Present work deals with the failure analysis of fuel pump in transport utility vehicles. The fuel pump assembly failed at 70536km. Various types of failures in pump and its different components are analyzed. Failure mode and effect analysis (FMEA) of the acquired data has been carried out. The pump components with substantial contribution in failure are determined using risk priority number analysis and the failure causes are postulated. Using scanning electron microscopy (SEM) for pump parts as rollers and cam plates the types failures are observed. Presence of water in fuel tank indicated the reason for rusting of bottom surface of tank. Pitting failure due to rust particles has been identified in pump parts after SEM observations. Energy Dispersive Spectroscopy (EDS) of pump parts has also been carried out to identify levels of unnormalized constituent elements responsible for failure. From EDS presence of oxygen responsible for oxidation reaction with iron is identified. Significant percentage of oxygen at different locations indicated the presence of moisture in the system. Remedial measure to avoid pump failure has been suggested in present work.
The common rail fuel injection system is finding increasing use engines as it has the potential to drastically cut emissions and fuel consumption. This system provides control of many important parameters linked to the injection system. It has a wide range of applications, From small to heavy-duty engines.
PPT describes the engine performance parameters of the I.C. engine.
Engine performance is an indication of the degree of success of the engine performs its assigned task, i.e. the conversion of the chemical energy contained in the fuel into the useful mechanical work. The engine performance is indicated by the term efficiency, η. Five important engine efficiencies and other related engine performance parameters are:
Power
Indicated Thermal Efficiency (ηith)
Brake Thermal Efficiency (ηbth)
Mechanical Efficiency (ηm)
Volumetric Efficiency (ηv)
Relative Efficiency or Efficiency Ratio (ηrel)
Mean Effective Pressure (Pm)
Specific Fuel Consumption (sfc)
Fuel-Air or Air-Fuel Ratio (F/A or A/F)
Calorific Value (CV)
Power:-
The main purpose of running an engine is to obtain mechanical power.
Brake Power (B.P.)
The power developed by an Engine at the output shaft is called the brake power.
Brake Power= Brake Workdone/Time
B.P.=BWD/sec.
Indicated power (I.P.)
The total power developed by Combustion of fuel in the combustion chamber is called indicated power.
Indicated Power= Indicated Workdone/Time
I.P.=IWD/sec.
Frictional Power (F.P.)
The difference between I.P. and B.P. is called frictional power (f.p.).
FP = IP – BP
Thermal Efficiency (ηth)
Thermal efficiency is the ratio of Power to energy supplied by the fuel.
ηth= Power/ Energy
In I.C. Engine, thermal efficiency can be classified into two categories i.e.
Indicated Thermal Efficiency (ηith)
Indicated thermal efficiency is the ratio of indicated power to the heat supplied or added.
ηith= IP/Qs
2. Brake Thermal Efficiency (ηith)
Brake Thermal Efficiency is the ratio of brake power to the heat supplied or added.
ηbth= BP/Qs
Volumetric Efficiency (ηv)
This is one of the most important parameters which decide the performance of four-stroke engines. Four stoke engines have distinct suction stoke, volumetric efficiency indicates the breathing ability of the engine.
Volumetric efficiency is defined as the ratio of actual flow rate of air into the intake system to rate at which the volume is displaced by the system.
ηv= (푚 ̇"a/a" )/(푉푑푖푠푝푎푐푒푑 푋 푁/2)
"a"= Inlet density is taken atmospheric air density
N= Number of the cylinder in use
The heart of an automobile is its engine, and the heart requires a constant and ingenuous supply of blood, fuel in this case. There had been carburetors faithfully doing this holy work, but technology never seizes to move up. Therefore, the latest offering is the fuel injector for petrol engin es. Though it all started with a simple objective of supplying a controlled amount of fuel at proper intervals of time, it’s, as of now, not as simple as that. With emission norms getting stricter and changing trends in engine technology – high-speed engines, Variable displacement engines, Hybrid engines, etc – it became more and more of a necessity than a luxury to improve the fuel supply system.
Today’s fuel injection unit not only improves engine performance, but also helps in giving a cleaner exhaust that too with a increased fuel economy. The objectives can be attained using a microprocessor that directs the injector using a number of various input parameters. These parameters include manifold temperatures, throttle position, ignition timing, engine speed, load, and a lot more of other factors. The various strategically placed sensors measures these physical quantities and convey the same to the processor in electronic signals. The paper deals with the brief functionality and basic concept of operation of a modern fuel injector used in petrol engines.
in this presentation , the different engine inefficiencies has been discussed including all sort of friction losses which affects the brake power of the engine. It includes volumetric efficiency, thermal efficiency, IMEP, BMEP, brake power etc.
The common rail fuel injection system is finding increasing use engines as it has the potential to drastically cut emissions and fuel consumption. This system provides control of many important parameters linked to the injection system. It has a wide range of applications, From small to heavy-duty engines.
PPT describes the engine performance parameters of the I.C. engine.
Engine performance is an indication of the degree of success of the engine performs its assigned task, i.e. the conversion of the chemical energy contained in the fuel into the useful mechanical work. The engine performance is indicated by the term efficiency, η. Five important engine efficiencies and other related engine performance parameters are:
Power
Indicated Thermal Efficiency (ηith)
Brake Thermal Efficiency (ηbth)
Mechanical Efficiency (ηm)
Volumetric Efficiency (ηv)
Relative Efficiency or Efficiency Ratio (ηrel)
Mean Effective Pressure (Pm)
Specific Fuel Consumption (sfc)
Fuel-Air or Air-Fuel Ratio (F/A or A/F)
Calorific Value (CV)
Power:-
The main purpose of running an engine is to obtain mechanical power.
Brake Power (B.P.)
The power developed by an Engine at the output shaft is called the brake power.
Brake Power= Brake Workdone/Time
B.P.=BWD/sec.
Indicated power (I.P.)
The total power developed by Combustion of fuel in the combustion chamber is called indicated power.
Indicated Power= Indicated Workdone/Time
I.P.=IWD/sec.
Frictional Power (F.P.)
The difference between I.P. and B.P. is called frictional power (f.p.).
FP = IP – BP
Thermal Efficiency (ηth)
Thermal efficiency is the ratio of Power to energy supplied by the fuel.
ηth= Power/ Energy
In I.C. Engine, thermal efficiency can be classified into two categories i.e.
Indicated Thermal Efficiency (ηith)
Indicated thermal efficiency is the ratio of indicated power to the heat supplied or added.
ηith= IP/Qs
2. Brake Thermal Efficiency (ηith)
Brake Thermal Efficiency is the ratio of brake power to the heat supplied or added.
ηbth= BP/Qs
Volumetric Efficiency (ηv)
This is one of the most important parameters which decide the performance of four-stroke engines. Four stoke engines have distinct suction stoke, volumetric efficiency indicates the breathing ability of the engine.
Volumetric efficiency is defined as the ratio of actual flow rate of air into the intake system to rate at which the volume is displaced by the system.
ηv= (푚 ̇"a/a" )/(푉푑푖푠푝푎푐푒푑 푋 푁/2)
"a"= Inlet density is taken atmospheric air density
N= Number of the cylinder in use
The heart of an automobile is its engine, and the heart requires a constant and ingenuous supply of blood, fuel in this case. There had been carburetors faithfully doing this holy work, but technology never seizes to move up. Therefore, the latest offering is the fuel injector for petrol engin es. Though it all started with a simple objective of supplying a controlled amount of fuel at proper intervals of time, it’s, as of now, not as simple as that. With emission norms getting stricter and changing trends in engine technology – high-speed engines, Variable displacement engines, Hybrid engines, etc – it became more and more of a necessity than a luxury to improve the fuel supply system.
Today’s fuel injection unit not only improves engine performance, but also helps in giving a cleaner exhaust that too with a increased fuel economy. The objectives can be attained using a microprocessor that directs the injector using a number of various input parameters. These parameters include manifold temperatures, throttle position, ignition timing, engine speed, load, and a lot more of other factors. The various strategically placed sensors measures these physical quantities and convey the same to the processor in electronic signals. The paper deals with the brief functionality and basic concept of operation of a modern fuel injector used in petrol engines.
in this presentation , the different engine inefficiencies has been discussed including all sort of friction losses which affects the brake power of the engine. It includes volumetric efficiency, thermal efficiency, IMEP, BMEP, brake power etc.
This slides are about inline injection pump and calibration of the pumps .The working of the pump is described in simple words and with examples of daily usable devices.
It is a free-piston engine coupled with a linear alternator.
It converts chemical energy from fuel into electric energy. Because of its versatility, low weight and good efficiency, it can be used in a wide range of applications, although it is of special interest to the mobility industry as range extenders for electric vehicles.
This slides are about inline injection pump and calibration of the pumps .The working of the pump is described in simple words and with examples of daily usable devices.
It is a free-piston engine coupled with a linear alternator.
It converts chemical energy from fuel into electric energy. Because of its versatility, low weight and good efficiency, it can be used in a wide range of applications, although it is of special interest to the mobility industry as range extenders for electric vehicles.
Maximize Intrinsic Reliability, through focus in early project phases - Uptim...Mohammad Naseer Uddin
Implementing a reliability program in the early phases of a new capital project (engineering design, procurement, construction and commissioning) gives the greatest benefits. The reliability initiatives taken during the initial phases of the life cycle of a project results in maximising the intrinsic reliability of the assets, thereby delivering higher uptime performance, improved safety and reduced operation and maintenance costs for the project’s life. For more information contact naseer70@gmail.com
Failure Analysis of Feedstock Preheater Unit of the Kaduna Refinery using Fai...theijes
The use of failure modes effects and criticality analysis (FMECA) as a failure or reliability analysis tool, checks the probabilities that an item will perform a required function under stated condition(s) when operated properly.Failure analysis of process equipment is an important issue in any process industry. This study aims at analyzing the failure of feedstock preheater unit of the Kaduna Refining and Petrochemicals (KRPC), Fluid Catalytic Cracking Unit (FCCU), using the failure mode, effects and criticality analysis (FMECA). The unit failure and its effects were identified through seven sub-units (fresh feed surge drum, heavy naphtha exchanger, light cycle oil exchanger, heavy cycle oil exchanger, fractionator bottom exchanger, feed preheater and fresh feed charge pump), using the failure mode effects analysis (FMEA). Both quantitative and qualitative criticality analyses (CA) were used for failure analysis of the unit (feedstock preheater). For the qualitative analysis, items risk priority number (RPN) were computed and it was found that, four sub-units (heavy naphtha exchanger, main fractionator bottom exchanger, feedstock preheater, and fresh feed charge pump) had their Risk Priority Number (RPN) greater than 200, these sub-units are said to be critical. Three of the sub-units (fresh feed surge drum, light cycle oil exchanger, and heavy cycle oil exchanger) had their RPN less than 200, these sub-units are said to be less critical. For the quantitative analysis, items criticality number (Cr) were computed and it was found that most of the sub-units had their Cr>0.002. In addition, the results of the criticality matrix showed that, eight out of the sixteen failure modes identified were above or closely below the criticality line. Finally, FMECA was effectively used for failure analysis of the feedstock preheater andpredictive maintenance was recommended.
Maintenance cost reduction of a hydraulic excavator through oil analysisIJERA Editor
The purpose of this article is to present the economic advantages that the Oil Analysis can offer to companies
operating with hydraulic excavators. The financial advantages are the result of lower maintenance costs and
increased productivity of the equipment. Real situations of an infrastructure construction company in which there
were mechanical failures that could have been avoided if implemented with efficiency analysis of lubricants.
Analysis of failure of Brakes due to leakages of cylinder through CFDIOSR Journals
Today’s world is very fast moving and in this world we all are well understand that the how
important brake is? Effectiveness of braking system are essentials part to avoid accidents and save life. Also
majority of accidents in vehicles are happen due to chassis failure and braking failure. Here I take the subject to
understand the causes of failure of hydraulic brake systems in SUV. The brakes are the most important
active safety of a car and one of its key pieces. However, many drivers do not seem to understand it well.
According to a statistics, about 40% of the defects detected by the ITV correspond to the brakes. It is not enough
to bring the car to the shop when something goes wrong.
Leakage is major problem in TMC. In any case if tmc leak it may leads to accident. So
leakage and performance of tmc is most important. Various parts of tmc such as piston, spring does not leak.
The body of tmc may leak as well seals used in assembly of piston.
In this project the different reasons of leakages are finding and simulation with CFD are carried out
CONTROL OF EXHAUST EMISSIONS OF TWO STROKE AND FOUR STROKE COPPER COATED SPAR...IAEME Publication
Alcohols are important substitutes for gasoline, as their properties are comparable to gasoline. They are renewable in nature. Investigations were carried out to determine exhaust emissions of two stroke and four stroke of single cylinder, spark ignition (SI)engine having copper coated engine [CCE, copper-(thickness, 300 μ) coated on piston crown and inner side of cylinder head] provided with catalytic converter with copper as catalyst with methanol blended gasoline (80% gasoline and 20% methanol by volume) and compared with conventional engine (CE) with neat gasoline operation. Carbon monoxide (CO) and un-burnt hydrocarbons (UBHC) are the exhaust emissions from SI engine. Breathing of these emissions causes human hazards and also they cause environmental disorders. Hence control of these emissions is an urgent task. Exhaust emissions were varied with different values of brake mean effective pressure (BMEP). The engine was provided with catalytic converter with copper as catalyst. There was provision for injection of air into the catalytic converter. CCE showed improvement in the pollutants when compared with CE with both test fuels. Four-Stroke engine decreased exhaust emissions effectively in comparison with two-stroke engine with both versions of the engine. Catalytic converter with air injection significantly reduced pollutants with different test fuels on both configurations of the engine.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Vibration measurement and spectral analysis of chassis frame mounted structur...Dr.Vikas Deulgaonkar
Chassis mounted structure is a base component for shelters or containers mounted on heavy transport vehicles. When the vehicle is driven in rough terrains or during off-road transportation this structure has a significant role in protecting the sophisticated cargo and intelligent tracking systems placed inside the shelters. During off-road transportation or warhead conditions the vehicle is subjected to large unevenness in load due to road or soil irregularities in rough terrains, which causes vibrations to be induced in the vehicle. As the nature of vibrations induced in vehicle during travel on off-road or cross-country terrains is random and unpredictable, there is a concern to analyse the vibration response of chassis and chassis mounted structures is needed. Present work deals with vibration measurement and spectral analysis of a chassis mounted structure designed for off-road and commercial transport vehicles. The road profile on which the vibration measurement has been carried out includes paved road and cross-country terrain segments. The vibration measurement has been carried at three different vehicle speeds. Signal analysis procedure for the acquired test data is discussed. The chassis mounted structure under concern is intended to hold two shelters or containers. From the vibration measurement at critical locations, g-(RMS) and g-(peak) values for paved and cross-country roads have been found out. Power spectral density values have also been found on chassis and structure for the same transport situations. Major inferences include the evaluation of minimum and maximum g-values (peak & RMS) on chassis and chassis mounted structure. Power spectral density graphs are constructed from which the dominant frequency for both road profiles is found out
Strain characteristicts in a unique platform integrated with truck chassis un...Dr.Vikas Deulgaonkar
Present work deals with the process of determination of strain in a structural member under intense load for a typical Indian truck. Characteristics of mechanical strain at various locations on the structure are assessed. Strain gauge selection along with process of locating significant positions for strain measurement on the structure is described. Experimental process is employed for strain measurement. From the experimentation carried on the structure, the results reveal that the tri-axial stresses are dominant over bi-axial and uni-axial stresses at critical points on the structure. Contemporary data acquisition systems are utilized to acquire the strain signals. Computer simulation is carried out to have perception of the behavior of the structure under consideration. Static and Dynamic strain measurement is carried out at constant speeds on various tracks. As there are no assumptions involved in measurement like theoretical modeling and analysis, the experimental method provides the actual strain/stress values at the selected locations. Locations have been selected at cross-members where they are supported at the longitudinal members. As the stresses at these locations are not unidirectional, rosettes have been used to acquire strain in three directions. Linear strain gauges used at locations on longitudinal members.
Review and diagnostics of noise and vibrations in automobiles ijmer 2011Dr.Vikas Deulgaonkar
The present work describes various automotive noise & vibration sources and their contribution. Noise and vibration reduction technique is studied through energy flow path. Various international and Indian standards for vehicles consider two types of noise measurement i.e. pass by noise and stationary noise. This paper discusses the appropriateness of SN test for in use vehicle. A methodology for interior noise source identification and its analysis is descried. Two vehicles of same class but of different makes were compared and evaluated for interior noise and vibration levels. The effectiveness of the firewall, silencers and engine mounts are checked and compared. The correlation between pressure and vibration levels of different sources with acoustical and structure transfer path are studied. Basic causes, design guidelines and validation techniques using lab simulation and data acquisition are discussed. Application of damping technology using viscous materials to control noise and vibration in vehicles is described.
Optimization in mechanical seal design for api 682 category i applications ij...Dr.Vikas Deulgaonkar
The paper covers development of mechanical seal design to optimize the adaptive part for API 682 category 1 applications. Under the guidelines of Forschungskuratorium Maschinenbau (FKM) the static strength is investigated using local stresses. Static structural load case is carried out on the adaptive parts with non-average element-nodal stresses. The new design performance is investigated using finite element analysis in terms of equivalent stress. Improved features in the design and their effects on manufacturing benefits, seal performance leading final product cost/weight optimization are discussed. Evaluation of centrifugally cast stainless steel raw material instead of forged wrought raw material is discussed.
Noise and vibrations in automobiles review and diagnostics ijmperd 2011Dr.Vikas Deulgaonkar
The present work describes various automotive noise & vibration sources and their contribution. Noise and vibration reduction technique is studied through energy flow path. Various international and Indian standards for vehicles consider two types of noise measurement i.e. pass by noise and
stationary noise. This paper discusses the appropriateness of SN test for in use
vehicle. A methodology for interior noise source identification and its analysis is descried. Two vehicles of same class but of different makes were compared and evaluated for interior noise and vibration levels. The effectiveness of the firewall, silencers and engine mounts are checked and compared. The correlation
between pressure and vibration levels of different sources with acoustical and structure transfer path are studied. Basic causes, design guidelines and validation techniques using lab simulation and data acquisition are discussed. Application of damping technology using viscous materials to control noise and vibration in vehicles is described.
Modeling and finite element analysis for a casting defect in thin wall struct...Dr.Vikas Deulgaonkar
The casting of pump impeller blades is a difficult operation due to its thin wall structure. In the casting process for thin wall impeller structure, the prediction of shrinkage defect is a one of the important issue and failure of such thin wall structure is a commonly encountered problem. The non-uniform heat transfer rate is the main cause of such failure. The uniformity of heat transfer rate may enhance by placing the runner at appropriate position and riser based on the geometrical attributes. The flow of liquid metal and its solidification has time based temperature variation, shrinkages and porosity distributions in such structures. An attempt is made for the analysis of optimization in the placement of runner and riser through this experimentation. The experiment contains the analysis of finite element simulation of fluid flow and solidification of metal execution at various temperatures, prediction of shrinkages based on the geometry of the casting and flow curvature and porosity distribution. This work also focuses on the prediction of casting defects in aluminum thin wall pump impeller structure using commercially available software (ANSYS-FLUENT). The experimental validation of the simulation result is also done to confirm the same.
Mechanics of strain propogation in members of a platform structure devised fo...Dr.Vikas Deulgaonkar
This research paper deals with the mechanics of mechanical strain and its propagation in a steel structure through experimental analysis of a distinctive platform integrated with vehicle chassis. Dynamic values of strain components are evaluated on all constituents of the platform structure at various critical locations. Strain gauge classification for experimentation of the platform structure is described. Different nature of stresses at significant locations is evaluated with the aid of linear and rosette gauges.
Present-day data acquisition systems are utilized for acquiring the strain values. Static and dynamic strain values are evaluated for constant speeds on cross-country track.The experimentation reveals exact strain values, as there are no assumptions for measurement. Cross-country road characteristics are exactly simulated for this measurement process.
The optimum vehicle speed is maintained for the entire measurement process. Tri-axial values of strains are calculated using rosette reduction technique. Linear strain values are evaluated on longitudinal members of the platform structure. Values of strain acquired different locations reveal the critical areas of the structure for possible design modifications.
Mathematical analysis of section properties of a platform integrated with veh...Dr.Vikas Deulgaonkar
The present work depicts mathematical behavior of a vehicle mounted platform/frame integrated with chassis structure in terms of plane stresses and plane strains for non-uniform loads. The load type considered in present work is concentrated load for which the mathematical model is formulated. A different type of combination of longitudinal and cross members in platform/frame design is formulated. The dimensions of platform members are determined using IS standards. After analysis of all possible combinations of longitudinal and cross members present design is anticipated. Section properties of longitudinal and cross members of the platform are determined & deduction of bending stress and shear force based on the load pattern are the fundamental steps in design and analysis of platform structure. The peculiarity of this analysis is the calculation of combined section modulus of three members. These are evaluated by excel programs developed indigenously.
Chassis mounted structures provide a levelled base to the transport vehicles intended for on-road and off-road driving. These structures acts as cushioning elements to sophisticated cargos like intelligent tracking systems placed in shelters’ closed environment. These structures need sufficient strength and rigidity to withstand the load variations arising from tire-road interactions during rough road travel. Such structures need special attention during the design phase itself in order to improve the specified payload carrying capacity with optimized dimensions. Present paper focuses on formulation of a specialized structure mounted on chassis intended to carry shelters. A scaled prototype is manufactured and tested for different grade-load combinations. This is done through experimental strain measurement and analysis of the results. The data is acquired for nine different load magnitudes and is categorised into three sets as low, moderate and high magnitudes. Interrelation between the stress/strain values acquired during each load and gradient state is developed. The structure behaviour is hypothesized through the gradient strain measurement outcomes. Major design concerns include the spacing & orientation of cross-members, load locations on the structure and the road profiles. Cross-country and rough road terrain behavior of the structure is attempted in present work.
Finite element simulation and investigation of thin wall impeller casting ija...Dr.Vikas Deulgaonkar
In case of casting of thin wall impeller structure, the prediction of shrinkage defect is a difficult operation and failure of such thin wall structure is a commonly encountered problem. Such failures are due to non-uniform heat transfer rate. The uniformity of heat transfer rate may enhance by placing the runner at appropriate position and riser based on the geometrical attributes. An attempt is made for the analysis of optimization in the placement of runner and riser. The present work focuses on the simulation of aluminum thin wall pump impeller blade using commercially available software (ANSYS) and experiments for optimum placement of risers and reducing defects.
Finite element analysis of chassis integrated structure for tractor trolley i...Dr.Vikas Deulgaonkar
This paper deals with the design evaluation of chassis integrated structure intended to carry tractor trolleys. This structure is either bolted along with tractor trailer chassis or attached to the trolley using special attachments. Such structure is located in between the trolley chassis and tractor trolley. The role of this structure is to provide a support to the trolley during transportation in agricultural terrains. This structure transmits and upholds the load variations during tractor travel in agricultural terrains. Present work deals with design evaluation of one such structure. In this work, the structure under consideration is designed to house and support one axle semi-trailer trolley. Locations of attachment of the structure to the chassis or trolley depend upon the weight and size restrictions mentioned in Indian Standards. Major design considerations for the structure include height of the semi-trailer trolley, nature of load or cargo placed inside the trolley, restrictions on axle load and tractor geometry parameters as departure angle & ground clearance. In order to evaluate structure characteristics of stress and deflection computer simulation is carried for the road-load conditions. Road profiles for structure simulation and analysis include typical Indian agricultural terrains comprising of black cotton soil and soil lumps.
Finite element analysis of center pin and bracket of jig fixture assembly ijm...Dr.Vikas Deulgaonkar
The manufacturing industry caters the range of products to satisfy the ever changing market needs.
To overcome the increasing production demands, the industry implies various techniques. We need a technique for
increasing the production of drilling two holes on a Railway Pinion, improve the quality of product and reduce the
operation time. This project aims to design the Jig and Fixture for the same. The 3-dimensional Computer Aided Model
of the components is made using CATIA V5-R21 software. To study the behavior of component, simulation is carried out.
Preprocessing of the CAD model is carried in Hypermesh software. Boundary conditions are applied using physical
situations of the components. Finite element analysis of the components is done, and the results obtained are compared
with the theoretical analysis and also with the available literature. The stresses and deformations are found within desired limits. Using FE analysis, the parts are manufactured and assembled.
Finite element analysis and experimental simulation of chassis mounted platfo...Dr.Vikas Deulgaonkar
Chassis mounted platform is an intermediate component between vehicle chassis and chassis mounted shelter, and is intended to act as a levelled base for shelters. Shelters in combat vehicles provide a closed stipulated environment to computerized tracking systems, sophisticated defense combat equipments to suit the operational and environmental requirements during warhead situations. Platform carries transfers & sustains unevenness in load arising from the road or soil irregularities during off-road vehicle travel. Present work deals with development, evaluation and improvement of one such platform for 8x8 vehicles. In this work, the platform under consideration is designed to accommodate two shelters, each being secured to the platform using standard twist locking arrangements. Securing locations are dependent on the size & weight of the commodity to be placed inside shelter. Major design ruminations of the platform include nature & pattern of load, flange orientations of channel sections, span between webs of consecutive channels, axle load distribution and vehicle geometry constraints as ground clearance & departure angle. Finite element analysis is carried out in to order evaluate stress and deflection in the present platform configuration. Experimental strain measurement at critical locations on the platform is carried at Automotive Research Association of India (ARAI) to evaluate the performance of the platform under specified load-speed conditions. Relation between experimental stress values and strain gauge locations on the platform is assessed for different load magnitudes.
Experimental investigation of inmitiable platform on heavy vehicle chassis ij...Dr.Vikas Deulgaonkar
This research paper deals with the experimental investigation of a unique platform structure by evaluation of strain through experimental technique. Strain characteristics at critical locations on the structure are evaluated for dynamic load. Strain gauge categorization for experimentation of the platform structure is described. Different nature of stresses at significant locations is evaluated with the aid of linear and rosette gauges. Present-day data acquisition systems are utilized for acquiring the strain values. Static and dynamic strain values are evaluated for constant speeds on cross-country track.
The experimentation reveals exact strain values, as there are no assumptions for measurement. Cross-country road characteristics are exactly simulated for this measurement process. The optimum vehicle speed is maintained for the entire measurement process. Tri-axial values of strains are calculated using rosette reduction technique. Linear strain values are evaluated on longitudinal members of the platform structure. Values of strain acquired different locations reveal the critical areas of the structure for possible design modifications
Development and validation of chassis mounted platform design for heavy vehic...Dr.Vikas Deulgaonkar
Hand calculations, finite element (FE) analysis and experimental validation of chassis mounted platform design for defence and commercial off-road vehicles have been attempted in this work. The work was commenced with the thorough study of platform configuration, loading pattern, platform mount location & configuration on the vehicle chassis and relevant vehicle characteristics. Calculation of section modulus, shear force and bending moment of various structural members under specified loading has been carried out before proceeding with the FE modeling and analysis of platform. FE model of the chassis mounted platform has been made using shell elements and the boundary conditions have been imposed based on the loading pattern with an assumption of rigid vehicle chassis. Static and gradient analyses of the platform have been carried out for full scale and reduced scale prototype FE models. Experimental strain measurement at critical locations under different static and gradient loads has been carried out for design validation of chassis mounted platform using the scaled prototype. Close correlation has been found between the experimental stress values and FE stress analysis results for static and gradient load conditions. From the entire load tests conducted, it is observed that the strain values in rear portion are less as compared with those in front and mid portions of the platform in-spite of the rear overhang provision.
Development and design validation of pneumatic tool for stem seal collet fi...Dr.Vikas Deulgaonkar
The present work deals with the design development and design validation of special purpose pneumatic tool to optimize the steps in assembly and consequently production process. An attempt is made to develop a pneumatic tool that uses power of compressed air to generate a force enough to press the stem seal and the collet, collet cup collectively. Detailed calculations of section properties of various members of the tool assembly are carried out. Calculation for force to be generated is done by considering possibilities i.e. hydraulic generation and pneumatic. Prior to fabrication, detailed CAD modeling of each component of assembly is carried out using CATIA V5 software which gives a correct perception of the assembly and its components. Fabrication of each component of the assembly is carried out by various manufacturing processes as Grinding, milling, drilling. To enhance surface hardness induction hardening is carried out. Close correlation between the calculated and generated force validates the design.
Design evaluation of chassis mounted platform for off road wheeled heavy vehi...Dr.Vikas Deulgaonkar
Chassis mounted platform is an intermediate component between vehicle chassis and shelter, and acts as a levelled base for shelters. Platform transfers & sustains unevenness in load arising from the road or soil irregularities during vehicle travel in rough terrains. Present work deals with development, evaluation and improvement of one such platform. In this work, the platform under consideration is designed to accommodate two shelters, each being secured to the platform using standard twist locking arrangements. Securing locations are dependent on the size & weight of the commodity to be placed inside the shelter. Major design modifications of the platform include nature & pattern of load, flange orientations of channel sections, span between webs of adjacent channels, axle load distribution and vehicle geometry constraints as ground clearance & departure angle. Hand calculations, computer aided design and finite element analysis are carried to evaluate the stress and deflection for different platform configurations. Road profiles for platform analysis include rough road and cross-country terrains. Experimental strain measurement at critical locations on the platform is carried out to evaluate the performance of the platform under specified load-speed conditions. Mathematical relation between experimental stress values and strain gauge locations on the platform is developed for different load magnitudes and loading patterns.
Design and analysis of state transport (s.t) utility vehicle ~ bus ijvss 2019Dr.Vikas Deulgaonkar
Passenger transport is an inseparable ingredient of public transport system for developing and developed nations. In present work design and analysis of state transport utility vehicle ~ bus is carried out. Present paper focuses on the design enhancements in structural features of sub and superstructure without any alterations on the chassis provided by OEMs. Limiting dimensions of bus as prescribed by automotive industry standard and central motor vehicle rules are the design constraints accounted in the present work. This work was commenced with the thorough study of sub and superstructure configurations, seat locations, passenger load patterns, locations of doors, windows & emergency exits and other relevant bus attributes. Hand calculations for evaluation gross section modulus of chassis and cross member combination are presented. Usage of shear force and bending moment diagrams to evaluate the stress and deflection for the proposed load patterns is made before proceeding for finite element analysis. Finite element modelling and analysis of the sub and super structure combination is carried using shell elements with the presumption that chassis of the bus is rigid. Roll-over analysis of bus for the present configuration is presented.
Analysis of vibration characteristics of transport utility vehicle by finite ...Dr.Vikas Deulgaonkar
Present work deals with the design and analysis vibration characteristics for transport utility vehicle. The transport utility vehicle is designed using automotive industry standards. The dynamic behaviour of vehicle depends on the selection of overall dimensions, wheel base, track width, overall height and width that are decided using central motor vehicle rules. The selected dimensions for vertical and horizontal pillar members of the transport bus are modified to enhance the strength, stiffness and stability of the superstructure during travel. This increased stability enhances the ride comfort and passenger safety. Analysing the effect of utilizing manual meshing in complex areas of a transport utility vehicle for vibration analysis and passenger ride comfort has also been carried out. Modal analysis to evaluate the dynamic behaviour of transport utility vehicle model is also carried. Further with the use of finite element analysis deflection vehicle structure is evaluated. The outcomes from the analysis are compared with the behaviour of chassis mounted platform in dynamic conditions and are found in close correlation. The vehicle structure behaves as a single entity in dynamic situations, so surface model is prepared. Element selection for the finite element analysis is carried by considering plane stress condition. Two-dimensional quadrilateral shell elements are extensively used for meshing of the computer model of the vehicle structure. Complex areas in the optimized vehicle structure are meshed using relevant combination of quads & trias. The values of vector sum displacement and frequencies are found to be in good agreement with the experimental ones.
An investigation of structural integrity of chassis mounted platform subjecte...Dr.Vikas Deulgaonkar
The present work deals with the investigation of strength of a specialized chassis mounted platform/structure designed to carry concentrated load. This work deals with the mathematics behind braking through shear and bending diagrams analysis processes. The perceptible loading case in the present analysis comprises braking load and its effect on the platform/structure by usage of simple shear force & bending moment diagrams. These diagrams reveal the distribution of shearing force during braking for typical Indian truck. Present analysis accentuates on the design stage aspects of the platform as this research is a step in doctoral study. Effect of load during braking for an atypical type of combination of longitudinal and cross members in platform/frame design is formulated. This paper provides a new technique for computation of strength using shear and bending diagrams. Peculiarity of this analysis is the usage of combined section modulus of three members for computation of stress.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
2. Failures of major fuel-injection components are shown in Figs. 1 to 4.
For eighty-nine fuel pumps, partwise failure data is gathered. The gathered data is represented in Fig. 5. In this, number of times
the component failed is represented on ordinate while the component is represented on abscissa.
2.1. Failure mode and effect analysis (FMEA) of fuel pump components
Failure mode and effect analysis is systematic and step-by-step process used for failure analysis. It evaluates processes for failures
and gives inferences for preventing them with efficient quality and reliability. In present work FMEA of fuel pump parts is conducted
by listing failures of all components, failure causes and effects. In addition to this the severity of the failures, their actual occurrence
and detection were also figured out. Further to prioritize the components for experimental analysis, risk priority number (RPN) is
calculated related to every failure. Failure analysis of eighty-nine pumps has been carried out. While carrying out the analysis, each
component of the pump causing failure is accounted. In this work, we have actual failure data for each component and the same is
utilized during the analysis [1]. The failed component and number of times the same failed in a total of eighty-nine pumps was
enlisted. Failure of pump occurred due to a total of thirteen components and the number of times the failure detected was also
observed and noted during failure analysis. The component, number of times the component failed and number of times same was
detected is enlisted in Table 2.
To conduct risk priority number (RPN) analysis, the number of times the component failed is treated as occurrence (O), the
number of times the failure was detected is considered as detection (D) and a severity number (S) is assigned considering severity of
failure. RPN has been presented in Table 3. RPN is the product of S, O and D. The calculation of same is carried as RPN = S * O * D.
e.g. RPN of Lever bush = 4*8*10 = 320. Table 3 shows the detailed failure mode and effect analysis along with risk priority number
evaluation for every failure. (See Table 3.)
From above table, the components with RPN greater than 600 are selected for further analysis. Prioritizing the components by
their RPN, it is observed that cam plate, rollers, time device piston and supply pump possess RPN above 600, indicating that these are
major contributors for pump failure. The above results of RPN analysis are plotted in Fig. 6, which is further used in decision
regarding experimental analysis. The results from risk priority analysis are plotted in graphical format and the components prioritized
Table 1
System components and their failure causes.
Fuel-injection pump system System component Failure cause
Pressure generating system Supply pump Friction between vanes and rotor arising due to dry run, presence of water and thermal expansion of
vane
Pressure control valve Frequent expansion and contraction due to temperature variation
Motion Transmitting System Drive shaft Torsional fatigue, excessive load, key slot expansion and improper gear shifts
Cam plates Pitting due to fuel impurities, dry run and water presence causing corrosion
Roller plates Pitting due to fuel impurities, dry run and water presence causing corrosion
Hydraulic delivery system Hydraulic head Accumulation of burrs and impurities
Head Spring Corrosion due to water
Control system Fulcrum lever system Play due to continuous acceleration
Overload controlling unit Time device piston Expansion due to dry run of pump
Solenoid valve Clogging of fuel impurities resulting in choking
Fig. 1. Original and failed cam plate of motion transmitting system in fuel pump.
V.R. Deulgaonkar, et al. Engineering Failure Analysis 105 (2019) 1262–1272
1263
3. for further analysis.
3. Discussion of failure causes
From the above predicative failure mode and effect analysis, the components identified for failures of fuel injection pump includes
cam plates, rollers and timing device piston. These three components with RPN greater than 600 are major contributors in pump
failure. It is observed that cam plate and rollers, fail due to pitting. One of the main reasons of pitting, is water being flashed on hot
metal surfaces. However other failure reasons include but not limited to rusting, corrosion, abrasion, etching, spalling, fuel oxidation
etc. [2]. All these phenomena of failure except spalling, include water as an agent. Iron oxide is produced when water encounters
with steel and causes the contacting material to rust e.g. fuel tank. This rust gets introduced into the system as hard particulate and
cause wear. Combination of water with acids in fuel causes corrosion of pump parts leading to failure [6]. Absence of enough
thickness of lubricant film causes abrasion. Sources of water getting introduced into the system include but not limited to, on delivery
from fuel stations, human error, leakage into tank which occurs due to high pressure washing, rain and ground water. Condensation
phenomena in fuel tank causes formation of water which further passes into the system. Humidity is also major contributor for
formation of water in fuel tank which further gets into fuel pumps. At high pressure, hydrocarbons and water molecules are in-
troduced into the fuel pump from fuel tank. This water droplet when meets any of the pump components, gets settled on it and
Fig. 2. Original and failed roller plate of motion transmitting system in fuel pump.
Fig. 3. Original and failed pressure-control valve of pressure generating system in fuel pump.
Fig. 4. Original and failed drive shaft of motion transmitting system in fuel pump.
V.R. Deulgaonkar, et al. Engineering Failure Analysis 105 (2019) 1262–1272
1264
4. reduces the lubricant oil film thickness. Once the thickness of lubricant is reduced the metal to metal contact of pump components
occurs leading to failure. The water molecules deposited into micro-cracks on metal surfaces, beneath the extreme pressure gets
decomposed and releases hydrogen in a mini-explosion that enlarges cracks and creates wear particles.
4. Experimental analysis of failure in cam plate and roller of fuel pump
The experimental analysis of the above-mentioned components is carried using SEM and EDS. SEM or Scanning Electron
Microscopy of the failed parts is carried at magnification level of 500×. EDS or Energy Dispersive Spectroscopy conducted in present
work confirms the failure reason by indicating oxygen content. SEM observations of cam plate surface are shown in Figs. 7, 8 & 9.
Fig. 7 shows the 500× magnified view of cam plate surface. It is observed that rust particles are responsible for deteriorating the
quality of surface finish of cam plates. During operation these rust particles adhere to surface and score the surface, due to this, pits
are formed on the surface leading to pitting corrosion [3]. Fig. 8 1000× magnified view shows the scale formation on the cam plate
surface. A thick layer of scale can be clearly observed, which affects the functioning of cam plate and consequently leads to pump
failure. Fig. 9 2000× magnified view shows the pit dimensions. Pits of diameters as large as 20 μm are observed on the cam plate
surface (shown in Fig. 9 are 10.54 μm) and 18.06 μm, which further becomes housing for water leading to rusting and pitting
corrosion. Pitting corrosion, or pitting, is extremely localized corrosion leading to formation of small holes in the metal. Driving
influence for pitting corrosion is the de-passivation of a small area, which becomes anodic while an unknown but potentially vast area
becomes cathodic, leading to very localized galvanic corrosion. The corrosion penetrates the mass of the metal, with a limited
diffusion of ions. The mechanism of pitting corrosion is same as crevice corrosion. Scale is hard mineral coating and corrosion deposit
made up of solids and sediments. Scaling occurs because of high temperature water containing carbonates or bicarbonates of calcium
and magnesium.
Figs. 10 to 12 indicate the surfaces observed under SEM. Fig. 10 viewed 500× magnification shows surface pits formed due to
pitting corrosion.
Fig. 11 viewed under 1000× magnification shows rust particles inserted into the cam plate. It can be observed that the rust
particles present on the surface deteriorate the surface finish of the roller which further affects the pump functioning. Fig. 12 viewed
0
2
4
6
8
10
12
14
16
Fuel pump components
Occurences
Fig. 5. Occurrences of failure versus components of fuel pump
Table 2
Occurrence of failure in components of pump and their detection.
Name of the Component Number of times the Component Failed Number of times the failure was detected
Lever bush 06 10
Cam Plate 19 09
Rollers 14 09
Adjusting Plug 01 10
Body 10 03
Shim 05 10
Drive Shaft 11 03
Lever Shaft 08 09
TD Piston 12 08
Solenoid Valve 02 06
Supply Pump 05 07
Spring 05 08
Pressure Valve 02 07
V.R. Deulgaonkar, et al. Engineering Failure Analysis 105 (2019) 1262–1272
1265
6. Table 3
Unnormalized oxygen and iron percentages.
Spectrum Number Unnormalized
Oxygen (%) Iron Fe (%)
s2 10,758 14.71 55.06
s2 10,760 11.51 76.10
s2 10,757 7.31 81.32
s2 10,761 4.78 83.90
0
100
200
300
400
500
600
700
800
900
1000
Pump Components vs RPN (Risk Priority Number)
Risk Priority Number
Fig. 6. Risk priority number versus components of fuel pump.
Fig. 7. SEM observation of cam plate rust particles and pits due to surface corrosion.
V.R. Deulgaonkar, et al. Engineering Failure Analysis 105 (2019) 1262–1272
1267
7. Fig. 8. SEM observation of cam plate scale formation.
Fig. 9. SEM observation of cam plate indicating dimensions of pits on surface.
V.R. Deulgaonkar, et al. Engineering Failure Analysis 105 (2019) 1262–1272
1268
8. under 2000× magnification shows scale and pits formed on the roller surface due to occurrence of water emulsion into the system.
Energy Dispersive X-Ray Spectroscopy (EDS or EDX), a chemical microanalysis technique is used in combination with scanning
electron microscopy in present work. The water presence is depicted by the oxygen content as evaluated from the spectrum analysis.
EDS image viewed in 1000× magnification is shown in Fig. 13.
For each portion of the surface a spectrum number is assigned. The corresponding spectrum for each number is plotted between
Fig. 10. SEM observation of roller surface indicating pits on surface.
Fig. 11. SEM observation of cam plate indicating rust particles & pits.
V.R. Deulgaonkar, et al. Engineering Failure Analysis 105 (2019) 1262–1272
1269
9. Fig. 12. SEM observation of roller surface indicating scale & pits.
Fig. 13. EDS observation of cam plate indicating oxygen and other elements.
V.R. Deulgaonkar, et al. Engineering Failure Analysis 105 (2019) 1262–1272
1270
10. cycles per second per electron (cps/eV) volt vs kilo electron volt(keV). At spectrum number s2 10,758 the level of unnormalized
oxygen is depicted is 14.71%. and corresponding iron level is 55.06% leading to iron oxide (rust) formation. Plot for s2 10,758 is
shown in Fig. 14.
From similar analysis of remaining spectrum numbers as s2 10,760, s2 10,757, and s2 10,761 the unnormalized iron and oxygen
percentages are evaluated from graphs like graph 3 of all remaining spectrum numbers. The unnormalized oxygen and iron per-
centages are tabulated in Table 3.
5. Conclusion
Fuel pump failure data has been collected and analyzed for eighty-nine pumps. The number eighty-nine quantifies enough fuel
pumps to have a substantial insight for understanding the pump failure. Failure in different components of fuel pump and its
occurrence during initial phase gives enough insight for failure analysis. Further from this data, failure mode and effect analysis has
been carried out for all components of fuel pump. Water presence in the fuel pump system has been identified as the primary reason
for pump failure. Components which failed critically were identified and selected using risk priority number analysis. For components
whose risk priority number is above 300 are impact fuel pump life and quality and were cam plates, roller surfaces, time device piston
and supply pump. SEM of these components has been carried out to identify the failure modes and it is observed that these com-
ponents fail due to pitting corrosion. Outcomes from EDS shows presence of excess oxygen leading to oxidation thus confirming the
presence of moisture [5]. The presence of water in the injection system is due to malfunctioning of water-separator requiring periodic
repair and maintenance. Further, a water in fuel sensor that detects the excess amount of water in separator which gets introduced
into the system is suggested to be installed at the bottom of fuel filter and connected to the electronic circuit unit that alerts driver to
address it, hence the pump life and performance can be enhanced.
6. Recommendation to avoid fuel pump failure
The significant cause of pump failure is the intrusion & emulsion of water in fuel line. The fuel line has a water separator that
separates water from fuel tank and prevents it from entering the fuel pump, however it operates till its capacity, after which the
excess water needs to be manually removed. This excess water gets intruded into the fuel pump causing failures. Hence, an automatic
sensing system that identifies water in the separator and alerts the operator even before the engine is cranked is recommended. A
water in fuel sensor detects the presence of water in diesel fuel and gasoline using the difference of electric conductivity between two
electrodes through water and fuel. Detection of water in fuel can prevent or too much extent reduce damage, the water could cause to
fuel injectors. Presence of water in engine fuel system causes injection system damage, hard starting, loss of power, misfiring, surging
or stalling. Water in fuel sensors are placed at the bottom of a fuel filter water separator which provides a space at the bottom of
2 4 6 8 10 12 14
keV
0
1
2
3
4
5
cps/eV
FeFe
O
C
Mo
Mo
Ti
Ti
Cr
Cr
Mn
Mn
Ni
Ni
Fig. 14. Spectrum for s2 10,758.
V.R. Deulgaonkar, et al. Engineering Failure Analysis 105 (2019) 1262–1272
1271
11. separators for collection of water. The signal generated is further transferred to electronic control unit or dashboard indicator, giving
alert to the operator that the filter needs to be addressed.
References
[1] Xiao-lei Xu, Zhi-wei Yu, Bing Yu, Fatigue failure of an intermediate transition block in fuel injection pump fork assembly of a truck diesel engine, Eng. Fail. Anal.
94 (2018) 13–23, https://doi.org/10.1016/j.engfailanal.2018.07.019.
[2] D.G. Karalis, N.Ε. Melanitis, Analysis of a premature failure of a hub from a diesel generator of high-speed motor ship, J. Fail. Anal. Prev. 14 (2014) 236–246,
https://doi.org/10.1007/s11668-014-9788-4.
[3] W. Muhammad, N. Ejaz, S.A. Rizvi, Failure analysis of high-speed pinion gear shaft, J. Fail. Anal. Prev. 9 (2009) 470–478, https://doi.org/10.1007/s11668-009-
9268-4.
[4] Xiaolei Xu, Zhiwei Yu, Yuzhou Gao, Micro-cracks on electro-discharge machined surface and the fatigue failure, Eng. Fail. Anal. 32 (2013) 124–133, https://doi.
org/10.1016/j.engfailanal.2013.03.011.
[5] D. Ghosh, H. Roy, A. Mondal, Failure investigation of condensate pump shaft, J. Fail. Anal. Prev. 14 (2014) 450–453, https://doi.org/10.1007/s11668-014-
9845-z.
[6] http://www.mycleandiesel.com/pages/ProblemWater.aspx.
V.R. Deulgaonkar, et al. Engineering Failure Analysis 105 (2019) 1262–1272
1272
![Contents lists available at ScienceDirect
Engineering Failure Analysis
journal homepage: www.elsevier.com/locate/engfailanal
Short Communication
Failure analysis of fuel pumps used for diesel engines in transport
utility vehicles
Vikas Radhakrishna Deulgaonkara,⁎
, Kundan Pawarb
, Pratik Kudleb
,
Atharva Raverkara
, Amod Rautc
a
Department of Mechanical Engineering, Marathwada Mitramandal's, College of Engineering, Karvenagar, Pune 411052, MS, India
b
Helical Auto Technology Pvt Ltd, Pune, MS, India
c
Dynomerk Controls, Pune, India
A B S T R A C T
Present work deals with the failure analysis of fuel pump in transport utility vehicles. The fuel pump assembly failed at 70536 km. Various types of
failures in pump and its different components are analyzed. Failure mode and effect analysis (FMEA) of the acquired data has been carried out. The
pump components with substantial contribution in failure are determined using risk priority number analysis and the failure causes are postulated.
Using scanning electron microscopy (SEM) for pump parts as rollers and cam plates the types failures are observed. Presence of water in fuel tank
indicated the reason for rusting of bottom surface of tank. Pitting failure due to rust particles has been identified in pump parts after SEM ob-
servations. Energy Dispersive Spectroscopy (EDS) of pump parts has also been carried out to identify levels of unnormalized constituent elements
responsible for failure. From EDS presence of oxygen responsible for oxidation reaction with iron is identified. Significant percentage of oxygen at
different locations indicated the presence of moisture in the system. Remedial measure to avoid pump failure has been suggested in present work.
1. Introduction
One of the important components for passenger vehicles or buses using fuel as diesel is fuel-injection pump. Fuel pump not only
distributes the measured amount of fuel to the cylinder but also assists in controlling engine speed. A typical fuel-injection system
comprises of pressure generating system, motion transmitting system, control system, hydraulic delivery system and a system or unit
to handle overload [4]. The fuel-injection pump is indirectly driven by the crankshaft through gearing arrangement. Fuel injection
system includes several components possessing motion relative to each other, however no separate unit is used for lubrication as fuel
itself acts a lubricant during the fuel pump action. In present work a total of 89 fuel-injection pumps were analyzed for different types
of failures. Failure of pumps occurred at 70536 km far before the actual life of 200,000 km stated by original equipment manu-
facturer. Fuel pump failure is faced by all state transport systems and present work is conducted in one of the state central workshops
utilized for regular maintenance and bus body building. The failure data collected is analyzed using various techniques and remedial
action is devised which further affected the performance of fuel-injection pumps.
2. Investigation of fuel pump failures
Fuel pumps under consideration failed due to improper functioning of the pressure generating, hydraulic delivery, control systems
and overload control unit. Part wise failure data is collected and analyzed. Major systems, system components and causes of their
failure are enlisted in Table 1.
https://doi.org/10.1016/j.engfailanal.2019.07.048
Received 16 May 2019; Received in revised form 12 July 2019; Accepted 18 July 2019
⁎
Corresponding author.
E-mail address: vikasdeulgaonkar@gmail.com (V.R. Deulgaonkar).
Engineering Failure Analysis 105 (2019) 1262–1272
Available online 21 July 2019
1350-6307/ © 2019 Elsevier Ltd. All rights reserved.
T](https://image.slidesharecdn.com/failureanalysisoffuelpumpsusedfordieselenginesintransportutilityvehiclesefa2019-190906112154/85/Failure-analysis-of-fuel-pumps-used-for-diesel-engines-in-transport-utility-vehicles-efa-2019-1-320.jpg)
![Failures of major fuel-injection components are shown in Figs. 1 to 4.
For eighty-nine fuel pumps, partwise failure data is gathered. The gathered data is represented in Fig. 5. In this, number of times
the component failed is represented on ordinate while the component is represented on abscissa.
2.1. Failure mode and effect analysis (FMEA) of fuel pump components
Failure mode and effect analysis is systematic and step-by-step process used for failure analysis. It evaluates processes for failures
and gives inferences for preventing them with efficient quality and reliability. In present work FMEA of fuel pump parts is conducted
by listing failures of all components, failure causes and effects. In addition to this the severity of the failures, their actual occurrence
and detection were also figured out. Further to prioritize the components for experimental analysis, risk priority number (RPN) is
calculated related to every failure. Failure analysis of eighty-nine pumps has been carried out. While carrying out the analysis, each
component of the pump causing failure is accounted. In this work, we have actual failure data for each component and the same is
utilized during the analysis [1]. The failed component and number of times the same failed in a total of eighty-nine pumps was
enlisted. Failure of pump occurred due to a total of thirteen components and the number of times the failure detected was also
observed and noted during failure analysis. The component, number of times the component failed and number of times same was
detected is enlisted in Table 2.
To conduct risk priority number (RPN) analysis, the number of times the component failed is treated as occurrence (O), the
number of times the failure was detected is considered as detection (D) and a severity number (S) is assigned considering severity of
failure. RPN has been presented in Table 3. RPN is the product of S, O and D. The calculation of same is carried as RPN = S * O * D.
e.g. RPN of Lever bush = 4*8*10 = 320. Table 3 shows the detailed failure mode and effect analysis along with risk priority number
evaluation for every failure. (See Table 3.)
From above table, the components with RPN greater than 600 are selected for further analysis. Prioritizing the components by
their RPN, it is observed that cam plate, rollers, time device piston and supply pump possess RPN above 600, indicating that these are
major contributors for pump failure. The above results of RPN analysis are plotted in Fig. 6, which is further used in decision
regarding experimental analysis. The results from risk priority analysis are plotted in graphical format and the components prioritized
Table 1
System components and their failure causes.
Fuel-injection pump system System component Failure cause
Pressure generating system Supply pump Friction between vanes and rotor arising due to dry run, presence of water and thermal expansion of
vane
Pressure control valve Frequent expansion and contraction due to temperature variation
Motion Transmitting System Drive shaft Torsional fatigue, excessive load, key slot expansion and improper gear shifts
Cam plates Pitting due to fuel impurities, dry run and water presence causing corrosion
Roller plates Pitting due to fuel impurities, dry run and water presence causing corrosion
Hydraulic delivery system Hydraulic head Accumulation of burrs and impurities
Head Spring Corrosion due to water
Control system Fulcrum lever system Play due to continuous acceleration
Overload controlling unit Time device piston Expansion due to dry run of pump
Solenoid valve Clogging of fuel impurities resulting in choking
Fig. 1. Original and failed cam plate of motion transmitting system in fuel pump.
V.R. Deulgaonkar, et al. Engineering Failure Analysis 105 (2019) 1262–1272
1263](data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7)