Experimental study on the impact characteristics of a sandwich composite with an aluminum foam core

The need for composites has been increasing in various industries because composites have good mechanical properties for their weight and superior stiffness and strength. The composites addressed in this study were multi-pore aluminum foam with a specific gravity of 1/10 composed of solid aluminum metal. This composite has excellent impact energy-absorption capability. In this study, impact tests on an aluminum foam core sandwich composite with a porous core were conducted to examine its mechanical properties. The specimen was a sandwich structure with an aluminum foam core, and different impact energies, such as 50J, 70J, and 100J, were applied to the specimen. Consequently, a maximum load of 5.5 kN occurred when the striker penetrated the upper face sheet in all experiments. The maximum load occurred at 4.2 ms for 50J, 3.5 ms for 70J, and 3.0 ms for 100J, indicating that the greater the impact energy was, the shorter the time was until the maximum load. After the maximum load occurred, that is, after the penetration of the upper face sheet, the striker penetrated 10 mm further, causing the core to be damaged in the 50J test, while the lower face sheet remained intact. In the 70J test, the striker penetrated the core and caused damage to the upper face sheet at 10 ms. Finally, in the 100J test, the striker penetrated both the upper face sheet and core and even the lower face sheet at 10 ms. Given the result above, the maximum load occurred when the striker penetrated the upper face sheet and the sandwich composite with aluminum foam core; the load then gradually decreased and then rapidly increased when the striker reached the lower face sheet, and the maximum load lasted slightly longer than the time required for the upper face sheet to be penetrated.     

Operating speed pattern optimization of railway vehicles with differential evolution algorithm

The railway transportation system has much advantage in eco-friendliness, punctuality and safety compared to any other transportation system. Most of the railway system administrators have to control and operate under limited resources such as trains and facilities. It is necessary to control traveling time and energy consumption for efficient operation in the railway systems, because the board rate of passenger is inconstant with time variance. It is common that the shorter traveling time causes the greater energy consumption. In this study, a new optimization method considering operation time or energy consumption is proposed by using differential evolution algorithm and some cases are reviewed. The total energy change due to operation time variation are investigated by using the proposed optimization method for tangent and gradient track conditions. Both cases, the total energy decreases exponentially. However, because of gradient the total energy are saturated after a certain time for gradient track.     

Dynamic analysis of a pantograph-catenary system using absolute nodal coordinates

The dynamic interaction between the catenary and the pantographs of high-speed trains is a very important factor that affects the stable electric power supply. In order to design a reliable current collection system, a multibody simulation model can provide an efficient and economical method to analyze the dynamic behavior of the catenary and pantograph. In this article, a dynamic analysis method for a pantograph-catenary system for a high-speed train is presented, employing absolute nodal coordinates and rigid body reference coordinates. The highly flexible catenary is modeled using a nonlinear continuous beam element, which is based on an absolute nodal coordinate formulation. The pantograph is modeled as a rigid multibody system. The analysis results are compared with experimental data obtained from a running high-speed train. In addition, using a derived system equation of motion, the calculation method for the dynamic stress in the catenary conductor is presented. This study may have significance in providing an example that a structural and multibody dynamics model can be unified into one numerical system.     

Implementation of discharging/charging current sensorless state-of-charge estimator reflecting cell-to-cell variations in lithium-ion series battery packs

This paper offers novel insights to the design and implementation of an innovative state-of-charge (SOC) estimator for the lithium-ion (Li-Ion) series battery pack. The most interesting feature of this approach is that it can utilize information from each filtered terminal voltage of the Li-Ion cells connected in series for SOC estimation of the battery pack. Without actual sensing each discharging/charging current (DCC) applied to the Li-Ion cells, it is possible to extract each DCC estimation from the corresponding filtered terminal voltages with an equivalent electrical circuit model (EECM) identification of all Li-Ion cells in the battery pack. There are two advantages to SOC estimation of the battery pack with this approach. First, the proposal can be implemented simply and effectively, reducing the computational steps required for SOC estimation. By reducing computational steps, the proposal is expected to be more cost-effective. Second, the approach guarantees an improved SOC performance, even if the battery pack results in inevitable cell-to-cell variation among Li-Ion cells. Accordingly, there are fewer differences to previously estimated DCCs among Li-Ion cells. Specifically, all values from the estimated DCCs are properly compensated for by simultaneous parameter modification according to each cell’s electrochemical characteristics. Experimental results clearly demonstrate that our DCC sensorless SOC estimator provides robust SOC performance for the battery pack. This approach considered an experimental battery pack (12S1P) connected in series using 2.6 Ah LiCoO2 cells produced by Samsung SDI.     

Prediction of the dimensional deformation of the addendum and dedendum after the warm shrink fitting process using a correction coefficient

The warm shrink fitting process is generally used to assemble automobile transmission parts (shafts/gears). However, this process causes a deformation in the addendum and dedendum of the gear depending on the fitting interference and gear profile, and this deformation causes additional noise and vibration between the gears. To address these problems, the warm shrink fitting process is analyzed by considering the error in the dimensional deformation of the addendum and dedendum found when comparing the results of a theoretical analysis and finite element analysis (FEA). A correction coefficient that reduces this error is derived through an analysis of the difference in the cross-sectional area between the shapes used for the theoretical analysis and that of the actual gear, and a closed-form equation to predict the dimensional deformation of the addendum and dedendum is proposed. The FEA method is proposed to analyze the thermal-structural-thermal coupled field analysis of the warm shrink fitting process (heating-fitting-cooling process). To verify the closed-form equation using the correction coefficient, measurements are made of actual helical gears used in automobile transmissions. The results are in good agreement with those given by the closed-form equation.     

Topology optimization of gas flow channel routes in an automotive fuel cell

An efficient topology optimization method for fluid-structure problems was developed in an effort to determine the optimum flow channel route in a fuel cell bipolar plate from first principles. This study describes the derivation and solution of new mathematical equations for topology optimization combining a density-based algorithm, the interpolation method of moving asymptotes (MMA), and the incompressible Navier-Stokes equation with a term representing the chemical reaction between hydrogen and the catalyst. The present method is based on the finite element method with a newly developed reaction rate equation. In this model, a topology variable of 0 represents viscous flow, whereas a value of 1 indicates porous flow. The flow velocity and pressure were obtained from the Navier-Stokes equation and constraints and element matrices for sensitivity analyses during the optimization. MMA was utilized to calculate the optimum flow routes in the design domain. The influence of the key design parameter q and the pressure drop on the optimum topology were also investigated. The channel topology became smoother with decreasing q, and the number of channels increased with increasing pressure drop.     

Aerodynamic design optimization of rear body shapes of a sedan for drag reduction

This study proposes an aerodynamically optimized outer shape of a sedan by using an Artificial Neural Network (ANN), which focused on modifying the rear body shapes of the sedan. To determine the optimization variables, the unsteady flow field around the sedan driving at very fast speeds was analyzed by CFD simulation, and fluctuations of the drag coefficient (C _D ) and pressure around the car were calculated. After consideration of the baseline result of CFD, 6 local parts from the end of the sedan were chosen as the design variables for optimization. Moreover, an ANN approximation model was established with 64 experimental points generated by the D-optimal methodology. As a result, an aerodynamically optimized shape for the rear end of the sedan in which the aerodynamic performance is improved by about 5.64% when compared to the baseline vehicle is proposed. Finally, it is expected that within the accepted range of shape modifications for a rear body, the aerodynamic performance of a sedan can be enhanced so that the fuel efficiency of the sedan can be improved. The YF SONATA, a sedan manufactured by Hyundai Motors Corporate, played a major role in this research as the baseline vehicle.     

A self-powering system based on tire deformation during driving

Tire intelligence is vital in the improvement of the safety of vehicles because the tire supports the car body and is the contact point between the vehicle and the road. To create an intelligent tire, sensors must be installed to measure the behavior of the tire. However, it is difficult to apply a wired sensor system on the wheel of the tire. Hence, it is necessary to implement a self-powering, wireless system (a type of energy harvesting system) that can be mounted inside the tire. The purpose of this study is to convert the strain energy caused by deformation of the tire while driving into useful electrical energy to supply the sensor system. A flexible piezofiber is utilized for the energy conversion. The variation in strain, due to changes in speed, load, and the internal pressure of the tire, was measured along two axial directions to evaluate the amount of available strain energy. The amount of strain changed from 0.15% to 0.8%. To predict the amount of available energy from a tire, we perform an analysis of the relationship between the strain and the voltage. In addition, experiments for impedance matching between piezofiber and related circuits were conducted to optimize the external loads for transferring energy efficiently. Based on the procedure mentioned above, at least 0.58 mJ of electrical energy can be generated by using the laterally oriented strain (1500 to 2500 micro strain). The result of this study is expected to enhance the potential realization of self-generating wireless sensor systems for so-called ??intelligent?? tires.     

Analysis process of a steering system using a concept model for idle vibration

This paper describes the development of an optimal design process for a steering column system and supporting system. A design guide is proposed at the initial concept stage of the development process to obtain sufficient stiffness of the steering system while reducing the idle vibration sensitivity of the system. Case studies on resonance isolation are summarized, where vibration modes among the systems are separated by applying a vibration mode map at the initial stage of the design process. This study also provides design guidelines for an optimal dynamic damper system using a CAE (computer aided engineering) analysis. The damper FE (finite element) model is added to the vehicle model to analyze the relation between the frequency and the sensitivity of the steering column system. This analysis methodology makes it possible to achieve target performance in the early design stage and reduction of damper tuning activity after the proto car test stage. Through the proposed steering column system development process, a lightweight vehicle with high stiffness is possible prior to the proto build stage. Furthermore, the improved process is expected to contribute to reducing the overall development period and the number of proto car tests necessary to achieve the desired steering system performance.     

Fatigue design for plug/ring type gas welded joints of sts301l including welding residual stresses

This paper presents a fatigue design method for plug and ring type gas welded joints, which incorporates welding residual stress effects. A non-linear finite element analysis (FEA) was first performed to simulate the gas welding process. The numerically predicted residual stresses of the gas welds were then compared to experimental results measured using a hole drilling method. In order to evaluate the fatigue strength of the plug and ring type gas welded joints, a stress amplitude (σ _a ) _R taling the welding residual stress of the gas weld into account was introduced and is based on a modified Goodman equation incorporating the effect of the residual stress. Using the stress amplitude (σ _a ) _R , the ΔP-N _f relations obtained from fatigue tests for plug and ring type gas welded joints having various dimensions and shapes were systematically rearranged into (σ _a ) _R -N _f relations. It was found that the proposed stress amplitude (σ _a ) _R could provide a systematic and reasonable fatigue design criterion for the plug and ring type gas welded joints.