Vehicle Structure Research Articles

DOCOL 1100M WELDING IN THE CONSTRUCTION OF ELECTRIC MEANS OF TRANSPORT

Advanced high-strength steels are important for the automotive sector. Metal active gas (MAG) is the most popular method for joining grades of steel. The goal of the paper is to analyze the mechanical properties of the MAG welding joint made of high-strength DOCOL 1100M intended for the construction of electric vehicles. The manuscript shows a basic understanding of the properties of DOCOL joints. This type of material is characterized by a martensitic microstructure, which makes it difficult to make a proper joint. The tensile strength, metallographic structure, and type of non-metallic inclusions were analyzed as a function of the oxygen amount in the protective gas mixture. Investigations of oxide non-metallic inclusions were carried out using scanning electron microscopy. This article attempts to obtain high joint strength of the electric vehicle structure by controlling the average size of non-metallic inclusions in the weld, which is influenced by shielding gas in the MAG welding process. The solution has application potential for the automotive industry, especially for electric vehicles.

Assessing the possibility of using a variable-length launch vehicle with a polymer body for orbiting payload

The object of this study was the motion of an ultralight class variable-length launch vehicle made of a polymer body along the active phase of the trajectory. The work considers the solution to the problem of designing low-cost means of delivery to orbit, namely to the assessment of the possibility of removing the payload by a carrier rocket with a polymer body of variable length beyond the dense atmosphere of the Earth. For this purpose, ballistic projection of the trajectory of the launch vehicle was carried out taking into account overloading; its aerodynamic characteristics and peculiarities of aerothermodynamic processes occurring during flight in the atmospheric phase of the trajectory were determined. The closeness (up to 10 %) of the obtained results with known experimental data is shown. The influence of the aerodynamic force on the parameters of the launch vehicle motion was studied. A flight simulation was conducted, the results of which showed the fundamental possibility of launching a CubeSat 24U class payload using a launch vehicle with a polymer body of variable length to a suborbital trajectory with an altitude of about 300 km. At the same time, the effective longitudinal overload on the body of the launch vehicle does not exceed 4 units, and the temperature on the surface of the body does not exceed 300 K. A feature of the research is the use of a multidisciplinary approach, which implies taking into account the interrelationship of aerodynamic, thermodynamic, and ballistic processes. The established motion parameters, aerodynamic characteristics, and the surface heating temperature of the launch vehicle body are key values for further research on the design and analysis of a launch vehicle with a polymer body of variable length. These data could be used to calculate the mechanical and thermal loads acting on the structure of the launch vehicle during flight

Analytical Prediction of Crushing Thin-Walled Square Tube with Static Axial Loads Using Elliptical Holes as Crush Initiators

In the structure of passenger vehicles there are components that absorb the impact load, which components are commonly thin-walled square tube. The design of the impact energy absorber model can be carry-out by experiment, simulation, and analysis. In the design of this impact energy absorbing component, an elliptical hole was used as a crush initiator to reduce peak loads and set the start of the bending pattern. Analytical predictions were made to reduce costs and speed up time to obtain mean load and peak loads values from the same shape model. In this study, a thin-walled square tubes model is used with an elliptical hole that have ratio of horizontal axis and vertical axis is from 3:7 until 7:3. The result of this study showed that the prediction of the peak load and average load by analytical means has a good conformity with the simulation. Keywords: Impact energy absorber, analytical, square tube, elliptical hole.

Optimization Study of Fire Prevention Structure of Electric Vehicle Based on Bottom Crash Protection

As the market share of electric vehicles continues to expand, fire accidents due to impacts from the power battery located at the bottom of the electric vehicles are receiving increasing attention. Lithium-ion batteries, as the mainstream choice of power battery for electric vehicles solving the problem that they are prone to thermal runaway due to damage when impacted, are the key to preventing and controlling fire accidents in electric vehicles. To address the protective problem of the bottom power battery of electric vehicles when it is impacted by road debris, two new types of sandwich structures with an enhanced regular hexagonal structure and semicircular arch structure as the core layer, respectively, are innovatively proposed in this article. They are used to protect the bottom power battery of electric vehicles and are compared with the traditional homogeneous protective structure in terms of protective performance. A local finite element simulation (FEM) of an electric vehicle containing the necessary components was established for simulation. Stress distribution, deformation, and energy absorption data for each component of an electric vehicle assembled with a protective structure when subjected to a bottom impact were obtained safely and cost-effectively. Three evaluation coefficients, namely, the cell shape variable (Bcmax), the protective effect parameter (ƒPE), and the total energy absorption of the structure (Ea), are proposed to compare and analyze the simulation results of different protective structures under equal mass conditions. The maximum values of the battery deformation of arched sandwich construction and reinforced honeycomb sandwich construction were 0.35 mm and 0.40 mm, respectively, which are much smaller than that of the maximum deformation of the battery under the protection of a homogeneous protective structure, which is 0.62 mm. Their protective effect parameters are 43.55 and 35.48, respectively, which proves that the optimization degree of the protective structure of the bottom of the electric vehicle after the application of the new structure is 35% or more. The total energy absorptions of the two structures are 91.77 J and 87.19 J, respectively, accounting for more than 70% of the kinetic energy in the system, which proves that the deformation of the sandwich structure can effectively absorb the kinetic energy of the collision between the road obstacle and the bottom of the car. The final results show that the arched sandwich structure showed the best impact resistance in the simulation, which can be used for the power battery’s protective structure on the electric vehicle’s bottom. This study fills a gap in local finite element modeling in electric vehicle crash simulations and provides ideas for fire prevention designs of electric vehicle structures.

Design and characterization of a pyroshock reduction structure based on local resonance mechanisms

In the spacecraft Pyrotechnic shock process, the explosion generated by the strong shock wave and preload force release of the vehicle structure produces a transient, high-frequency, and high-amplitude shock response, resulting in a harsh shock environment prone to failure or damage to many precision equipment or components on the spacecraft, a fatal impact on the launch mission. This paper designed a local resonance shock mitigation structure based on local resonance theory for the Pyrotechnic shock environment and optimized the parameters of the structure by the genetic algorithm. A Pyrotechnic shock simulation experimental device was built to verify the impact reduction effect of the designed shock reduction structure. This experimental device can well restore the pyrotechnic shock environment. In addition, a finite element simulation model was established, and the impact reduction effect of the protective structure was verified both numerically and experimentally. The experimental and numerical analysis results show that the impact response decays significantly in the structural band gap range with the same transfer path, and the shock response spectrum amplitude decreases 9.8 dB in the 100–10,000 Hz frequency band.

A material-structure coupled design method to study the impact response of CFRP apron board for railway vehicle

It is of great significance to improve the design efficiency and guide material selection for carbon fiber reinforced polymer (CFRP) vehicle structures, thereby, contributing to lightweight high-speed trains. This study proposes a material-structure integrated design approach that bridges the computational relationship between design variables across multiple scales and the impact responses of CFRP vehicle structures. Computational models are constructed at the micro-scale, meso-scale, and macro-scale to capture the multi-scale characteristics of the CFRP structures. At micro-scale, finite element simulations are used to determine the effective properties of fiber bundles using a representative volume element (RVE) model. This information is then transferred to the meso-scale RVE model to calculate the homogenized mechanical properties of the lamina. Finally, a macro-scale model is established to investigate the damage mechanisms and impact resistance of the CFRP apron board against the projectile impact. The influences of design variables, such as fiber type and volume fraction, are analyzed to provide further insights into the design of CFRP apron boards.

Prospects for the development of drivetrain systems in trucks

The article presents the directions of development of drive systems in trucks. A database of vehicles and their technical data was developed. This data contains information about the drivetrain configuration. The external characteristics of the engines and the structure of the drivetrain were analyzed. It was found that the factors determining development are primarily economic and ecological aspects. It was noticed that, based on the configuration of the drive system, vehicles can be divided according to their purpose and type of transport. Vehicles intended for international transport are characterized by low gears and engines that achieve high torque at low engine speeds. Construction vehicles and vehicles intended for oversize transport are characterized by large gear ratios and torque amplification systems. The structure of electric vehicle drive systems is different from conventional vehicles. Gearboxes usually have two gears, drive axles may have integrated engines located next to the main gear or in the final drive position. The study also made it possible to outline the problem of the short range of such cars and the need for further work on increasing it.

Flow and heat transfer characteristics of hydrocarbon fuel in lightweight C/SiC regenerative cooling combustor

To meet the requirements of higher thermal protection ability and lower structural weight of regenerative cooling structures in advanced hypersonic vehicles, carbon-fiber-reinforced silicon carbide (C/SiC) composites with high permittable service temperatures and low densities are promising for application in thermal protection systems. In this study, four cylindrical regenerative cooling configurations applying C/SiC composites for a designated scramjet engine combustor are proposed, and the thermal protection performance under the influence of the cooling equivalence ratio (0.4∼1.0) and anisotropic thermal conductivity is studied. The results show that the C/SiC composites can significantly improve the heat resistance of the entire regenerative cooling structure owing to their relatively low thermal conductivity, which reduces the total heat flux transferred to the inner structure. The thermal protection ability can be maintained, whereas the coolant flow rate is reduced by 50%. C/SiC composites with higher thermal conductivities in the circumferential direction are beneficial for uniform temperature distribution. A flow distribution deterioration phenomenon caused by the thermal cracking of the coolant and the increasing flow resistance in the cooling channels can be observed under certain conditions, leading to a mass flow rate difference of 2.5 times among the cooling channels. Moreover, introducing C/SiC composites into the regenerative cooling structure design can significantly reduce the total structural weight by over 50% compared to traditional superalloys.

Features of the operation of the training stand “Electric vehicle motor” in determining the operation characteristics of electric transport

In the modern world, the problem of the ecological state of our planet is acute. The environmental situation depends on many factors, these include both natural phenomena and human actions. One solution to this problem is to replace traditional internal combustion engines with more environmentally friendly electric vehicles.THE PURPOSE. The objective of this study is to analyze the internal structure of an electric vehicle, based on the training stand “Electric Vehicle Motor”, as well as to study the functions of this device, located at the Kazan State Energy University.METHODS. The authors of the article processed and analyzed the capabilities of modern laboratory equipment that simulates the operation of a particular component of an electric vehicle.RESULTS. The technology of the laboratory bench operating the electric vehicle, together with the DVT Customer software, allows for full control of the electric motor, as well as monitoring and changing a large number of parameters that affect the operation of the entire device as a whole.CONCLUSION. Since electric vehicles are gaining more and more popularity every year, the demand for people capable of diagnosing, repairing, and even improving existing ones and developing new components and assemblies in the field of electric vehicles is growing significantly. Using the “Electric Vehicle Motor” stand for teaching technical subjects and conducting research work can serve as a good basis for the formation of a general knowledge base about electric transport, its structure, the operating principle of all the main elements, monitoring and diagnostics of an electric vehicle.

A physics knowledge-based neural network method for three-dimensional fracture mechanics of attachment lugs

The lug type joint serves as a critical connecting structure in aerospace vehicles, allowing for convenient assembly and disassembly, and transfer the load during service. However, cracks often initiate at the stress concentration location near the lugs hole, posing a significant threat to the safety of the aircraft structure. Therefore, evaluating the stress intensity factors for complex lug structures is of great significance. In this study, a physics knowledge-based neural network method of calculating the stress intensity factors of attachment lugs is proposed. Three types of cracked lug structures are analyzed: through-thickness crack in straight lug, quarter elliptical corner crack in straight lug and quarter elliptical corner crack in tapered lug. Various complex influencing factors in actual situations are also considered, such as the impact of the interference fit between the pin and the lug, as well as different loading directions and crack positions of tapered lugs. The stress intensity factor dataset generated by 3D finite element method, and then the neural network with its powerful learning ability and prior physical knowledge are used to achieve accurate fitting of the data. The results demonstrate that incorporating physical knowledge features significantly improves the model performance of the neural network. This method can be extended to analyze crack in structures with arbitrary geometry and complex loading conditions.

Efficient performance analysis and rapid evaluation for spot-welded stainless steel vehicles

Abstract The structural performance analysis and solder joint strength evaluation of spot-welded stainless-steel vehicles are associated with many working conditions, significant data, and repeated work. This will help researchers evaluate and improve calculation efficiency quickly. Taking the body structure of a spot-welded stainless-steel vehicle as the research object, this study conducted a finite element simulation analysis of its stiffness, static strength, mode, fatigue strength, and solder joint strength by the EN12663 standard. A rapid evaluation system for the solder joint strength was developed. The results showed that the performance of the vehicle body under various working conditions can meet the design requirements, and the evaluation results of the solder joint strength confirm the practicability and rapidity of the system, which can provide technical support for the subsequent improvement and optimization of vehicle body structures.

Dynamic Analysis of All-Terrain Vehicle Structure

Dynamic Analysis of All-Terrain Vehicle Structure

A Low-Cost 3D SLAM System Integration of Autonomous Exploration Based on Fast-ICP Enhanced LiDAR-Inertial Odometry

Advancements in robotics and mapping technology have spotlighted the development of Simultaneous Localization and Mapping (SLAM) systems as a key research area. However, the high cost of advanced SLAM systems poses a significant barrier to research and development in the field, while many low-cost SLAM systems, operating under resource constraints, fail to achieve high-precision real-time mapping and localization, rendering them unsuitable for practical applications. This paper introduces a cost-effective SLAM system design that maintains high performance while significantly reducing costs. Our approach utilizes economical components and efficient algorithms, addressing the high-cost barrier in the field. First, we developed a robust robotic platform based on a traditional four-wheeled vehicle structure, enhancing flexibility and load capacity. Then, we adapted the SLAM algorithm using the LiDAR-inertial Odometry framework coupled with the Fast Iterative Closest Point (ICP) algorithm to balance accuracy and real-time performance. Finally, we integrated the 3D multi-goal Rapidly exploring Random Tree (RRT) algorithm with Nonlinear Model Predictive Control (NMPC) for autonomous exploration in complex environments. Comprehensive experimental results confirm the system’s capability for real-time, autonomous navigation and mapping in intricate indoor settings, rivaling more expensive SLAM systems in accuracy and efficiency at a lower cost. Our research results are published as open access, facilitating greater accessibility and collaboration.

Drag reduction characteristics of the placoid scale array skin sup-ported by micro Stewart mechanism based on penalty immersed boundary method

Sharkskin performs an excellent flow drag reduction property, leading to numerous biomimetic research to obtain artificial drag reduction structures for underwater vehicles. The existing work mainly focused on replicating or simplifying the morphology of the placoid scale, however, such bionic structures cannot fully reproduce the drag reduction effects of sharks swimming in natural environments. This is because the existing research has not considered the influence of the multi-degree freedom motion characteristics of the placoid scale. Therefore, a new bionic drag reduction skin is proposed by combining micro Stewart mechanisms and placoid scales, where the micro Stewart mechanism is able to achieve the multi-degree freedom motion characteristics. The numerical results indicate that micro Stewart mechanisms inhibit the generation and development of the streamwise and spanwise vortex structures in the bionic placoid scale array, which can delay flow separation and improve the drag reduction effect of the placoid scale array. Compared with the bionic placoid scale skin and the blade groove skin without multi-degree freedom motion foundation, the new bionic skin achieves relative drag reduction efficiency of 15.78 % and 14.18 % at maximum, respectively, by reasonably adjusting the bionic skin parameters including the leg stiffness, leg damping, upper platform mass, upper platform center of mass height of the micro Stewart mechanism and the skin element distribution spacing. The research presents a novel sharkskin bionics design and reveals the mechanism of skin drag reduction to some extent.

Static mechanical properties and failure behaviors of self-piercing riveted joints in aluminum alloy 5A06 after aging

This paper conducts an investigation on the static mechanical properties and failure behavior of self-piercing riveted joints in aluminum alloy 5A06 after being subjected to the aging process. The study involves three distinct categories of joint specimens: original specimens, 1-year aged specimens and 1-year aged specimens that have been additionally heat-treated at 200 °C. The research findings affirm that strain aging is responsible for a reduction in the peak strength of the joints. Furthermore, the weakest failure chain within the self-piercing riveted joint shifts towards the upper sheet due to a more significant reduction in internal stress experienced by the upper plate. This leads to a failure model characterized by upper sheet pull-off. Through Weibull distribution analysis, it has been established that the 5 % lower limit value for the strength of the SPR joint experiences an 86 % decline following 1-year aging. In practical terms, this means that for a vehicle structure with 7000 riveting points will lose an overall structural strength equivalent to the initial strength of 1000 riveting points within one year.

Development And Characterisation Of Natural Hybrid Composites Using Abaca, Basalt, Glass Fibres

This paper proposes some considerations that are related to the impact protection of the battery pack, with particular reference to the side impacts against a fixed obstacle, such as a pole, We manufacture our battery cases from BASALT fiber, GLASS fiber(20% & 40%) in the form of sandwich composites material using Epoxy. The excellent properties of the fiber composite construction make the battery enclosure a supporting element of the vehicle structure.

Study on the effect of high temperature on the mechanical properties of composites plates containing initial defects

In this study, against the background of the high temperature environment faced by hypersonic vehicles, an in-depth study is carried out to investigate the influence of temperature on the mechanical properties of reinforced wall plates of composites containing initial defects. First, the in-plane shear mechanical property data and failure morphology of two groups of specimens of T1100/5405 composites at different test temperatures (25°C, 150°C) were obtained through experimental tests. The tests show that high temperature accelerates the damage failure process of the wall plate structure, the shear capacity of the wall plate is weakened, and the ultimate load decreases by 26.06%. Secondly, a numerical model based on the CZM and the CDM of the composite is established, and the accuracy of the model is verified by combining with the test results. The work carried out in this paper has certain engineering application value for the design of composite structures for hypersonic vehicles.

Research on Dynamics Characteristic of The Filling Liquid Tank

The dynamics characteristic of the rocket tank with liquid propellant in it, which takes the large part of a carrier rocket, make a great influence to the whole rocket. The tank of some model was investigated systematically by the PATRAN finite element software. Firstly, it established a finite element modal of the tank and calculated the modal frequency and shape of the empty or filling tank by the virtual fluid mass and acoustic-structure coupling analysis. Then, it contrasted the veracity and applicability of the two methods and investigated how the liquid depth and density and the middle clapboard’s thickness influenced the immanent frequency of tank. Further, the filled tank’s characteristic of response was researched by the coupled acoustic-structural analysis. Finally, it investigated how the liquid depth and density influenced the filling tank’s characteristic of response. The main conclusions are shown below:1.The result of the filling tank’s modal is approaching to the test.2.Augmenting the density of liquid reduces the modal frequency of tank and increases the pulsant pressure of liquid.3.Raising the depth of liquid reduces the modal frequency of tank and increases the pulsant pressure of liquid.The paper’s achievement and conclusion will help to avoid the coupling between the launch vehicle structure and propulsion system and improve the dynamic stability. It also can provide references for design of the new tank according to the result.

Investigations on the Johnson-Cook Constitutive and Damage-Fracture Model Parameters of a Q345C Steel

Due to the rapid development of high-speed trains, the service safety of vehicle body materials and structures has become a focal point in transport and impact engineering. Numerical simulations on the collision resistance of vehicle materials and structures are crucial for the safety assessment and optimal structural design of high-speed trains but have not been fully investigated due to the lack of damage model parameters. This study focuses on the Johnson-Cook (J-C) constitutive and damage-fracture models of a typical vehicle material, Q345C steel. A series of mechanical tests are conducted on the Q345C steel, including the quasi-static and dynamic compression/tension tests, quasi-static tension tests at different temperatures, and fracture tests along different stress paths, using the material test system and the split Hopkinson pressure/tension bar. Then, the parameters of the Johnson-Cook constitutive and damage-fracture models are calibrated based on the experimental results. In terms of the damage parameters related to stress paths, a new method of combining experiments and simulations is proposed to obtain the real, local fracture strains of the Q345C steel samples. This method allows the measurements of equivalent plastic strain and stress triaxiality histories under nonlinear stress paths, which are hardly accessible from individual experiments, and facilitates the accurate calibration of stress-path-related damage parameters. In addition, a high-speed plate penetration test is used to validate the J-C parameters, which can be directly implemented in the commercial finite element software Abaqus. The projectile trajectories from the simulation and experiment agree well with each other, demonstrating the reliability of the model parameters for impact scenarios and the efficiency of the experimental procedures utilized for calibration.

Predicting ground vibrations from railway tunnels using an improved 2.5D FEM-PML model with soil spatial variability

PurposeThis study establishes a method for predicting ground vibrations caused by railway tunnels in unsaturated soils with spatial variability.Design/methodology/approachFirst, an improved 2.5D finite-element-method-perfect-matching-layer (FEM-PML) model is proposed. The Galerkin method is used to derive the finite element expression in the ub-pl-pg format for unsaturated soil. Unlike the ub-v-w format, which has nine degrees of freedom per node, the ub-pl-pg format has only five degrees of freedom per node; this significantly enhances the calculation efficiency. The stretching function of the PML is adopted to handle the unlimited boundary domain. Additionally, the 2.5D FEM-PML model couples the tunnel, vehicle and track structures. Next, the spatial variability of the soil parameters is simulated by random fields using the Monte Carlo method. By incorporating random fields of soil parameters into the 2.5D FEM-PML model, the effect of soil spatial variability on ground vibrations is demonstrated using a case study.FindingsThe spatial variability of the soil parameters primarily affected the vibration acceleration amplitude but had a minor effect on its spatial distribution and attenuation over time. In addition, ground vibration acceleration was more affected by the spatial variability of the soil bulk modulus of compressibility than by that of saturation.Originality/valueUsing the 2.5D FEM-PML model in the ub-pl-pg format of unsaturated soil enhances the computational efficiency. On this basis, with the random fields established by Monte Carlo simulation, the model can calculate the reliability of soil dynamics, which was rarely considered by previous models.