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Equivalent Radiated Power driven optimization for driveline housings using simulation tools to cut-down the project time

VE Commercial Vehicles Ltd-Suresh Kumar Kandreegula
  • Technical Paper
  • 2019-28-2533
To be published on 2019-11-21 by SAE International in United States
In the field of Automotive industry, being competitive makes you succeed. Industry is moving towards advancement day by day. New technologies to improve fuel efficiency, crash resistance, vehicle noise levels have been trending. At VECV, we have traditionally worked on CAE of driveline housings (clutch housing & transmission housing) based on static, dynamic and transient loadings. Currently, weight optimization technique depends on the structural and dynamic loading conditions, but do not consider acoustic concerns. Powertrain housings are highly prone to vibrations and leads to high level of noise. Noise has been constant issue in the casting components associated to driveline. There have been lot of research going on to reduce the level of noise and vibrations in the vehicle driveline, which ultimately leads to fuel efficiency and ergonomic benefits. Low noise generation can also lead to saving of lot of resources deployed to dampen the noises. In order to capture the acoustic responses of the system and to improve the design based on acoustic responses, a comprehensive analysis of newly developed driveline housings (clutch housing…

Design, Simulation and Validation of Front End Auxiliary Drive (FEAD) Mounting Bracket for Electric Powertrain Application

VE Commercial Vehicles Ltd-Kamal Rohilla, Suresh Kumar Kandreegula, Saurabh Agrawal, Jasvir Bisht, Pungaraj Muthaiah
Published 2019-01-09 by SAE International in United States
The main driving force behind recent innovations in automotive sector is the need to decrease the dependability on fossil fuels and move towards alternative sources for energy. While there is still substantial scope for improvement in conventional diesel and petrol engine based powertrains, the inherent dependency on limited and rapidly depleting carbon based fuels make their long term usage impractical highlighting the need for alternative non-conventional powertrain setups.In the recent past, electric powertrains have come out as favorable alternative as they are extremely flexible in adopting to scenarios where energy for use might be drawn from multiple sources such as solar power, hydroelectric, nuclear reaction, etc. The advantages can further be magnified by adopting the electric power based powertrains in mass transportation application such as bus application. However, the adoption of electric power based powertrains requires a complete redesign of powertrain mounting architecture.This study is specifically focused on redesigning the Front End Accessory Drive (FEAD) mounting bracket for bus application. The new design will also include the provision for the mounting of prime mover (electric…
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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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Optimization of Propeller Shaft Vibrations in Truck Segment through Physical and Virtual Simulations

VE Commercial Vehicles Ltd-Jeevan Jathar, Sonu Paroche, Kunal Kamal, Suresh Kumar Kandreegula
Published 2018-07-09 by SAE International in United States
This paper presents theoretical calculation, analysis and simulation (validation and verification) of driveshaft torsion vibration. The vibration measurement validation verification has been carried out on vehicle (4x2) having four cylinder engine 85kw@2800 rpm and six speed manual transmission for getting correlation between values of theoretical calculations and CAE results.This analysis has been done in order to achieve vehicle good performance in terms of driving comfort as well as smooth functionality with zero vibration frequency at high speed. The propeller shaft series selection and refinement has been done using theoretical iteration with operating angle of prop shaft which exits in between the universal joint planes. A frequency of vibration analysis has evaluated at different propeller shaft layout and duty cycle.The vibration performance predictions for vehicles with these design is rigorously done. The required parameters are recorded, compared in tabulated form shown in graphical way. The lowest operating angle of drive shaft design leads to optimize the vibration and provide better overall vehicle performance at different speed. An effective selection of drive shaft layout has been done…
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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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Design and Development of Hybrid Single Rod Gear Shift Lever (SRGSL) System With Extra Degree of Freedom

VE Commercial Vehicles Ltd.-Naveen Tripathi, Aravally Patel, Hemant Nishad, Suresh Kumar Kandreegula
Published 2018-04-03 by SAE International in United States
Manual Gear shifting mechanism is a customer touch point in vehicle driving conditions and it is a frequently used functional part of the vehicle. Inherent challenges exist to develop a gear shifting system that achieves better comfort shifting gears in manual transmissions, i.e. gear shift levers should be comfortable, efficient and reliable. There are several traditional concepts available for designing a mechanical interface for gear shift system like cable GSL (Gear Shift Linkages), mechanical GSL, engine mounted SRGSL (single rod gear shift linkages), directly transmission mounted GSL. All are having pros and cons over another.A unique attempt is made to provide an efficient single rod type gear actuation system for commercial vehicle where one end is directly mounted on the cowl floor of the bus/Truck and another end is connected to transmission lever. Spherical ball mechanism is used for shifter lever mounting on cowl floor and lower part of this lever is connected to single rod through a yoke type mechanism. This paper is about the design & simulation part of this hybrid type single…
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Manual Gear Shifting Mechanism Integrated with Cabin Tilting Provision by Providing Telescopic Rod Type Arrangement with Cam and Follower Mechanism

VE Commercial Vehicles Ltd.-Naveen Tripathi, Aravally Patel, Suresh Kumar Kandreegula
Published 2018-04-03 by SAE International in United States
In manual driven vehicle, gear change mechanism is a component that is too often taken granted but it is one of the most important feature of the vehicle. Customer touches, feels the entire vehicle through gear shift mechanism hence it must be quick and smooth in action, efficient and totally reliable. In cab over engine type truck configuration, the mechanical single rod is preferable and best efficient option for gear shift mechanism. In conventional single rod design, one end of gear shifting linkage is mounted on the engine through bracket and the lever comes inside from the cabin, beside the driver seat for changing the gears. Another end of this linkage is connected to vehicle transmission shift lever. In this conventional design, gear shift lever is having huge induced vibration, which is irritating and frustrating in nature.And during the cabin tilting at its axis, a cut out is required on cabin floor which allows cab tilting when GSL is mounted on engine. Sealing this cut out from engine heat, hot air and noise is a…
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Innovative Approach of Wedge Washer to Avoid Bolt Loosening in Automotive Applications

SAE International Journal of Passenger Cars - Mechanical Systems

VE Commercial Vehicles Ltd.-Suresh Kumar Kandreegula, Rahul Jain, Shivdayal Prasad, Rahul Machiya, Avinash Mandyam
  • Journal Article
  • 06-11-01-0004
Published 2017-10-08 by SAE International in United States
Automotive vehicle includes various systems like engine, transmission, exhaust, air intake, cooling and many more systems. No doubt the performance of individual system depends upon their core design. But for performance, the system needs to be fastened properly. In automotive, most of the joints used fasteners which helps in serviceability of the components. There are more than thousands of fasteners used in the vehicle. At various locations, we found issue of bolt loosening and because of this design intent performance has not met by the system. During product development of ECS (Engine cooling system), various issues reported to loosening the bolt. The pre-mature failure of bolt loosening, increases the interest in young engineers for understanding the behavior of fastener in vehicle running conditions. This paper focuses on the design of wedge shape of washer to avoid bolt loosening. Further, the paper is reinforced with FEA simulation for understanding the behavior of the bolt loosening. The joint in ECS is tested experimentally and FE simulated using simulation tools with various methods under different vibration conditions like…
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Simulation and Validation of Propeller Shaft Mounting Brackets for Heavy Duty Commercial Vehicles

VE Commercial Vehicles Ltd-Suresh Kumar Kandreegula, Kamal Rohilla, Naveen Sukumar, Kunal Kamal
Published 2017-07-10 by SAE International in United States
A propeller shaft is a mechanical component of drive train that connects transmission to drive wheels/axle with the goal to transfer rotation and torque. It is used when the direct connection between transmission and drive axle is not possible due to large distance between their respective assigned design spaces. In commercial vehicles especially in heavy duty (GVW/GCW>15 tons) a single piece propeller shaft is seldom used due to its inherent disadvantages and therefore, most if not all, of the setups consists of multiple pieces of propeller shaft which are directly mounted on to frame cross members with the help of mounting brackets. As such the mounting bracket assembly undergoes various dynamic and static loading conditions and should be able to withstand these loads.This paper will focus on the FEA analysis of propeller shaft mounting assembly system. Furthermore, these results will be correlated with physical tests results collected from test rig and physical vehicle testing. The design of mounting system is of high importance in commercial vehicle sector as the failure of mounting assembly will result…
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Integration of Cylinder Head and Intake Manifold for Powertrain Downsizing and Light Weighting Using Simulations Tools

VE Commercial Vehicles Ltd-Suresh Kumar Kandreegula, Jham Tikoliya, Hemant Nishad
Published 2017-03-28 by SAE International in United States
As the commercial vehicle engine heads towards the next generation of stringent emissions and fuel economy targets, all aspects of the internal combustion engine are subject to close scrutiny. Inherently, ICE’s are very inefficient, with efficiency varying between 18 ~ 40%. This efficiency is a function of friction losses, pumping losses and wasted heat. Currently, automotive OEM’s globally are hard at work trying to attack these issues with various solutions to achieve incremental gains.The leading trend is getting more power from less space, also known as downsizing. Due to the importance of downsizing, direct injection and other technologies, it is imperative to highlight another key area, where OEM’s are expanding their limits to gain those extra few kilometers per liter of fuel i.e. weight reduction. From an emissions perspective, it is estimated that every 50 kg of weight reduced from an average 1,500 kg vehicle cuts CO2 emissions by 4 ~ 5 grams.The key areas of the powertrain on which OEM’s will focus their weight reduction efforts will be engine, transmission, exhaust, fuel system, casing,…
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