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Self-Loosening of Three Similar Bolted Joint Designs Using Finite Element Analysis

Univ. of Siegen-Shiva Kumar Manoharan, Christoph Friedrich
Published 2014-04-28 by The Automotive Research Association of India in India
Self-loosening of bolted connections is a crucial failure mode for joints under transverse dynamic load. For some years, three dimensional finite element analysis has been enabled for avoiding experimental investigations of self-loosening. The aim of this paper is to emphasize the effect of joint design on the self-loosening of bolted connections, which is important for product development in early design stage. Joints consisting of internally threaded nut components are often heavier and stiffer as compared with light weight designs consisting of a separate nut. The difference of self-loosening is significant between arrangements with nut thread component and separate nut, although the design versions only contain slight modifications. Hence it is necessary to evaluate the effect of light weight design on self-loosening.
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State-of-the-Art 3D simulation Tool as a Strategic Investment

Transvalor-Christiane Fourment, Julien Barlier, Mickael Barbelet, Patrice Lasne, David Cardinaux
Published 2014-04-28 by The Automotive Research Association of India in India
Virtual forming tools based on Finite Element simulation are routinely used in order to improve process design and to reduce time to market. However, with the growing requirements with regards to in-use properties of forged components, not only the forming processes must be simulated but the entire process chain, including the heat treatment processes that are carried out to improve the mechanical properties of the final part. In order to meet these needs, new heat treatment features have been introduced into the commercial code FORGE®. This paper presents an application of induction hardening to an industrial component. This application demonstrates the strategic capabilities of FORGE® commercial software to achieve production challenges.
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Introduction of High Strength Steel for Commercial Vehicles - Light Weighting of Vehicles

Essar Steel India Ltd.-Satyajit Mohapatra, Sumitra Das
Published 2014-04-28 by The Automotive Research Association of India in India
Light weighting is an increasingly important objective for auto manufacturers. Every gram of weight saved reduces CO2 emissions and thus makes the vehicles eco-friendlier. The reduction in sheet thickness by use of high strength steel is being increasingly adopted as an effective means for weight reduction, because of cost savings. The exhaustive research analysis by ULSAB (Ultra-Light Steel for Auto Body) /ULSAC (Ultra-Light Steel for Auto Concept) has demonstrated that steel is the only material suited to meet the conflicting demands of properties required for the auto applications and offers the possibility of weight saving potential and increased payload.ESSAR steel recognizes the need for stringent product needs for the increasing demands in the new scenario of increasing globalization and design of new generation world platforms. In this paper typical example of components by substitution of S650MC high strength steel grade for long member application for commercial vehicle is presented. Details of metallurgical product designing, development and stabilizing (product as well as customer) are presented to meet today's market demand in terms of weight saving which…
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Design of Automotive Shield using Concurrent Design Approach

TATA Technologies Ltd.-Shreyas Shingavi, Pankaj Bhirud, M. Nagi Reddy, Darshan Mishal
Published 2014-04-28 by The Automotive Research Association of India in India
In Automotive world, different types of shield are used to safe guard the assembly from dirt and dust. These can deteriorate the performance and functioning of systems. Typically the dirt shields are not load carrying members, so preferred to have low gauges and low weight. Dirt shield has to cover many subassemblies, so it has intricate shape as well. Due to low gauge and complicated shape, the manufacturing of these shields becomes challenging in terms of maintaining assembly tolerances. In order to overcome these concerns, concurrent design approach is used. Using this approach manufacturing process of the parts is virtually simulated and residual stresses, strains, permanent set, spring back effect are evaluated. These results are cascaded to assembly load analysis, and results are monitored for deflections. Based on these results various interferences during actual assemblies or failure during assemblies like flushness can be predicted well in advance and design correction can be carried out at very early stage, resulting lower product development cost and time.In this paper, brake assembly dirt shield design approach is presented.…
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Optimization in Forging Process Using Computer Simulation

The Automotive Research Association of India-A. R. Kumbhar, S. A. Kulkarni, J. M. Paranjpe, N. V. Karanth
Published 2014-04-28 by The Automotive Research Association of India in India
New process development of forging component require lot of process knowledge and experience. Even lots of trial-and-error methods need to be used to arrive at optimum process and initial billet dimensions. But with help of reliable computer simulation tools, now it is possible to optimize the complete process and billet dimensions without a single forging trial. This saves lot of time, energy and money. Additionally, simulation gives much more insight about the process and possible forging defects.In this paper, a complete forging process was needed to be designed for a complex component. With the help of computer simulation, the complete conventional forging process and modified forging process were simulated and optimized. Forging defects were removed during optimization of the process. Also billet weight optimization was carried out. Deciding the pre-forming shape of the billet was the main challenge. With use of computer simulation, an innovative pre-forming shape was arrived resulting in reducing billet input weight. The entire forging process and billet pre-form was optimized in such a way that complete filling of cavity was achieved…
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Sliding Wear Behavior of Compacted Graphite Iron Cylinder Liner Material

Ashok Leyland Technical Centre-V.S Sreenivasan, S. Dhanasekaran, Samir Sharma, M. Sathya Prasad
Published 2014-04-28 by The Automotive Research Association of India in India
Cylinder liner and piston ring materials play an important role in the tribological performance of engines. It is possible to reduce friction and wear of cylinder liner and piston ring by using wear resistant material. Compacted graphite iron finds increasing application as a liner material because of its high strength and good wear resistance. In this work, wear performance of two different grades of compacted graphite iron has been compared with that of gray cast iron liner material. Wear characteristics were evaluated using cylindrical specimens in a pin on disc sliding apparatus. High strength compacted graphite iron grade is found to have the best wear resistance among the three materials evaluated in this study. Increased volume fraction of pearlite enhances the wear resistance of high strength compacted graphite iron grade.
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Light Weight, High Flow, High Modulus Colored Polypropylene Compound with Good Gloss for Automotive Interior and Exterior Applications

Mahindra and Mahindra Ltd.-Kuldeepak Mahto, K.V. Balaji, A. Zainulabedin
Published 2014-04-28 by The Automotive Research Association of India in India
The present paper discusses about a glossy polypropylene composition which can replace ABS and PC-ABS in the aesthetic interior and exterior bezels of a car with good stiffness and high flow. High Melt flow index of this composition minimizes the number of gate locations thereby drastically improving the aesthetics. Usage of Special Additives, and High Aspect ratio talc reduced the density of this composition as compared to a conventional PP compound. The combined benefits of lower weight, adequate stiffness, good gloss, scratch resistance and weathering resistance in the unpainted form makes this composition attractive for Interior and exterior aesthetic bezels. Again, this composition is cost-effective thereby reducing the part costs of interior and exterior bezels significantly.
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Titanium - A Futuristic Material for Vehicle Exhaust System and Powertrain Components

Vel-Tech-Vikrant Garud, Avinash Arankalle
Published 2014-04-28 by The Automotive Research Association of India in India
India is blessed with considerable quantity of titanium based mineral resources accounting to about 20% of the world's availability holding and third largest reserves. The main titanium minerals are ilmenite and rutile available in beach sand deposits in the coastal states like Kerala with production of about 0.6 MT by mining & mineral separation process to provide environmental friendly titanium alloys. Though the major usage of titanium alloys are for aeronautics, defense, space, atomic energy sectors, its usefulness with special properties is yet to be exploited for the Indian automotive sectors. The principle advantages of Titanium alloys for automotive application that can be exploited are - 45% lighter than steel, virtually total resistant to acidic attack, four times more corrosion resistance than stainless steel, high specific strength, good ductility and ease to form by forging and machining operations. However at present, cost of extraction, alloying with other metals, casting and metal forming processes makes it difficult to penetrate in automotive industry. The R & D efforts are essential between academia, research institutes, and industry to…
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Development of Tubular Stabilizer for Commercial Vehicle Using Advanced High Strength Steel Material

Tube Investments of India-Rohitt Ravi, Sivasubramanian, Bade Simhachalam, Dhanooj Balakrishnan, Krishna Srinivas
Published 2014-04-28 by The Automotive Research Association of India in India
Tubular stabilizer bar for commercial vehicle is developed using advanced high strength steel material. Tubular section is proposed to replace the existing solid section. The tubular design is validated by component simulation using ANSYS Software. The tubes are then manufactured of the required size. The bend tool is designed to suit the size of the profile stabilizer bar and the prototypes are made using the tube bending machine. The strength of the tubular stabilizer is increased by using robotic induction hardening system. The tubular stabilizer bar is tested for fatigue load using Instron actuators. Higher weight reduction is achieved by replacing the existing solid stabilizer bar with the tubular stabilizer bar.
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A Lightweighting Solution for Converting an Aluminum Bracket to Plastic Using Long Fiber Thermoplastic Technology

Indore Composite Pvt Ltd-Saral Bhanshali
Published 2014-04-28 by The Automotive Research Association of India in India
This breakthrough development involves material conversion from aluminum die cast to polypropylene long fiber thermoplastic (40% long glass filled) for a two wheeler bracket of a leading automotive OEM.The plastic bracket was developed working in collaboration with the molder, glass supplier, technology collaborator and the OEM. The new part needed to be designed lighter in weight, easier to process and suitable for painting, outdoor exposure and stringent dynamic conditions. The scope of this study includes the evaluation of the new material from different viewpoints and comparison of the same with the existing material.The submission will go through the intricate analyses carried out in the development process and highlight the key advantages over aluminum. Studies will include static and dynamic analysis, fiber orientation studies, gate location studies, etc.
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