The chatter of racing motorcycles

The chatter of motorcycles appears during braking and consists of a vibration of the rear and front unsprung masses at a frequency in the range of 17-22 Hz depending on the motorcycle. This vibration could be very strong and acceleration of the unsprung masses can reach 5-10 g. The chatter is an auto-excited vibration and this fact explains why it appears suddenly when the mechanism of auto-excitation is generated. This paper presents the chatter phenomenon both from an experimental and a numerical point of view. First, the chatter is defined on the basis of some experimental data from racing motorcycles and from the comments of some racing teams technicians. Then, chatter is analysed in different motion conditions and for different braking styles by means of linear and non-linear simulations of the motorcycle dynamics. A physical interpretation of the phenomenon is also proposed.     

杭州湾跨海大桥混凝土结构耐久性原位监测预警系统

为了确保杭州湾跨海大桥混凝土结构达到百年设计使用寿命,评价混凝土结构耐久性状况的动态发展,通过对预埋式钢筋腐蚀无损监测传感系统的国际合作研究,确定了基于电化学原理和辅助光纤技术的耐久性监测技术思路,制定了该工程耐久性动态预报监测平台的构架技术方案,捕获了结构各部位腐蚀预警的个性化判据,优化了全桥测点的布置,集成、改良并安装了控制关键部位的全套系统(共计48套监测单元)。工程实测结果表明:测试数据稳定,并且与实验室研究数据吻合。     

Model-based design of a variable nozzle turbocharger controller

Variable Nozzle Turbocharger (VNT) was invented to solve the problem of matching an ordinary turbocharger with an engine. VNT can harness exhaust energy more efficiently, enhance intake airflow response and reduce engine emissions, especially during transient operating conditions. The difficulty of VNT control lies in how to regulate the position of the nozzle at different engine working conditions. The control strategy designed in this study is a combination of a closed-loop feedback controller and an open-loop feed-forward controller. The gain-scheduled proportional-integral-derivative (PID) controller was implemented as the feedback controller to overcome the nonlinear characteristic. As it is difficult to tune the parameters of the gain-scheduled PID controller on an engine test bench, system identification was used to identify the plant model properties at different working points for a WP10 diesel engine on the test bench. The PID controller parameters were calculated based on the identified first-order-plus-dead-time (FOPDT) plant model. The joint simulation of the controller and the plant model was performed in Matlab/Simulink. The time-domain and frequency-domain performances of the entire system were evaluated. The designed VNT control system was verified with engine tests. The results indicated that the real boosting pressure traced the target boosting pressure well at different working conditions.     

Off-set crack propagation analysis under mixed mode loadings

An assessment was carried out herein to study the eccentricity of cracks subjected to mixed-mode loadings. Several loading locations relative to a central line were selected to induce mixed-mode loadings, which were computed using a finite element method. An adaptive meshing technique was adopted during the simulation of crack propagation to ensure the singularity of stress at the tip of the crack. The stress intensity failure criterion was used and programmed, and the node splitting technique was used when the stress intensity factor reached the fracture toughness of the material to simulate crack propagations. It was found that large variations in the stress intensity factor were observed when off-set cracks were used, and that K _II decreased when loading distance increased, but increased when the off-set crack distance was increased. Both crack eccentricity and loading distance played important roles in producing mixed-mode loading, compared to the influence of central cracks. Correction factors were introduced to modify the calculation of stress intensity factors under mixed-mode loadings. Simulations of crack propagation were also conducted to study the effects of crack eccentricities and loading distances. It was found that the crack length, the loading distance relative to the central crack and the crack eccentricity dominated calculations of the integrity of cracked structures.     

Design framework for FlexRay network parameter optimization

Because the FlexRay protocol has more than 70 configuration parameters and these parameters correlate with each other, designing a FlexRay network is a complex and difficult task. In this study, we propose a design framework that optimizes the two main FlexRay network parameters that are highly relevant to the application algorithm. The design process is composed of two steps for optimizing parameters. In the first step, the static slot length is optimized using a frame-packing algorithm. This algorithm binds network signals into static frames based on their periods and signal groups. In the second step, the communication cycle length is optimally designed with frame-scheduling algorithm and worst-case reponse time analysis. Based on the frame-scheduling algorithm, the response times are analyzed. The proposed design framework was applied to a unified chassis control system as a case study, and the analytical results were verified.     

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.     

Hybrid neural network model for history-dependent automotive shock absorbers

The method of numerical multi-body simulation is an often used and well-understood development tool in the automotive industry. In order to reproduce the ride comfort or handling behaviour of vehicles, mathematical models have to be built up. To achieve accurate simulation results, highly detailed component models are required. However, the formulation of appropriate physically-based model equations of complex automotive components (e.g. air springs, shock absorbers, rubber bearings, tyres, etc.) can be very difficult. To handle this, empirical modelling methods have been developed. Simple algebraic equations are used to describe complex system behaviour. This simplification is very effective, although it largely ignores the natural laws of mechanics and thermodynamics but is still capable to predict the component response. This article illustrates how to take advantage of this approach in numerical simulations. We describe the development of a hybrid automotive shock absorber model based on both spline and neural network (NN) approaches. By combining these different approaches, an accurate model is achieved without loss of variability. Non-isothermal laboratory force-displacement measurements of an automotive shock absorber are being used to estimate the parameters of the NN. As shown, the model replicates the measured data with sufficient accuracy, especially the hysteresis. Finally, we present a set of quarter-car simulations with a built-in hybrid NN shock absorber.     

Fatigue life prediction of a rubber material based on dynamic crack growth considering shear effect

This paper suggests a fatigue life calculation method (A fatigue life calculation method is suggested) for rubber components based on the dynamic crack growth considering shear effect. Dynamic tearing tests were carried out, and the crack length was measured using an optical microscope to calculate the dynamic crack growth rate which characterizes and determines the fatigue life. The algorithm was numerically implemented in finite element code, ABAQUS standard, by using the user subroutine and applied to several rubber components. In the finite element analysis, deformation mode of an element was classified into tension and shear, and a weighting factor was multiplied to a strain energy density according to the degree of shear strain. Tension and compression of an elliptic dumbbell specimen was simulated in order to verify the material parameters of the suggested fatigue life prediction equation and to enhance the reliability of the algorithm. Finally, the fatigue life of a vehicle suspension bushing was calculated and compared with test. There were good agreements in the failure location and the magnitude of the fatigue life.     

Preview suspension control for a full tracked vehicle

In this study, preview control algorithms for the active and semi-active suspension systems of a full tracked vehicle (FTV) are designed based on a 3-D.O.F model and evaluated. The main issue of this study is to make the ride comfort characteristics of a fast moving tracked vehicle better to keep an operator’s driving capability. Since road wheels almost trace the profiles of the road surface as long as the track doesn’t depart from the ground, the preview information can be obtained by measuring only the absolute position or velocity of the first road wheel. Simulation results show that the performance of the sky-hook suspension system almost follows that of full state feedback suspension system and the on-off semi-active system carries out remarkable performance with the combination of 12 on-off semi-active suspension units. The results simulated with 1^st and 2^nd weighting sets mean that the suspension system combined with the soft type of inner suspension and hard type of outer suspension can carry out better ride comfort characteristics than that with identical suspensions. The full tracked vehicle (FTV) system is uncontrollable and the system is split into controllable and uncontrollable subspace using singular value decomposition transformation. Frequency response curves to four types of inputs, such as heaving, pitching, rolling, and warping inputs, also demonstrate the merits of preview control in ride comfort. All the frequency characteristic responses confirm the continuous time results.