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Windshield Defrosting Analysis: A Numerical and Experimental Approach

Maruti Suzuki India Ltd.-Chandan Kumar, Mohan Makana, Felix Regin, Amit Garg, Durga Prasad Pedamallu
Published 2019-10-11 by SAE International in United States
The outside visibility through the windshield and ORVM visibility through the side glasses are critical for safe driving. The frost deposition on the Windshield and side glasses in the cold climatic condition impairs the outside and ORVM visibility during driving and hence leads to an unsafe driving condition. In India, the regulation AIS-084 governs the defrosting standard. The defrosting performance evaluation by testing cannot be performed at concept stage when the vehicle prototype is not available. It also increases the cost of vehicle development due to increase in the number of prototype used for testing.This paper explains about the in-house developed CFD methodology to evaluate the windshield defrosting performance of the vehicle in the concept stage when no vehicle proto is available and cost of countermeasure for defrosting performance improvent is very less. This methodology is implemented for some of the existing models. The results of CFD simulations are compared to the experimental data using a correlation study and the correlation coefficient of numerical and experimental measurements were reported. CFD simulation was in good agreement…
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Aerodynamic Design Optimization in Rear End of a Hatchback Passenger Vehicle

Maruti Suzuki India, Ltd.-Devesh Bajpai, Felix Regin
Published 2019-03-25 by SAE International in United States
Aerodynamic evaluation plays an important role in the new vehicle development process to meet the ever increasing demand of Fuel Economy (FE), superior aero acoustics and thermal performance. Computational Fluid Dynamics (CFD) is extensively used to evaluate the performance of the vehicle at early design stage to overcome cost of proto-parts, late design changes and for time line adherence.CFD is extensively used to optimize the vehicle’s shape, profiles and design features starting from the concept stage to improve the vehicle’s aerodynamic performance. Since the shape of the vehicle determines the flow behavior around it, the performance is different for hatchback, notchback and SUV type of vehicles. In a hatchback vehicle, the roof line is abruptly truncated at the end, which causes flow separation and increase in drag.In this paper, the effect of shape of a hatchback vehicle at the rear end is studied along with drag reduction features like roof end extension, edges on c-pillar, rear combination lamp and rear bumper. Response surface method (RSM) is used to explore the sensitivity of various design parameters.…
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Aerodynamic Development of Maruti Suzuki Vitara Brezza using CFD Simulations

Maruti Suzuki India, Ltd.-Ashit Kumar, Amarjeet Singh, Dinesh S Dhankhar, Felix Regin
Published 2017-01-10 by SAE International in United States
Recent automotive trend shows that customer demand is moving towards bigger size vehicle with more comfort, space, safety, feature and technology. Global market of SUV is projected to surpass 21 million units by 2020. Despite economic slowdown and weak new car sales worldwide, India and China will continue to be primary market for SUV due to sheer size of population, urban expanding middle class and larger untapped rural market. However, stricter emission norms push for clean and green technology and unfavorable policy towards use of diesel vehicle has made the SUV design very challenging due to conflicting needs. Due to bigger size of vehicle, aerodynamic design plays an important role in achieving emission targets and higher fuel efficiency.This paper highlights the aerodynamic development of Maruti Suzuki Vitara Brezza, which is an entry level SUV vehicle with high ground clearance of 198 mm and best in class fuel economy of 24.3 kmpl.CFD has been extensively used for exploring the various design configurations and has helped in selecting the optimized aero-parts configuration based on aerodynamic performance at…
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Passenger Car Water Wading Evaluation Using CFD Simulation

Maruti Suzuki India Ltd-Mohan Makana, Gaurav Kumar, Felix Regin
Published 2016-02-01 by SAE International in United States
Water Wading refers to the situation where a car is moving through relatively deep water at low speed. The challenges of an automotive Original Equipment Manufacturer (OEM) is to integrate the functional parts like bumper, bumper grille, engine undercover, intake system etc., to enhance the vehicle quality and performance. One of the challenges in vehicle front end and engine room design is to prevent water entry into the air intake system during wading. If significant amount of water enter the air intake, some of the water could subsequently enter the engine cylinder, which would damage the critical components within the engine beyond repair.In general practice wading tests have been carried out during proto stage of vehicle development program to ensure vehicle performance. However a Computational Fluid Dynamics (CFD) method for carrying out water wading calculations early during the development phase offers reduction in development cost and time for a new vehicle. This paper explains the CFD methodology to evaluate the water entry into the air intake system. A detailed process development has been done for…
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Analysis of Flow Induced Noise in a Passenger Car Exhaust System - An Experimental and Numerical Approach

Maruti Suzuki India Limited-Deepak Rana, Felix Regin, Mohan Makana
Published 2011-05-17 by SAE International in United States
A muffler or silencer is an integral part of the exhaust system and is a device used to prevent sound from reaching the openings of the exhaust duct and radiating as far field noise. Different acoustical design and analysis techniques are used to predict the acoustical performance of exhaust systems. Flow noise from exhaust tail pipe is one of the major noise sources in a vehicle. Flow noise is generated mainly during fast acceleration operating condition due to complex flow behavior. In this paper, we have studied the detailed flow field and tried to establish an analyses procedure for flow noise prediction. The flow analysis is carried out in commercial CFD solver Star CCM+. The transient engine boundary conditions are obtained from the experimental testing. The flow noise generated from the muffler was calculated by acoustic analogy of Lighthill using the above boundary conditions.The strong fluctuation of pressure inside the muffler generates the broadband noise in the frequency range 1000 - 8000 Hz and the same is validated with experimental data. The experiment was carried…
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A Numerical Analysis on Air-cooling Performance of Passenger Cars

Maruti Suzuki India Limited-Felix Regin
Published 2010-04-12 by SAE International in United States
The influence of environmental changes on underhood and underbody components of a vehicle is an important issue in new vehicle design as increased engine power, cabin comfort demands and package space limitations create an increasingly difficult problem to solve. Sufficient airflow needs to be available for adequate cooling of the underhood components. The amount of air mass flow depends on the underhood geometry details: positioning and size of the grilles, fan operation, and the positioning of the other underhood components. This paper describes a prediction methodology that significantly streamlines the process of passenger car underhood thermal management by utilizing state-of-the-art computer simulation of airflow. The methodology uses a complete 3-D CAD model of all pertinent underhood components of a passenger car with a general purpose Computational Fluid Dynamics (CFD) code to simulate underhood airflow. The heat exchangers condenser and radiator were modeled using a porous media approach by giving the porous coefficient values from the experimentally obtained flow rate versus pressure drop data. The results obtained from the simulation is compared with the experimental values…
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