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Deshmukh, Himanshu
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Physical and Virtual Simulation of Lightweight Brake Drum Design for Heavy Duty Commercial Vehicles Using Alternate Material Technologies

VE Commercial Vehicles Ltd.-Suresh Kumar Kandreegula, Himanshu Deshmukh, Shivdayal Prasad, Sonu Paroche, Ashesh Anil Shah
Published 2018-10-05 by SAE International in United States
Brake drum in commercial vehicles is very important aggregate contributing towards major weight in brake system module. The main function of brake drum is to dissipate kinetic energy of vehicle into thermal energy, as a results in braking operation major load comes on brake drum. Hence this is very critical component for vehicle safety and stability [1].Objective of this paper is to increase the pay load, which is utmost important parameter for commercial vehicle end customers. To achieve the light weighing target, alternate materials such as Spheroidal graphite iron (SGI) has been evaluated for development of brake drum. Many critical parameters in terms of reliability, safety and durability, thickness of hub, wheel loading, heat generation on drum, manufacturing and assembly process are taken into consideration. The sensitivity of these parameters is studied for optimum design, could be chosen complying each other’s values.Digital thermal performance evaluated in house, fine-tuned and verified by correlating with test data available for existing cast iron design and then applied for new design with alternate materials. In two different designs around…
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Finite Element Simulation and Validation of Planetary Gear System

VE Commercial Vehicles Ltd-Sonu Paroche, Himanshu Deshmukh, Suresh Kumar Kandreegula, Alok Muley
Published 2018-07-09 by SAE International in United States
The planetary gear system is a critical component in speed reduction of gear system. It consists of a ring gear, set of planetary gears, a sun gear and a carrier. It is mainly used in high speed reduction transmission. More speed variation can be achieved using this system with same number of gears. This speed reduction is based on the number of teeth in each gear. The size of new system is compact. A theoretical calculation is performed at concept level to get the desired reduction of speed. Then the planetary gear system is simulated using ANSYS software for new development transmission system. The final validation is done with the testing of physical parts. This concept is implemented in 9speed transmission system. Similar concept is in development for the hub reduction with planetary gears. The maximum 3.67 reduction is achieved with planetary system. The stresses in each pin is calculated using FEA.
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