Browse Topic: Fuel tanks

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Research on Ventilation Performance of Slotted Honeycomb Panels for Civil aircraft2026-99-09138/7/2026
Auxiliary fuel tank systems for civil aircraft are typically employed in extended-range aircraft. As a critical structure for fuel storage, the structural safety of auxiliary fuel tanks directly impacts aircraft safety. Such tanks are generally constructed from honeycomb sandwich composite panels. Owing to their outstanding advantages, including high specific strength, light weight, and corrosion resistance, honeycomb sandwich composite panels have become the material of choice for civil aircraft fuel tanks. However, to meet the safety requirements for ventilation and leakage drainage in the sandwich structure of fuel tanks, dedicated flow channels must be created by slotting inside the honeycomb composite panels to ensure timely discharge of fuel vapor and accumulated fluid from the tank sandwich. Conventional flow channels are symmetrically arranged on the end faces of the honeycomb core, making it difficult for ventilation airflow to penetrate the center of honeycomb cells. This results in ventilation and drainage blind spots within the cells, which tend to cause accumulation of fuel vapor and residual fluid over prolonged service. Consequently, the aging of the core layer is accelerated, compromising the structural integrity of the composite panel and the service life of the fuel tank. This paper proposes an asymmetric ventilation flow channel design. By optimizing the slotting position, size, and distribution pattern of the flow channels, the limitations of the traditional symmetric layout are overcome. To accurately investigate the effect of this design on the internal ventilation performance of honeycomb composite panels, a three-dimensional flow field model of the honeycomb sandwich composite panel is established using computational fluid dynamics (CFD). The ventilation airflow distribution, velocity, and flow rate characteristics under different flow channel designs are simulated and compared with those of the conventional symmetric flow channel design. The results demonstrate that the asymmetric ventilation flow channel design improves the ventilation uniformity inside the honeycomb cells and completely eliminates the ventilation and drainage blind spots at the cell center inherent in the traditional design. Meanwhile, the design significantly enhances the ventilation gas velocity and flow rate at the center of honeycomb cells, accelerating the discharge of fuel vapor and drainage of accumulated fluid. The overall ventilation efficiency is considerably higher than that of the traditional symmetric design. This study provides a theoretical basis and technical support for the safety design of honeycomb composite panels used in auxiliary fuel tanks of civil aircraft.
Yao, Lijun, Chen, Jun
Finite Element Analysis and Structural Optimization of Aluminum Alloy Fuel Tanks2026-99-01937/31/2026
To address the failures observed in aluminum-alloy fuel tanks, specifically, cracking of the dual-chamber sealing partition, end cover, and drain boss, finite element analysis was employed for comprehensive calculation and structural optimization. Stress, strain, and displacement under varying load conditions were evaluated, revealing that failures of the sealing partition and end cover were due to stress concentration. At the same time, the cracks in the drain boss were caused by weaknesses in the weld heat-affected zone. Three optimization measures were proposed: adding an R5 chamfer to sealing baffles, incorporating R5 transitional fillets on the reinforcing ribs of the end caps, and designing the drain boss as an asymmetrical elliptical shape with a central transitional fillet. Following these optimizations, the maximum stress on the components was significantly reduced, and the safety factor markedly increased. Results from sealing, pressure, and vibration tests confirmed that these measures effectively enhance the structural strength of aluminum-alloy fuel tanks and extend their service life. This study provides robust support for the design and analysis of aluminumalloy fuel tanks.
Chi, Hong, Lei, Haisen, Sun, Liying, Zhang, Zhitong, Wu, Xiaoci
Collapse Strength and Crush Space Analysis in Lateral Side Pole Impact of an Electric Vehicle2026-01-50527/31/2026
High-Voltage Battery (HVB) protection in lateral pole impact is very important due to severe nature of the impact. Unlike frontal impacts, vehicles have limited range of space and capacity to absorb kinetic energy in lateral side impacts. Nowadays, computer-aided engineering (CAE) using finite element analysis (FEA) is utilized routinely to simulate high-speed crash events of varied type, including side pole impact. These CAE applications focus on the analysis and design of HVB when the vehicle structure is well-developed. CAE methods are time-consuming and are not suited during the pre-program stage when the structure is only in a concept stage and not even a reasonable CAD is available/developed in any sense to use these methods. There is no analytical tool available to understand how to define the characteristics of the structure that surrounds and protects the HVB. The primary motive of this publication is to help with this aspect of vehicle planning/development. Needless to state that this procedure can also be used in planning/developing of internal combustion engine (ICE) and hybrid vehicles, as well. The objective therefore is to develop a simple method/procedure that can give reasonably accurate estimation of the collapse/crush force required for a specified crush space and hence protect the critical components, such as HVB and fuel tank. This analytical method also gives some insight into the optimal use of the upper body (rocker and floor cross-members) and underbody (ladder frame) parts. It was found, for a problem under consideration, optimum kinetic energy to be absorbed by the upper body is 32.5% to avoid intrusion into HVB.
Alavandi, Bhimaraddi, Midoun, Djamal, Frank, Randy
Study on Fuel Sloshing in Launch Vehicle Tanks and Response of Anti-Sloshing Plates2026-99-08437/30/2026
Violent shaking induced by motion excitation in a dynamic environment can generate significant additional forces and moments in liquid propellants, affecting spacecraft stability and attitude control. This study employs the CEL method to establish a fluid-structure interaction model for a launch vehicle fuel tank. The penalty function approach addresses FSI and hinged contact behavior, while the control volume method quantifies liquid pressure on anti-sloshing plates and propellant volume changes. Initial filling angles were used to simulate motion excitation equivalently. For partial filling conditions, the effects of equivalent filling height, initial filling angle, and anti-shake plate thickness on impact resistance were analyzed. Results indicate that at a fixed initial liquid filling angle, increasing the equivalent liquid filling height elevates both the maximum pressure and displacement of the anti-sloshing plate, though the rate of increase diminishes with greater plate thickness. At a fixed equivalent liquid filling height, increasing the initial liquid filling angle raises the maximum pressure, while the enlarged liquid-solid contact volume suppresses propellant sloshing, thereby reducing the displacement of the anti-sloshing plate. This study provides theoretical support for the structural design of anti-sloshing plates in rocket tanks.
Jiang, Longxuan, Le, Guigao
Filler Pipes and Openings of Motor Vehicle Fuel TanksJ1140_202607 (Current)7/21/2026
This SAE Recommended Practice was developed primarily for gasoline-powered passenger car and truck applications to interface vapor recovery systems, but it may be used in diesel, marine, industrial, and similar applications where a nozzle is required for filling. The zones cover nozzle spout access and handle clearance to a refilling port. In addition, this recommended practice includes a design window for nozzle manufacturers to develop with.
Fuel Systems Standards Committee
Performance and Combustion Characteristics of Coryton SUSTAIN Classic Super 80 Carbon-Neutral Fuel versus EN 228 in a 1980s Fiat 500 Engine2026-37-00336/9/2026
The energy transition requires a rapid reduction in the use of fossil fuels, whose combustion generates substantial greenhouse-gas emissions. In Europe, transport alone accounts for roughly a quarter of total greenhouse-gas emissions, with road transport being the predominant component. In this context, the use of biofuels has emerged as a potential solution for limiting further increases in CO₂ emissions. However, most studies available in the literature evaluate the performance of these fuels on modern engines, while their effects on historic carburetted engines remain largely unexplored. This is particularly significant given the large fleet of historic vehicles across Europe, supported by a long-standing tradition of vehicle preservation, associations, and classic car collectors. The main historic-vehicle federations advise caution and the use of low-ethanol formulations so as not to damage elastomers, fuel tanks, and carburettor float bowls. For this reason, a few suppliers have developed fuels specifically for classic vehicles. Among this minority, in 2023 Coryton Advanced Fuels introduced the SUSTAIN Classic line, including the Super 80 variant. In the present study, the performance, fuel consumption, and emissions of an air-cooled, four-stroke Fiat 500 engine fueled with commercial RON 95 gasoline and Coryton SUSTAIN Classic Super 80 were analyzed. A first test comprised a complete sweep from 1000 to 5000 RPM and a second test evaluated four different main jets at maximum torque speed and maximum power speed. To evaluate the performance, the engine was installed on a test bench equipped with a torque meter. Static pressure and temperature sensors were employed to characterize the engine operating conditions, while a dynamic pressure sensor installed in the combustion chamber was used to analyze the combustion characteristics. Exhaust emissions were also measured using a gas analyzer, allowing for a detailed and accurate comparison of the effects associated with the use of the two fuels.
Tarchiani, Marco, Fossati, Federico, Raspanti, Sandro, Baroni, Alberto, Ferrara, Giovanni, Romani, Luca
Weight Estimation of Novel Aircraft Configurations in Early Design Phase2026-26-07736/1/2026
Initial weight estimation from Top Level Aircraft Requirements (TLAR) is a critical first step in aircraft design, yet existing empirical methods are inadequate for novel configurations such as those using Liquid Hydrogen (LH2) or Sustainable Aviation Fuels (SAF). This paper presents a hybrid methodology for top-level weight estimation of such unconventional aircraft. The approach is based on modifying a conventional baseline aircraft, integrating a new statistical model with component-specific weight estimations. A multivariate regression model to estimate the empty weight fraction (We/W0) was developed from a dataset of 44 conventional aircraft, yielding an R-squared value of 0.833. This statistical model was integrated with physics-based models for novel components, including cryogenic fuel tanks and fuel systems. The methodology accounts for iterative changes to fuselage structure and parasitic drag. Four configurations were analyzed: fuel types being Jet A1, SAF, LH2 with aft-fuselage tanks, and LH2 with under-wing podded tanks. The results demonstrate that while LH2 configurations introduce weight penalties for tanks and systems, these are significantly offset by a reduction in fuel weight, resulting in a final Maximum Takeoff Weight (MTOW) comparable to or lower than the conventional baseline. The modular nature of this methodology makes it a viable tool for exploring the design space in early-stage conceptual design.
Goyal, Tushar
Conceptual Design of Hydrogen Fuel-Cell-Based Utility Aircraft2026-26-07836/1/2026
The aviation industry contributes to around 2% of global carbon dioxide emissions. As various sectors of the economy look to reduce their global carbon footprint, the aviation industry is positively acknowledging alternatives to jet fuel. Hydrogen proves to be one such alternative having a high energy density and producing zero carbon emissions on combustion. Hydrogen when used in a jet engine produces water vapour and NOx emissions. In order to reduce the effect of GHGs, the current study aims to develop aircraft concepts suitable with hydrogen propulsion through fuel cells for a short-haul commercial mission profile. Aircrafts such as Metro-23 and Dornier 228-212 were referenced for the requirements of a utility turboprop aircraft. The weight estimation was done to obtain the take-off weight of 10,863 kg following the optimization of thrust to weight ratio and wing loading to calculate the initial dimensions. OpenVSP was used to model the initial structure of the aircraft. For the propulsion system, the PEM fuel cell was sized for the aircraft to achieve a range of 2,065 km and endurance of 6 hours in two configurations. Also, various configurations of fuel tanks and their positions were analyzed. The design was able to achieve a reduction of up to 18% in the propulsion system weight through fuel stack configuration. Iterations were performed to achieve static stability and CG was estimated to be 31% of root chord. The final configuration layout with cabin seats, propellers, fuel tank and fuel cells were analysed for static stability. The flight performance of the aircraft is comparable to the reference aircrafts. The proposed design leads towards the path of sustainable aviation.
Bhattacharya, Anisha, Seetha Ramu, Sree Valli, C N, Lakshmi Manasa, Rohit, Benjamin
From Racing Car to Rocket Tank26AERP06_086/1/2026
German startup Blackwave is building carbon parts for rocket tanks. Technical University of Munich, Munich, Germany Carbon fiber has become indispensable in high-performance industries such as automotive engineering and aerospace. It's lightweight, extremely durable, and can be shaped in almost any way. The start-up Blackwave, founded at the Technical University of Munich (TUM), specializes in this versatile composite material. What began with custom components for sports cars and aircraft has evolved into the development of high-pressure tanks for space applications. As is so often the case in engineering, a small detail determines technological progress. In the case of rockets, it is the high-pressure tanks that are specially designed for the fuel systems. As rockets are designed to be as light as possible, they lose structural stability when the fuel tanks, known as primary tanks, are emptied. A trick is used to counteract this: alongside fuel combustion, noble gases are released from internal high-pressure tanks, known as secondary tanks. These gases fill the resulting empty space, maintaining structural integrity.
Thermal Management of Gasoline Fuel Tanks2026-01-01144/7/2026
This study presents a fully integrated, vehicle-level thermal management model for gasoline fuel tanks, designed to predict transient fuel temperatures, tank wall heating, and vapor generation under real-world driving conditions. The model simulates coupled thermal contributions from exhaust radiation, transient underbody airflow, conductive heat transfer, in-tank pump heating, and dynamic changes in fuel composition and level. Validation against on-road measurements shows strong agreement for fuel temperature and vapor flow profiles. Results confirm that exhaust radiative heating is the dominant thermal load, particularly during the post-shutdown heat soak period. A well-designed heat shield reduced peak tank wall temperature by approximately 27 °C, significantly lowering fuel heating and evaporation. Parametric analysis indicates that while fuel Reid Vapor Pressure (RVP) and tank material influence evaporation, their effect is secondary to external heat mitigation. While this model employs simplifications, such as assuming a uniform bulk fuel temperature and using empirically based convective correlations, these assumptions proved adequate for vehicle-level thermal management analysis. This adequacy is supported by the strong correlation between the model’s predictions and experimental field data across realistic driving scenarios. As a practical tool, the model successfully supports the optimization of thermal protection strategies and guides heat shield design decisions. Future work to incorporate measurement uncertainties, localized thermal stratification, and experimental validation of vapor composition would further strengthen predictive accuracy and extend the model's applicability to more detailed design phases.
El-Sharkawy, Alaa, Asar, Mona, Taha, Nahla, Sheta, Mai
Ambient and Initial Temperature Effects on Battery Electric Vehicle (BEV) Range and Energy Consumption Rate Modeled in FASTSim2026-01-02774/7/2026
Ambient and initial temperatures significantly impact the energy consumption rate (ECR) of battery electric vehicles (BEVs) due to auxiliary loads and the temperature dependence of battery efficiency. This study introduces a streamlined, physics-based thermal modeling approach within the FASTSim tool that bridges the gap between oversimplified constant-load models and computationally expensive high-fidelity simulations. By employing a lumped thermal mass framework, the model captures fundamental energy balances and critical non-linear energy penalties while maintaining the computational efficiency required for expansive sensitivity studies. The simulations evaluated a compact BEV hatchback with a resistive heater over city (UDDS) and highway (HWFET) test cycles. Compared to a 22°C initial and ambient temperature baseline, a -7°C initial/ambient temperature resulted in a 221% increase in the ECR for the city cycle and a 100% increase for the highway cycle. Conversely, a 45°C initial / 40°C ambient temperature resulted in a 40% increase for UDDS and an 18% increase for HWFET. These results demonstrate that while cold conditions impose the most severe energy penalties due to resistive heating, the impact is consistently more pronounced in city driving where auxiliary loads represent a larger proportion of total energy. This lightweight yet robust framework enables researchers to rapidly quantify BEV thermal sensitivity across diverse climates without the need for high-overhead simulation environments.
Baker, Chad, Steuteville, Robin, Holden, Jake, Gonder, Jeffrey, Carow, Kyle
CFD-Based Investigation of Fuel Tank Sloshing: Crash Safety and Noise Concerns2026-01-04904/7/2026
A computational study using the Volume of Fluid (VOF) method in SimericsMP+ was conducted to investigate fuel sloshing in automotive fuel tanks under both crash and sudden stop conditions. The SEALs method was employed to rapidly generate the fuel tank mesh, enabling efficient simulation setup. At the outset, a benchmark sloshing case was simulated and compared against experimental data, showing excellent agreement to validate the simulation method. This simulation method was then applied to the fuel tank sloshing scenarios mimicking crash and sudden stop conditions. The study initially focused on a crash scenario in which fuel waves impact valves, pumps, and other internal structures. Capturing these localized impact forces is critical for evaluating the risk of component failure and potential leakage. A baffle-equipped tank was simulated and compared with sensor data. Results show that the computed shock forces on valves and baffles closely matched the measurements, demonstrating the high accuracy of the CFD method in predicting crash safety performance and confirming the effectiveness of baffles in reducing fuel wave impacts. The validated framework was then applied to four new unbaffled tank designs to assess NVH performance during low-speed sudden stop maneuvers. Pressure fluctuations on tank walls, which are directly linked to cabin noise, were analyzed and compared against reference pressure measurements from physical tests to ensure compliance with NVH standards. Simulations revealed significant pressure peaks in certain designs, indicating sub-optimal acoustic performance and highlighting how the absence of internal columns or baffles amplifies wave propagation and surface loading. The computational strategy presented in this study provides a powerful tool for evaluating both crash safety and NVH behavior early in the design process. By delivering accurate predictions before physical prototypes are built, it helps guide fuel tank design development, reduces reliance on costly testing, and minimizes the risk of late-stage design failures.
Jia, Kun, Rahman, Ashique, Pandey, Ashutosh
Thesaurus for Fuel System ComponentsAIR1615B (Current)3/12/2026
This document provides a summary of names commonly used throughout the industry for aircraft fuel system components. It is a thesaurus intended to aid those not familiar with the lexicon of the industry.
AE-5A Aerospace Fuel, Inerting and Lubrication Sys Committee
Leveraging Telematics Big Data Analytics for Real-Time Monitoring of Catalytic Converter Failures and Root Cause Identification for Emission Compliance2026-26-05911/16/2026
The automotive industry is continuously evolving at high pace to meet rising customer expectations, reliability, reduced maintenance, and most relevant, compliance with stringent emission norms. Traditionally, the analysis of vehicle emissions relies heavily on periodic inspections and manual checks. These conventional methods are often time-consuming, prone to human error, and lack the ability to provide real-time insights. Also, identifying failures due to non-manufacturing issues require meticulous physical inspections and historical data reviews, which are not always accurate or timely. Telematics or Connected cars technology being one of the major technological innovations in recent times revolutionizes these processes by enabling real-time data exchange between vehicles and external systems. The current study presents an innovative approach to utilizing telematics data for real-time monitoring of vehicle emissions and pinpointing Catalytic converter failures by analyzing vehicle probe data retrieved from telematics system aimed to identify fuel adulteration events or CNG kit retrofitments that can compromise vehicle performance and longevity. The methodology involves continuous data transmission from telematics devices to the cloud, where the system monitors vehicle emissions in real-time and alerts customers of potential failures. Further to identify the cause of failure, the telematics raw data is processed and aggregated for analysis using statistical models to detect potential fuel tank cleaning due to incorrect or adulterated fuel filling done in the past. This process is validated through a two-level model, ensuring accuracy in detecting fuel adulteration instances. The key advantage of this approach lies in its server-based high-speed processing, which eliminates the resource burden involved during physical inspection and testing of failed parts and enhances detection capabilities compared to existing solutions. This innovative method not only improves vehicle maintenance and customer satisfaction but also ensures compliance with emission norms, thereby contributing to a cleaner and more sustainable environment.
Dev, Triyambak, Prasad, Kakaraparti Agam, Kalkur, Varun, Modak, Saikat, AGARWAL, Shashank, Chandra, Animesh, Paul, Varsha, Garg, Amit, Sundararaman, Venkataraman, Bose, Sushant
Optimization of Propeller Shaft Design to Eliminate Launch Undulation (Lateral Shake) and Vibration Level2026-26-03341/16/2026
During vehicle launches in 1st gear, a lateral shake (undulation) and a pronounced metallic hitting noise were observed in the underbody. The noise was identified as the propeller shaft's second universal joint (UJ) yoke striking the fuel tank mounting bracket. Sensitivity to these issues varied with acceleration inputs: light pedal input during a normal 1st gear launch on a flat road resulted in minimal undulation, whereas wide open throttle (WOT) conditions in 1st gear produced significant lateral shake and intensified hitting noise. Further investigation revealed that the problem persists across all gears and occurs consistently during normal driving conditions, with continuous impact between the propeller shaft yoke and the fuel tank mounting bracket. Extensive experimental measurements at the vehicle level indicated that these issues were primarily caused by the center-mounted propeller shaft joint deviating from its central position and rotating eccentrically under torque. This eccentric movement was linked to the improper propeller shaft split ratio and shorter fitting length. A detailed design study combined with vehicle-level experiments (Design of Experiments, DOE) confirmed that these factors significantly contribute to the positional shift of the second UJ connection and its resulting eccentric behavior. This study provides a comprehensive approach to addressing the issue, focusing on reducing vibrations transmitted to the floor and seats and give NVH refinement through the propeller design optimization. By doing so, it ensures improved vehicle performance without compromising other critical parameters.
Sanjay, L, S, Manickaraja, Kumar, Sarvesh, Kanagaraj, Pothiraj, Senthil Raja, T, B, Prem Prabhakar, M, Kiran
Development of Integral Forming for New “NMAX” YECVT Parts Using the Plate Forging Method2025-32-000511/3/2025
Yamaha Motor Engineering Co., Ltd. provides plastic processing technology based on fuel tank press forming technology, and is developing various plastic processing methods, including forging, and developing mold equipment to realize them. This time, the core parts of the YECVT unit mounted on Yamaha Motor Co., Ltd.'s small premium scooter "NMAX" were not made by welding individual parts to each other, but by integrally forming them from a single thick plate using the cold forming method, resulting in lightweight, compact, high-strength, high-precision parts. By incorporating a composite plastic processing method that takes advantage of the characteristics of the material while making full use of analysis technology and mold technology, we were able to develop a composite plastic processing method (plate forging method) that creates new added value and mass produce it. In addition,this development has made it possible to achieve a thickness increase of 1.7 times the standard material thickness as a mass production method.
Hongo, Hironari, Tamaru, Shogo, Uda, Shinnosuke
Research on Vehicle Fuel Abnormal Reduction Monitoring and Alert System Based on Dual-Mode Energy-Saving Control Technology2025-99-002510/17/2025
As an important bridge connecting cities and rural areas, highway transportation has an irreplaceable role in regional economic development [1]. Accompanied by the booming development of long-distance transportation industry, strengthening highway transportation is of great significance to improve people's living standards [2], but because of the special characteristics of truck transportation, fuel theft is frequent, seriously endangering the driver's life and the safety of goods transportation, although the police in the severe crackdown, but fuel theft seems to be in addition to inexhaustible, truck drivers lose oil incidents still occur from time to time, due to the increasingly serious energy problems, the world's countries have Due to the increasingly serious energy problems, countries around the world have formulated strict automotive fuel consumption rate (hereinafter referred to as fuel consumption) regulations [3], in the transportation process to prevent fuel theft is of great significance. Foreign research on fuel theft prevention can be traced back to around 2009, when the International Road Transport Union (IRU) conducted a relevant study in the UK [4]. In addition, the research on fuel theft of trucks in the EU-funded TSS project in 2018 has been more systematic [5]; in 2020, more research literature on fuel theft has also appeared. Domestic related starting research is late, research on fuel monitoring and vehicle tracking only appeared around 2012, after which research gradually increased; a commercial vehicle antitheft fuel alarm device design was proposed in 2013. However, with the continuous development of automotive technology, the original fuel anti-theft research is no longer applicable to the development of modern fuel tank components and has certain limitations. Therefore, this study takes this opportunity to deeply investigate the means of fuel theft and the defects of existing measures, draw on advanced concepts at home and abroad, innovatively put forward the dual-mode architecture system program according to the length of the vehicle stopping time, integrating energy-saving control, multilevel alarms, and location information processing technology, and is made of hardware selection, software programming, and model assembly and debugging. After testing, the system is stable in all functions, effectively monitors fuel anomalies and accurately grades alarms, solves the problem of excessive energy loss by long-time parking anti-theft, and plays an effective warning and reminder effect by utilizing the long-distance and short-distance dual-alarm processing system. However, there are fluctuations in the stability of data transmission and occasional delays in the response of some sensors under extreme complex electromagnetic interference, and the technical flaws will be overcome to improve stability and robustness.
Liu, Yuzhen, Duan, ShuWen
Factors Influencing Energy Consumption in Plug-In Hybrid Vehicles: A Field Study2025-01-041410/7/2025
The paper assesses the impact of key factors influencing energy consumption for a Plug-in Hybrid Vehicle (PHEV) passenger car based on actual operating conditions over a period of one year. The tests were carried out in various climatic conditions, by random drivers, on the roads and streets of a medium-sized city in Poland. The use of PHEV with the prepared measuring procedure allowed for the analysis of energy consumption separately for the internal combustion and electric drive system. The total energy consumption directly depends on the way the car is used and on the availability of energy in fuel tank and traction battery. The calculated energy consumption varied from 20.19 to 41.97 kWh/100 km. The results were compared to other vehicles operated in real conditions, registered in a public database. The recorded minimum values of energy consumption correspond to the electric drive system, and the maximum values to the internal combustion drive system.
Mamala, Jaroslaw, Graba, Mariusz, Bieniek, Andrzej, Prażnowski, Krzysztof, Hennek, Krystian, Burdzik, Rafał
Aircraft Flexible Tanks General Design and Installation RecommendationsAIR1664A (Current)7/28/2025
This SAE Aerospace Information Report (AIR) includes general information about the various types and styles of flexible tanks and the tank-mounted fittings that adapt the tank to the surrounding structure and fluid-system plumbing. Recommendations are given relative to the dimensional layout of the tank when these recommendations serve to avoid tank fabrication problems and tank/structure interface problems. As a part of these recommendations, critical dimensions of plumbing adapter fittings are discussed and recommendations made. Tank manufacturing tolerances are given. Recommendations are made relative to cavity design and preparation to facilitate a reliable installation. The special installation requirements of nonself-sealing, self-sealing, and crash-resistant tanks are discussed. This document is not intended to replace the information or requirements of the military and commercial procurement specifications listed in Section 2. No attempt has been made, except in a very general way, to include physical property data such as weight and thickness of the composite materials available in the industry. Such materials are too numerous and vary too much between manufacturers. Whenever specific data or advice is required, it is necessary that the tank manufacturers be consulted.
AE-5A Aerospace Fuel, Inerting and Lubrication Sys Committee
Aerospace Fuel System Specifications and StandardsAIR1408B (Current)7/16/2025
This report lists documents that aid and govern the design of aircraft and missile fuel systems. The report lists the military and industry specifications and standards and the most notable design handbooks that are commonly used in fuel system design. Note that only the principle fuel specifications for the U.S. and Europe (Military Specifications, ASTM, and Def Stan) have been included within this report. The specifications and standards section has been divided into two parts: a master list arranged numerically of all industry and military specifications and standards, and a component list that provides a functional breakdown and a cross-reference of these documents. It is intended that this report be a supplement to specifications ARP8615, MIL-F-17874, and JSSG 2009. Revisions and amendments which are correct for the specifications and standards are not listed. The fuel system design handbooks are listed for fuels and for system and component design.
AE-5A Aerospace Fuel, Inerting and Lubrication Sys Committee
Dispenser Nozzle Spouts for Liquid Fuels Intended for Use with Spark Ignition and Compression Ignition EnginesJ285_202507 (Current)7/9/2025
This SAE Recommended Practice provides standard dimensions for liquid fuel dispenser nozzle spouts and a system for differentiating between nozzles that dispense liquid fuel into vehicles with spark ignition (SI) engines and compression ignition (CI) engines for land vehicles. Current legal definitions only distinguish between “Unleaded Fuel” and “All Other Types of Fuel.” These definitions are no longer valid. This document establishes a new set of definitions that have practical application to current automobile liquid fuel inlets and liquid fuel dispenser nozzle spouts.
Fuel Systems Standards Committee
Coating, Corrosion-Preventative, for Aircraft Integral Fuel Tanks for Use to 250 °F (121 °C)AMSC27725E (Current)7/1/2025
This specification establishes requirements for three types of corrosion-preventative coatings for protection of aircraft integral fuel tanks.
AMS G8 Aerospace Organic Coatings Committee
Aircraft Fuel System and Component Icing TestARP1401C (Current)6/27/2025
This SAE Aerospace Recommended Practice (ARP) covers a brief discussion of the icing problem in aircraft fuel systems and the different means that have been used to test for icing. Fuel preparation and icing test procedures for aircraft fuel systems and components are proposed herein as a recommended practice to be used for fixed wing and rotary-wing aircraft within their operational environment. This ARP mostly addresses aircraft fuel system level testing and provides a means to address the requirements of FAR 14 CFR § 23.951(c), § 25.951(c), § 27.951(c), and § 29.951(c). In the context of this ARP, the engine and the auxiliary power unit (APU) are not considered to be components of the aircraft fuel system. However, some of the methods described in this document can be applied to the engine, APU, and other aircraft (system or component level) icing tests. This revision does not completely address new developments in ice accretion and release resulting from internal flow in tubing (see 2.3.6). This will be addressed in a different document when more experimental data is available.
AE-5A Aerospace Fuel, Inerting and Lubrication Sys Committee
Prediction and Validation of Sloshing and Fluid-Structure Interactions Using FPM for VTOL ApplicationsF-0081-2025-04005/20/2025
Accurate simulation of fluid-structure interactions (FSI) is critical for designing aircraft systems, particularly for applications involving fuel tank sloshing and large deformations. Traditional added mass methods often fail to capture the nonlinear and frequency-dependent behavior of these coupled systems. This study applies the Finite Pointset Method (FPM), a mesh-free computational fluid dynamics (CFD) technique, coupled with an explicit finite element solver, to predict complex FSI phenomena. Validation is performed using benchmark experiments, including a harmonic tank sloshing test and a guided plate ditching scenario, with results demonstrating strong agreement with measured pressures and structural responses. Additional validation on a composite fuel tank drop impact test confirms FPM's ability to model large deformations and rupture under dynamic loading. The findings highlight FPM's robustness and adaptability for aerospace FSI problems, offering a powerful alternative for virtual prototyping and certification workflows where conventional methods are insufficient.
Dwarampudi, Ramesh, Vaz, Ignatius
2024 Student Competition Undergraduate Winner: Georgia Tech Aerolay Design Multi-Mission Modular UAS for Disaster ReliefF-0081-2025-04265/20/2025
Unmanned Aerial Systems (UAS) are essential in disaster relief. VTOL UAS can take off and land in confined areas without infrastructure, efficiently accessing disaster zones for life-saving missions. The AeroLay, designed for disaster relief, delivers up to 54 kg and can loiter for 17.2 hours to relay cell signals. It features quick battery swaps and an accessible fuel tank for rapid redeployment.
Lutsenko, Aleksandr
Study on Flex Fuel Compatible Coatings for Automotive Fuel Tank2024-32-00764/18/2025
Reducing CO2 emissions is now a major focus in India heading towards net zero emissions by 2070. India is the 3rd largest automobile market in the world and the transportation sector is the 3rd largest CO2 emitter. In this direction, it is necessary to reduce the carbon footprint from the automobile sector to combat climate change. The adoption of sustainable biofuels such as ethanol will enable us to reduce emissions, as ethanol is carbon neutral fuel. However, vehicle manufacturers are facing challenges in manufacturing flex fuel compatible parts in the vehicle mainly fuel systems. Ethanol has both nonpolar and polar bonds, making it miscible to both gasoline and water, thereby water contamination is inevitable in ethanol blend fuels. In addition, control of ethanol contamination by sulfates and chlorides during ethanol production is challenging. Thus, ethanol blend fuels are considered more corrosive and tendency towards deposit formation than normal gasoline fuels. Design and development of corrosion resistant and flex fuel compatible materials for fuel systems are important without compromising the functional requirements. In fuel systems, fuel tank is one of the major parts, which acts as a reservoir for fuel supply and needs to have good chemical and corrosion resistance. This paper describes the comparative study of three different coating systems of single layer coating with and without topcoat on top of steel sheet to withstand up to 85% ethanol fuel blends. In all these coated samples, base metal used is low carbon steel sheet which is commonly used for automotive fuel tank application. The fuel tank internal corrosion study is conducted using test fuel as aggressive ethanol blend fuel at coupon level as per SAE J1747. The test fuel has been selected to simulate the effect of possible contamination in the real usage condition and to provide accelerated corrosion test. The selection criteria used for the evaluation are base material corrosion, pitting, weight loss, formation of reaction products and its elution behavior into the test fuel. No pitting, perforation and weight loss were observed in all the coating systems after the test. Base material corrosion was encountered in only 2 coating systems and reaction products were observed as deposits in all coating systems for higher ethanol blend test fuels. The reaction products were analyzed in SEM-EDS and their elution effect into the fuel was studied under both static and dynamic fluid conditions.
Pandi, Dinesh Babu, Shanmugam, Gomathy Priya, Nagarkatti, Arun, Gopal, Manish, Anbalagan, Prathap
Fuel Tank Filler Cap and Cap Retainer ThreadedJ1114_202504 (Current)4/14/2025
This SAE Recommended Practice was developed primarily for passenger car and truck applications, but it may be used in marine, industrial, and similar applications.
Fuel Systems Standards Committee
Fuel Tank Filler Cap and Cap RetainerJ829_202504 (Current)4/14/2025
This SAE Standard was developed primarily for passenger car and truck applications for the sizes indicated, but it may be used in marine, industrial, and similar applications.
Fuel Systems Standards Committee
Fuel Tank Filler, Capless ClosureJ3144_202504 (Current)4/14/2025
This SAE Recommended Practice was developed primarily for passenger car and truck applications, but it may be used in marine, industrial, and similar applications.
Fuel Systems Standards Committee
A DEM-FEM Coupled Analysis of Ultrasonic Shot Peening Dynamics and Surface Modification Parameters in Aluminum Alloys2025-01-82394/1/2025
The significant mechanical features of aluminum alloy, including cost-effectiveness, lightweight, durability, high reliability, and easy maintenance, have made it an essential component of the automobile industry. Automobile parts including fuel tanks, cylinder heads, intake manifolds, brake elements, and engine blocks are made of aluminum alloy. The primary causes of its engineering failure are fatigue and fracture. Aluminum alloys' fatigue resistance is frequently increased by surface strengthening methods like ultrasonic shot peening (USP). This article discusses the shot peening dynamics analysis and the influence of ultrasonic shot peening parameters on material surface modification using the DEM-FEM coupling method. Firstly, the projectile motion characteristics under different processes are simulated and analyzed by EDEM. The projectile dynamics characteristics are imported into Ansys software to realize DEM-FEM coupling analysis, and the surface modification characteristics of shot peening materials are obtained. The distribution laws of projectile impact velocity and impact angle are summarized through EDEM simulation of USP with different parameters. At the same time, taking the projectile impact velocity and impact angle as input parameters, combined with ANSYS analysis software, the maximum residual stress and average residual stress of the material under the known peening process conditions are calculated.
Adeel, Muhammad, Azeem, Naqash, Xue, Hongqian, Hussain, Muzammil
Heavy Tracked Vehicles: Preliminary Design for Mobility2025-01-83374/1/2025
Modern military operations prove that increased terrain mobility is critical for heavy tracked vehicles’ (HTVs) survivability and lethality. HTV major system packaging as a component of preliminary design with many physical constraints and assumptions poses great challenges for mobility. This paper develops an approach and a method that accounts for such constraints/assumptions and optimizes the packaging of the HTV system assembly, including vehicle armor, armament and munition, powertrain, and fuel tanks. The optimization purpose is to accommodate the center of gravity for improving ground pressure distribution and then reducing the sinkage. This work is based on a literature review and combines numerous techniques rooted in Western literature and Eastern Soviet- and post-Soviet-era literature. The optimization process is developed using a genetic algorithm. The Mean Relative Design (MRD) parameter is proposed to study the average system rearrangement (i.e., re-packing) that is necessary to achieve an optimized design for an HTV, quantifying how well it is designed relative to its potential. Two HTVs with similar physical characteristics but different system assemblies are examined by using the MRD parameter and then optimized for lowering sinkage. The proposed method provides feasible results for packaging vehicle main systems. The optimization outcomes can be implemented during the initial phase of preliminary design and thus will facilitate the next phase of the HTV preliminary design for vehicle mobility performance. For the latter-mentioned purpose, future research will extend the proposed method to the optimization of vehicle mobility performance.
Vardi, Haggay, Vantsevich, Vladimir, Gorsich, David
Modeling and Experimental Study on Evaporation of Vehicle Fuel Tank2025-01-70381/31/2025
In the existing evaporation emission control and monitoring system, it is still necessary to popularize and develop more suitable evaporation emission monitoring, diagnosis and control methods. This study developed a design for the control system of evaporative emissions in hybrid vehicles, focusing on monitoring and controlling fuel evaporative emissions. A fuel evaporation model for automotive fuel tank was established. In this study, the key component of vehicle evaporative emission system, the fuel tank, is modeled and simulated. Through 6-hour and 12-hour experimental studies on fuel evaporation characteristics inside the tank, measurements were taken to determine the amount of evaporation under different liquid levels, temperatures, and vibration states. When the temperature increased from 12°C to 17°C and then further to 28°C, the rate of fuel evaporation increased by 25% and 50%, respectively. The increase in temperature significantly enhanced the rate of evaporation. A detailed simulation model for fuel evaporation was established by studying its composition as well as characteristics specific to different types of fuels. This allowed for the prediction of both components present during evaporation as well as their respective quantities. The average accuracy of evaporation model is 92.7%. providing a foundation for the subsequent development of carbon canister adsorption models.
Zheng, Yushuo, Yu, Xiaohong, Yao, Zhuoxiao, Feng, Yifang, Li, Zhijun, Chen, Tao
A Hybrid Model for Mitigation of Automotive Fuel Tank Slosh Noise2024-28-027112/5/2024
Slosh, a phenomenon occurring in a vehicle's tank during movement, significantly contributes to noise and vibration, often exceeding idle levels. Existing methods for evaluating NVH performance of fuel tanks primarily rely on subjective assessment, highlighting the need for a quantifiable approach to address this dynamic noise. This paper introduces a hybrid methodology to standardize the slosh phenomenon by establishing vehicle-level acceleration, braking, and driving profiles. Noise and vibration data capture, combined with defined boundary conditions, categorizes slosh noise into Impact and Roll noise, differentiated by distinct driving profiles and frequency content. Vehicle level performance is then cascaded down to subsystem level. A dedicated test rig is designed that replicates these conditions at the subsystem level where vehicle speed and braking profiles are translated into rig-specific acceleration and deceleration profiles, enabling consistent data capture for correlation with vehicle-level results. Computational Fluid Dynamics (CFD) analysis utilizes these boundary conditions and profiles to predict forces on the fuel tank walls and identifying partial shortcomings, with forces directly correlating to noise levels. The relationship between forces and noise supports design changes for existing fuel tanks, such as optimizing baffle designs. Several baffle designs were analyzed in CFD for their effectiveness during Impact and Roll events. The optimal design resulted in significant decrease in slosh noise and achieving acceptable cabin comfort levels. Additionally, this methodology facilitated the creation of design rules and target setting for NVH performance. Insights gained from this study were applied to design new fuel tanks for subsequent programs, setting a new benchmark in the segment for reduced slosh noise. This not only improved occupant comfort but also reduced Direct Material Costs (DMC) by eliminating the need for additional baffles. The methodology presented in this paper offers a valuable tool for future vehicle development.
Titave, Uttam Vasant, Zalaki, Nitin, Vardhanan K, Aravindha Vishnu, Naidu, Sudhakara, Virmani, Nishant
‘First of Its Kind’ Composite Material to Help Space Vessels Travel Longer DistancesTBMG-5212612/1/2024
The future of space travel is seemingly changing by the day and a Coventry University academic is doing his bit to stay at the front of the space race.
A Homogenization-Based Technique for a Simplified Numerical Finite Element Approach to Describe the Structural Behaviour of Cylindrical Cells Battery Pack2024-24-00219/18/2024
The continuously increasing demand for Battery Electric Vehicles, together with the customer requirement for higher ranges poses new challenges on the battery pack design. Drawing inspiration from aerospace design principles, wherein fuel tanks are integrated structurally into airframes to save weight and increase efficiency, structural battery packs are also experiencing growing use in the automotive field. In fact, when a structural battery pack is considered, significant weight savings can be achieved, potentially extending the vehicle range. Additionally, this weight saving could be further exploited to increase the battery pack size with respect to a non-structural battery pack, further enhancing the vehicle range without adding extra weight. To address the complexity of integrating structural battery packs, Finite Element simulations are typically adopted to evaluate battery pack integrity and estimate its contribution to the structural behaviour of the overall vehicle. However, the detailed modelling of large number of cells and their interactions with components like cell carriers, busbars, and plates is computationally intensive. To overcome this limit, this contribution proposes a methodology to derive a simplified model of the cells module, deriving an equivalent homogeneous orthotropic material. The results of this simplified approach have been compared to the results obtained from a complete model considering all the individual cells and all related components. The reduced computational effort resulting from the proposed methodology makes it suitable for integration into a more complex full vehicle model. This enables an optimization of the overall design, leading to possible significant improvements in vehicle performance, range and costs.
Mangeruga, Valerio, Renso, Fabio, Sassetti, Riccardo, Giacopini, Matteo
Optical Equipment Safety in Aircraft Fuel TanksARP7977 (Current)8/1/2024
The recommended practices of this document are intended for optical devices and associated optical cables and connectors installed inside transport category aircraft or environments of equivalent ignitability. This document covers optical radiation in the wavelength range from 380 nm to 10 μm. As explained in this document, wavelengths below this range are capable of igniting fuel-air mixtures through an ignition mechanism not considered at this issue of ARP7977. Use of wavelengths outside the range 380 nm to 10 μm should be discussed with the relevant Certification Authority.
AE-5A Aerospace Fuel, Inerting and Lubrication Sys Committee
Sealing Compound, Polythioether Rubber Fast Curing for Integral Fuel Tanks and General Purpose, Intermittent Use to 360 °F (182 °C)AMS3277L (Historical)6/28/2024
This specification covers polythioether rubber fuel-resistant sealing compounds supplied as a two-component system that cures at room temperature.
AMS G9 Aerospace Sealing Committee
Sealing Compound, Low Adhesion, for Removable Panels and Fuel Tank Inspection PlatesAMS3284D (Current)5/28/2024
This specification covers a polysulfide sealing compound with low adhesive strength, supplied as a two-component system that cures at room temperature.
AMS G9 Aerospace Sealing Committee
Fluid-Structure Interaction of Fuel Tanks and Airframe Structures During a Crash EventF-0080-2024-11735/7/2024
This paper presents the results of a research and development (R&D) effort focused on fluid structure interactions between airframe structures and bladder type fuel tanks during a crash environment. During this R&D effort, fuel tank and surrounding structure crash impact tests were conducted using an innovative test configuration that allowed low-cost fabrication of test articles which represented several different design architectures. LS-DYNA models of the crash test article configurations were also developed and correlated with the tests data. Good correlation between the test data and LS-DYNA analysis results was achieved. The paper also includes recommendations for design of the airframe structures around the fuel tanks based on the fluid structure interaction insights gained from the crash tests and analyses.
Bolukbasi, Akif, Weisenburger, Richard
Sealing Compound, Integral Fuel Tanks and General Purpose, Intermittent Use to 360 °F (182 °C)AMS3276H (Current)4/25/2024
This specification covers fuel-resistant polysulfide (T) sealing compounds supplied as a two-component system.
AMS G9 Aerospace Sealing Committee
Fuel and Lubricant Tanks for MotorcyclesJ1241_202404 (Current)4/15/2024
This SAE Recommended Practice is applicable to two- or three-wheel motorcycles intended for highway use. Unless noted, requirements apply to both metallic and nonmetallic tanks. Accessory or aftermarket tanks as well as original equipment tanks are covered.
Motorcycle Technical Steering Committee
The Influence of Fundamental Processing Parameters of Ultrasonic Shot Peening on Surface Characteristics of 7B50-T7751 Alloy2024-01-26814/9/2024
Aluminum alloy has become an indispensable part of the automotive industry because of its excellent mechanical properties such as lightweight, high strength, high reliability, maintainability, and low cost. Aluminum alloy is used in automobiles, such as engine blocks, cylinder heads, intake manifolds, brake components, and fuel tanks. Fatigue and fracture are the main reasons for its engineering failure. Surface strengthening techniques, such as ultrasonic shot peening (USP), are often used to improve the fatigue resistance of aluminum alloys. This article expounds on the working principle of USP and elucidates the influence of USP process parameters on the surface characteristics of aluminum alloy. Experimental results observed the effects of USP parameters on surface properties such as surface roughness, microhardness, and surface morphology. The effects of shot peening (SP) diameter, vibration amplitude of ultrasonic vibrating head, and sample placement angle on the surface state of shot-peened materials were studied. Two different shot sizes of 2 mm and 4 mm shot diameter are utilized with two specimen angles at 90° and 0°, having three vibrational amplitudes of 25 μm, 40 μm, and 60 μm for a peening duration of 5 minutes each. The experimental analysis shows that when the SP time is 5 minutes, the surface grain size is significantly refined to the nanoscale. Compared with untreated samples, the surface roughness of treated samples decreases gradually for lower surface coverage. In addition, SP can effectively improve the hardness of the material. In USP treatment, the maximum microhardness increases, and the crack growth rate decreases by increasing the SP diameter and ultrasonic vibration amplitude).
Adeel, Muhammad, Azeem, Naqash, Xue, Hongqian
Strength Evaluation of Motorcycle Fuel Tank subject to Vehicle Drop through Finite Element Analysis2024-01-28144/9/2024
Motorcycles which are designed for both regular as well as rough terrains experience more severe vertical impact loads from ground in comparison with motorcycles which travel only on regular terrains. Therefore, drop test is considered an important method to evaluate durability for said vehicles. Fuel Tank mounted over front frame of a motorcycle is the most critical component from safety point of view and hence, need to be analysed for vertical drop load case. To do so, modelling of whole vehicle can be a hectic task and has to be avoided. In the present work, behaviour of fuel tank mounted over frame support and subjected to vertical drop from H(m) height is studied with the help of support excitation method incorporated with explicit non-linear time integration scheme using Finite Element Analysis (FEA) code in commercial FEA software. Through this scheme, effect on Fuel Tank of vehicle drop can be studied without actually modelling the whole vehicle. Results from FEA software were compared with that of testing to correlate and validate the accuracy of said technique.
Sharma, Ashish, Khare, Saharash
Design Consideration of Liquid Fuel Tank System with Low Fuel Filling Circuit Position in Automotive Vehicle2024-26-03801/16/2024
Fuel system in a vehicle plays vital role in vehicle as it stores the fuel safely to facilitate vehicle running for desired range. Fuel system being a safety critical component is designed to endure varied environmental conditions and defined robustness for all usage conditions. Liquid fuel system consists of three major systems viz. filling system, storage system and vapor management system. Of the three, the filling system’s major function is to assist proper re-fueling of the storage system. Pre-mature shut-off, spillage and fuel spit back are the three major risks associated to system performance. In general, fuel filling system is connected to fuel tank via inlet pipe which houses a flapper to avoid fuel spillage from filler neck during re-filling operation. Fuel filling creates positive pressure inside the tank which causes the tank to bulge. In the process of regaining the original shape fuel is pushed out of the inlet pipe to neck which might cause spillage. To avoid spillage a one-way valve mechanism (flapper) is added to the system. The filling performance of the system also depends on the height of liquid column i.e., height of fuel neck with respect to breather port in vehicle layout. If neck height is very low with respect to fuel tank breathing port position, addition of flapper causes hinderance in fuel filling. This hindrance further increases if breathing port height with respect to inlet pipe is large. This paper addresses the root cause analysis of the problem and counter measure action plan.
Bagga, Rajat, Badyal, Rochak, Rawat, Mohit, Pal, Kiran
DRBFM Methodology Applied to Design Changing in Fuel Supply Modules2023-36-00541/8/2024
Robustness and reliability are key elements for product success in the automotive market. On this purpose, the Design Review Based on Failure Modes (DRBFM) is a product development methodology to guide on potential risks assessment related to new design proposals. This paper shows the DRBFM structure and mindset for new products, using function and behavior evaluation. Moreover, the methodology will be demonstrated for a real automotive case, considering a new component design for Fuel Supply Module (FSM). The FSM is responsible to deliver fuel to the engine and maintain the pressure in the fuel rail during the spark engine operation. To fit these main functions, the electrical fuel pump inside the module must be always working submerged even if the fuel tank is almost empty. This the reason for this product has the jet pump component that is responsible to actively drag fuel during this worst fuel tank volume condition. During a new FSM customer application, the function presented previously had failure in the test bench, so a new design for the Jet Pump Connector (JPC) was proposed to solve the issue. Using an analytical model and experimental results to prove the correlation between design and function, it was possible to validate the influence of the new design proposed to meet the specification. Additionally, due the methodology applied, it was possible to confirm that this change will guarantee all functional and behavior necessary for this product application in the customer’s vehicle.
de Azevedo Fernandes, Luiz Eduardo, de Oliveira Melo, Lazaro Benedito, André, Marco Pellizzon
Investigations on Wire Electrical Discharge Machining of Magnesium Alloy for Automobile Parts2023-28-015511/10/2023
Magnesium alloy, known for its high strength and lightweight properties, finds widespread utilization in various technical applications. Aerospace applications, such as fuselages and steering columns, are well-suited for their utilization. These materials are frequently employed in automotive components, such as steering wheels and fuel tank lids, due to their notable corrosion resistance. The performance of magnesium alloy components remains unimproved by normal manufacturing methods due to the inherent characteristics of the material. This work introduces a contemporary approach to fabricating complex geometries through the utilization of Wire-Electro Discharge Machining (WEDM). The material utilized in this study was magnesium alloy. The investigation also considered the input parameters associated with the Wire Electrical Discharge Machining (WEDM) process, specifically the pulse duration and peak current. The findings of the study encompassed the material removal rate and surface roughness. Taguchi successfully employed a single aspect optimization technique to ascertain the ideal combination that would enhance the efficacy of the WEDM process. The findings of the investigation revealed that the proposed technique significantly improved the efficiency of the WEDM approach.
Natarajan, Manikandan, Pasupuleti, Thejasree, D, Palanisamy, Kumar, V, Kiruthika, Jothi, Polanki, Vamsinath
CFD Analysis of Fuel Tank to Reduce Liquid Sloshing2023-28-008411/10/2023
This paper demonstrates the sloshing phenomena of a cylindrical tank with and without baffles. The main objective of this study is to design baffles of different configurations to reduce sloshing in a cylindrical tank partially filled with gasoil-liquid subjected to only longitudinal acceleration and deceleration. Two different baffle designs have been introduced in the present study. A 3-D transient analysis of a cylindrical tank was carried out using ANSYS-FLUENT with and without baffles. Volume of Fluid (VOF) method was used to study the free surface profile of the fluid in the considered tank. Pressure distribution, velocity distribution and force distribution have been studied in the present study. It has been observed that the new design of baffle was able to reduce sloshing effectively.
Nallanukala, Prasad, Bhaskara Rao, Lokavarapu, Alampally, Sainath, Biswas, Sayan, Dehadray, Prathamesh
Application of Taguchi Approach on Wire Electrical Discharge Machining of SS304 for Automotive Applications2023-28-015111/10/2023
SS304 is a type of stainless steel that is well-known for its high ductility and resistance to corrosion; as a result, it is typically utilized in a variety of applications, such as the exhaust systems of automobiles and the springs that are used in seatbelts. Because of its qualities, it will eventually be employed in a variety of body parts, including fuel tanks and chassis, among other things. Due to its properties, SS304 is known to be incredibly difficult to machine using conventional methods. Through a wire electrical discharge machining process, it is easier to cut complex materials with high surface finishes. In this study, a study was conducted on the WEDM process parameters of SS304 to optimize its machining process. The study was carried out using the DoE approach, which involved planning the various experiments. The parameters of the process, such as the pulse on time, peak current, and off time, were analyzed to determine their performance. The various performance measures included surface roughness, overcut, and removal rate. The results of the study were then analyzed with an interaction plot analysis. The influence of the various process variables on the output measures were then studied through this analysis.
Natarajan, Manikandan, Pasupuleti, Thejasree, Katta, Lakshmi Narasimhamu, Somsole, Lakshmi Narayana, D, Palanisamy, Kiruthika, Jothi
Guidelines for Liquid Level IndicatorsJ48_202310 (Current)10/6/2023
This SAE Recommended Practice pertains to liquid level determination for any fluid compartment of off-road work machines as defined in SAE J1116 and ISO 6165.
Machine Technical Steering Committee
Mazda again producing rotary engines23AUTP08_088/1/2023
Mazda, the automaker with the longest and richest history of using the Wankel rotary engine announced that it resumed mass production of rotary engines for a new variant of the MX-30 compact crossover. Mazda provided little detail about the engine itself, which serves as a generator for the MX-30 e-SKYACTIV R-EV, a plug-in hybrid (PHEV) variant of the MX-30 crossover. Mazda hasn't used the unique powerplant for a production vehicle for more than a decade. The MX-30 e-SKYACTIV R-EV employs the rotary engine in a series-hybrid layout to generate electricity to replenish the vehicle's 17.8-kWh lithium-ion battery, which when fully charged, can provide up to 85 km (31 miles) of driving range on Europe's Worldwide Light Vehicle Test Procedure (WLTP) cycle. Gasoline from a 50-L (13.2-gal.) fuel tank supplies the rotary when its operation is required to provide electricity for extended-range driving. In a release, Mazda explained it “positioned it [the rotary engine] on the same axle as a high-output motor and a generator” in the front engine bay.
Visnic, Bill
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