Currently automotive sector is facing bi-fold challenge of light weighting and cost reduction. As end-customer is getting more focused on total cost of ownership, it is need of time that light weighting and cost reduction goes hand in hand. Presently lightweight materials such as magnesium, aluminum & composites are used but often this impact towards cost increase. In present study, a novel approach has been followed which not only focus on light weighting but also integrate design functions of two engine systems.
This paper deals with the new system design to focus on low cost, light weight, NVH friendly and low development time. In design phase, function of two engine systems i.e. engine cover and Air filter were integrated followed by structural analysis. In final phase of this project, the experimental component was developed and validated for its intended function. In this study, current sheet metal design engine cover has been converted in to Thermoplastic cover with integrated Air filter. The complete engine cover with integrated air filter design has been validated at Test bed and Vehicle level for durability, performance, leakages, NVH. At end results were analyzed and compared. Results indicates that new design is a better solution over the existing design. The study demonstrates that this novel approach of light weighting and design function integration can achieve better performance while providing substantial cost saving and weight reduction.