Mechanical Engineering
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Browsing Mechanical Engineering by Author "Drignei, Dorin"
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Item EXPERIMENTAL IMPLEMENTATION OF A NEW DURABILITY / ACCELERATED LIFE TESTING TIME REDUCTION METHOD(2021-11-13) Baseski, Igor; Mourelatos, Zissimos P.; Latcha, Michael; Drignei, Dorin; Wang, XiaFatigue can be defined as a cyclic degradation process resulting in a failure at lower stress levels than the ultimate load. Fatigue reliability is defined as the probability that a structure will perform its intended function throughout its lifetime without any fatigue failure. Durability testing aims to predict fatigue damage in order to estimate the remaining useful life (RUL) based on fatigue. The latter is a useful metric in design for life-cycle cost. The objective of this research is to develop a new durability time reduction method to experimentally estimate the fatigue life of a vehicle component or system with accuracy using a short duration test. We assume that the loading random process (e.g. terrain configuration) is stationary and ergodic so that a single time trajectory can quantify the loading statistics. For the single time trajectory of the load process, we measure the corresponding output stress trajectory at a specified location on the structure. The latter is cycle counted using the 4-point rainflow counting algorithm. The cycle counting identifies all signal (stress) peaks and valleys using a peak picking algorithm and uses them to identify the range of all individual fatigue damage cycles and the time they occur based on a chosen fatigue damage model. Using this information (range of each cycle and the time it occurs), we build a synthetic signal exhibiting the same fatigue damage cycles in the sequence they occur in the actual stress signal. The sequence can be important in order to properly account for the cumulative damage accumulation. Finally, based on the fact that the cycle damage is independent of the time it occurs, we compress the synthetic signal so that its Power Spectral Density (PSD) does not exceed an upper limit dictated by the durability equipment. This proposed durability approach achieves therefore, the same cumulative damage with the original signal in a much shorter testing time. We demonstrate the new durability approach with two examples, and validate it experimentally using a commonly used Belgian block terrain excitation on the suspension coil spring of a military HMMWV (High Mobility Multi-purpose Wheeled Vehicle).Item GENERATION OF INTERNAL COMBUSTION ENGINE MAPS AND SPARK TIMING PROFILES USING METAMODELS(2022-03-14) Tafreshi, Ali; Mourelatos, Zissimos; Sangeorzan, Brian; Drignei, Dorin; Maisonneuve, JonathanWith the growth of computing technologies, many leading automotive companies tend to use simulation tools to reduce the number of actual engine testing for evaluating the performance of Internal Combustion (IC) engines. However, a high-fidelity engine model which is very complex and computationally demanding, is needed. In this dissertation, we present efficient and accurate metamodels to predict an engine fuel map and to also obtain the spark timing profile to generate a specified torque curve. Time-dependent Kriging metamodels using Singular Value Decomposition (SVD) and Nonlinear Autoregressive metamodels with Exogenous inputs (NARX) in conjunction with Neural Networks (NN) are developed and used. A sequential process was first developed to generate steady-state engine fuel maps using Kriging accounting for different engine characteristics at different operating conditions. The generated map predicts engine output parameters such as Brake Mean Effective Pressure (BMEP) and fuel flow rate. The Kriging metamodels are created sequentially to ensure acceptable accuracy with a small number of expensive engine simulations. Two optimization problems are solved for full load and part load conditions, respectively. We demonstrate that the estimated fuel map is of high accuracy compared to the actual map. The internal combustion engine is a source of unwanted vehicle vibration produced by engine mount forces which depend on the engine torque profile during a transient tip-in or tip-out maneuver. A methodology was also developed to obtain the desired engine torque profile to minimize the unwanted vibration by controlling a set of engine calibration parameters. A set of design coefficients defining a spark timing profile and the corresponding engine torque profiles are used to construct time-dependent metamodels using SVD and Kriging. The accuracy of the approach is demonstrated using GT-Power engine simulations. In addition, we developed a time-dependent NARX-NN metamodel to predict engine spark timing and cylinder pressure profiles corresponding to a desired torque profile. The NARX-NN metamodel predicts the spark timing accurately using a very small number of engine simulations.