Analysis of Failure of Body Control Module Under Various Impact and Vibration Loading

The Body Control Module regulates the operation and coordination between the different parts of the car also by using signals of some sort. The various electronic parts of the vehicle are actually controlled by a Body Control Module – from the car light to the simple door locks; each part has a module that controls it. In today’s automotive setups, these modules are operating under a single assembly – they are now controlled by the Body Control Module. It may seem like the module performs a very complex function. Hence this Body Control Module has been protected from the damage during handling and vehicle running condition. This Body Control Module is subjected to various loading conditions such as vibration loading, Impact loading, mechanical shock. One of the case studies is doing to modify the existing Body Control Module. These modifications are carried out by using Computer Aided Engineering approach and verified by the experimental results. The software being used for the simulation is ANSYS and Ls-DYNA/explicit method.

Validation of Design of Regular Carbon Fabric Composite Plate with Woven Fabric using Tensile Loading

In many recent years the use of composite materials increases in many fields, for example agricultural uses, where these materials are characterized by good mechanical properties, tenacity and light weight. Among many other materials for the reinforcement of composites, technical fabrics are increasingly being used for the same purpose, especially from carbon fiber, which have good mechanical properties. During tensile stress these fabrics are elongated in the direction of tensile force, and at the same time they contract crosswise in relation to the action of the tensile force. In this Project the tensile properties of regular carbon fabrics and woven fabrics made from carbon fiber yarns were investigated. Static structural analysis of Regular carbon fabrics and woven fabrics base carbon fiber specimen will be done using ACP tool in ANSYS 19 software.

Comparisons of VRP Optimization Algorithmic Methods for the Optimal Routing of Multiple Delivery Vehicles with Time Constraint

Transportation costs account for a large portion of business expense in any logistics firm; thus, achieving proper solutions that manage those transportation activities well and reduce such expense should be the number one priority for the business. Essentially, such logistics management involves the routing plans for company vehicles that perform delivery/pick up and also the number of vehicles utilized. This study investigated and compared the optimization performances of routing algorithms using simulated geographic data based in Chiang Rai, Thailand, emulating the post office operation which had 1 post office, 4 delivery vehicles and 2 delivery zones (2 vehicles per zone): 65 customer locations for zone A and 74 for zone B. The major objective of this particular routing problem, called Vehicle Routing Problem (VRP), was that the total delivery distance of those 4 delivery vehicles combined should be minimized; moreover, those vehicles mush finish their delivery operation within a time constraint, set at 2 hours. The optimization algorithms, employed for the routing procedures, were Large Neighborhood Search (LNS), Particle Swarm Optimization (PSO), Differential Evolution (DE) and Ant Colony Optimization (ACO), combined into 3 hybrid algorithms (LNS|PSO, LNS|DE and LNS|ACO). Those hybrid algorithms including pure ones (DE, PSO and ACO) were compared for their optimization performances; and the results showed that LNS|ACO hybrid algorithm was superior than the other two hybrid ones and also far better than pure DE, PSO and ACO algorithms at various parameter variants. Additionally, most algorithms (hybrid and pure ones) finished the delivery routing within the time constraint of 2 hours except only for the pure algorithms at minimum parameter variant.

Design Optimization of Electric Vehicle Wheel using Composite Materials

In an electric vehicle, the wheels are one of the heaviest components of the vehicle. This paper aims to reduce the mass of the existing wheels for reduction in energy consumption as well as increasing the precision in steering. In this paper, an electric sedan is taken as the reference for studying the wheel and the boundary conditions are decided according to its specifications. Reduction in mass is achieved by designing a composite wheel for the boundary conditions. A reduction of 58% is achieved on the total mass of wheel.

Design Improvement of Steering Upright by Investigating Static and Dynamic Analysis

A steering upright is one of the vital components in vehicle dynamics which links all suspension components between the wheel and therefore the vehicle. Upright provides the linkage between the upper & lower ball joints. The upright connects components as an example, control arms, steering arms, suspension springs, shock absorber, brake disc, wheels & tire. Steering upright is a part of mechanical system which contains the wheel hub and assembles to the suspension components. It's the pivot point of the steering and mechanical system, which allows the front wheels to show & more. Agenda of this project is design optimization of steering upright to achieve weight reduction along with required strength and stiffness. Optimized design of upright is necessary with correct material selection further as valid finite element analysis. Optimization is accomplished considering static stress, strain and total deformation analysis with acceptable material selection. Modal and Fourier analysis is to be performed to see natural frequencies and deformation. The experimental testing is going to be performed on UTM. By making the comparative analysis, result and conclusion is drawn.

Brake Squeal Analysis using Finite Element Analysis Method

The Finite Element Analysis (FEA) is widely used for solving many Engineering problems. This paper focuses on use of FEA for Brake Squeal Analysis. Automobiles generates several kinds of noises like Groan, chatter, judder, moan, and squeal. Brake squeal can be defined as an unwanted noise that occurs due to dynamic instability of the system. It generally occurs in the frequency range of 1 KHz to 16 KHz.The aim of the project is to predict the squeal noise occurring at particular frequencies at an early stage of development using full corner brake model. The preprocessing of the full corner brake model is done using Hypermesh while the processing and post-processing is to be carried out by using Abaqus. Analysis uses non-linear static simulation which is followed by Complex Eigen Value (CEA) extraction for carrying out the squeal Simulation. It provides the relation between damping ratio and frequency (Real part of the complex Eigen value). If the damping ratio at any particular frequency is above one, it can be said that squeal will occur at that particular frequency.

Green Sand Mould Production of Aluminum Alloy Bimetallic Castings

A green sand moulding system was applied to produce alumunum alloy bimetallic castings. Al alloys 6101 and 242 were combined in the production of the bimetals. Mould firing temperature, pouring temperature and grain fineness number taken at three levels were the parameters used in the study. This was done to know the number of times the experiments would be run using L9 orthogonal array of Taguchi’s approach to design of experiment. Nine experiments were conducted in all, taking into cognisance the role of design of gating system for each of the castings to avoid turbulence. UTS and hardness values were determined as core mechanical properties of the components. There was a down trend of the values as the values of the process parameters increased. However, there were exceptions to this pattern of behaviour perhaps some hot spots were in the castings that exhibited the kind of behaviour.

Investigation of the Effect of Nano Particles on Visco-elastic Behaviour of CFRP Hybrid Nanocomposites

The aim of the study is to do an experimental analysis and investigation of visco-elastic behaviour of CFRP hybrid nanocomposites, which contains the small percentage of nanoclay and nanoZnO particles mixed for the improvement in the various properties of the CFRP composites. Also there is try to focus on the combined effect of another variable, i.e., fiber angle of orientation along with changing the percentage of nano particles.A hand layup method followed by process of vacuum bagging was used to make the samples of composite. Dynamic mechanical analyzer (DMA) was used to inspect the dynamic mechanical properties of CFRP hybrid nanocomposite specimens with changing temperature. The OVAT analysis is carried out for three mentioned variables and studied effect of variables on the various visco elastic properties like flexural storage modulus, loss modulus, Glass transition temperature and tan etc. It is found that due to the presence of nano particles there is tremendous change in the value of storage modulus ,it gets almost doubled, i.e., 200%because of the presence of nano particles. The experimental result also shows the positive effect on the loss modulus because of the nano particle contribution .Similarly there is considerable change in GTT(Glass transmission temperature) and change in length in DMA (Dynamic mechanical analysis ).

Crack Propagation in the Spur Gear of Tubler Gear Mechanism of Lathe Machine

An estimation of the spur gear service life and crack path analysisis proposed in this paper. Ip theory using numerical solution is used to find the fatigue crack propagation rate, service life, and crack path due to bending fatigue. A spur gear of tumbler gear mechanism of lathe machine, is implemented for this analysis. An experimental test on gear specimens was carried out to analyze the crack propagation due to fatigue. Besides, service life estimated by the theory was compared with the most common Paris law. Hence further, extended finite element approach (Ansys)is implemented for the simulation of gear crack propagation trajectory. The simulation results are verified with experimental test. The service life and crack trajectory of the gear is obtained with ‘Ip’ theory and found in good agreement with experiment.In overall, this study signifies the gear failure prediction methodology during crack propagation in respect of life cycles and trajectory path.

Modeling of Full Vehicle to Evaluate the Impact of Electric Powertrain on Steering Performance

The study of dynamic behavior of Electric Power Steering System (EPAS) is very critical to understand the overall handling of the vehicle. The appropriate feedback from the steering to the driver is crucial so that the driver get the precise steering feel in order to control the vehicle with ease during all kinds of maneuvers. For a maximum tire life, the steering system should maintain, a proper tire road contact, and proper tire geometry with respect to the chassis both during cornering and straight-ahead driving. The driver should be able to turn the vehicle with ease during low as well as high speed maneuver. A complete steering system dynamic model is developed and is integrated with the full vehicle model using AMESIM 1D simulation platform. The simulation is carried out as per the guidelines laid by the ISO 7401 standard criterion. In this project we have performed the simulation on three different vehicle models in which a behavioral comparison of EPAS between their Conventional & Electric variants is performed. A thorough implementation of various vehicle SPMM parameters and KnC files is done in AMESim simulation model. Finally a list of Performance Aggregate Target Parameters is calculated. The resulting PAT parameter values are then compared with the test data and an appropriate design modification has been suggested accordingly.