Thermomechanical and Isothermal Fatigue Behavior of Gray Cast Iron for Automotive Brake Discs 147 Omar Maluf, Jéferson Aparecido Moreto, Maurício Angeloni, Marco Antônio Colósio, José Ca
Trang 1NEW TRENDS AND DEVELOPMENTS IN
AUTOMOTIVE SYSTEM ENGINEERING
Edited by Marcello Chiaberge
Trang 2New Trends and Developments in Automotive System Engineering
Edited by Marcello Chiaberge
Published by InTech
Janeza Trdine 9, 51000 Rijeka, Croatia
Copyright © 2011 InTech
All chapters are Open Access articles distributed under the Creative Commons
Non Commercial Share Alike Attribution 3.0 license, which permits to copy,
distribute, transmit, and adapt the work in any medium, so long as the original
work is properly cited After this work has been published by InTech, authors
have the right to republish it, in whole or part, in any publication of which they
are the author, and to make other personal use of the work Any republication,
referencing or personal use of the work must explicitly identify the original source.Statements and opinions expressed in the chapters are these of the individual contributors and not necessarily those of the editors or publisher No responsibility is accepted for the accuracy of information contained in the published articles The publisher
assumes no responsibility for any damage or injury to persons or property arising out
of the use of any materials, instructions, methods or ideas contained in the book
Publishing Process Manager Iva Lipovic
Technical Editor Teodora Smiljanic
Cover Designer Martina Sirotic
Image Copyright hxdbzxy, 2010 Used under license from Shutterstock.com
First published January, 2011
Printed in India
A free online edition of this book is available at www.intechopen.com
Additional hard copies can be obtained from orders@intechweb.org
New Trends and Developments in Automotive System Engineering,
Edited by Marcello Chiaberge
p cm
ISBN 978-953-307-517-4
Trang 3free online editions of InTech
Books and Journals can be found at
www.intechopen.com
Trang 5M.A.Kalam and H.H Masjuki
Analytical Methods for Determining Automotive Fuel Composition 13
Jonas Gruber, Renata Lippi, Rosamaria W C Li and Adriano R V Benvenho
Automotive Fuel Consumption in Brazil:
Applying Static and Dynamic Systems of Demand Equations 29
Mariana Iootty, Helder Pinto Jr and Francisco Ebeling
Material Characterization and Improvements 45 Fatigue and Fracture Behavior
of Forging Die Steels 47
Ryuichiro Ebara
Optimization of Injection Moulded Polymer Automotive Components 65
Ribeiro, C.J and Viana, J.C
High Mn TWIP Steels for Automotive Applications 101
B C De Cooman, Kwang-geun Chin and Jinkyung Kim
Powder Injection Moulding – An Alternative Processing Method for Automotive Items 129
Berenika HausnerovaContents
Trang 6Thermomechanical and Isothermal Fatigue Behavior
of Gray Cast Iron for Automotive Brake Discs 147
Omar Maluf, Jéferson Aparecido Moreto, Maurício Angeloni, Marco Antônio Colósio, José Carlos Santos,
Waldek Wladimir Bose Filho and Dirceu Spinelli
Advanced Robotic Radiative Process Control for Automotive Coatings 167
Fan Zeng and Beshah Ayalew
New Components and Related Technologies 187 DC/DC Step-Up Converters for Automotive Applications:
a FPGA Based Approach 189
M Chiaberge, G Botto and M De Giuseppe
The Thermo-mechanical Behavior
in Automotive Brake and Clutch Systems 207
Abdullah M Al-Shabibi
Dynamic Analysis of an Automobile Lower Suspension Arm Using Experiment and Numerical Technique 231
S Abdullah, N.A Kadhim, A.K Ariffin and M Hosseini
Increased Cooling Power with Nucleate Boiling Flow in Automotive Engine Applications 249
Helfried Steiner, Günter Brenn,Franz Ramstorfer and Bernd Breitschädel
The “Equivalent Cable Bundle Method”:
an Efficient Multiconductor Reduction Technique to Model Automotive Cable Networks 273
Guillaume Andrieu, Xavier Bunlon, Lamine Koné, Jean-Philippe Parmantier, Bernard Démoulin and Alain Reineixl
Fatigue Characteristic of Automotive Jounce Bumper 297
Aidy Ali, R.S Sidhu and M.S.A Samad
Control Systems and Algorithms 307
On the Control of Automotive Traction PEM Fuel Cell Systems 309
Ahmed Al-Durra, Stephen Yurkovich and Yann Guezennec
An AdaptiveyTwo-Stage Observer in the Control
of a New ElectromagneticyValve Actuator for Camless Internal Combustion Engines 343
Trang 7Integrated Controller Design
for Automotive Semi-Active Suspension
Considering Vehicle Behavior with Steering Input 369
Masaki Takahashi, Takashi Kumamaru and Kazuo Yoshida
Design of an Embedded Controller
for Some Applications of an Automotives 383
Preeti Bajaj and Dinesh Padole
Arbitration Schemes for Multiprocessor Shared Bus 395
Preeti Bajaj and Dinesh Padole
Towards Automotive Embedded Systems
with Self-X Properties 411
Gereon Weiss, Marc Zeller and Dirk Eilers
4D Ground Plane Estimation Algorithm
for Advanced Driver Assistance Systems 433
Faisal Mufti, Robert Mahony and Jochen Heinzmann
Infotainment and Navigation Systems 449
The Car Entertainment System 451
Niels Koch
Information and Communication Support
for Automotive Testing and Validation 473
Mathias Johanson
Trends towards Automotive Electronic
Vision Systems for Mitigation
of Accidents in Safety Critical Situations 493
Ciarán Hughes, Ronan O’Malley, Diarmaid O’Cualain,
Martin Glavin and Edward Jones
Advancements in Automotive Antennas 513
Brendan D Pell, Edin Sulic, Wayne S T Rowe,
Kamran Ghorbani and Sabu John
Development Tools 539
Automotive VHDL-AMS Electro-mechanics Simulations 541
Mariagrazia Graziano and Massimo Ruo Roch
Potential and Drawbacks of Raman (Micro)Spectrometry for the Understanding of Iron and Steel Corrosion 567
Trang 8Computational Techniques for Automotive Antenna Simulations 585
Faik Bogdanov, Roman Jobava, David Karkashadze,Paata Tsereteli, Anna Gheonjian, Ekaterina Yavolovskaya,Detlef Schleicher,Christoph Ullrich and Hicham Tazi
Voltage Stability Analysis of Automotive Power Nets Based on Modeling and Experimental Results 611
Tom P Kohler, Rainer Gehring, Joachim Froeschl,Dominik Buecherl and Hans-Georg Herzog
Vehicle Design 631 Urban and Extra Urban Vehicles:
Re-Thinking the Vehicle Design 633
Andrea Festini, Andrea Tonoli and Enrico Zenerino
Analysis Approach of How University Automotive Competitions Help Students to Accelerate
Their Automotive Engineer Profile 649
Francisco J Sánchez-Alejo, Miguel A Álvarez, Francisco Aparicio and José M López
Trang 11So, vehicle design is becoming more and more diff erentiated and the vehicle behavior does not actually meet one single standard but is following the market trends The vehicles are being designed according to detailed specifi cations and the product is characterized by specifi c customer’s profi le looking for specifi c solutions to their own problems, which may be diff erent for diff erent customer’s profi le.
In this complex scenario the defi nition of niche product is becoming obsolete and the automobile market is becoming a sum of many and very diff erent vehicle categories: micro car, city car, minivan, SUV, roadster
Also technological needs are changing, and the race to luxury and big comfortable, high powered sedan is now leaving place to “smart” vehicles designed to look for an intelligent solution to diff erent mobility problems
Or at least this is how it should be
The vehicle of the future, and the vehicle that customers are looking for nowadays, is designed upon the basic needs, starting the vehicle and subsystems design according
to the main mission of the vehicle itself: carrying people and goods
Many aspects are “fi ghting” each other in the “design process”, spanning from nomic/strategic needs (maintenance costs, taxes used to depend on engine displace-ment and/or insurance on power, parking areas, driving licenses, etc.) to emerging standards (The Corporate Average Fuel Economy CAFÉ, new rating method NCAP, EUROxx regulations, etc.) ending with more technological mission/comfort needs:
eco-• Ergonomic needs
• Small vehicles for urban environment, to reduce traffi c jams
• Fuel effi ciency and pollution reduction
o Lightweight
Trang 12All these considerations lead to the conclusion that the optimization of the vehicle can
be done only by optimizing the entire system, not looking for the optimum solution in each single subsystem
The purpose of this book is therefore to try to present the new technologies ment scenario, and not to give any indication about the direction that should be given
develop-to the research in this complex and multi-disciplinary challenging fi eld
Marcello Chiaberge
Mechatronics Laboratory – Politecnico di Torino
Italy
Trang 15Part 1
Fuel Efficiency and ESU Improvements
Trang 171
Experimental Test of a Diesel Engine using
Envo-Diesel as an Alternative Fuel
M.A.Kalam and H.H Masjuki
Department of Mechanical Engineering, University of Malaya
of the usage lead to increase the demand for petroleum fuel The world is presently confronted with crises of fossil fuel depletion and environmental degradation
The present energy scenario has stimulated active research interest in non-petroleum, renewable, and non-polluting fuels The world reserves of primary energy and raw materials are, obviously, limited According to an estimate, the reserves will last for 218 years for coal, 41 years for oil, and 63 years for natural gas, under a business-as-usual scenario (Agarwal 2007)
The depletion of world petroleum reserves and increasing of demand also causes rise in fuel prices The prices of crude oil keep rising and fluctuating on a daily basis which are at near record levels and are stabilizing at about US$140 per barrel now at Malaysia This necessitates developing and commercializing unconventional fuel from natural sources This may well be the main reason behind the growing interest for unconventional bio-energy sources and fuels around the world especially developing countries, which are striving hard to offset the oil monopoly
This study concentrates on assessing the viability of using alternative fuels in the existing internal combustion engines In Malaysia, many researches are carried out on palm oil to produce biofuel or biodiesel as an alternative fuel Malaysia has become the biggest palm oil producer country in the world followed by Indonesia Recently, Malaysian Palm Oil Board (MPOB) has been produces the P5 palm oil-based biofuel called "Envo Diesel" for local use After palm oil, coconut oil is the next potential oil that can be produced as biofuel because of its high amount of oxygen contents that enhance the combustion process The objective of this study is to carry out an experimental investigation of the performance and the exhaust emission characteristics of a diesel engine fueled with Envo Diesel and coconut oil blends and compared them with ordinary diesel fuel
2 Experimental setup and procedures
The schamatic of the experimental setup for used engine test bed can be seen in Fig.1 A commertial diesel (2L series) was selected for this investigation The engine is type 2L, 53.6
Trang 18New Trends and Developments in Automotive System Engineering
4
kW capacities, fixed speed (4000 rpm) It is water-cooled, indirect diesel injection engine The specifications of engine are shown in Table 1
Fig 1 Schematic Diagram of Engine Test Bed
Model 2L
Combustion IDI, naturally aspirated
Number of cylinder 4
Bore x Stroke 92 x 92mm
Displacement 2.4 L (2446 cc)
Compression ratio 22.3 :1
Combustion chamber Swirl chamber
Nozzle type Throttle
Cooling system Pressurized circulation
Trang 19Experimental Test of a Diesel Engine using Envo-Diesel as an Alternative Fuel 5
2.1 Exhaust gas analyzer
Horiba exhaust gas analyzer was used to measure HC, CO,CO2 and NOx emissions The analyzer was interfaced with engine controlled software so that all the data from emission analyzer and engine are logged at same time The Hartridge smoke meter was used to measure smoke emission
2.2 Test fuel
The analysis and the preparation of test fuels were conducted at the Engine Tribology Laboratory, Department of Mechanical Engineering, University of Malaya A total of three test fuels were selected for this investigation The test fuels chosen are (1) 100% conventional diesel fuel (B0) supplied by Malaysian petroleum company (Petronas), (2) P5 as 5% palm olein and 95% B0 It can be mentioned that fuel P5 is known as “Envo diesel” in Malasyia (3) C5 as 5% coconut oil and 95% B0 The fuel C5 is being selected to be compared with Envo diesel Details about Envo diesel can be seen in below-
2.3 Envo Diesel (Direct blending)
Envo Diesel consists of 5 percent processed palm oil commonly known as cooking oil and 95 percent conventional diesel fuel The Malaysian Government has decided on the Envo Diesel for the local market because production cost of palm olein is RM1 per litre cheaper than ethyl ester The Envo Diesel will be implemented in stages starting with vehicles of selected governmental agencies and then moving on the public use The Malaysian palm oil board (MPOB) is using the blends of processed palm oil with petroleum diesel to produce Envo Diesel The advantages of envo diesel are:
a No engine modification is required
b Results in terms of engine performance, fuel consumption, exhaust emissions, repair and maintenance are acceptable
2.4 Fuel properties test
The main properties of fuel tested such as calorific value, viscosity, specific density and flash point have been tested through standard method The ordinary diesel fuel properties are compared with blended fuels
Heat calorific value: Oxygen Bomb Calorimeter was used to obtain the heating value of
each fuel The sample was ignited and burned in the combustion chamber in the presence of
20 bar of oxygen, and the energy released is transferred to the surrounding water The energy contain in the fuel was calculated on the basis of the conservation of energy principle
by measuring the temperature rise of the water Mass of fluid x Caloric value = (Mass of water + water equivalent of bomb) x Corrected temperature rise x specific heat capacity of water
Viscosity:Automatic viscometer was used for determining the kinematic viscosity of fuels It
provides a measure of the time required for a volume of fuels to flow under gravity through
a calibrated glass capillary tube
Specific gravity: Model DMA 4500/5000 specific gravity concentration meter was used to
obtain the specific density value of tested fuels The fuels density is measure at 15oc in g/cm3
Flash point: Flash Point Tester HFP 380 Pensky Martens was used to measure the flash
point value of each tested fuels The flash point is determined by heating the fuel in a small
Trang 20New Trends and Developments in Automotive System Engineering
6
enclosed chamber until the vapors ignite when a small flame is passed over the surface of
the fuel.The temperature of the fuel at this point is the flash point
The test fuel physicochemical properties and compositions can be seen in Table 2 and Table
3 respectively
Properties/Fuels
Rape seed methyl ester
Soy bean methyl ester
Palm oil methyl ester
Envo diesel
P5 (Envo diesel) 5% palm olein and 95% B0
C5 5% coconut oil and 95% B0
Table 3 Test Fuel Compositions
3 Results and discussion
From physicochemical test results, it is found that, the C5 has better heating value than P5
The higher heating value contributes more power output after burning the fuel in the engine
cylinder The heating values of both the P5 and C5 are slightly lower as compared to B0
From viscosity test result, it is found that the C5 fuel has lower viscosity than P5 Lower
viscosity of a fuel contributes better atomization However, the viscosity of both P5 and C5
are slightly higher than B0 Similar differenecs of all other properties along with biodiesel
properties from other countries can be seen in Table 3
Engine brake power versus speed at constant 85% throttle setting can be seen in Fig.2 It can
be seen that brake power increases with increasing engine speed untill 3000 rpm and then
power starts to drop due to the effect of higher frictional force The maximum brake power
obtained by B0, C5 and P5 are 36.7 kW, 36.10 kW and 36.20 kW respectively at 3000 rpm
The lower brake power by C5 and P5 as comapared to B0 is mainly due to their respective
lower heating values The average brake power all over the speed range is found as 28.28
kW, 28.08 kW and 27.94 kW by B0, C5 and P5 respectively
The variation of exhaust gas temperatures of all the fuels are shown in Fig 3 Exhaust gas
temperatures of the blended fuels are lower than those of the diesel fuel due to the lower