Model-based analysis of the mechanical subsystem of an air brake system

Most commercial vehicles such as buses and trucks use an air brake system, often equipped with an S-cam drum brake, to reduce their speed and/or to stop. With a drum brake system, the clearance between the brake shoe/pad and the brake drum may increase because of various reasons such as wearing of the brake shoe and/or brake drum and drum expansion caused by high heat generation during the braking process. Hence, to ensure proper functioning of the brake system, it is essential that the clearance between the brake shoe and the brake drum is monitored. In this paper, we present a mathematical model for the mechanical subsystem of the air brake system that can be used to monitor this clearance. This mathematical model correlates the push rod stroke transients and the brake chamber pressure transients. A kinematic analysis and a dynamic analysis of the mechanical subsystem of the air brake system were performed, and the results are corroborated with experimental data.     

Cycle-simulation turbulence modelling of IC engines

Numerical simulations of IC engines are of high interest for automotive engineers worldwide. The simulation models should be as fast as possible, low-computational effort and predictive tool. The correct prediction of turbulence level inside the combustion chamber of spark ignition engines is the most important factor influencing to the engine working cycle. This paper presents a development of the k-ε turbulence model applied to the commercial cycle-simulation software with the high emphasis on the intake part. The validation was performed on two engine geometries with the variation of engine speed and load comparing the cycle-simulation results of the turbulent kinetic energy and in-cylinder temperature with 3-D CFD results. In order to apply the cycle-simulation turbulence model for the simulation of entire engine map, the parameterization model of turbulence constants was proposed. The parameterized turbulence model was optimized using NLPQL optimization algorithm where the single set of turbulence model parameters for each engine was found. A good agreement of the turbulent kinetic energy during the expansion was achieved when the turbulence affects the flame front propagation and combustion rate as well.     

Origin–destination table disaggregation using biproportional least squares estimation

This paper describes a group of techniques for disaggregating origin–destination tables for travel forecasting that makes explicit use of observed traffic on a network. Five models within the group are presented, each of which uses nonlinear least-squares estimation to obtain row and column factors for splitting trip totals from and to larger geographical areas into smaller ones. The techniques are philosophically similar to Fratar factoring, although the solution method is quite different. The techniques are tested on a full-sized network for Northfield, MN and are found to work effectively.     

A tyre slip-based integrated chassis control of front/rear traction distribution and four-wheel independent brake from moderate driving to limit handling

This paper presents a tyre slip-based integrated chassis control of front/rear traction distribution and four-wheel braking for enhanced performance from moderate driving to limit handling. The proposed algorithm adopted hierarchical structure: supervisor – desired motion tracking controller – optimisation-based control allocation. In the supervisor, by considering transient cornering characteristics, desired vehicle motion is calculated. In the desired motion tracking controller, in order to track desired vehicle motion, virtual control input is determined in the manner of sliding mode control. In the control allocation, virtual control input is allocated to minimise cost function. The cost function consists of two major parts. First part is a slip-based tyre friction utilisation quantification, which does not need a tyre force estimation. Second part is an allocation guideline, which guides optimally allocated inputs to predefined solution. The proposed algorithm has been investigated via simulation from moderate driving to limit handling scenario. Compared to Base and direct yaw moment control system, the proposed algorithm can effectively reduce tyre dissipation energy in the moderate driving situation. Moreover, the proposed algorithm enhances limit handling performance compared to Base and direct yaw moment control system. In addition to comparison with Base and direct yaw moment control, comparison the proposed algorithm with the control algorithm based on the known tyre force information has been conducted. The results show that the performance of the proposed algorithm is similar with that of the control algorithm with the known tyre force information.     

Finite element modeling of static tire enveloping characteristics

To investigate static tire enveloping characteristics, a three dimensional (3-D) finite element model is proposed. The vertical stiffness of the tire is studied on a flat surface with and without cleat. Tire rubber materials and cord layers are represented independently using “rebar” elements available in MSC Marc Mentat. Comparisons of numerical and experimental results are given to show the validity of the proposed model. It is shown that after a certain displacement, the results of the proposed model agree well with experimental results. In addition, the model results show that regardless of the type of the cleat placed under the rim center (hub center), all vertical force curves intersect after a certain displacement, which indicates typical static enveloping characteristics. Moreover, another typical characteristic of the radial tires that is unlike those of bias-ply constructions confirms that the contact patch does not expand laterally after a level vertical load is applied to the tire, which is directly related to fuel consumption and tire tread life.     

Development of hot stamped center pillar using form die with channel type indirect blank holder

The hot stamping process has been used in the automotive industry to reduce the weight of the body-in-white and to increase passenger safety via improved crashworthiness. However, defects such as fracture and wrinkle occur when hot stamping is performed using a conventional drawing or forming method. In this study, a channel-type indirect blank holder (CIBH) is proposed to develop a high-strength center pillar in form-type hot stamping, so that the aforementioned drawbacks are overcome. This type of blank holder plays an important role in reducing severe wrinkling at the flange; such wrinkling leads to folding after the completion of form-type hot-stamping. First, we investigated the effect of the channel shape on the indirect blank holding force by using a simplified two-dimensional plane-strain stamping process. Second, we selected the slope angle and corner radius of the channel as the main shape parameters by finite element analysis and artificial neural network (ANN). It is known that fracture at the hot formed wall and wrinkle at the flange are significantly affected by the slope angle of the channel, and the appropriate value for eliminating fracture and wrinkle is determined to be 99°. By performing hot stamping using a form die with the selected channel, we can manufacture a high-strength center pillar without wrinkle and fracture.     

Computer Simulation of Thermal-Mechanical Processing

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Influence of load and inflation pressure on the tyre rolling resistance

Tyre load and inflation pressure are important factors controlling rolling resistance of road vehicles. The article presents results obtained in the Technical University of Gdańsk during laboratory and road measurements of different car tyres rolling on different pavements. The knowledge of rolling resistance characteristics is important for modelling car dynamics as well as fuel consumption. It is also necessary to establish proper test conditions in the future standardized on-road method of measuring rolling resistance. The results indicate that while an increase of load always leads to the increase of rolling resistance force, the influence on Coefficient of Rolling Resistance is more complicated and unpredictable. They also indicate that tyres with high rolling resistance are more sensitive to inflation pressure changes than low rolling resistance tyres.     

Multiaxial stress creep rupture mechanisms of AZ31 magnesium alloy

The maximum principal stresses, von Mises effective stresses and principal facet stresses at the time of creep rupture were compared in uniaxial, biaxial, and triaxial stress states for AZ31 magnesium alloy. The creep rupture of this alloy was experimentally controlled by cavitation, which was the result of a low damage tolerance, λ. Creep deformation could be correlated with the von Mises effective stress parameter. The failure-mechanism control parameter governing the stress state coincided with the experimental results of the rupture of the materials under multiaxial stress states. Finally, the theoretical prediction based on constrained cavity growth and continuous nucleation agreed with the experimental rupture data to within a factor of three.