Substantially lightweight brake discs with high wear resistance are highly desirable in the automotive industry.This paper presents an investigation of the precision-engineering design and development of automotive br...Substantially lightweight brake discs with high wear resistance are highly desirable in the automotive industry.This paper presents an investigation of the precision-engineering design and development of automotive brake discs using nonhomogeneous Al/SiC metal-matrixcomposite materials.The design and development are based on modeling and analysis following stringent precision-engineering principles,i.e.,brake-disc systems that operate repeatably and stably over time as enabled by precision-engineering design.The design and development are further supported by tribological experimental testing and finite-element simulations.The results show the industrial feasibility of the innovative design approach and the application merits of using advanced metal-matrix-composite materials for next-generation automotive and electric vehicles.展开更多
Within today＇s product development process, various FE-simulations （finite element） for the functional validation of the desired characteristics are made to avoid expensive testing with real components. Those simul...Within today＇s product development process, various FE-simulations （finite element） for the functional validation of the desired characteristics are made to avoid expensive testing with real components. Those simulations are performed with great effort for discretization, use of simulations conditions, like taking different non-linearities （i.e., material behavior, etc.） into account, to create meaningful results. Despite knowing the effects of deformations occurring during the production processes, always the non-deformed design model of a CAD-system （computer aided design） is used for the FE-simulations. It seems rather doubtful that further refinement of simulation methods makes sense, if the real manufactured geometry of the component is not considered for in the simulation. For an efficient exploit of the potential of simulation methods, an approach has been developed which offers a geometry model for simulation based on the existing CAD-model but with integrated production deviations as soon as a first prototype is at hand by adapting the FE-mesh to the real, 3D surface detected geometry.展开更多
针对某直列四缸增压柴油机排气歧管在台架耐久试验中出现开裂现象,应用有限元(finite element analysis,FEA)-计算流体力学(computational fluid dynamics,CFD)耦合方法对排气歧管进行了热应力分析。排气歧管热应力分析模型中的材料性...针对某直列四缸增压柴油机排气歧管在台架耐久试验中出现开裂现象,应用有限元(finite element analysis,FEA)-计算流体力学(computational fluid dynamics,CFD)耦合方法对排气歧管进行了热应力分析。排气歧管热应力分析模型中的材料性质随着温度变化的关系由试验测定;在相应发动机工况下对模型预测的温度场和台架上测量的排气歧管温度进行对比,以对模型进行标定。应用标定后的模型分析排气歧管在给定热负荷条件下的应力-应变分布。FEACFD耦合分析结果表明:发生开裂的区域为高塑性应变区,从而推论导致排气歧管开裂原因为热力耦合应力作用下产生的塑性变形,即失效形式为热机械疲劳。以等效塑性应变作为塑性变形的度量及许可的等效塑性应变经验值为判据对排气歧管进行了设计改进,并从三种改进方案中找出最安全的方案进行试验验证,改进后的排气歧管顺利通过发动机台架耐久试验考核。展开更多
Microengines are regarded as the potential replacements for batteries.Aimed at the unsatisfactory thermal property of silicon used in the combustion chambers,ceramics are chosen as the construction material in this pa...Microengines are regarded as the potential replacements for batteries.Aimed at the unsatisfactory thermal property of silicon used in the combustion chambers,ceramics are chosen as the construction material in this paper.The fabrication process where alumina has been chosen as the microengine material is discussed.Vigorous FEA has been carried out,and it is found that the material satisfies the stress and deformation requirements of the design.Then the alumina fabrication process is described.Soft reusable polydimethylsiloxane(PDMS)moulds are produced from SU-8 resist masters,and alumina microengine parts are produced using the PDMS moulds.Images of the ceramic components show that the fabrication satisfies the design requirements.展开更多
To eliminate the defects during piston skirt isothermal forming process,simulations under different process parameters such as the deformation temperature and friction factor were analyzed with the rigid-plastic FEA.D...To eliminate the defects during piston skirt isothermal forming process,simulations under different process parameters such as the deformation temperature and friction factor were analyzed with the rigid-plastic FEA.Deformation pattern,metal flow and influence of process parameters were concluded.The prediction load value with a relative error of 4.98% is more accurate to the testing one than that from the empirical formula whose relative error is up to 50.8%.Finally,based on the simulation results,an improved process at 300 ℃ and 0.005-0.05 s-1 was verified without any defects by the physical try-out.展开更多
文摘Substantially lightweight brake discs with high wear resistance are highly desirable in the automotive industry.This paper presents an investigation of the precision-engineering design and development of automotive brake discs using nonhomogeneous Al/SiC metal-matrixcomposite materials.The design and development are based on modeling and analysis following stringent precision-engineering principles,i.e.,brake-disc systems that operate repeatably and stably over time as enabled by precision-engineering design.The design and development are further supported by tribological experimental testing and finite-element simulations.The results show the industrial feasibility of the innovative design approach and the application merits of using advanced metal-matrix-composite materials for next-generation automotive and electric vehicles.
文摘Within today＇s product development process, various FE-simulations （finite element） for the functional validation of the desired characteristics are made to avoid expensive testing with real components. Those simulations are performed with great effort for discretization, use of simulations conditions, like taking different non-linearities （i.e., material behavior, etc.） into account, to create meaningful results. Despite knowing the effects of deformations occurring during the production processes, always the non-deformed design model of a CAD-system （computer aided design） is used for the FE-simulations. It seems rather doubtful that further refinement of simulation methods makes sense, if the real manufactured geometry of the component is not considered for in the simulation. For an efficient exploit of the potential of simulation methods, an approach has been developed which offers a geometry model for simulation based on the existing CAD-model but with integrated production deviations as soon as a first prototype is at hand by adapting the FE-mesh to the real, 3D surface detected geometry.
文摘针对某直列四缸增压柴油机排气歧管在台架耐久试验中出现开裂现象,应用有限元(finite element analysis,FEA)-计算流体力学(computational fluid dynamics,CFD)耦合方法对排气歧管进行了热应力分析。排气歧管热应力分析模型中的材料性质随着温度变化的关系由试验测定;在相应发动机工况下对模型预测的温度场和台架上测量的排气歧管温度进行对比,以对模型进行标定。应用标定后的模型分析排气歧管在给定热负荷条件下的应力-应变分布。FEACFD耦合分析结果表明:发生开裂的区域为高塑性应变区,从而推论导致排气歧管开裂原因为热力耦合应力作用下产生的塑性变形,即失效形式为热机械疲劳。以等效塑性应变作为塑性变形的度量及许可的等效塑性应变经验值为判据对排气歧管进行了设计改进,并从三种改进方案中找出最安全的方案进行试验验证,改进后的排气歧管顺利通过发动机台架耐久试验考核。
基金Sponsored by the Natural Science Foundation of Heilongjiang Province (Grant No.E2004-06)
文摘Microengines are regarded as the potential replacements for batteries.Aimed at the unsatisfactory thermal property of silicon used in the combustion chambers,ceramics are chosen as the construction material in this paper.The fabrication process where alumina has been chosen as the microengine material is discussed.Vigorous FEA has been carried out,and it is found that the material satisfies the stress and deformation requirements of the design.Then the alumina fabrication process is described.Soft reusable polydimethylsiloxane(PDMS)moulds are produced from SU-8 resist masters,and alumina microengine parts are produced using the PDMS moulds.Images of the ceramic components show that the fabrication satisfies the design requirements.
文摘To eliminate the defects during piston skirt isothermal forming process,simulations under different process parameters such as the deformation temperature and friction factor were analyzed with the rigid-plastic FEA.Deformation pattern,metal flow and influence of process parameters were concluded.The prediction load value with a relative error of 4.98% is more accurate to the testing one than that from the empirical formula whose relative error is up to 50.8%.Finally,based on the simulation results,an improved process at 300 ℃ and 0.005-0.05 s-1 was verified without any defects by the physical try-out.
