Thermomechanical Behavior of Brake Drums Under Extreme Braking Conditions

Braking efficiency is characterized by reduced braking time and distance, and therefore passenger safety depends on the design of the braking system. During the braking of a vehicle, the braking system must dissipate the kinetic energy by transforming it into heat energy. A too high temperature can lead to an almost total loss of braking efficiency. An excessive rise in brake temperature can also cause surface cracks extending to the outside edge of the drum friction surface. Heat transfer and temperature gradient, not to forget the vehicle's travel environment (high speed, heavy load, and steeply sloping road conditions), must thus be the essential criteria for any brake system design. The aim of the present investigation is to analyze the thermal behavior of different brake drum designs during the single emergency braking of a heavy-duty vehicle on a steeply sloping road. The calculation of the temperature field is performed in transient mode using a three-dimensional finite element model assuming a constant coefficient of friction. In this study, the influence of geometrical brake drum configurations on the thermal behavior of brake drums with two different materials in grey cast iron FG200 and aluminum alloy 356.0 reinforced with silicon carbide (SiC) particles is analyzed under extreme vehicle braking conditions. The numerical simulation results obtained using FE software ANSYS are qualitatively compared with the results already published in the literature.     

复合材料构件步行车辆的弹性振动分析

复合材料具有高强度-重量比和高刚度-重量比,它用于步行车辆结构设计可减轻相对运动部件的重量,降低能量消耗,抑制弹性振动.本文利用动力学虚功原理建立了具有复合材料构件步行车辆系统的动力学有限元模型,对四足步行车辆模型进行了模拟计算,以说明使用复合材料的优越性.     

A material selection approach to evaluate material substitution for minimizing the life cycle environmental impact of vehicles

Weight reduction is commonly adopted in vehicle design as a means for energy and emissions savings. However, selection of lightweight materials is often focused on performance characteristics, which may lead to sub optimizations of life cycle environmental impact. Therefore systematic material selection processes are needed that integrate weight optimization and environmental life cycle assessment. This paper presents such an approach and its application to design of an automotive component. Materials from the metal, hybrid and polymer families were assessed, along with a novel self-reinforced composite material that is a potential lightweight alternative to non-recyclable composites. It was shown that materials offering the highest weight saving potential offer limited life cycle environmental benefit due to energy demanding manufacturing. Selection of the preferable alternative is not a straightforward process since results may be sensitive to critical but uncertain aspects of the life cycle. Such aspects need to be evaluated to determine the actual benefits of lightweight design and to base material selection on more informed choices.     

汽车控制臂衬套在整车工况下的有限元仿真

汽车控制臂衬套对汽车的操控性和舒适性都有很大影响,分析橡胶臂衬套在整车载荷中的变形规律对于产品设计和验收有很大意义。该文首先分析了控制臂衬套在整车中的受力特点;然后进行了橡胶部件的力学性能实验,确定了材料模型和参数;对控制臂衬套在球头销处承受整车x向和y向载荷的工况进行了仿真。结果表明控制臂衬套在该文安装方式下,整车x向力下后衬套的变形接近K1方向;在整车y向载荷下,后衬套变形可以忽略,载荷主要由前衬套承担。该文对衬套刚度设计和台架疲劳寿命实验有指导意义。     

Analysis of cushion systems for impact protection design of bridges against overheight vehicle collision

Based on several theoretical models of elastic and elastic–plastic impact as well as energy method, a systematic methodology for design analysis of cushion structures for impact protection of bridges against overheight vehicle collision is presented with consideration of the shear-off effect of projectiles and the nonlinear crushing behavior of sandwich cores. Three design criteria based on contact force, deflection, and energy are proposed, and the theoretical models for elastic, elastic–plastic, and after-densification impact including the shear-off effect of projectile are developed to improve the analysis and design of cushion structures against overheight vehicle impact. Realistic analysis of cushion structures is resulted from the above models, and it can be applied to design of cushion structures for the sake of bridge protection from overheight vehicle collision.     

钢铅组合耗能器力学性能试验研究

为了设计具有竖向耗能能力的抗倾覆装置,介绍了一种钢铅组合耗能器。通过对其静力、动力、电液伺服动静万能试验机实验结果的分析,表明该阻尼器能够使钢铅两种材料协同工作、共同耗能,具有制作工艺简单,能够满足位移小、阻尼大,耗能稳定的要求。通过分析还给出了耗能器的力学性能和恢复力模型。对大高宽比隔震结构的仿真计算分析表明,安装钢铅组合耗能器的抗倾覆装置具有一定的耗能能力,并能够避免结构倾覆。     

Reliability Reallocation for Fuel Cell Vehicles Based on Genetic Algorithm

A fuel cell vehicle (FCV) is a type of alternative energy vehicle that could help resolve the energy crisis, mitigate environmental problems, and contribute to sustainable development. Developing an FCV with high reliability is an important goal for automobile factories and research institutions. Other key factors required by FCVs include mass production and customer approval. An FCV is a complex mechanism composed of many subsystems. During the development of the overall vehicle, steps should be taken to ensure that every subsystem is reliable. However, such development must also consider costs, which must be kept as low as possible. To ensure the reliability of FCV while operating under conditions that demand minimal cost, a genetic algorithm is employed to reallocate the reliability of the overall vehicle system. First, the growth factor of the reliability–feasibility of each subsystem is determined according to the complexity, importance, and technological level of the FCV subsystems. The FCV cost model is then established on the basis of such parameters as subsystem cost, reliability–feasibility growth factor, initial reliability, limit reliability, and so on. A genetic algorithm is then used to compute for the reliability of FCV subsystems. The rationality of reliability reallocation is verified according to the subsystem importance coefficient. This method considers the benefits for both enterprises and customers by applying principles of engineering and conducting a reliability study. Copyright © 2014 John Wiley & Sons, Ltd.     

Design of an adaptive secondary mirror: a global approach

We present the mechanical and actuator design of an adaptive secondary mirror that matches the optical requirements of the active and adaptive corrections. Conceived for the particular implementation for the 6.5-m conversion of the multiple-mirror telescope, with small variations of the input parameters this study is suitable for applications for telescopes of the same class. We found that a three-layer structure, i.e., a thin deformable shell, a thick reference plate, and a third plate that acts as actuator support and heat sink, is able to provide the required mechanical stability and actuator density. We also found that a simple electromagnetic actuator can be used. This actuator, when optimized, will dissipate a typical power of a few tenths of watts.     

Key Technologies for Preparing Nanoparticles of Hydrogen Storage Material by Combining Ball Milling with Aerosol Generation

The developing trend of vehicle is electrical vehicle in future,and fuel cell will become the one of the main batteries of electrical vehicle because of its the prominent properties.The one of current obstacle for fuel cell in popularization and applications is lacking of excellent performance hydrogen storage materials and advanced technologies of preparing nanoparticles for hydrogen storage materials.The principles,typical classifications and characteristics of chemically and physically preparing nanoparticles for hydrogen storage materials are briefly introduced.And it predicts that physical method is going to be the major developing direction for nanoparticles for hydrogen storage material fabrication.The principle,the system composition &characteristics of method by means of combining ball milling with aerosol generation preparing nanoparticles for hydrogen storage materials are expounded.The ball milling process for hydrogen storage material is needed to conduct effective cooling process,and the lower cooling temperature has better milling results.The cooling media for ball milling include room temperature water,ice water,pure ethanol with dry ice and liquid nitrogen.The proper level of vacuum in canister is significant for injecting aerosol particles during the ball milling.In order to maximize the friction force,it is better to design multi-level stirring rod and the profile of stirring rod with large contact area,therefor stirring rod with cylinder has less grinding effect than with ring profile.The more stirring rod with more layers will obtain higher stirring efficiency.The distance between each layer of branches is 2.5times larger than diameter of the ball.The simulation results show that the average speed has 120% increases from 400 rpm to 800 rpm.Based on the kinetic energy equation,it is obtained that there is 350% increase in energy from 400 r / min to 800 r / min.The higher stirring speed will generate the finer material.And the discussion of this article provides a favorable basis of preparing nanoparticles for hydrogen storage materials in fuel cell vehicle.     

Lightweight design of vehicle components based on strengthening effects of low‐amplitude loads below fatigue limit

A new lightweight design method for vehicle components is proposed based on the strengthening effects of low‐amplitude loads below the fatigue limit. The new method is technically based on the strength feature of strengthening and damaging of vehicle components under loading spectrum, while combining dynamic strength equations with the residual strength of vehicle components. It ensures the maximum exploitation of the material's strength potential and fully realises the lightweight design of vehicle components at a low cost. As an application of the new lightweight design method, a light truck's front axle was redesigned. The lightweight potential of the front axle was first estimated by fatigue and static strength experiments of four‐point bending. Then the lightweight design was realised by finite element analysis and experimental results. The weight of this front axle was reduced by 5.5 kg.     

Low velocity impact tests of laminate glass-fiber-epoxy matrix composite material plates

This work deals with the characterization of composite material suitable for constructing structural parts devoted to dissipate kinetic energy during impacts. In particular glass-fiber-epoxy matrix laminates are considered, both with unidirectional layers and with woven layers stacking, with three different layers orientations.Experimental tests are performed according to ASTM standards using a free-fall drop dart testing machine. The specimens are plates completely constrained on a circular edge by the clamping fixture. Two energy absorption parameters (namely saturation impact energy and damage degree), two relevant characteristic values of the impact force history (namely the first damage force and the maximum force) and the sensitivity of the material mechanical characteristic to the strain rate effect are considered in order to describe the impact behavior of the material. Diagrams are presented to show the history of relevant kinematical, dynamic and energetic quantities, both to synthesize the dependency of the energy parameters and force threshold values on the impact velocity. The considered materials, under the considered loading conditions, show no sensitivity to the strain rate effect.     

Snapping algorithm and heterogeneous bio-tissues modeling for medical surgical simulation and product prototyping

This paper presents a novel technique for modeling soft biological tissues as well as the development of an innovative interface for bio-manufacturing and medical applications. Heterogeneous deformable models may be used to represent the actual internal structures of deformable biological objects, which possess multiple components and non-uniform material properties. Both heterogeneous deformable object modeling and accurate haptic rendering can greatly enhance the realism and fidelity of virtual reality environments. In this paper, a tri-ray node snapping algorithm is proposed to generate a volumetric heterogeneous deformable model from a set of object interface surfaces between different materials. A constrained local static integration method is presented for simulating deformation and accurate force-feedback based on the material properties of a heterogeneous structure. Biological soft tissue modeling is used as an example to demonstrate the proposed techniques. By integrating the heterogeneous deformable model into a virtual environment, users can both observe different materials inside a deformable object as well as interact with it by touching the deformable object using a haptic device. The presented techniques can be used for surgical simulation, bio-product design, bio-manufacturing, and medical applications.     

Snapping algorithm and heterogeneous bio-tissues modeling for medical surgical simulation and product prototyping

This paper presents a novel technique for modeling soft biological tissues as well as the development of an innovative interface for bio-manufacturing and medical applications. Heterogeneous deformable models may be used to represent the actual internal structures of deformable biological objects, which possess multiple components and non-uniform material properties. Both heterogeneous deformable object modeling and accurate haptic rendering can greatly enhance the realism and fidelity of virtual reality environments. In this paper, a tri-ray node snapping algorithm is proposed to generate a volumetric heterogeneous deformable model from a set of object interface surfaces between different materials. A constrained local static integration method is presented for simulating deformation and accurate force-feedback based on the material properties of a heterogeneous structure. Biological soft tissue modeling is used as an example to demonstrate the proposed techniques. By integrating the heterogeneous deformable model into a virtual environment, users can both observe different materials inside a deformable object as well as interact with it by touching the deformable object using a haptic device. The presented techniques can be used for surgical simulation, bio-product design, bio-manufacturing, and medical applications.     

Progress in braided composite tube crush simulation

The high Specific Energy Absorption (SEA) of composite tubular structures makes them attractive candidates in energy absorbing structural applications such as front rails in vehicles. To incorporate primary composite components in vehicle structures requires numerical simulation tools that can predict the structural performance of the vehicle under various loading conditions including crashworthiness. In previous studies, axial crush simulations of braided composite tubes tended to generate global buckling, which are inconsistent with the steady crush behavior observed in experiments. It was found that the constitutive models based on the continuum damage mechanics (CDM) framework are inadequate to represent the unloading response of damaged composites. In axial crush experiments, braided composite tubes form multiple continuous crush fronds. Local unloading occurs when material moving out of the crush front becomes part of the crush frond. Improper representation of the material unloading response affects the computed total energy absorption of the structure. To address this issue, an analog model was developed to describe the unloading path of compressively damaged composites. This approach was implemented in CODAM, as a user defined composite CDM model for the explicit finite element code LS-DYNA^®. The improved CODAM model results in a significantly improved prediction of the tube crush.     

Adaptive control of a micromachined continuous-membrane deformable mirror for aberration compensation

The nonlinear response and strong coupling of control channels in micromachined membrane deformable mirror (MMDM) devices make it difficult for one to control the MMDM to obtain the desired mirror surface shapes. A closed-loop adaptive control algorithm is developed for a continuous-surface MMDM used for aberration compensation. The algorithm iteratively adjusts the control voltages of all electrodes to reduce the variance of the optical wave front measured with a Hartmann-Shack wave-front sensor. Zernike polynomials are used to represent the mirror surface shape as well as the optical wave front. An adaptive experimental system to compensate for the wave-front aberrations of a model eye has been built in which the developed adaptive mirror-control algorithm is used to control a deformable mirror with 19 active channels. The experimental results show that the algorithm can adaptively update control voltages to generate an optimum continuous mirror surface profile, compensating for the aberrations within the operating range of the deformable mirror.     

被动防护网中U形消能件的力学性能分析

U形消能件是被动防护网中的一种新型消能构件,由钢板带、圆柱滚轴和套头组成,主要功能是降低作用在锚杆及钢丝绳上的荷载,吸收落石的冲击能量。由于国内尚未有相关设计理论和工程应用经验,为此对U形消能件进行了重复性拟静力拉伸试验,试验结果表明:U形消能件具有较好的重复拉伸性能;由于钢板带材料的塑性强化效应,U形消能件在前三次重复拉伸试验中,启动力阈值和耗能能力逐渐增大,在第四次重复拉伸试验中,钢板带发生了类似疲劳破坏的脆性断裂。依据重复拉伸试验现象及相关结果的研究,提出了采用能量法对消能件启动力阈值和耗能性能进行理论分析,建立了U形消能件启动力阈值和静力耗能能力的理论计算方法,并与试验结果进行了对比验证,理论计算方法可作为U形消能件工程设计的依据。     

减压环耗能性能的静力试验及动力有限元分析

摘 要：被动柔性防护系统中采用的减压环由钢管及铝管套筒组成,应用中将钢丝绳穿过钢管连接在防护系统的支撑绳及拉锚绳上,起到吸收能量和缓冲冲击荷载的作用。根据被动防护系统中减压环的工作状态,将减压环的受力形式简化为一端固定,另一端受荷载作用,并进行了静力试验和动力有限元分析。在较低的冲击荷载作用下,数值计算结果与试验结果较吻合,随着冲击荷载速度的增大,启动荷载逐渐增大,减压环耗能能力有一定的提高。另外,采用数值计算方法研究了减压环中的铝管套筒长度对耗能性能及启动荷载的影响。结果表明：减压环在动力荷载作用下的耗能能力开始增大比较明显,后期耗能能力无明显增大,而启动荷载随着套筒长度的增大先减小而后增大,当铝管套筒在合适长度范围内时,减压环在动力荷载作用下理想吸能效率与静力试验结果较接近。     

The design of space vehicles

In this paper, an attempt has been made to summarise the essential elements of a space vehicle design. After giving an overview of the methodology of spacecraft sizing and configuration, a brief outline of the technical considerations related to the design of different subsystems of the vehicle has been presented. The essential aspects related to manned systems are also discussed. The article concludes with the identification of some of the important payload interfaces, that are relevant to the design of material processing experiments in space.     

基于共旋坐标和力插值纤维单元的RC框架结构连续倒塌构造方法

悬链机制会使钢筋混凝土框架结构产生有助于抵抗连续倒塌的附加承载能力,对结构抗连续倒塌能力至关重要。悬链机制处于几何大变形和材料非线性下降段的状态下,需要同时考虑材料非线性和几何非线性,因此对数值分析模型提出了更高的要求。为了解决基于力插值的纤维单元同时处理材料非线性和几何非线性的问题,该文采用基于共旋坐标法,提出了一种基于共旋坐标法的力插值纤维单元。该单元在形成中把变形体和刚体分开,局部坐标系的变形体内采用纤维划分考虑材料非线性,然后加上刚体位移,从局部坐标系到整体坐标系的转换中采用共旋坐标法以考虑几何非线性,给出了二维单元形成原理及非线性求解过程。实例分析结果表明基于共旋坐标法的力插值纤维单元能够较准确的模拟RC框架结构连续倒塌,梁机制阶段主要是材料非线性起控制作用,悬链线机制阶段主要是几何非线性起控制作用。     

An experimental and finite element investigation into the energy absorption characteristics of a steering wheel armature in an impact

Understanding the energy absorption characteristics of automotive components is necessary for the development of safe and crashworthy vehicles. This research experimentally and numerically studies the energy absorption performance of a steering wheel armature in contact with a deformable chestform (bodyform) during a collision. Variations in the location of impact on the armature, armature orientation, and chestform impact velocity are considered to investigate how these factors affect the energy absorption characteristics of the two contacting entities. By implementing standardized testing procedures (under experimental and numerical testing methods) steering wheel armature design can be evaluated and improved on in the design stage of steering wheels. Comparisons between experimental and finite element analysis testing methods were conducted and correlated using load versus displacement profiles over the duration of impact. A good relationship between the two methods was found which allows for investigation into the energy analysis of the armature and the chestform. Experimental methods do not provide a method of determining the energy absorbed by any single entity in this “deformable to deformable” contact. The energy absorbed by both structures can be experimentally determined, however, this does not provide engineers and steering wheel designers with specific information regarding the safe design of just the steering wheel armature. Numerical simulations do provide a means of quantifying the energy absorbed by specific structures in the analysis and do significantly help in isolating the energy absorption characteristics of the steering wheel armature. The results of this research show that the steering wheel armature is responsible for the majority of energy absorbed by the impact. In addition, the percentage of energy absorbed by the armature is not significantly dependent upon the location of impact and the impact velocity.