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Dynamic Strength Co-Simulation of Valve Train Mechanism Design Virtual Validation

Maruti Suzuki India Ltd-Bhupinder Singh, Sanjay Poonia
Maruti Suzuki India, Ltd.-Ved Prakash Choudhary
  • Technical Paper
  • 2020-01-0949
To be published on 2020-04-14 by SAE International in United States
As the automotive market is very dynamic and vehicle manufactures tries to reduce the vehicle development cycle time, more focus is being given to CAE simulation technologies to reduce the design cycle time and number of physical tests. CAE engineers are continuously working on improving the accuracy of CAE simulation, such as using flexible body dynamic simulation in place of linear static analysis. Strength calculation under dynamic condition is more accurate as compared to static condition as it gives more clear understanding of stress variation with motion, contacts and mass inertia. Failure has been observed in new development of valve train pivot screw under test conditions. As per linear static analysis, design was judged OK. Normal linear static analysis is a two stage process. In 1st stage loads are calculated by hand or peak loads are taken from Multi body dynamic (MBD) rigid body analysis. In 2nd stage stress calculation is carried out for peak load in quasi static condition using Finite element analysis (FEA). To investigate the reason of failure and prediction of stress…
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Abatement of passenger vehicle judder through optimized engine mounting design

Maruti Suzuki India Ltd-Adheesh Agrawal, Priyesh Bhadani, Vivek Singh
Maruti Suzuki India, Ltd.-Pradyumna Saripalli, Chiranjit Ghosh
  • Technical Paper
  • 2020-01-0420
To be published on 2020-04-14 by SAE International in United States
The modern automobile industry has experienced a paradigm shift in recent years. Product sales are no longer driven by manufacturers’ offerings but by the customer expectations. Even budget vehicles strive to offer a superior driving experience so as to distinguish them from competition. Also, there is an enhanced focus on fuel efficiency as regulations are getting more stringent by the day. The focus on fuel efficiency demands the engine idle rpm to be lowered. Also, during vehicle take-off, the engine rpm drops further in case of partial clutch engagement, resulting in sudden vibrations called vehicle judder. This judder phenomenon can be countered either through ECU calibration with additional torque during clutch release, or through engine mount optimization. The former requires additional fuel supply thus reducing fuel efficiency. This paper emphasizes on the latter methodology to contain judder through design modification of engine mounting.
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Improving Rough Road NVH by Hydraulic Mount Design Optimization

Maruti Suzuki India Ltd-Adheesh Agrawal
Maruti Suzuki India, Ltd-Vivek Singh
  • Technical Paper
  • 2020-01-0422
To be published on 2020-04-14 by SAE International in United States
Vehicle cabin comfort creates or emphasizes a specific image of a brand and its product quality. Low frequency power train induced noise and vibration levels are a major contributor affecting comfort inside passenger cabin. Thus, using hydraulic mount is a natural choice. Introduction of lighter body panels coupled with cost effective hydraulic mounts has resulted in some additional noises on rough road surfaces which are challenging to identify during design phase. This paper presents a novel approach to identify two such noises i.e. Cavitation noise and Mount membrane hitting noise based on component level testing which are validated at vehicle experimentally. These noises are encountered at 20~30 kmph on undulated road surfaces. Sound quality aspect of such noises is also studied to evaluate the solution effectiveness.
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CFD Simulation of Transmission for Lubrication Oil Flow Validation and Churning Loss Reduction

Maruti Suzuki India Ltd-Ved Prakash Choudhary
Maruti Suzuki India Ltd.-Arun Kumar
  • Technical Paper
  • 2020-01-1089
To be published on 2020-04-14 by SAE International in United States
Rapidly changing emission and fuel efficiency regulations are pushing the design optimization boundaries further in the Indian car market which is already a very cost conscious. Fuel economy can be improved by reducing moving parts friction and weight optimization. Driveline or Transmission power losses are major factor in overall efficiency of rotating parts in a vehicle. Transmission efficiency can be improved by using low viscosity oil, reducing oil quantity and reducing churning losses in Car Transmission. Changes like low viscosity and reduced oil volume give rise to challenges like compromised lubrication and durability of rotating parts. This further leads to extended design cycles for launching new cars with better transmission efficiency and fuel economy into the market. Design cycle time can be reduced by using CFD simulation for oil flow validation in the early design stage. CFD simulation of Transmission is challenging due to interaction of fluid and multiple gears/shafts rotating at high speed. It is also complex as lubrication is done only by splash generated by gears and oil flow thru narrow galleries further…
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A Methodology to Enhance the Directional Load Bearing Performance of Cowl Cover and its Effect on Pedestrian Head Impact

Maruti Suzuki India, Ltd.-Nikhil Jayanth, Chandra Sekhar S
  • Technical Paper
  • 2020-01-0911
To be published on 2020-04-14 by SAE International in United States
In the modern automobile scenario in developing countries, the customers are getting more meticulous and the market more competitive. Now even the budget vehicle customer expects desirable vehicle performance in specific use cases of the vehicle that were previously not focused by designers. Hence, the focus on perceived quality challenges automobile engineers to go the extra mile when it comes to the cost-effective design of parts that are tangible to the customer. A vehicle's cowl cover is one such exterior component. The primary functions of this part are to provide air intake opening for the HVAC system and cover the components like wiper motor. The aesthetic function is to cover the gaps between windshield, hood, and fender as seamlessly as possible. A specific role of cowl cover, which calls for a designer's attention, is its load-bearing capability. This component has to be stiff enough to bear external loads like snow accumulation or application of hand on the part by customer or service personnel. Simultaneously, it plays a significant role in absorbing the energy of a…
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Entry Level Connected Infotainment Unit with Smartphone and Vehicle Integration

Maruti Suzuki India, Ltd.-Soundharya N, Tarun Aggarwal, Ritesh Khandelwal, Satish Pandey, Satish Kumar Pandey, Himanshu Kumar Ojha
  • Technical Paper
  • 2019-28-2434
Published 2019-11-21 by SAE International in United States
As we transition towards Internet of Things (IoT) - humans are connected to each other & outside world through the smartphone.Customers tend to use smartphones for varied purposes ranging from communication to entertainment. However, the concern of distraction exists due to poor visibility & accessibility of the phone’s screen in driving condition.One of the repercussion of being connected to smartphone particularly in driving condition includes higher number of road accidents due to distraction. This paper explains one of the key initiatives taken by Maruti Suzuki India Limited to address the same. This is done by offering an entry level connected infotainment system which comprises of the following three components:(a) An entry-level infotainment with basic display & vehicle connectivity, (b) A Dock mounted on infotainment panel enabling safe usage of smartphone due to its position i.e. accessibly and visibility in driving condition, (c) A Driving App specifically designed for driving usage where one can access calling, messaging, navigation on the go with a vibrant UI & easy to use gestures.The infotainment unit is connected to vehicle’s…
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SmartPlay Studio: A Connected Infotainment Development

Maruti Suzuki India, Ltd.-Pankaj Kumar Bharti, Shashi Kant Roy, Surendra Raghuwanshi, Satish Pandey, Ritesh Khandelwal, Tarun Aggarwal, Satish Kumar Pandey
  • Technical Paper
  • 2019-28-2440
Published 2019-11-21 by SAE International in United States
Infotainment has always been an important aspect of life which has made its way to car design. The cars today are much more advanced compared to their predecessors. The in-vehicle Infotainment advancements have followed the consumer electronics market in terms of technologies such as Touchscreen; App based Navigation, Voice Assistant and other multimedia services. This trend is going to expand further as smartphones have revolutionized the Infotainment domain with awareness and accessibility to customers. The Infotainment system in the cars are expected to be connected not only to the cloud but various vehicle controllers to display host of information & controls at customer`s fingertips. To design a system that supports connectivity to both cloud and vehicle is challenging in terms of cost and design for the OEMs.With focus on Indian market condition and global trends, this paper analyzes the customer expectation for Connected Infotainment system. It also explains the methodology adopted by Maruti Suzuki India Limited to: (i) Provide a seamless Connected Infotainment system (Smartplay Studio) for its model line-up (ii) Leveraging Smartphone Linkage technologies…
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Study of Handling Behavior of a Passenger Vehicle after Addition of CNG Tank

Maruti Suzuki India, Ltd.-Lakshmi Narasimha Varma Jelli, Raghav Budhiraja, Akash Goel, Deepak Bakshi, Rakesh K
  • Technical Paper
  • 2019-28-2405
Published 2019-11-21 by SAE International in United States
The objective of this paper is to study the change in handling behaviour of the dual-fuel vehicle fitted with a CNG tank to that of its single fuel (gasoline) counterpart. A validated CarSim model is run through steady state and transient state handling tests before and after the addition of CNG tank. The simulation results are used to compare the handling characteristics of the CNG vehicle with the reference vehicle. Further based on these results the suspension parameters are changed to find an optimum set-up for the actual CNG vehicle.
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Methodology for Failure Simulation Using 4 Corner 6 DOF Road Load Simulator of Overhanging Components: An Experimental Approach

Maruti Suzuki India, Ltd.-Naveen Malik, Ayan Bhattacharya, Sahil Jindal, Sayed Zergham Ali Naqvi
  • Technical Paper
  • 2019-28-2404
Published 2019-11-21 by SAE International in United States
Nowadays, Road Load Simulators are used by automobile companies to reproduce the accurate and multi axial stresses in test parts to simulate the real loading conditions. The road conditions are simulated in lab by measuring the customer usage data by sensors like Wheel Force transducers, accelerometers, displacement sensors and strain gauges on the vehicle body and suspension parts. The acquired data is simulated in lab condition by generating ‘drive file’ using the response of the above mentioned sensors. Due to non- linear nature of the vehicle parts, transmissibility of load is a complex phenomenon.Due to this complex transmissibility, good simulation at wheel center does not always ensure good correlation at all vehicle locations. The low level of correlation is common at the locations like engine mount, horn bracket and other overhanging brackets which are away from the wheel center. However, during countermeasure evaluation for vehicle development, often it becomes essential to simulate failure at this kind of low correlation zones.In this paper, an experimental approach was applied for focused failure simulation of engine mount which…
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Evaluating Effects of Roll Stiffness Change at Front and Rear Axles on Vehicle Maneuverability and Stability

Maruti Suzuki India, Ltd.-Eric Pranesh Reuben, Raghav Budhiraja, Sreeraj N, Rakesh K, Amardeep Singh
  • Technical Paper
  • 2019-28-2406
Published 2019-11-21 by SAE International in United States
To cater the push towards “Vehicle Light Weighting”, both sprung and unsprung mass are being reduced. This results in reduced stiffness and thus has a profound undesirable effect on the overall vehicle handling. To understand the effect of different reduction ratios of sprung to unsprung mass; it is desired to understand how changes in stiffness affect the overall vehicle handling characteristics. Therefore, the study was conducted to experiment with different values of roll stiffness, at both front and rear axles and comparing the frequency response and phase change of Yaw Gain observed through a Pulse Input test. The present work is further correlated with subjective feedback to predict the shift in vehicle balance and handling characteristics.
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