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Self-loosening of bolted connections is a crucial failure mode for joints under transverse dynamic load. For some years, three dimensional finite element analysis has been enabled for avoiding experimental investigations of self-loosening. The aim of this paper is to emphasize the effect of joint design on the self-loosening of bolted connections, which is important for product development in early design stage. Joints consisting of internally threaded nut components are often heavier and stiffer as compared with light weight designs consisting of a separate nut. The difference of self-loosening is significant between arrangements with nut thread component and separate nut, although the design versions only contain slight modifications. Hence it is necessary to evaluate the effect of light weight design on self-loosening.

India is blessed with considerable quantity of titanium based mineral resources accounting to about 20% of the world's availability holding and third largest reserves. The main titanium minerals are ilmenite and rutile available in beach sand deposits in the coastal states like Kerala with production of about 0.6 MT by mining & mineral separation process to provide environmental friendly titanium alloys. Though the major usage of titanium alloys are for aeronautics, defense, space, atomic energy sectors, its usefulness with special properties is yet to be exploited for the Indian automotive sectors. The principle advantages of Titanium alloys for automotive application that can be exploited are - 45% lighter than steel, virtually total resistant to acidic attack, four times more corrosion resistance than stainless steel, high specific strength, good ductility and ease to form by forging and machining operations.

The objective of this paper is to present the results of the GT Power calibration with engine test results of the air loop system technology down selection described in the SAE Paper No. 2012-01-0831. Two specific boosting systems were identified as the preferred path forward: (1) Super-turbo with two speed Roots type supercharger, (2) Super-turbo with centrifugal mechanical compressor and CVT transmission both downstream a Fixed Geometry Turbine. The initial performance validation of the boosting hardware in the gas stand and the calibration of the GT Power model developed is described. The calibration leverages data coming from the tests on a 2 cylinder 2-stroke 0.73L diesel engine. The initial flow bench results suggested the need for a revision of the turbo matching due to the big gap in performance between predicted maps and real data. This activity was performed using Honeywell turbocharger solutions spacing from fixed geometry waste gate to variable nozzle turbo (VNT).

Nanofluid is a new class of heat transfer fluids containing nano-sized particles, fibers, or tubes that are stably suspended in a carrier liquid. They possess very high potential technological significance which is yet to be realized. This paper intends to provide a brief overview of area of effectual applicability of nanofluids in automotive application. Investigation and research studies pointing out the significance of nanofluids, emphasizing their improved heat transfer properties that are controllable and their specific characteristics that make them suitable for such application have been reviewed and presented. The synergy within an integrated experimental and analytical approach is being used to guide the development of nanofluids with improved effectiveness and applicability in automotive application.

As IC engines decrease in displacement, their cylinder surface area to swept volume ratio increases. Examining power output of IC engines with respect to cylinder surface area to swept volume ratio shows that there is a change in power scaling trends at approximately 1.5 cm−1. At this size, it is suggested that heat transfer from the cylinder becomes the dominant thermal loss mechanism and performance and efficiency characteristics suffer. Furthermore, small IC engines (>1 cm−1) have limited technical performance data compared to IC engines in larger size classes. Therefore, it is critical to establish accurate performance figures for a family of geometrically similar engines in the size class of approximately 1.5 cm−1 in order to better understand the thermal losses that contribute to lower efficiencies in small IC engines. The engines considered in this scaling study were manufactured by 3W Modellmotoren, GmbH.

As for automobile, the mass production period of Electric Vehicle(EV) has begun by the rapid progress of the battery performance. But for EV- Motorcycle(MC), it is limited for the venture companies' releases. The design and evaluation methodologies are not yet established or standardized so far. This paper provides the practical and the experimental examples. To study the feasibility of EV-MC, we developed the prototypes in the present technical and suppliers' parts environments, and evaluated them by the practical view of the MC usage. The developed EV-MC has the equivalent driving performance of the 250cc internal combustion engine(ICE)-MC and a cruising range of 100km in normal use. In the prototype development, the reliability and the ability of protection design of the battery in the whole vehicle against the environmental loads are mainly studied, especially, heat and cold, water, shock, and the accident impact.

The Instant Mileage Assistance (IMA), as the name indicates, is a system to guide the vehicle users to realize maximum fuel economy (mileage). This system is targeted to provide users with instantaneous mileage indication depending on the current driving pattern, correct gear operating zone (in case of a geared vehicle) through gear up/down shift assist indication and the accurate distance the vehicle can travel before the fuel tank is empty, thereby assisting the user in harnessing maximum fuel economy the vehicle can deliver and also safely reach the next refilling station. The instantaneous mileage is calculated by mapping the distance travelled by the vehicle and the respective amount of fuel consumed, during a particular period of time, and is displayed using an instrument cluster.

The proposed paper is on electrical energy conservation in a two wheeler. Electrical energy generation adds a 12% load torque on an engine and hence saving electrical energy would ultimately reduce the consumption of fuel. Load Control Module (LCM) is a single intelligent device which is placed in between electrical energy generation and consumption. The module controls and distributes energy to the corresponding loads depending on parameters like battery voltage, engine RPM, overhead light illumination levels and load usage time. The module prioritizes battery charging for prolonging the life of the battery. The Module has a microcontroller and load drivers and it is programmed with a novel algorithm for prioritization and energy distribution with respect to input conditions.

To downsize a spark ignited (SI) internal combustion engine (ICE), keeping suitable power levels, the application of turbocharging is mandatory. The possibility to couple an electric drive to the turbocharger (electric turbo compound, ETC) can be considered, as demonstrated by a number of studies and the current application in the F1 Championship, since it allows to extend the boost region to the lowest ICE rotational speeds and to reduce the turbo lag. As well, some recovery of the exhaust gas residual energy to produce electrical energy is possible. The present paper shows the first numerical results of a research program under way in collaboration between the Universities of Pisa and Genoa. The study is focused on the evaluation of the benefits resulting from the application of ETC to a twin-cylinder small SI engine (900 cm3).

Nowadays the challenge in design of auxiliary devices for automotive small engines is focused on packaging reduction and on the increase of the performance. These requirements are in contrast to each other and in order to fulfil the project specifications, new and more refined design tools and procedures need to be developed. This paper presents a calculation loop developed by Pierburg Pump Technology Italy S.p.A. (PPT). It supports the design of a variable displacement oil pump component for engine applications. The work is focused on the fatigue life evaluation of a joint, which transmits the drive torque from the engine to the oil pump. The aim of the procedure is to calculate the onset of the surface fatigue phenomenon in the hexagonal joint which drives the oil pump, taking into account the axes misalignment and the flat-to-flat clearance. The study has involved several matters, experimental measures, CFD, MBA and FEM analyses.

In the next future, improvements of direct injection systems for spark-ignited engines are necessary for the potential reductions in fuel consumptions and exhaust emissions. The admission and spread of the fuel in the combustion chamber is strictly related to the injector design and performances, such as to the fuel and environmental pressure and temperature conditions. In this paper the spray characterization of a GDI injector under normal and flash-boiling injection conditions has been investigated. The paper is mainly focused both on the capability of the injection apparatus/temperatures controller system to realize flash-boiling conditions, and the diagnostic setup to catch the peculiarities of the spray behavior. The work aims reporting the spray characterization under normal and flash-boiling conditions.

Composite materials can bring significant weight saving in the design of a new component. These materials are one of the solutions offered to designers to achieve new fuel efficiency regulation. New challenge arises in term of design optimization and manufacturing. Shifting from a metal to composite paradigm requires a dedicated tool for composite design in order to take into account the specific composite behavior. Material performance varies widely over the entire part mainly due to the manufacturing process and the corresponding microstructure. Classical design tools are not able to describe accurately the local composite material behavior, leading to the introduction of safety factors and lack of confidence in the design. Accurate modelling of composites require the use of a multi-scale approach. The composite is not seen as a homogeneous material anymore but as a heterogeneous material made of several constituents.

Current catalytic formulations for motorcycles consist of so called three way catalysts (TWC) that are able to reduce the emissions of carbon monoxide (CO), nitrous oxides (NOx) and hydrocarbons (THC) below the regulatory emission limit. These catalysts mostly contain platinum (Pt), palladium (Pd) and rhodium (Rh), also called platinum group metals (PGM) in different ratios and concentrations. Another important component is the so-called oxygen storage material (OSC) that is compensating fluctuations in lambda during acceleration and deceleration. Currently existing catalyst formulations must be modified to fulfill the more stringent emission limits with simultaneous consideration of a more realistic test cycle. In this paper we will present the modification of an existing catalytic formulation for a 690 cm3 motorcycle from model year 2012. The motorcycle is equipped with a quick-change muffler to be able to compare different formulations in a simple way.

Automotive shock absorbers are key elements in the dynamic behavior of vehicles. Their degradation is slow, gradual and progressive, so that the driver of the vehicle eventually gets used to the decrease of the damper's performance without noticing it. This article describes how a test bench was developed based on existing market models, however having as its main goal the low cost of production. The Crankshaft and Scotch Yoke mechanisms were studied in an analog way and simulated in CAD software. After this analysis the Scotch Yoke system was chosen because its motion describes a perfect sine function. To drive the system it was used a 5HP electric motor, and a frequency inverter to control the motor's speed with capability of 7.33A, allowing the device to have the ability to test not only production line vehicles but also competition dumpers.

Stringent emissions legislation is being applied to small motorcycles and scooters around the world. This is forcing, gradually, the replacement of carburetors by electronic fuel injection (EFI) systems. The integration of this new technology creates new constraints on the engine and also on the vehicle. This study will provide an overview of these constraints and also technical solutions to reduce the impact on engine and vehicle. A special focus will be done on the fuel system, where the development of an advanced technology will be discussed in detail. This technology marks a break with the standard automotive fuel system architecture in order to fulfill the specific requirements of scooters and small motorcycles: low size, low weight, low energy demand, as well as simple integration.

Brazil, that presents one of the highest accidents indexes of the world, does not have any specific regulation related to the use of an external light during the day time which provides a better visibility of the vehicle in movement and according to studies gives more reaction time for the other road users. Many countries in Europe and North America shows good results since they adopted the lights on during the day with collision reduction of vehicle to vehicle, vehicle to pedestrian and vehicle to cyclists. The aim of this study is to show the benefits of the Daytime Running Lights (DRL) and its relation to the reduction of the traffic accidents, as well as a brief analysis on the use of a dedicated system, which can be more efficient since it can be designed to provide a light distribution allowing a better visibility as possible.

Normally the automaker uses a specific Engineering criteria for serviceability with minimum clearance specification. Due to Front Over Hang reduction (Figure 1) regarding to Emerging Markets countries and technology inside in the hood compartment, the H4 bulb serviceability is affected. This paper shows a solution that provides an easy service procedure reducing package and complete sealed connector system for an H4 head lamp bulb. Figure 1 Front over Hang Reduction.

On Current Automotive Application, including Brazil, there are significant initiatives to reduce fuel consumption and emissions, like INOVAR Auto and others worldwide. There are several initiatives for Hybrid vehicles, electrical vehicles and other fuel cell energy vehicles, besides the additional energy supply in order to reduce the fuel energy consumption and consequently the emissions. The vehicle features represents a huge part of energy consumption, because the generator needs to feed all of those features. To reduce this energy required from generator and consequently from vehicle accessory drive and engine itself, we are aiming to reuse one of the bigger energy wasted on vehicle combustion engine, the thermal one. For that end, the Thermal Energy Generator is applied on major heat sources and convert the thermal energy through electrical energy due to “See-beck effect cells”.

In recent past years, the most important challenges for car manufacturers in terms of crashworthiness have been related to the introduction of the Frontal Small Overlap crash test promoted by the IIHS. The introduction of this new configuration presents a new and critical load case that manufacturers are on the way to solving. Now, with several OEM's starting to achieve good results, a new configuration is being studied for introduction: the frontal oblique crash test against a deformable barrier based on the National Highway Traffic Safety Administration (NHTSA) proposal in the US. Towards providing the best tools for passive safety development, a tool to enable the analysis of the loads transmitted to the barrier in both tests has been developed.

According to the “Report 2010” of the Association des Constructeurs Européens de Motocycles (European motorcycle manufacturers' association), the number of motorcycles throughout the European Union rose from 16 million to more than 22 million between 2001 and 2008. Taking all two-wheeled motor vehicles into account, in 2008 approximately 33 million vehicles were registered. At the same time, motorcycles are by far the most dangerous means of transport. Two groups (children and elderly people) are especially vulnerable due to their weakness against impact, reflexes and reaction to risk, resistance to the generated forces, etc. According to the latest accidents data from the European Community database on road accidents (CARE), more than 110 children under 14 years old who were passengers on PTW's were killed on the roads of the Community between 1991 and 2000.