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Symposium on International Automotive Technology 2015
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Developing & Simulating the Duty Cycle on Engine Dynamometer based on Engine RWUP

Amrita School of Engineering-Sivanesan Murugesan, Lakshmikanthan Chinnasamy
Mahindra Heavy Engines Pvt. Ltd.-Abhijeet Patil
Published 2015-01-14 by SAE International in United States
Appropriate test cycle is required for engine testing. To do so, a new methodology is developed for deriving Engine Test Cycle based on real world duty cycle. Transient speed and load is to be collected from the functional engine on the field. The duty cycle for cyclic operation will be developed from the actual transient speed and load conditions. An iterative process and the comparison of chi-square statistical data is used to categorize typical microtrips, segments of engine operation collected during performance of certain activities. Different microtrips of all activities were combined together to make up a cycle of operation and test cycle as well. These data's are compared to statistical data which is used to illustrate the raw data. On successful comparison, the transient test cycle is validated on the test bed. To facilitate further engine testing, the cycle is transformed into a schedule of torque and speed points at One second intervals. FTP (Federal Test Procedure) is used for normalizing the Data. From the conducted work a representative test cycle is developed for…
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Dynamic Analysis of Body Control Module

Finite Four Technologies-Abhijit Majage S
Vishwakarma Institute of Technology-Nikhil V. Mahajan, Shriniwas Chippa P
Published 2015-01-14 by SAE International in United States
Nowadays, the passenger cars are employing more and more electronic devices for controlling various mechanisms. This has increased the demand for such equipments in the passenger car. The electronic devices for controlling the mechanisms such as keyless entry, window, wiper controllers, mirror controls, engine performance monitors, security systems, lighting control are mounted on Printed Circuit board (PCB) which is enclosed inside the plastic cover assembly called Body Control Module (BCM). The BCM is attached inside the dashboard assembly which is subjected to various loading conditions. In addition, space and height constraints should also be taken into consideration. In present work, dynamic analysis of existing design of BCM is carried out. It has been observed that, the existing design fails under impact loading condition. To overcome the failure, modifications in design are proposed. The modified design of BCM has been tested through both, numerical simulations and experiments. Further, modified design of BCM has been tested for vibration loading and mechanical shock condition using numerical simulation. The results show that the component is safe under these loading…
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CFD Modeling of Advanced Swirl Technique at Inlet-Runner for Diesel Engine

ARAI-Kamalkishore Vora
Moscow Institute of Physics & Technology-Sparsh Sharma
Published 2015-01-14 by SAE International in United States
This paper summarizes the research work incorporated in the exploration of the potential of swirling in CI Engine and designing of a new mechanism, particularly at inlet, to deliver it to improve the in-cylinder air characteristics to eventually improve mixing and combustion process to improve the engine performance.The research is concentrated on the measures to be done on engine geometry so as to not only deliver advantage to any specific fuel. According to the CI combustion theory, better engine performance may be achieved with Higher Viscous Fuel by improving the in-cylinder air-fuel mixing by increasing the swirl (rotation of air view from top of the cylinder) and tumble (rotation of air view from front of the cylinder) of in-cylinder air inside the fuel-injected region. The proposed inlet component is embedded with airfoil and is suitably designed after being iterated from four steps. The deciding factors of shape and orientation of these airfoils are height, chord length and number of blades. The preliminary assessment of the proposed component is performed on a CFD code using incompressible…
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Predicting and Optimizing CNG Vehicle Performance on Chassis Dynamometer through 1D Simulation by using Vehicle Performance Algorithm

A R A I-Mohammad Jamadar, Kishor Kumar Kavathekar, S D Rairikar, S. S Ramdasi, S.S Thipse, N. V Marathe
VIT University / A R A I Academy-Rahul R Kartha
Published 2015-01-14 by SAE International in United States
The paper deals with the simulation of a Light Commercial Vehicle (LCV) using vehicle performance algorithms. This method speeds up the product development process. Also by using these kind of methodology in vehicle simulation there is much noticeable reduction in cost of testing. The simulation model is used for parametric studies of the vehicle and also to attain objectives such as to optimize transmission ratio, full load acceleration, maximum tractive force, gradient performance, fuel consumption and the exhaust emission.In this case study, simulation model of a CNG, LCV is used to analyze the performances similar to that done in a chassis dynamometer. The simulation leads to the prediction and evaluation of various parameters such as fuel consumption, exhaust emissions, full load acceleration, gradient performance & maximum tractive effort for Indian Driving Cycle. The methodology of optimization of transmission ratio includes the design and mathematical calculation of transmission ratios. The values of transmission ratios are obtained by theoretical mathematical calculations and the second category of ratios are based on the bench marked values from different products.…
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A CAE Approach towards Development of an Optimized Design of Bumper

Maruti Suzuki India Ltd.-Arpit Kulshrestha, Nalin Rawat
Published 2015-01-14 by SAE International in United States
During the conceptualization of vehicle, it is big challenge for automotive manufacturer to design a vehicle which has an excellent aesthetic looks as well as meet the stringent vehicle regulations. In the vehicle styling, bumper plays an important role in deciding of the contemporary looks of the vehicle. To improve customer satisfaction, it is important to design a bumper which provides feeling and sense of durability.In addition, bumper should sustain low-speed impact and protects the peripheral components such as parking lights, headlamps, hood, back door and safety related installed equipments like Rear parking camera, parking sensors, etc. Bumper should be dent resistant and be able to regain its original shape on removal of the applied load. An elegant design of bumper should be light weight with high strength.This paper explains about a new CAE methodology developed to simulate the real life loading condition of bumper and to calculate the deformation in the bumper. Physical testing is being conducted to validate the design. On the basis of CAE and test correlation results, an optimized design of…
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Failure Correlation and CAE Based Design Development for Seat Belt Anchorage as per AIS-015

Mahindra & Mahindra, Ltd.-Rakesh Kumar, Aditya Malladi, Sridhar lingan Sr
Published 2015-01-14 by SAE International in United States
For the purpose of effective occupant restraint, seat belt anchorage test is devised to prevent any failure at the anchorage locations during vehicle crash. In India Seat Belt Anchorages (SBA) certification test is mandatory for M and N types of category vehicles with regards to forward and rearward facing seats in the vehicle.During the development phase failure at seat anchorage location was observed in physical test, which resulted in vehicle not meeting the regulatory requirement. This phenomenon of anchorage failure was captured through Finite Element (FE) simulations and correlation was done to understand the root cause of failure for future development. Computer Aided Engineering (CAE) based design proposals were developed by considering various parameters which influence the load path and force distribution at seat belt and seat anchorage locations. This paper talks about a detailed study done to estimate effects of variation in design, material and thickness properties at anchorage locations. After various feasibility checks, an optimized FE driven design has been considered for physical testing and was successfully validated with good correlation. Furthermore, during…
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Rubber Tire Characterization Using Experimental and Computational Methods in Crash Applications

Tata Motors Ltd-Chaitanya Pendurthi, Sourabh Tiwari
Tata Technologies-Sujit Chalipat, Ganesh Bhagwant Gadekar
Published 2015-01-14 by SAE International in United States
Tire plays an important role in frontal impacts as it acts as a load path to transfer loads from barrier to side sill or rocker panels of passenger vehicles. In order to achieve better correlation and more reliable predictions of vehicle crash performance in CAE simulations, modeling techniques are continuously getting refined with detailed representation of vehicle components in full vehicle crash simulations. In this study, detailed tire modeling process is explored to represent tire dynamic stiffness more accurately in frontal impact crash simulations. Detailed representation of tire internal components such as steel belts, body plies, steel beads along with rubber tread and sidewall portion have been done. Passenger car tubeless radial tire was chosen for this study. Initially, quasi-static tensile coupon tests were carried out in both longitudinal and lateral direction of tread portion of tire. After achieving decent CAE correlation at coupon level tests, static compression test was carried out on tire assembly with Universal Testing Machine and dynamic impact test with moving trolley. Complete tire model was characterized for static and dynamic…
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Reduction of Flow Induced Noise Generated by Power Steering Pump Using Order Analysis

Tata Motors Ltd.-Jayant Sinha, Ajit Kharade, Shrihari Matsagar
Published 2015-01-14 by SAE International in United States
An interior sound quality is one of the major performance attribute, as consumer envisage this as class and luxury of the vehicle. With increasing demand of quietness inside the cabin, car manufactures started focusing on noise refinement and source separation. This demand enforces hydraulic power steering pump to reduce noise like Moan and Whine, especially in silent gasoline engine.To meet these requirements, extensive testing and in-depth analysis of noise data is performed. Structured process is established to isolate noises and feasible solutions are provided considering following analysis. a)Overall airborne noise measurement at driver ear level (DEL) inside the cabin using vehicle interior microphone.b)Airborne and Pressure pulsation test by sweeping pump speed and pressure at test bench.c)Waterfall analysis of pump at hemi anechoic chamber for order tracking and noise determination.The work presented in this study involves an experimental approach to characterise the noise & reduce the same by order analysis and attenuate the parts at dominant frequency.All significant process variable & factors are identified which affect the quality characteristic of noise. Co-relation of vehicle in-cab noise…
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Design and Development of Composite Road Wheel for Tracked Vehicles

ASL, DRDO-Kalyan Vedula
Institute Of Technology Management-Shashi Bhushan Singh
Published 2015-01-14 by SAE International in United States
The Armoured fighting vehicle designers are continuously fighting for ways to reduce vehicle weight, increase fuel efficiency, improve reliability, and reduce cost. Customized engineering design and materials are becoming more widespread on all fronts. Also, vehicle emission norms are getting stringent day by day and there is increasing pressure to reduce fuel consumption. One important method of achieving the fuel economy and improve vehicle performance is to reduce vehicle weight.In view of the above advanced materials like Carbon Fiber Reinforced Polymer (CFRP) composites are promising to be the material to look for when it comes to reduce weight of structural elements due to its high strength to weight and high stiffness to weight ratios and hence was used for the development of Bogie Wheel of a light tracked vehicle.This paper illustrates the developmental methodology of Carbon Fiber Reinforced Polymer (CFRP) Road wheel for 20 ton class of tracked vehicle. The Composite Road wheel was tested on the test rig which simulated all the loading conditions of the ICV (Infantry Combat Vehicle).
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Dynamic Analysis and Shape Optimization of Free Falling Steel Insert Used In Hand Brake Valve

Wabco India, Ltd.-N. Prabhakar, Suresh Gayakwad J, P. Lingeswaramurthy, P.S. Lakshman
Published 2015-01-14 by SAE International in United States
The present investigation deals with the design and shape optimization of the steel insert used in the hand brake valve to withstand the impact load during brake off condition. This hand brake valve is used in the vehicles for parking brake application. It consists of a steel insert with a helical coil spring for locking and unlocking of a lever during brake on and off condition. Also a torsion spring with a cam mechanism is used for opening and closing of a hand brake valve. When the lever is locked the flexible elastic object (torsion spring) stores the mechanical energy when it is twisted. When it is unlocked (braking off) it exerts a force (actually torque) in the opposite direction, proportional to the angle it is twisted. During the braking off condition the steel insert gains the angular velocity from the stored mechanical energy of the torsion spring. There by the steel insert hits the top cover of the hand brake valve Subjected to the repetitive shock impulses where the force acts for a very…
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