proper airflow distribution inside the cabin, the AC duct & vanes ability to direct airflow must be evaluated. Objective of this work is to propose a methodology for developing the vane design of AC system duct using CFD approach. Two different goals are attempted. Firstly, the effect of horizontal and vertical vane angle on airflow directionality is investigated with DoE approach. Then factors influencing the airflow directionality are investigated using factorial study approach. CFD based factorial analysis (L9 orthogonal array) was conducted using three components at three levels. The impact of number of horizontal vanes, number of vertical vanes and distance between them on
Mahesh, A, Baskar, Subramaniyan, Raju, Kumar, Gopinathan, Nagarajan
Characterization of HVAC Noise and its Dynamic Interplay within the Vehicle's Environment2024-28-01139/19/2024
Vehicle HVAC noise performance is an important vehicle design validation criterion since it significantly links the brand image of a vehicle. It affects the customer’s buying decision and the business of selling vehicles because it directly affects driving comfort. Customers expect continuous improvement in HVAC noise without compromising cooling performance. The process of cascading vehicle-level acoustic performance to subsystem and component levels becomes an important factor in the vehicle NVH development process. It was found that the component-level [HVAC unit without duct] performance of an HVAC system measured in an anechoic chamber was at par when compared to targets, whereas the subsystem-level performance [HVAC unit with duct and dashboard] was on the higher side of the targets. Advanced NVH tools were used to identify the source of noise at the subsystem level. It helped to locate the source and its transfer path. A design modification done at the transfer path location
Titave, Uttam Vasant, Kalsule, Shrikant, Naidu, Sudhakara
A Study to Establish an Evaluation Method for Selecting Suitable Packing Adhesives for A/C Ducts to Ensure Sustained Adhesiveness in Thermal and Condensation Conditions over the Vehicle's Lifetime2024-28-00969/19/2024
The purpose of air conditioning (AC) duct packing is multifaceted, serving to prevent condensation, eliminate rattle noise, and provide thermal insulation. A critical aspect of duct packing is its adhesive quality, which is essential for maintaining the longevity and effectiveness of the packing's functions. Indeed, the challenge of achieving adequate adhesivity on AC ducting parts is significant due to the harsh operating conditions to which these components are subjected. The high temperatures and presence of condensation within the AC system can severely compromise the adhesive's ability to maintain a strong bond. Moreover, the materials used for these parts, such as HDPE, often have low surface energy, which further hinders the formation of a durable adhesive bond. The failure of the adhesive under these conditions can lead to delamination of the duct packing, which can result in customer inconvenience due to rattling noises, potential electrical failures if condensed water
M, Amala Rajesh, Sonkar, Surabhi, Kumar, Mukesh
Enhanced Thermal Management in Oil Spray-Cooled Motors: A Novel Approach to Replacing NTC Sensors14-14-01-00058/12/2024
Motor temperature plays a critical role in controlling pump speed and regulating coolant flow to prevent overheating during motor operation. Presently, negative temperature coefficient (NTC) sensors are commonly used for motor temperature measurement, typically installed at the motor winding’s end for ease of installation. However, in oil spray-cooled motors, the temperature distribution is uneven due to the spray pipe, leading to lower temperatures near the pipe compared to other areas. This results in a challenge where relying solely on NTC measurements at the winding end may not meet the motor’s cooling requirements. To address this issue and improve temperature signal accuracy, a novel approach has been developed that utilizes four signals derived from the motor controller: motor speed, motor torque, along with oil pump speed, oil temperature. Employing the lumped parameter method, a model established in Simulink aims to estimate the average temperature in the motor’s high
Lu, Junjie, Li, Qiang, Chen, Binglin, Zhu, Lunzhi, Wu, Jian, Yan, Pingtao
Research on the Forming Process of Bimetal Composite Pipe by Hydroforming2024-01-50011/15/2024
Bimetal composite pipe has higher strength and is more corrosion and high temperature resistant compared to single metal pipe, making it a new type of pipe that is being gradually applied to important industrial fields such as aviation and aerospace manufacturing. To study the hydraulic forming mechanism of bimetal composite pipes, the forming process is divided into three stages: liner pipe elastic–plastic deformation, base pipe loading, and unloading. The stress and strain relation between the liner and base pipe during the gradual increase in hydraulic pressure is analyzed, and the range of selected internal pressure required for composite pipe formation and the relation between residual contact pressure and internal pressure for the liner–base pipe interface are obtained. The accuracy of analytical predictions for the contact pressure and the axial and circumferential strains on the outer wall of the base pipe during the forming process is verified through numerical simulation and
Tang, Yue
Hydraulic Flanged Tube, Pipe, and Hose Connections, Four-Screw Flange Connection - Part 2: 42 MPa (Code 62)J518/2_202312 (Current)12/26/2023
This SAE Standard covers general and dimensional specifications for the Code 62 metric (Type 1) and inch (Type 2) flanged heads, flange clamps (FC and FCM), and split flange clamps (FCS and FCSM) applicable to four-screw flange type tube, pipe, and hose connections. Also included are the recommended port dimensions and port design considerations. Type 2 (inch) flange clamps and split flange clamps are not for new design. The flanged heads specified are incorporated into fittings having suitable means for attachment of tubes, pipes, or hoses to provide connection ends. These connections are intended for application in hydraulic systems, on industrial and commercial products, where it is desired to avoid the use of threaded connections. The rated working pressure of an assembly shall not exceed the least of all the component working pressure rated values. The following general specifications supplement the dimensional data contained in the tables with respect to all unspecified detail
Hydraulic Hose and Hose Fittings Committee
Metallic Connections for Fluid Power and General Use - Part 3: NPTF Pipe Adapters and NPSM Adapter UnionsJ514/3_202312 (Current)12/13/2023
This part of SAE J514 covers general and dimensional specifications for NPTF pipe adapters and 30 degree NPSM adapter unions. These fittings are intended for general application in hydraulic systems on industrial equipment and commercial products. These fittings are capable of providing leak-proof, full-flow connections in hydraulic systems operating at working pressures as specified in Table 6. Since many factors influence the pressure at which a hydraulic system will or will not perform satisfactorily, the values shown in Table 6 should not be construed as a guaranteed minimum. For any application, it is recommended that sufficient testing be conducted and reviewed by both the user and fitting manufacturer to assure that performance levels will be safe and satisfactory.
Hydraulic Tube Fittings Committee
Building More Dexterous RobotsTBMG-4958312/1/2023
Imagine grasping a heavy object, like a pipe wrench, with one hand. You would likely grab the wrench using your entire fingers, not just your fingertips. Sensory receptors in your skin, which run along the entire length of each finger, would send information to your brain about the tool you are grasping.
Numerical Investigation on the Design and Development of Automotive Exhaust Muffler –A Case Study2023-28-008511/10/2023
Attaining better acoustic performance and back-pressure is a continuous research area in the design and development of passenger vehicle exhaust system. Design parameters such as tail pipe, resonator, internal pipes and baffles, muffler dimensions, number of flow reversals, perforated holes size and number etc. govern the muffler design. However, the analysis on the flow directivity from tail pipe is limited. A case study is demonstrated in this work on the development of automotive muffler with due consideration of back pressure and flow directivity from tail pipe. CFD methodology is engaged to evaluate the back pressure of different muffler configurations. The experimental and numerical results of backpressure have been validated. The numerical results are in close agreement with experimental results. It was observed that the influence on back pressure with reducing the quantity of baffle plate, Increasing the tail pipe diameter and twin tail pipe with bypassing flow through inner
Baskar, Subramaniyan, Lingala, Vivek, Raju, Kumar
Development of a Lightweight One-Piece Aluminum Casting Swingarms2023-01-180810/24/2023
Fuel-efficient motorcycles are essential for energy conservation and environmental load reduction. To achieve low fuel consumption, reducing the weight of the body parts of the motorcycle is important. This study focuses on reducing the weight of the swingarms, a relatively heavy body part. However, reducing the weight of swingarms is challenging owing to the low flexibility in their shape because swingarms are conventionally made of multiple pipes and casting parts welded together. Therefore, we utilized the integral casting technology and examined a new light weight shape. However, creating a new shape manually is difficult. Thus, we examined a new shape using the shape optimization technology, which has been recently used in additive manufacturing. The shapes fabricated using this technology are generally complex and difficult to manufacture by casting. Therefore, we adjusted optimization condition with casting. We derived a new shape which can not only be casted but also has good
Yamamoto, Kodai, Ito, Takafumi, Watanabe, Kentaro, Hosokawa, Shohei, Nagasaka, Kazuya, Endo, Yudai, Yoshihiro, Masuda, Imamura, Yusuke, Maeda, Fujio
Visualization of Physical / Thermal Evaporation Phenomena with Experimental and PIV-DDM Analysis in Urea-SCR Dosing System of Multi-Phase Flow2023-32-00989/29/2023
This study was visualized by experimental and numerical analysis for the unknown injected droplet phenomena with the multi-phase flow in the Urea-SCR dosing system. Visualization experiments were conducted on the droplet behavior inside the pipe with simulated urea SCR injection system. Although the total number of droplets decreases at gas temperatures of 150°C and 200°C, a significant number of injected droplets remained at the position corresponding to the SCR catalyst. That is physical kinetic energy was found to dominate over thermal evaporation. However, the impingement of droplets into the pipe wall had occurred complex behavior by physical/thermal evaporation, and these droplets weren't on gas airflow at the lower part of the pipe. Furthermore, these actual phenomena were reflected in experimental coefficients for new reduction model analysis instead of CFD.
NOHARA, Tetsuo, SUGIYAMA, Naoki, NARA, Shotaro, ONO, Jyo, ONOUE, Hiroki, OSADA, Rina, KAWAMOTO, Yuki, OCHIAI, Masayuki, TAKAHASHI, Shun, OOSUMI, Kazuo, ISHIKAWA, Naoya
Improvement of Post-Oxidation Phenomena with Lambda-split, Post-Injection and Mixing Improvement of Exhaust Gas in Turbocharged GDI Engine2023-32-00949/29/2023
Post-oxidation has been used to enhance the chemical reactions in the exhaust gas pipes, leading to the activations of the turbocharger and catalyst at cold state. In this research, a detailed study of the various mechanisms for post-oxidation is performed. For the post-oxidation activation, the unburned gas species (CO, THC, H2) in the exhaust manifold must be produced by some methodologies, such as scavenging, lambda-split, and post-injection. The required amount of O2 concentration can be either supplied by the scavenging (valve overlap tuning) or the secondary air injection (SAI) system. Mixing the species is also an important key to promoting post- oxidation, and an internal bypass adapter with a modified exhaust adapter shape was developed and evaluated.
Ishikawa, Teruaki, Kumar*, Madan, Moriyoshi, Yasuo, Kuboyama, Tatsuya
A New Gen ‘Super-Efficient Condenser’ for Mobile Air Conditioning Application2023-28-00439/14/2023
In the modern era of automotive industry, occupant comfort inside the cabin is a basic need and no more a luxury feature. With increase in number of vehicles, the expectations from customers are also changing. One of the major expectations from real world customers is quick cabin cooling thru all seasons, particularly when the vehicle is hot soaked and being used in summer conditions. Occupant thermal comfort inside the vehicle cabin is provisioned by a mobile air conditioning (MAC) system, which operates on a vapor compression-based cycle using a refrigerant. The main components of a direct expansion (DX) based MAC system are, a compressor, condenser, evaporator, and expansion valve. Conditioned air is circulated inside the cabin using a blower, duct system and air vents. The AC condenser is the most critical component in AC circuit as it rejects heat, thereby providing for a cooling effect inside the cabin. Right sizing and packaging of condenser, optimizing the condenser core
Shukla, Ankit Kumar, Tadigadapa, Suresh, Dimble, Nilesh
Improvement of AC System for Bus with Tropical/Hot Ambient Application2023-28-00169/14/2023
AC system provides the human comfort inside the cabin of a vehicle but at the expense of consumption of energy from the vehicle. On a global perspective for the bus segment, there is an increased demand for cooling in tropical countries. Optimization needs to be done in existing AC systems w.r.t packaging, cost & performance constraints. Major elements contributing to heat ingress are engine hood, front firewall, windshield & side glasses and bus body parts. Due to these reasons inadequate passenger comfort and poor cool down performance of the vehicle is observed. This paper refers to the reduction of heat ingress through different DOE (Design of Experiment) in the area of design & validation for duct & vent layout, insulation, glass & paint technology, evaporator blowers. The new duct design has been evaluated using a CFD tool by varying various parameters to generate desired output. The integrated use of the modifications was found significant improvement at vehicle level.
Dodwad, Abhishek, Nagarhalli, Prasanna V, Fartade, Sunil, Ahire, Uttam Namdeo
Comparative Study of HVAC Noise Sources Using Acoustical Duct Method and Near Field Method2023-28-00369/14/2023
As the automotive industry is transitioning from conventional engine driven to electric battery driven, many of the vehicle aggregates are getting re-engineered and changing accordingly. Being air-conditioning manufacturer one of the aggregates that needs attention and focused effort is the Heating Ventilation and Air Conditioning system (HVAC). Acoustic comfort of electric vehicle gets impacted due to the HVAC noise in absence of engine and hence other noise sources becomes prominent which were earlier masked by the engine noise. It is important to understand the HVAC noise sources for implementing right countermeasures for masking the noise. There are three methods of noise source identification namely acoustical duct method, cocooning or lead covering method and near field method. Out of these method, acoustical duct method and near field methods are used for minor and major noise identification in this study. The present paper describes the comparative study of HVAC noise source
Goel, Arunkumar, Sen, Somnath
Investigation of HVAC Kinematics Mechanism & Door Noise through Acoustical Duct Method2023-28-00329/14/2023
As HVAC noise is becoming one of the key factors to end users in terms of enhanced comfort, it is important to understand and evaluate various noise sources of HVAC in details. With detailed understanding of various sources, it becomes easier to take appropriate countermeasures in design and subsequently eliminate. There are many methods available in industry to investigate the noise sources in details however those options are expensive and time consuming and require deep understanding of the acoustic. Acoustical duct methods are one such method which proves to be very much helpful in identifying the noise sources from different aggregates like kinematics mechanism, door/damper, servomotors, heat exchangers etc. These sources are typically defined minor noise sources. The present paper describes the detailed investigation of those minor noise sources through the use of acoustical duct method. An existing HVAC from passenger car was considered for this study. In order to take the noise
Sen, Somnath, Goel, Arunkumar
Ice Protection System Design for the Next Generation Civil Tiltrotor Engine Intake2023-01-13746/15/2023
This paper focuses on the design of the thermoelectric ice protection system (IPS) for the engine air intake of the Next Generation Civil Tiltrotor (NGCTR), a demonstrator under development in Leonardo Helicopters. A specific IPS design strategy for the novel intake configuration is proposed. The main constraint which driven the design strategy is a maximum power of 10.6 kW available for the full intake IPS system. The IPS was designed for safe aircraft operations within the Appendix-C icing envelope. The numerical approach adopted to perform the design and the resulting IPS concept are presented. Calculations of the required IPS heat fluxes revealed that maintaining running wet conditions on the entire intake surface is not feasible due to the limitation to the maximum IPS power demand. Therefore, a de-icing IPS design strategy is proposed. The anti-icing mode is adopted only on the lip region to avoid formation of ice caps whereas de-icing zones are defined within the intake duct
Tormen, Damiano, Zanon, Alessandro, De Gennaro, Michele
Monitoring Melting Ice Formations in Aircraft Fuel Tank by Acoustic Emission2023-01-14376/15/2023
Considerable amounts of water accumulate in aircraft fuel tanks due to condensation of vapor during flight or directly during fueling with contaminated kerosene. This can result in a misreading of the fuel meters. In certain aircraft types, ice blocks resulting from the low temperatures at high altitude flights or in winter time can even interfere with the nozzles of the fuel supply pipes from the tanks to the engines. Therefore, as part of the maintenance operations, water has to be drained in certain intervals ensuring that no remaining ice is present. In the absence of an established method for determining residual ice blocks inside, the aircraft operator has to wait long enough, in some cases too long, to start the draining procedure, leading potentially to an unnecessary long ground time. A promising technology to determine melting ice uses acoustic signals generated and emitted during ice melting. With acoustic emissions, mainly situated in the ultrasonic frequency range, a very
Pfeiffer, Helge, Reynaert, Johan, Seveno, David, Jordaens, Pieter-Jan, Ceyhan, Ozlem, Wevers, Martine
Computational Icing Analysis on NASA’s SIDRM Geometry to Investigate Collection Efficiency2023-01-14766/15/2023
Computational icing analysis results were compared to experimental icing tunnel data including aerothermal (e.g., dry air) and supercooled water droplet rime-ice conditions from tests conducted in early 2022 at the NASA Icing Research Tunnel (IRT). The Simulated Inter-compressor Duct Research Model (SIDRM) test article was used in this study, and its geometry represents the inter-compressor duct region of a turbofan engine. The test article’s purpose is to study the physics of supercooled water icing and ice crystal icing. This study compared three different icing codes: FENSAP-ICE (Eulerian approach), LEWICE3D (Lagrangian approach), and GlennICE (Lagrangian approach). All three icing codes were conducted on SIDRM’s complex body flow-field and compared to different experimental supercooled water rime runs. The test article instrumentation (pressure taps, thermocouples, etc.) and 3D laser scans of final ice shapes were used to compare against the different icing code simulations. The
Stewart, Eric, Bartkus, Tadas
Snow Effects on the NGCTR Nacelle for Relevant Certification Conditions2023-01-13736/15/2023
This paper is focused on the numerical analysis of the impingement and water catch rate of snow particles on the engine air intake of the Next Generation Civil Tilt Rotor (NGCTR). This NGCTR is developed by Leonardo Helicopters. The collection efficiency and water catch rate for the intake geometry are obtained for the test cases that have been defined for the relevant snow conditions. These conditions are related to the flight envelope of the NGCTR, existing EASA/FAA certification specifications, and the snow characterization. The analyses have been performed for the baseline air intake geometry. A range of particle diameters has been simulated with a particle density equal to the density of ice and with a particle drag relation that disregards the particle shape. Based on the results for the water catch rate on the basic nacelle configuration in snow conditions it is concluded that the ‘cheeks’ of the duct are more susceptible to impingement of larger snow crystals (>75 μm), whereas
Kool, Nina, Van der Weide, Edwin, Spek, Ferdinand, van der Ven, Harmen, van 't Hoff, Stefan
Icing Physics Studies Using the 3D SIDRM Test Article: Aerodynamic and Supercooled Liquid Icing Analysis2023-01-13996/15/2023
In-flight icing is an important safety issue and is a factor that affects aircraft design and performance. Newer regulations are driving a need for improvements in airframe and engine icing simulation capability. Experimental data is required for development of icing physics models and simulation validation. To that end, this paper presents the analysis of the supercooled liquid icing data subset from tests conducted in 2022 at the NASA Icing Research Tunnel that studied both supercooled water and ice-crystal icing. The test article that was utilized replicated 3D geometrical features of an inter-compressor duct and strut region of a turbofan engine. The surfaces of the Simulated Inter-compressor Duct Research Model (SIDRM) can be heated to simulate the warm surfaces of the turbofan inter-compressor duct. The test article is instrumented with pressure taps, heaters, heat flux gauges, and thermocouples, while a 3D laser scanner, cameras, and a scale to measure ice mass were utilized to
Bartkus, Tadas, Lee, Sam, Stewart, Eric
HVAC Noise Prediction Using Lighthill Wave Method2023-01-11255/8/2023
Automotive Heating Ventilation and Air Conditioning (HVAC) system is essential in providing the thermal comfort to the cabin occupants. The HVAC noise which is typically not the main noise source in IC engine vehicles, is considered to be one of the dominant sources inside the electric vehicle cabin. As air is delivered through ducts and registers into the cabin, it will create an air-rush/broadband noise and in addition to that, any sharp edges or gaps in flow path can generate monotone/tonal noise. Noise emanating from the HVAC system can be reduced by optimizing the airflow path using virtual tools during the development stage. This paper mainly focuses on predicting the noise from the HVAC ducts and registers. In this study, noise simulations were carried-out with ducts and registers. A Finite Volume Method (FVM) based 3-dimensional (3D) Computational Fluid Dynamics (CFD) solver was used for flow as well as acoustic simulations. Large Eddy Simulation (LES) was used for flow field
George, Binoj K., Garikipati, Nagababu, Doroudian, Mark, Horne, Kevin, Voonna, Kiran, Erbig, Lars
A Study on the Impact of Corrosion under Insulation (CUI) on the Acoustic Performance of an Absorptive Muffler of Automobiles2023-01-10875/8/2023
Automobile exhaust systems help to attenuate the engine combustion noise as well as the high frequency flow noises which are generated as the gas expands and contracts through various ducts and orifices of muffler system. One of the solutions to mitigate the noise generated due to the latter is by means of an absorptive muffler, comprising a fibrous acoustic medium which helps to absorb noise of certain frequencies which are sensitive to the human ear. Typically, the construction of such a system consists of the fibrous acoustic medium encompassing a perforated inner pipe on the inside and enclosed by an outer metal case on the outside. The temperature limitations of the acoustic medium sometimes necessitate the placement of the fibrous acoustic system away from the engine source in order to prevent any damage to the fibers upon direct contact with the flue gas. However, this results in a potential for condensation of engine out gas in and around the inner pipe – fibrous system
Vineeth, S., Mishra, Manish, Tripathi, Manas
Thermal Management Design and Simulation of Symmetric Air-Cooled System for Lithium Battery2023-01-05174/11/2023
Good heat dissipation of Lithium battery can prevent the battery from shortening its life due to rapid aging or thermal runaway. In this paper, an air-cooled structure of 5 series and 3 parallel battery packs is designed, which combines the advantages of series and parallel air ducts and optimizes the heat dissipation effect and the space ratio of air ducts. First, the heat generation model of NCR18650PF lithium battery is established, and the heat generation rate and time under different discharge rates are calculated. Combined with the working conditions of the battery itself, the necessity of battery pack heat dissipation was found. Secondly, a preliminary three-dimensional model of the battery pack heat dissipation was established, and a simulation analysis was carried out to study the influence of the inclination angle of the inlet duct, the arrangement of the air inlet and outlet, and the influence of the deflector on the heat dissipation effect, and the optimization analysis was
Ding, Kangjie, Lin, Zhenmao, Xie, Beichen
Acoustic and Aerodynamic Performances of One Phononic Crystal Duct with Periodic Mufflers2023-01-04334/11/2023
The acoustic muffler is one of the practical solutions to reduce the noise in ducts. The acoustic and aerodynamic performances are two critical indices of one muffler for the air intake system of a hydrogen fuel cell electric vehicle (FCEV). In this study, the concept of phononic crystal is applied to design the muffler to obtain superior acoustic performance. One duct with periodic and compact resonator-type mufflers is designed for broadband noise attenuation. The two-dimensional (2D) transfer matrix method and bandgap theory are employed to calculate the transmission loss (TL) and acoustic bandgap. It is numerically and theoretically demonstrated that broadband noise attenuation could be acquired from 500Hz to 3500Hz. Afterwards, the three-dimensional (3D) computational fluid dynamics (CFD) approach is applied to predict the pressure distribution. The results indicate that the proposed hybrid muffler and the phononic crystal duct possess low pressure loss values. Furthermore, the
Liu, Panxue, Zuo, Shuguang, Wu, Xudong, Yin, Bin, Li, Shanran
Detecting COVID-Causing Virus with High-Tech BubblesTBMG-478424/1/2023
A new technique enables the detection of SARS-CoV-2, the virus that causes COVID-19, in the air by using a nanotechnology-packed bubble that spills its chemical contents like a broken piñata when encountering the virus. Such a detector could be positioned on a wall or ceiling, or in an air duct, where there’s constant air movement, to alert occupants immediately when even a trace level of the virus is present.
Hydraulic Flange Tube, Pipe, and Hose Connections Four-Screw Flange Connection - Part 1: 3.5 to 35 MPa (Code 61)J518/1_202303 (Current)3/1/2023
This SAE Standard covers general and dimensional specifications for the Code 61 metric (Type 1) and inch (Type 2) flanged heads, flange clamps (FC and FCM), and split flange clamps (FCS and FCSM) applicable to four-screw flange type tube, pipe, and hose connections. Also included are the recommended port dimensions and port design considerations. Type 2 (inch) flange clamps and split flanges are not for new design. The flanged heads specified are incorporated into fittings having suitable means for attachment of tubes, pipes, or hoses to provide connection ends. These connections are intended for application in hydraulic systems, on industrial and commercial products, where it is desired to avoid the use of threaded connections. The rated working pressure of an assembly shall not exceed the least of all the component working pressure rated values. The following general specifications supplement the dimensional data contained in the tables with respect to all unspecified detail. Parts
Hydraulic Hose and Hose Fittings Committee
Load variation using Ducted Fuel Injection - DFI, with different compression ratio in IC engine2022-36-00892/10/2023
Compression ignition engines are widely used in the cargo and passenger transport sectors, this is due to their high energy efficiency and can operate with renewable fuels. The search for increased efficiency in internal combustion engines and reduced emissions are increasingly stringent, so to meet regulatory emission standards, new technologies are being studied and developed to reduce emissions generated by engines, in the case of diesel engines compression ignition, studies of techniques to reduce NOx and soot have been carried out. One of the techniques studied is the application of the DFI - Ducted Fuel Injection concept, which makes the fuel spray pass through a small cylindrical duct installed upstream of the injection orifice of the injector nozzle, thus improving the air/fuel, making it more homogeneous and allowing a more complete combustion. This work addresses a study of this application of DFI with different compression ratios. To carry out the tests, a thermodynamic
Jairo Dias, Fábio, Lacava, Pedro Teixeira, Rufino, Caio, Castejon Garcia, Ezio, Lomonaco, Raphael
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