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Road Noise Prediction Assessment Using CAE Instead Of Costly And Time Consuming Physical Tests

Tata Technologies, Ltd.-Vishnu S, Prajith J, Muralidhara Holla, Patil Suhas, Indranil Bhattacharyya
  • Technical Paper
  • 2020-01-0492
To be published on 2020-04-14 by SAE International in United States
Virtual Product Development (VPD) with a vision to eliminate prototype testing is the trend in automotive industry. Reducing the total vehicle development period with optimized output has been the major requirement of this new trend, fueled by increasing competition and shorter product life cycle. In this regard, Computer Aided Engineering (CAE) has taken more significant role than ever in the vehicle development programs. Prediction of road noise in passenger car is one of the important attribute to NVH Simulations. In the present work, CAE - NVH simulation of road noise is carried out on the Finite element model of the vehicle, eliminating the costly and laborious test procedures. An alternative to the existing MBD/Test input method is explored in this work. Generating the load inputs for the structure-borne road noise in a cost and time saving method with accuracy is one of the challenges in these simulations. Enforced displacements in the frequency domain are generated using ISO 8608 standard road profiles and are used as input to the vehicle system for FE Simulation. By this…
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NVH Full Vehicle Development - Virtual Simulation Process for Low Frequency Structure-Borne Regions

Tata Technologies, Ltd.-Prajith J, Vinayak Sagade
  • Technical Paper
  • 2020-01-1266
To be published on 2020-04-14 by SAE International in United States
NVH (noise, vibration and harshness) is a key attribute in Vehicle development. Refined vehicle enhances customer’s perception and also the brand image. Most of the OEMS have well-articulated NVH Development process which is integrated in to Product development Cycle (PDC). The need for such process is essential to identify the inherent weakness or threats at earlier stage. And so the mitigation process need not warrant deviation or protection of resources, which would be a bottleneck at later stage. NVH is complex phenomena which deals with structure borne and airborne sources. So a NVH compliant vehicle is the product of resources which includes the skilled manpower, process and computational infrastructure. The stress for NVH front loading has gained traction in Global OEMS, to deliver “First Time Right “NVH products. Full Vehicle NVH (VNVH) simulation is one of the complex virtual methods, done to understand and mitigate the inherent weakness of the systems and integration. Evaluations are based on load cases which are designed to simulate RWUP (Real World Usage Profiles). A systematic - “Sub System to…
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Prediction of the variation on Steering Wheel Shimmy due to Tangential and Radial Force variation of the tyres.

Tata Technologies, Ltd.-Madhu Shurpali
  • Technical Paper
  • 2020-01-0650
To be published on 2020-04-14 by SAE International in United States
The objective of this work is to develop a process that predicts the amount of Steering wheel shimmy in a vehicle due to the tangential and radial force variation in the Tyre/Wheel assembly. Steering wheel shimmy is defined as the torsional oscillation of the steering wheel. The tangential and radial force variation was modelled based on test data and applied on the wheels as excitation. Variation of these forces with the vehicle velocity had to be considered. The various factors that affect shimmy were then established. These factors were then divided into two categories – Geometric and Non-Geometric. A DOE was done, while considering the manufacturing variations, to study the sensitivity of those factors on shimmy. The DOE results were used to fit a statistical model that predicts the shimmy velocity while considering the factors as inputs. The statistical model was then considered for a Montecarlo simulation to estimate a possible distribution of shimmy velocity. A Normal or Weibull distribution was considered for the MonteCarlo Simulation for each of the factors in the DOE study.…
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Replacing Twin Electric Fan Radiator with Single Fan Radiator

Tata Technologies, Ltd.-Aashish Bhargava, Gaurav Soni
Engine Design & Testing-Tushar Warkhade
  • Technical Paper
  • 2019-28-2381
Published 2019-11-21 by SAE International in United States
Downsizing is one of the crucial activities being performed by every automotive engineering organization. The main aim is to reduce - Weight, CO2 emissions and achieve cost benefit. All this is done without any compromise on performance requirement or rather with optimization of system performance.This paper evaluate one such optimization, where-in radiator assembly with two electric fan is targeted for downsizing for small commercial vehicle application. The present two fan radiator is redesigned with thinner core and use of single fan motor assembly. The performance of the heat exchanger is tested for similar conditions back to back on vehicle and optimized to get the balanced benefit in terms of weight, cooling performance and importantly cost. This all is done without any modification in vehicle interface components except electrical connector for fan. The side members and brackets design is also simplified to achieve maximum weight reduction.Further Cooling system performance of engine is evaluated along with Fuel efficiency; results are compared with present configuration.
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Development of Low Cost Lifesaving System for Automotive Vehicles during Road Accidents

Tata Technologies, Ltd.-Sachin Madhukarrao Pajgade, Aashish Bhargava
  • Technical Paper
  • 2019-28-2460
Published 2019-11-21 by SAE International in United States
Vehicular accidents are life-threatening and result in fatal casualties in developing country such as India. According to estimates, traffic accidents kill more people in India than diseases like Cancer and AIDS. More than 150,000 people are killed every year in traffic accidents in India, which works out to 400 fatalities a day, far higher than developed auto markets like the U.S., which had logged about 40,000 deaths in 2016. The World Health Organization estimates road accidents cost most countries about 3 per cent of their gross domestic product.India being the fastest growing economy will be the world’s third-largest car market after China and the U.S. by 2020, according to automobile researchers.According to research study most of death cause due to not getting help on time to the injured person. Research has proven that if injured person is not found any option of help then they also lose the power to fight such critical situation due to psychological effect. When vehicle met accident, people are not getting on time support, this delay is the major cause…
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Optimization of Bio-Diesel Fuel Filter Size Media and Configuration for Longer Service Interval

Tata Technologies, Ltd.-Gaurav Soni, Aashish Bhargava, Sujit Gavade
  • Technical Paper
  • 2019-28-2391
Published 2019-11-21 by SAE International in United States
Bio diesel is one of the most promising fuel which can not only replace the conventional fuels but also environment friendly in terms of Greenhouse gases emission. Adaptation of Bio diesel comes with reduced maintainability and high maintenance cost. Blends of biodiesel and conventional diesel are most commonly used in automotive diesel engines. Biodiesel is most popular choice as an alternate fuel of fossil diesel due to its easy availability, eco-friendly nature and minimum change in existing diesel engine for retro fitment.In this paper efforts have been taken to optimize the life of Fuel filter for bio diesel application. For improving Fuel filter life, modifications carried out in Fuel filter media, size and configuration. Further, Fuel filter tested on Engine test bed and Vehicle to establish the life of filter in real world usage condition. Testing Results were compared with existing diesel fuel filter.
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Optimization of Compression Ratio for DI Diesel Engines for Better Fuel Economy

Tata Technologies, Ltd.-Sujit Gavade, Aashish Bhargava, Gaurav Soni, Chandrakant Deshmukh
  • Technical Paper
  • 2019-28-2431
Published 2019-11-21 by SAE International in United States
Fuel economy is becoming one of the key parameter as it does not only account for the profitability of commercial vehicle owner but also has impact on environment. Fuel economy gets affected from several parameters of engine such as Peak firing pressure, reduction in parasitic losses, volumetric efficiency and thermal efficiency. Compression ratio is one of key design criteria which affects most of the above mentioned parameters, which not only improve fuel efficiency but also results in improvement of emission levels.This paper evaluates the optimization of Compression ratio and study its effect on Engine performance.The parameters investigated in this paper include combustion bowl volume in Piston and Cylinder head gasket thickness as these are major contributing factors affecting clearance volume and in turn the compression ratio of engine. Based on the calculation results, an optimum Compression Ratio for the engine is selected. Further Engine testing carried out with selected Compression ratios and parameters such as Fuel efficiency, In-cylinder pressure, and Brake thermal efficiency and Ignition delay were compared.
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Development of Low Cost Closed Crankcase Ventilation With Oil Mist Separation System on Light Duty Diesel Engine

Tata Technologies, Ltd.-Vishal Kailas Walhekar, Sujit Gavade, Gaurav Soni, Aashish Bhargava
  • Technical Paper
  • 2019-28-2578
Published 2019-11-21 by SAE International in United States
Currently automotive industry is facing bi-fold challenge of reduction in greenhouse gases emissions as well as low operating cost. On one hand Emission regulations are getting more and more stringent on other hand there is major focus on customer value proposition.In engine emission the blow by gases are one of the source of greenhouse gases from engine. Blow-by gases not only consist of unburnt hydrocarbons but also carry large amount of oil. If oil is not separated from these gases, it will led to major oil consumption and hence increase total operating cost of Vehicle.Considering the above challenges, effort taken to develop a low-cost closed crankcase ventilation with oil mist separation system on diesel engine. For cost-effective solution, two different design and configuration of oil mist separation system developed.Further, engine with two different above said configuration has been tested for blow-by gasses and oil consumption measurement on Engine test bed and vehicle to understand the behavior in real environment. Further results compared for both configuration and further actions proposed.
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Importance and Contribution of Alternate Fuels in India’s Green Mobility Story

Tata Technologies, Ltd.-Prafulla P Ghare, Meenakshi Agale, Tushar Warkhade, Vijay Sawant, Vaibhav Magdum
  • Technical Paper
  • 2019-28-2376
Published 2019-11-21 by SAE International in United States
Indian automotive industry has witnessed never-seen-before push towards Green mobility from the Government of India (GOI). GOI has maintained a firm stature while leap-frogging from BS-IV to BS-VI and has backed up its intent with equally firm actions of providing the facilities, infrastructure and necessary support to industry. After a lot of initial resistance, the Auto manufacturers have taken up the challenge and are well paced towards meeting the target of 1st April, 2020. Due to many aspects such as commercial viability, wide range of expectation from different type of customer segments e.g. 2-wheeler, 3-wheelers, SCV, Light & MHCV and passenger car segments etc. the overall landscape of market in terms of product segmentation, Diesel-Petrol share pattern is poised to change.Parallel to this development, a wave of electric vehicle enthusiasts has hit the world which boasts of being the ultimate solution towards Green mobility. Indian automotive market is no different in this development. In fact, for the first time in Indian automotive history, Indian market can be seen to be marching the new technology story…
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Improved Clutch Pedal Ergonomic Position through Adjustable Clutch Pedal Assembly as per Anthropometry

Tata Technologies, Ltd.-Chandrakant Gopalrao Musale, Ashish Deshpande, Sachin Latare, Mangesh Deshmuk
Published 2019-01-09 by SAE International in United States
In automotive sector, worlds demanding more riding comfort so accelerator, brake and clutch pedals plays important roles in providing comfort or discomfort to driver. Now days automotive OEMs paying more attentions on providing comfortable ergonomics positions of pedals but it is difficult meet the requirement of each and every (all percentile populations) person because of packaging/manufacturing/costing constraint.Here we are providing the solution to meet the requirement of comfortable ergonomics position as per drivers wish for all kind of persons/drivers (5th percentile to 95th percentile) by providing the adjustable clutch pedal assembly with simple mechanism.Currently adjustment provided in driver’s seat to adjust the comfortable driving position which provide the comfortable positions for 25th percentile to 95th percentile peoples also this arrangement having some limitations such as space constraint in cabin also high belly with low height persons may face the issue of belly obstacle while steering the vehicles. To overcome these issues adjustment in the pedal is must for comfortable driving position.
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