Automotive Experiences

Structural Analysis of Brake Shoe under Static Load Using Al Alloy, Cast Iron, Mg Alloy for Main Components, and Carbon Variants for Brake Linings

Dony Eko Prasetyo, Hadi Sutanto, Arka Dwinanda Soewono — Thu, 21 Nov 2024 00:00:00 +0000

The research is motivated by the issue faced by motorcycle users, namely the wear and tear of brake shoes, which can reduce braking effectiveness and increase the risk of accidents. The main objective of this study is to analyze the structural properties of motorcycle brake shoes with three different materials (aluminum alloy, cast iron, and magnesium alloy) and brake linings made of different carbon variants (alumina-carbon composite, carbon ceramics, and carbon fiber) under static pressures. Additional design aspects including weight and production cost are also evaluated during the material selection process for the motorcycle’s brake shoe and brake lining. The 3D modeling of the brake shoe and lining was done in Solidworks using measurement data from a Coordinate Measuring Machine (CMM). The finite element analysis was performed using ABAQUS software. Considering the results from the finite element analysis, weight, and economic aspects, the study found that aluminum alloy (Al alloy) and carbon composite can be suitable materials for brake shoes and brake lining. The Al alloy brake shoe provides 62.7% weight saving while exhibiting good structural properties under static load and a moderate increase in production cost compared to cast iron. Similarly, brake lining with alumina-carbon composite showed the least deformation under static load while maintaining modest production costs compared to the other carbon variants.

Experimental and Finite Element Study of Rollover Protection Structure for a 22-Seat Man Hauler Superstructure Vehicle

Thu, 21 Nov 2024 00:00:00 +0000

The application of man hauler which classified as heavy-duty vehicle and operated on the upper ground mining, requires high safety measurement as arrange in the UN-ECE No. 66. The safety measure demands vehicles to undergo both structural testing and analysis. The investigation of structural testing for heavy-duty vehicles has been developed to the rollover testing that used tilting platform, to see the deformation impact toward the residual space and foresight opportunities for further development on the vehicle structure or warning system. Rollover testing is costly and time consuming, so new or developed vehicle structure needs finite element model analysis, to predict the deformation level due to rollover incident. Both testing have the same goal which is to confirm the vehicle structure able to protect the passenger compartment. Therefore, this study aims to present a guidance to test a complete set of 22-seat man hauler vehicle with stress distribution analysis, quasi-static loading test of body section, and tilting platform. The results of the stress distribution test are that the load is concentrated on the element number 148 in the rear UNP 100 profile. The results of the quasi-static loading test are that the maximum stress that occurs is 33 % b the allowable stress. The simulation result under this condition shows that the maximum deflection value occurred in the side frame structure is 167.9 mm. The largest deformation due to rolling test occurred at point E has value of 27 mm located on the right side that experienced impact on the floor during the test. The overall testing and analysis are able to verify and confirm the vehicle structural strength, that the vehicle able to withstand the rollover impact and to protect the passengers.

Development of an Automatic Coupler for Railway Vehicles: A Topology Optimization Approach with Numerical and Experimental Validation

Fri, 13 Dec 2024 04:15:23 +0000

Topology optimization has demonstrated its effectiveness in generating lightweight and structurally efficient designs. This study focuses on refining the geometry of an automatic coupler body for trains using solid isotropic material with penalization and a level set method. These optimization methods are applied to the numerical model of the automatic coupler, and their results are compared to select the optimal design. The tensile strength of the automatic coupler is examined through numerical simulations and validated by experimental tensile tests conducted on a 1:1 scale prototype. The optimization outcomes reveal a remarkable 46.41% reduction in the mass of the automatic coupler body compared to the initial model. An evaluation of the tensile strength of the prototype demonstrates the ability of the automatic coupler to withstand the primary load without undergoing plastic deformation. Furthermore, a strong correlation is observed between the numerical and experimental results. This research contributes to advancing the design of next-generation automatic couplers, emphasizing the crucial aspects of lightweight design and structural performance.

Distillation, Characterizations, and Testing of Distillation Products from Waste Lubricant Oil (WLO) using Compression-Ignition Engine

Fri, 13 Dec 2024 05:50:20 +0000

Waste lubricant oil is always found in motor vehicle repair shops. Utilizing waste lubricant oil by distilling it will provide benefits. For this reason, waste lubricant oil was distilled in this research. Several characterizations were conducted to determine the viscosity, density, low heat value (LHV), and flash point of waste lubricant oil and distillation products. The distillation product is less viscous, denser, LHV, and flash point than lubricant oil waste. The distillation product was mixed with Pertamina DEX (0, 5, 10, and 15 vol.%) and then filled into the fuel tank for the engine performance test. The present experiment utilized a compression-ignition (CI) engine to measure performance. CI engine speed variations were carried out at 1000, 1500, 2000, and 2500 to see the influence of the mixed fuel on torque, power, specific fuel consumption (SFC), thermal efficiency, and smoke opacity. The increase in CI engine speed leads to an increase in torque, power, thermal efficiency, and smoke opacity, but at the same time, SFC decreases to 2500 rpm. Increasing the distillation product content in the mixed fuel decreased torque, power, SFC, thermal efficiency, and increased smoke opacity.

ROSES are Read, STEEP are Green: Mapping Sustainability Indicators Across Lifecycle Stages in EV Battery Production Through a Systematic Review

Sat, 14 Dec 2024 00:00:00 +0000

The rapid expansion of the electric vehicle (EV) market presents a paradox: while increasing production and lowering costs are essential for widespread adoption, these efforts also intensify the environmental and social impacts, particularly in lithium-ion (Li-ion) battery production. Comprehensive sustainability assessments are needed across all stages of battery production. This review employed the ROSES framework to analyze 40 Scopus-indexed research papers systematically. Extracted indicators are categorized by the STEEP (Sociocultural, Technological, Economic, Environmental, and Political-Legal) dimensions. The dual approach identifies critical sustainability gaps and examines the interplay between these dimensions. By mapping each indicator to a specific lifecycle stage—ranging from raw material extraction to end-of-life disposal—the review highlights critical stages for improving sustainability in EV battery production. The study uncovers complex relationships between sustainability factors and establishes a comprehensive framework to address these challenges. As a result, it provides policymakers, industry leaders, and researchers with a solid foundation for developing informed strategies to enhance the sustainability of EV battery production.

Potential of Grocery Bags Plastic Waste as a Fuel Substitute for Fossil-Based Fuels: A Characterization Study on the Non-Catalytic Low-Temperature Pyrolysis Process

Sat, 14 Dec 2024 00:00:00 +0000

Currently, pyrolysis is the primary choice for addressing the significant problems caused by plastic waste. Temperature and catalysts are the main parameters in pyrolysis. However, using catalysts can become a serious problem when scaling up production capacity, as the process can become more complex and expensive due to the high cost of catalysts. Without a catalyst, the required pyrolysis temperature must be sufficiently high to achieve high-quality pyrolytic fuel oil. In this work, plastic grocery bag is pyrolyzed followed by distillation to produce a liquid similar to conventional fuel, called distillate plastic fuel. Non-catalyst and low-temperature pyrolysis was performed at a single temperature of 350 °C, followed by distillation at temperatures of 250 °C and 350 °C to determine the effect of distillation temperature on the chemical properties of the obtained distilled fuel. Elemental and composition analyses were conducted using the GCMS method. Results indicated that the chemical properties and composition of distilled plastic fuel are similar to diesel fuel with a heating value of approximately 43.362 to 44.364 MJ/kg.

Prediction of Performance and Emission of Gasoline Engine Fueled with a Gasoline-Ethanol-Methanol Mixture Using One Dimensional Engine Modelling Based on Engine Test Results

Sat, 14 Dec 2024 07:37:23 +0000

The depletion of petroleum reserves as the basic raw material for gasoline production has driven studies into alternative fuels. One of the alternative fuels is alcohol, both ethanol and methanol. Due to their liquid form and physical-chemical properties similar to gasoline, small modifications to the engine are required. This paper will explain the effect of using a mixture of gasoline (in this case, RON 98 gasoline with methanol or methanol on engine performance and emissions. The fuel mixtures are as follows: G100, E10, E20, E30, M10, M20, M30. AVL Boost simulation software was used as a tool for 1-dimensional engine modelling, where the modeling is based on engine testing with G100 fuel. The results show that with increasing ethanol-methanol composition, torque and power decrease, and SFC increases. On the emission side, CO, CO2, and HC were decreased and NOx increased.

Crashworthiness Performance Study of 3D-Printed Multi-Cell Tubes Hybridized with Aluminum Under Axial Quasi-Static Testing

Sat, 14 Dec 2024 07:51:12 +0000

This study investigates the crashworthiness performance of 3D-printed hybrid tubes, fabricated using PLA and PACF filaments with varying shell thicknesses (1, 1.5, and 2 mm). The hybrid tubes, composed of a shell, aluminum, and multi-cell structure, were subjected to axial quasi-static testing. Results indicate that both shell thickness and filament type significantly influence crashworthiness. PLA specimens with a shell thickness of 2 mm absorbed 504 J of energy, whereas PACF specimens with the same thickness absorbed only 342.9 J. The deformation mode analysis revealed mixed deformation patterns, including diamond, fracture, and fragmented modes. The study also evaluated specific energy absorption (SEA) and crushing force efficiency (CFE). The PLA specimen with a 2 mm shell thickness exhibited the highest SEA value of 18.61 J/g among all specimens. In contrast, the PACF specimen with the same shell thickness demonstrated the highest CFE value of 0.82 among the tested specimens. Overall, this research contributes insights into the design optimization of 3D-printed hybrid tubes for enhanced crashworthiness.

Addressing Fire Safety, Ground Impact Resistance, and Thermal Management in Composite EV Battery Enclosures: A Review

Sat, 14 Dec 2024 08:06:11 +0000

Lithium-ion batteries are fundamental to modern electric vehicles, offering high energy density, long cycle life, and low self-discharge rates. However, thermal runaway—a critical safety issue involving uncontrolled temperature increases—can lead to fire or explosion. Ensuring flame retardancy is crucial in accidents where battery packs are exposed to external fires. Additionally, battery packs are susceptible to mechanical stresses and potential damage from ground impacts like debris or uneven road surfaces. Effective thermal management significantly impacts capacity and longevity. This review emphasizes the importance of researching flame retardancy, ground impact resistance, and thermal management, especially in composite battery enclosures. Composites serve as a lightweight alternative to metals and help overcome one of the main constraints of EVs, which is weight. Ground impact refers to the physical force battery packs endure during collisions, hitting potholes, debris, or accidents. Therefore, understanding the effects of ground impact on battery enclosures is crucial for design considerations. Effective thermal management is also essential, as it directly affects the performance and safety of Lithium-ion battery packs in EVs.

Exploration of Engine Parameters for Emission Reduction in Gasoline-Ethanol Fueled Engines

Tue, 17 Dec 2024 08:28:23 +0000

The main objective of this study is to develop spark ignition engine parameters that allow complete combustion while reducing dependence on fossil fuels. To achieve this goal, optimization of compression ratio, gasoline-ethanol mixture, ignition timing, and spark plug type was used. In addition, this study used water injection that continuously injects water before the intake manifold. In this study, the Taguchi method with the L9 orthogonal array was applied. According to the experimental verification results, the best combination to reduce exhaust emission levels is to utilize gasoline-ethanol (E70), a compression ratio (CR) of 15.6:1, an ignition degree of +4°, and a platinum spark plug. Meanwhile, the presence of water injection at 1.45 ml/s helps reduce vehicle exhaust pollutants.

Malaysian Public’s Perception Toward Event Data Recorder (EDR) in Vehicles

Thu, 19 Dec 2024 03:27:38 +0000

The Event Data Recorder (EDR) is an important device in a vehicle that can be used to analyze vehicle accidents. EDRs record and store crucial sensor data before, during, and after accidents, which can be used in reconstructing accident events. EDR has been regulated in the US and UK; however, its implementation in the ASEAN region, especially in Malaysia, is relatively new. In this study, a survey is conducted to investigate the perception of Malaysians toward EDR. There are three focuses of this survey: (1) the public's awareness of EDR's existence; (2) their perception of the benefits of EDR; and (3) their privacy concerns with the use of EDR in vehicles. The survey revealed that a majority (75.4%) of respondents were unaware of the existence of EDR, but 72.3% acknowledged that EDR could help identify accident causes, and 59.5% believed it could promote safer driving. Moreover, over 66% of respondents agreed that EDR could enhance vehicle and road safety. Besides, 40.3% expressed concern about potential privacy breaches and misuse of EDR data. Despite that, nearly 80% of respondents were in favor of installing EDR in their vehicles and allowing the data to be used in court. Additionally, 70% indicated that EDR would become a criterion for vehicle selection, and they would support mandatory EDR regulations.

Development of an Endurance Test Procedure for Vehicle Control Arm through Vehicle Dynamic Testing and Load Transfer Analysis

Thu, 19 Dec 2024 03:47:59 +0000

This research studies the forces applied to various vehicle control arms through different static and dynamic conditions during acceleration and braking condition. This study is targeting the important role that control arms play in ensuring stability and dynamics of vehicles, particularly when electric powertrains are added to chassis platforms created for conventional internal combustion engine (ICE). The study was designed with three phases: Fundamental of control arm dynamics (Phase 1), math formulations into theoretical models (Phase 2) and then experimental validation using the real rail component measurements (Phase 3). Tests were carried out on a straight track at a speed of 15 km/h and 30 km/h targeting the rear axle in an accelerating and the front axle in a braking condition. Results indicated that at 15 km/h, the acceleration of the rear axle was between 0.63 g and 0.49 g whereas at 30 km/h it was between 0.68 g and 0.70 g. During braking at 15 km/h, the front axle's acceleration ranged from a minimum of 0.62 g to a maximum of 0.70 g. At 30 km/h, the acceleration ranged from a minimum of 0.73 g to a maximum of 0.81 g. This suggests that there is a marked disparity in the dynamic action or response of sprung mass and unsprung mass at the different loading conditions. It emphasizes the need for additional support in the control arms and better control over the forces when the electric powertrains will be introduced. All of these have laid a basis for further research aimed at improving the designs of the vehicle structures in advance for the emerging powertrain technologies.

Reducing Exhaust Emissions from Palm Oil Biodiesel Diesel Engines by Adding Hydrogen Gas

Thu, 19 Dec 2024 03:49:01 +0000

The application of hydrogen enrichment of palm oil-based biodiesel in a compression ignition engine was examined in this work. Synthesized from crude palm oil (CPO), biodiesel was first fed into a single-cylinder diesel engine. The intake manifold received hydrogen gas at flows of 2.5 L/min, 5 L/min, 7.5 L/min, and 10 L/min. Operating at a constant speed of 2,000 rpm, the single-cylinder, direct-injection diesel engine used The aim of this work is to assess the performance and emissions of a diesel engine utilizing hydrogen gas and CPO biodiesel fuels. This work examined engine performance and exhaust emissions using smoke emissions, exhaust temperature, power, thermal efficiency, and fuel economy. Addition of hydrogen improved emissions and performance. Optimal engine performance was achieved by adding 2.5 L/min of hydrogen, which resulted in a 20.12% increase in brake thermal efficiency (BTE) and a 27.57% reduction in fuel consumption compared to biodiesel. The addition of hydrogen gas has a positive impact on exhaust emissions (HC, CO₂, and smoke opacity), but has a negative impact on NO emissions. At elevated loads of 2.5 lpm hydrogen flow, emissions measured were 40.00 ppm, 0.04%, 4.20%, and 44.20%, respectively, alongside a 45.72% increase in NO emissions. Including hydrogen gas improves the diesel engines running on biodiesel's performance and exhaust pollutants.

Thermal Performance Enhancement of Serpentine Cooling Design Using Branch Modification for Lithium-Ion Batteries

Thu, 19 Dec 2024 03:58:18 +0000

Lithium iron phosphate (LiFePO4) batteries offer advantages such as low cost, safety, environmental compatibility, and stability over repeated cycles. However, when subjected to high currents, this battery generates thermal issues, particularly when arranged in packs. This study aims to maintain the LiFePO4 80Ah battery within an optimal temperature range (20 °C – 40 °C) while minimizing pumping power. The proposed research introduces a serpentine channel with additional branches. The design variations include a gradient in branch spacing and changes in channel width. Each design is evaluated using dimensionless parameters representing maximum temperature, temperature uniformity, pumping power, and cooling efficiency coefficient. The best design from each variation is then compared with the conventional serpentine (CS) channel design, which is well-known for its superior thermal performance. The gradient variation reduces 𝑇𝑚𝑎𝑥∗ and 𝑇𝜎 by 0.07 and by 0.42, respectively, compared to the non-gradient channel design, at a Re 400 and a C-rate 3 C. The design with the largest channel width reduces 𝑇𝑚𝑎𝑥∗ by 0.57 or 11.32 °C compared to the design with the smallest channel width. At a Re 1000 and C-rate 3 C, the reduction in 𝑇𝑚𝑎𝑥∗ for the proposed channel design compared to the CS design is 0.017. In terms of the friction factor (𝑓), the proposed design is 0.0149 lower than the CS design. The results indicate that the thermal performance of the proposed channel design is better than that of the CS design, with reduced pumping power.