A numerical study of automotive turbocharger mixed flow turbine inlet geometry for off design performance

Mixed flow turbines represent a potential solution to the increasing requirement for high pressure, low velocity ratio operation in turbocharger applications. While literature exists for the use of these turbines at such operating conditions, there is a lack of detailed design guidance for defining the basic geometry of the turbine, in particular, the cone angle – the angle at which the inlet of the mixed flow turbine is inclined to the axis. This investigates the effect and interaction of such mixed flow turbine design parameters.
Computational Fluids Dynamics was initially used to investigate the performance of a modern radial turbine to create a baseline for subsequent mixed flow designs. Existing experimental data was used to validate this model.
Using the CFD model, a number of mixed flow turbine designs were investigated. These included studies varying the cone angle and the associated inlet blade angle.
The results of this analysis provide insight into the performance of a mixed flow turbine with respect to cone and inlet blade angle.

On the stabilising effect of gyroscopic moments in an automotive turbocharger

Automotive turbochargers, which operate at very high speeds, exceeding 180,000 r/min, exhibit two strong sub-harmonic modes of vibrations due to oil-whirl instability. These are a conical mode and an in-phase whirl mode. The gyroscopic effects can be very important in such a rotor system. This article presents a theoretical investigation into these effects on the conical whirl instability of a turbocharger induced by the angular (tilting) motion of a rigid rotor. A simplified linear model is used to analyse the rotor-bearing system by investigating the effects of the gyroscopic moment on the internal moments. A gyroscopic coefficient, defined by the geometry of the rotor, is shown to govern the stability of the conical whirl motion. A threshold value of 1/2 is determined for this coefficient to suppress the conical whirl. This value remains unaffected if the rotor is asymmetric and is supported by floating ring bearings, which is the case in a practical turbocharger.

Application of Design of experiments on the simulation of a process in an automotive industry

The objective of this article is to apply the Design of experiments technique along with the Discrete Events Simulation technique in an automotive process. The benefits of the design of experiments in simulation include the possibility to improve the performance in the simulation process, avoiding trial and error to seek solutions. The methodology of the conjoint use of Design of Experiments and Computer Simulation is presented to assess the effects of the variables and its interactions involved in the process. In this paper, the efficacy of the use of process mapping and design of experiments on the phases of conception and analysis are confirmed. © 2007 IEEE.

A case study of concurrent engineering application on the development of parts for the white goods industry in Brazil

This classical way to manage product development processes for massive production seems to be changing: high pressure for cost reduction, higher quality standards, markets reaching for innovation lead to the necessity of new tools for development control. Into this, and learning from the automotive and aerospace industries factories from other segments are starting to understand and apply manufacturing and assembly oriented projects to ease the task of generate goods and from this obtain at least a part of the expected results. This paper is intended to demonstrate the applicability of the concepts of Concurrent Engineering and DFM/DFA (Design for Manufacturing and Assembly) in the development of products and parts for the White Goods industry in Brazil (major appliances as refrigerators, cookers and washing machines), showing one case concerning the development and releasing of a component. Finally is demonstrated in a short term how was reached a solution that could provide cost savings and reduction on the time to delivery using those techniques.

MICROSTRUCTURAL CHARACTERIZATION OF DUAL AND MULTIPHASE STEELS APPLIED TO AUTOMOTIVE INDUSTRY

TRIP (Transformation Induced Plasticity) and DP (Dual-Phase) steels are written in a new series of steels which present excellent mechanical properties. As for microstructure aspect, TRIP steels consist on a ferrite matrix with a second phase dispersion of other constituents, such as bainite, martensite and retained austenite, while dual-phase steels consist on martensite dispersion in a ferrite matrix. In order to identify the different microconstituents present in these materials, microstructure characterization techniques by optical microscopy (using different etchants: LePera, Heat-Tinting and Nital) and scanning electron microscopy were carried out. This being so, microstructures were correlated with mechanical properties of materials, determined by means of tensile tests. It is concluded that steels assisted by TRIP effect have a strength and elongation relation higher than the dual-phase one. With microstructure characterization, it was observed phases present in these materials microstructure.

MICROSTRUCTURAL CHARACTERIZATION OF CP STEEL USED IN AUTOMOTIVE INDUSTRY

This study aims to characterize the microstructure of the complex phase steel (CP). Using the conventional and colored metallographic analysis with 3% Nital etchant, sodium metabisulfite 10% and LePera. Techniques were applied in this work of optical microscopy, using, besides the lighting in bright field, dark field illumination of the reverse contrast in bright field illumination, the method of polarized light, which generates colorful contrast, providing a complementary identification phases present in the microstructure, and the system by differential interference contrast (DIC). The results obtained by metallography CP indicates that the steel has a microstructure composed of ferrite, retained austenite, bainite and martensite and precipitates arranged in a refined and complex morphology. Besides bright field illumination others' optical microscopy's techniques such as dark field illumination were applied.

The prediction of flash evaporation in superheated fuel injections for automotive applications

In gasoline Port Fuel Injection (PFI) and Direct Injection (GDI) internal combustion engines, the liquid fuel might be injected into a gaseous ambient in a superheated state, resulting in flash boiling of the fuel. The importance to investigate and predict such a process is due to the influence it has on the liquid fuel atomization and vaporization and thus on combustion, with direct implications on engine performances and exhaust gas emissions. The topic of the present PhD research involves the numerical analysis of the behaviour of the superheated fuel during the injection process, in high pressure injection systems like the ones equipping GDI engines. Particular emphasis is on the investigation of the effects of the fuel superheating degree on atomization dynamics and spray characteristics. The present work is a look at the flash evaporation and flash boiling modeling, from an engineering point of view, addressed to keep the complex physics involved as simple as possible, however capturing the main characteristics of a superheated fuel injection.

Accelerometer based measurements of combustion in an automotive turbocharged diesel engine

The capability to detect combustion in a diesel engine has the potential of being an important control feature to meet increasingly stringent emission regulations, develop alternative combustion strategies, and use of biofuels. In this dissertation, block mounted accelerometers were investigated as potential feedback sensors for detecting combustion characteristics in a high-speed, high pressure common rail (HPCR), 1.9L diesel engine. Accelerometers were positioned in multiple placements and orientations on the engine, and engine testing was conducted under motored, single and pilot-main injection conditions. Engine tests were conducted at varying injection timings, engine loads, and engine speeds to observe the resulting time and frequency domain changes of the cylinder pressure and accelerometer signals. The frequency content of the cylinder pressure based signals and the accelerometer signals between 0.5 kHz and 6 kHz indicated a strong correlation with coherence values of nearly 1. The accelerometers were used to produce estimated combustion signals using the Frequency Response Functions (FRF) measured from the frequency domain characteristics of the cylinder pressure signals and the response of the accelerometers attached to the engine block. When compared to the actual combustion signals, the estimated combustion signals produced from the accelerometer response had Root Mean Square Errors (RMSE) between 7% and 25% of the actual signals peak value. Weighting the FRF’s from multiple test conditions along their frequency axis with the coherent output power reduced the median RMSE of the estimated combustion signals and the 95th percentile of RMSE produced from each test condition. The RMSE’s of the magnitude based combustion metrics including peak cylinder pressure, MPG, peak ROHR, and work estimated from the combustion signals produced by the accelerometer responses were between 15% and 50% of their actual value. The MPG measured from the estimated pressure gradient shared a direct relationship to the actual MPG. The location based combustion metrics such as the location of peak values and burn durations were capable of RMSE measurements as low as 0.9°. Overall, accelerometer based combustion sensing system was capable of detecting combustion and providing feedback regarding the in cylinder combustion process

DEVELOPMENT OF CONFORMABLE CNG TANK FOR AUTOMOTIVE APPLICATION

The purpose of this study is to design, develop and integrate a Compressed Natural Gas (CNG) tank that will have a conformable shape for efficient storage in a light-duty pick-up truck. The CNG tank will be a simple rectangular box geometry to demonstrate capability of non-cylindrical shapes. Using CAD drawings of the truck, a conformable tank will be designed to fit under the pick-up bed. The intent of the non-cylindrical CNG tank is to demonstrate improvement in size over the current solution, which is a large cylinder in the box of a pick-up truck. The geometry of the tank’s features is critical to its size and strength. The optimized tank design will be simulated with Finite Element Analysis (FEA) to determine critical stress regions, and appropriate design changes will be made to reduce stress concentration. Following the American National Standard Institute (ANSI) guide, different aluminum alloys will be optimized to obtain the best possible result for the CNG tank.

Fault diagnosis of an automotive suspension system

With the development of the embedded application and driving assistance systems, it becomes relevant to develop parallel mechanisms in order to check and to diagnose these new systems. In this thesis we focus our research on one of this type of parallel mechanisms and analytical redundancy for fault diagnosis of an automotive suspension system. We have considered a quarter model car passive suspension model and used a parameter estimation, ARX model, method to detect the fault happening in the damper and spring of system. Moreover, afterward we have deployed a neural network classifier to isolate the faults and identifies where the fault is happening. Then in this regard, the safety measurements and redundancies can take into the effect to prevent failure in the system. It is shown that The ARX estimator could quickly detect the fault online using the vertical acceleration and displacement sensor data which are common sensors in nowadays vehicles. Hence, the clear divergence is the ARX response make it easy to deploy a threshold to give alarm to the intelligent system of vehicle and the neural classifier can quickly show the place of fault occurrence.

Inducing the development and adoption of socially efficient automotive technology. Final report.

Transportation Systems Center, Cambridge, Mass.

Increased fuel economy in transportation systems by use of energy management. Volume II - digital automotive propulsion simulator programs and description.

Transportation Department, Washington, D.C.

Analyses of selected automotive parts and assemblies for cost and material impacts. Final report.

National Highway Traffic Safety Administration, Office of Research and Development, Washington, D.C.

A Manual of procedures for short course presentation in traffic engineering /

Cover title.

Traffic administration in the nation's capital: positioning the traffic engineering function in the government of the District of Columbia. A report to the Board of Commissioners.

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