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NEXT GENERATION POWER DISTRIBUTION UNIT IN WIRING HARNESS

Mahindra & Mahindra Ltd-Boobala Krishnan D, T Vijayan, Apurbo Kirty
Mahindra Research Valley-Himanshi Dua
  • Technical Paper
  • 2019-28-2571
To be published on 2019-11-21 by SAE International in United States
Keywords – Miniaturization, Low Profile (LP) Relays, Low Profile (LP) Fuses, Fuse box, Wiring Harness Research and/or Engineering Questions/Objective With the exponential advancement in technological features of automobile’s EE architecture, designing of power distribution unit becomes complex and challenging. Due to the increase in the number of features, the overall weight of power distribution unit increases and thereby affecting the overall system cost and fuel economy. The scope of this document is to scale down the weight and space of the power distribution unit without compromising with the current performance. Methodology Miniaturization involves replacing the mini fuses and J-case fuses with LP mini and LP J-case fuses respectively. The transition doesn’t involve any tooling modification and hence saves the tooling cost. Furthermore, to address stringent weight and space targets, LP mini fuses and LP J-case fuses were further replaced with micro-2 fuse and M-case fuse respectively. Similarly, micro relay and mini relay were replaced with Ultra micro and High current micro relay respectively. Results We took MPV segment vehicle for our initial testing and validation…
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Effect of Gasoline-Ethanol blends on GDI engine to reduce cost of vehicle ownership

Mahindra & Mahindra Ltd-Kartick Ramakrishnan, Padmavathi Ramadandi
Mahindra & Mahindra-Karthikeyan N Krishnan
  • Technical Paper
  • 2019-28-2379
To be published on 2019-11-21 by SAE International in United States
A major challenge for combustion development is to optimize the engine for improved fuel economy, reduce greenhouse gases. Stringent CAFÉ and emission norms require the customer to pay higher capital on vehicles. To offset the cost of ownership- cheaper and alternative energy sources are being explored. Ethanol blend with regular Gasoline and CNG are such alternative fuels. The study was carried on turbo-charged gasoline direct injection engine. The effect of ethanol on engine and vehicle performance is estimated and simulated numerically. The work is split into three stages: first the base 1D engine performance model was calibrated to match the experimental data. In parallel, vehicle level Simulink model was built and calibrated to match the NEDC cycle performance. Second, the thermal efficiency of the ethanol blend is calculated as a linear function of theoretical Otto cycle efficiency. The engine performance for varying compression ratio & ethanol gasoline blend is studied for vehicle level using a MATLAB code. Third, 1D code was run to simulate the high-speed exhaust temperature & low speed knock intensity, this is…
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MOLD IN COLOR DIAMOND WHITE ASA MATERIAL FOR AUTOMOTIVE EXTERIOR APPLICATION

Mahindra & Mahindra Ltd-Karthik Govindaraj, K V Balaji, Murukesan Vimalathithan, Gandhi Samir, Ladhe Rajesh
  • Technical Paper
  • 2019-28-2562
To be published on 2019-11-21 by SAE International in United States
In this paper, mold in color diamond white ASA material has been explored for front bumper grill, fender arch extension and hinge cover applications. Other than aesthetic requirements, these parts have precise fitment requirement under sun load condition in real world usage profile. Structural durability of the design was validated by virtual engineering. Part design and material combinations with better tooling design iterations were analysed by using mold flow analysis. Complete product performances were validated for predefined key test metrics such as structural durability, thermal aging, cold impact, scratch resistance, and weathering criteria. This part met required specification. This mold in color ASA material-based parts has various benefits such as environmentally friendly manufacturing by eliminating environmental issues of coating, easily recycled, and faster part production because intended color achieved in one step during molding. Also, it lowers overall production energy footprint, less scrap with no secondary painting, and lower final part cost by eliminating secondary operations.
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High Durable PU Metallic Monocoat system for tractor sheet metal application.

Mahindra & Mahindra Ltd-Yogesh keskar, Nitin pagar
Mahindra & Mahindra Kandivali-SUDHIR SAWANT
  • Technical Paper
  • 2019-28-2541
To be published on 2019-11-21 by SAE International in United States
In sheet metal painting for various applications like Tractor, Automobile, most attractive coating is metallic paints and it is widely applied using 3 coats 2 bake or 3 coat 1 bake technology. Both options, results in high energy consumption, higher production throughput time & lower productivity in manufacturing process. During various brainstorming & sustainable initiatives, paint application process was identified for alternative thinking to reduce burden on environment & save energy. Various other industry benchmarking & field performance requirement studies helped us identify the critical to quality parameters. We worked jointly with supplier to develop mono-coat system without compromising the performance & aesthetical properties. This results in achieving better productivity, elimination of two paint layers, substantial reduction in volatile organic content, elimination of one baking cycle and energy saving. Metallic mono-coat formulated using strong polyurethane resins & latest technology pre-coated aluminum pigment for achieving metallic effect in finish. With new resin technology further, reduction of baking temperature is possible & reduce further energy consumption. The proposed technology is fully validated on component and ready. Proposed…
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Development of a Graphical User Interface (GUI) Based Tool for Vehicle Dynamics Evaluation

Mahindra & Mahindra Ltd-Saravanan Muthiah
Mahindra & Mahindra, Ltd.-Divyanshu Joshi
  • Technical Paper
  • 2019-28-2397
To be published on 2019-11-21 by SAE International in United States
Title Development of a Graphical User Interface (GUI) Based Tool for Vehicle Dynamics Evaluation Authors Mr. Shubham Kedia, Dr. Divyanshu Joshi, Dr. Muthiah Saravanan Mahindra Research Valley, Mahindra & Mahindra, Chennai Objective Objective metrics for evaluation of major vehicle dynamics performance attributes i.e. ride, handling and steering are required to compare, validate and optimize dynamic behavior of vehicles. Some of these objective metrics are recommended and defined by ISO and SAE, which involve data processing, statistical analysis and complex mathematical operations on acquired data, through simulations or experimental testing. Due to the complexity of operations and volume of data, evaluation is often time consuming and tedious. Process automation using existing tools such as MS Excel, nCode, Siemens LMS, etc. includes several limitations and challenges, which make it cumbersome to implement. In the current work, a GUI based post-processing tool is developed for automated evaluation of ride, handling and steering performance. Methodology This work is about development of a centralized platform for quantification, visualization and comparison of ride, handling and steering performance metrics from testing and…
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Steering and Handling Performance Optimization Through Correlation of Objective - Subjective Parameters and Multi-body Dynamics Simulation

Mahindra & Mahindra Ltd-Deva Ranjit Kumar rajarajan, Vinothprakash rajasekar, Shraddhesh rasal, Baskar Anthonysamy, Visweswara LENKA.
  • Technical Paper
  • 2019-28-2412
To be published on 2019-11-21 by SAE International in United States
RESEARCH OBJECTIVE: Automobile Industry has driven through the ages with continuous development with innovative technologies and frugal engineering. Expectation of customer is also increasing through the generations. To meet the customer demand for performance and be best in market, OEM needs to deliver best performance of vehicle with cost effective and short development process. Steering and Handling of vehicle is one of major customer touchpoints and needs to be tuned to achieve various conflicting requirements. The objective of this research is to optimize the steering and handling using correlation between three major methods of evaluation. METHODOLOGY: Methodology for optimization of steering and handling performance using correlation between subjective evaluation, objective measurement and multi-body-dynamic simulation is presented. In first phase, correlation of objective steering & handling parameters is established with subjective evaluation, based on evaluation of various vehicles in SUV segment. The objective parameters which give highest correlation are selected for target setting process. In second phase, Multi-body dynamic(MBD) model is developed in MSC ADAMS and is validated through physical kinematic and compliance data. Components such…
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A Study on the Repeatability of Vehicle Ride Performance Measurements

Mahindra & Mahindra Ltd-Saravanan Muthiah
Mahindra Research Valley-Divyanshu Joshi, Shubham Kedia
Published 2019-01-09 by SAE International in United States
Across the automotive industries, objective measurements and subjective assessment of vehicle ride performance are routinely carried out during development as well as validation phase. Objective measurements are receiving increased attention as they are generally believed to offer a higher degree of objectivity and repeatability compared to the subjective assessment alone. Typical industry practices include the acquisition of vehicle-occupant vibrational response on specified road sections, test surfaces on proving grounds or in a controlled input environment such as four-poster test rig. In presented work, a study is performed on the repeatability of vehicle ride performance metrics such as weighted RMS acceleration and frequency responses using the data acquired in repeated trials conducted using three different sports utility vehicles (SUVs) on a sufficiently long designated road section. Intra-vehicle and inter-vehicle ride performances are compared and studied against the mentioned metrics. Results indicate a significant variability of results in repeated trials, which in few cases is found to exceed the variation across the vehicles. These variabilities can be arguably attributed to several inevitable practical constraints such as vehicle…
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A Simulation Approach for Identification and Design Optimization to Prevent Headrest Rattle

SAE International Journal of Advances and Current Practices in Mobility

Mahindra & Mahindra Ltd-Nithin Baskar, Riyazuddin Mohammed, Prasath R
  • Journal Article
  • 2019-26-0190
Published 2019-01-09 by SAE International in United States
Squeak and rattle concerns account for approximately 10% of overall vehicle Things Gone Wrong (TGW) and are a major quality concern for automotive OEM’s. Seat is one of the major contributors of squeak and rattle issues observed in customer verbatim. Seat head rest rod and bezel are designed concentric to each other with a gap that allows free movement and a locking pin to position at different levels. Due to the design gap and weight of the head rest there is always tendency for relative displacement leading to rattle issues. Seat headrest, is close to the customer ear and any rattles at headrest will create annoying driving experience. Also, the contradictory requirements between efforts and rattle makes the scenario more difficult to fine tune the bezel specifications. The root cause for head rest rattle issues can also be related to free play between bezel and seat frame, free play between bezel and cap, looseness between locking pin and headrest rod etc. Identification of issue at physical testing is common practice subject to availability of test…
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Prediction of Oil Flow inside Tractor Transmission for Splash Type Lubrication

Mahindra & Mahindra Ltd-Tanmay Sushant Santra, Kumar Raju, Rahul Deshmukh, Udaya Paradarami, Ayush Agrawal
Mahindra Research Valley-Nagarajan Gopinathan
Published 2019-01-09 by SAE International in United States
This study introduces a method to examine the flow path of the lubricant inside a transmission housing of a tractor. A typical gearbox has several loads bearing elements which are in relative sliding motion to each other which causes heat to be released. The major sources of friction as well as heat are the meshing teeth between gears (sun/planet, planet/ring & power/range drive gear), thrust washers, thrust bearings and needle roller bearings. The churning of oil performs the vital function of both lubricating these sliding interfaces and cooling these sources of heat, thereby preventing failure of the gearbox.In this paper, we have applied VOF multiphase flow model and sliding meshing to simulate the fluid flow during splashed lubrication within a mating gear box. Lubrication oil dynamics and oil surface interaction with the air is modeled using VOF multiphase approach. The gear motion is imparted through sliding mesh technique, it automatically reconfigures the mesh for the space in accordance with the rotation of physical objects, which divides the space around the gears, centering on the axis…
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Slinger Design in Live 4WD Axle for Tractor

Mahindra & Mahindra Ltd-Navneet Chaudhari, Suvendu Kumar Sethi, Srinivasa Rao, Ramachandran Gopalswamy
Published 2019-01-09 by SAE International in United States
Proper lubrication is essential for any gear box & axle to get optimized performance. For getting desired life of gear train, we have to maintain minimum oil level inside the gear box or axle, whereas in case of rotating parts such as bearings and shafts, we have to provide sealing such as o rings & oil seals to stop oil coming out from the housing. But, if sealing is not proper seepage & leakage start and reduce the oil level inside the gear box. Oil deficiency leads to scuffing failure in gears and later occurrence of gear & bearing seizure ultimately fails the system.To sustain proper lubrication, we must seal the interfaces appropriately. There are different types of sealing available. Sealing is also depended on application and its location.To protect seal from external environment, we adopt a unique arrangement called slinger which enhances the life of seal.This paper speaks about this unique protection of oil seal in 4WD axle from outside contaminators such as mud, pebbles and water which should not come in contact with…
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