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To establish the correlation in between Computer Aided Engineering & physical testing of automotive parts returnable case (Stacktainer).

International Centre For Automotive Tech.-Ashish Singh
  • Technical Paper
  • 2019-28-2569
To be published on 2019-11-21 by SAE International in United States
Automotive returnable cases (Stacktainers) are being used to transport the automotive parts through surface & seaways. No automotive manufacturer wants to spend money on woods, paper & cardboard again and again, it`s better to pay once for robust & reusable cases. these provide better protection to parts from its manufacturing to assembly line of vehicle. While transporting, any kind of crack or failure of returnable cases may lead to loss of money, human & time. To ensure the safety, these pallets have to be validated for vibrations coming from surface irregularities, sea waves & load due to stacking of cases one above other. The objective of this study is to establish a correlation in between the physical testing & simulation in Computer added Engineering (CAE) of automotive returnable case (Stacktainers). There are different types of tests considered to validate the returnable case, rough road evaluation, Multi-axial Vibration & strength evaluation. After conducting the physical test & CAE simulation, a correlation & confidence level up to 90% is established.
 

Occupant Controlled Ventilation

Mahindra & Mahindra, Ltd.-Priyanka Marudhavanan
  • Technical Paper
  • 2019-28-2461
To be published on 2019-11-21 by SAE International in United States
Keywords-Coolant,Ventilation Research and/or Engineering Questions/Objective: Number of Occupants is the major parameter when we consider Air Conditioning System. The number of person who stays in the room may vary in the same way the person who travels in the automobile also vary throughout the distance. This is more prevalent in transportation system like bus, train and where lot of people will travel together and where dropping station in the vehicle is too frequent.In this type,operating A.C has to be varied Methodology: . Instead the number count in the vehicle will be monitored from time to time. Based on the number of count, the cabin has to be cooled or heated and accordingly corresponding power has to be drawn by the compressor from the engine. This human count can be detected based on the number of CO2 sensor located in the cabin. the amount of fresh air that should be added to a cabin can be controlled by a carbon dioxide level transmitter. When CO2 levels go up, fresh air is added until the CO2 levels…
 

NEXT GENERATION POWER DISTRIBUTION UNIT IN WIRING HARNESS

Mahindra & Mahindra Ltd-Boobala Krishnan D, T Vijayan, Apurbo Kirty
Mahindra Research Valley-Himanshi Dua
  • Technical Paper
  • 2019-28-2571
To be published on 2019-11-21 by SAE International in United States
Keywords – Miniaturization, Low Profile (LP) Relays, Low Profile (LP) Fuses, Fuse box, Wiring Harness Research and/or Engineering Questions/Objective With the exponential advancement in technological features of automobile’s EE architecture, designing of power distribution unit becomes complex and challenging. Due to the increase in the number of features, the overall weight of power distribution unit increases and thereby affecting the overall system cost and fuel economy. The scope of this document is to scale down the weight and space of the power distribution unit without compromising with the current performance. Methodology Miniaturization involves replacing the mini fuses and J-case fuses with LP mini and LP J-case fuses respectively. The transition doesn’t involve any tooling modification and hence saves the tooling cost. Furthermore, to address stringent weight and space targets, LP mini fuses and LP J-case fuses were further replaced with micro-2 fuse and M-case fuse respectively. Similarly, micro relay and mini relay were replaced with Ultra micro and High current micro relay respectively. Results We took MPV segment vehicle for our initial testing and validation…
 

Mechanical Property Evaluation of Paper Honeycomb reinforced Plastics

Hyundai Motor India Engineering PVT LTD-Vignesh balaji S G, Pradeep S, Aakash S K
  • Technical Paper
  • 2019-28-2538
To be published on 2019-11-21 by SAE International in United States
Mechanical Property Evaluation of Paper Honeycomb Reinforced Plastics Vignesh Balaji S G, Pradeep Hyundai Motor India Engineering Pvt. Ltd, Chennai. India Key Words: Paper Honeycomb, Epoxy Composites, Mechanical Properties, Tensile, Impact & Flexural Test Research and/or Engineering Questions/Objective : Composite Materials are widely being used in many engineering applications because of their desirable properties & Cost, Weight Effectiveness. They are widely being used as their Strength-Weight Ratio is Higher than any Other Material. Paper Honeycomb Material is basically a paper made of honeycomb shapes enforced between layers of Glass Mat. This paper deals with the evaluation of Tensile Strength, Flexural (Three-Point Bending) Strength & Flexural Modulus, Impact Strength of Paper Honeycomb Reinforced Epoxy Composites. The Scope of this Material defines the quality of Paper Honeycomb Reinforced Composites which can be used for Automotive Trim Parts. Methodology: Before beginning the tests, the specimens should be prepared and the steps for the preparation of paper honeycomb reinforced epoxy composites are shown below: 1. Mould Preparation 2. Mixing of Epoxy and Hardener with a ratio of 10:1 3.…
 

Load Distribution Optimization of seatbelts using validated finite element approach.

anshul satija-Anshul Satija
  • Technical Paper
  • 2019-28-2575
To be published on 2019-11-21 by SAE International in United States
The seat belt system is one of most imperative component of the safety instrument family in a vehicle. The main purpose of seat belt is to minimize the injuries by preventing the occupant from impacting hard interior parts of the vehicle and also the passenger from being thrown-out from the vehicle in case of rollover accidents. The standard three-point belts, mounted to the vehicle in three places, namely anchor, D ring and buckle. The position of D ring is very important to distribute the impact load evenly to the occupants. Very high load in any of these locations could cause breakage of the mountings and also concentrated loading on the occupant chest of pelvis. This study mainly focuses on the seatbelt assembly performance improvement against ECE-R16 sled test. The sled test was carried out first using 28g peak acceleration pulse and measurement of forces at shoulder and anchor position was measured using the load cell. FE (Finite Element) model of the complete seatbelt assemble was developed including buckle, retractor and anchor plate. The simulation was…
 

Characterization and Durability of Mold-In-Color Engineering Plastics

Mahindra & Mahindra, Ltd.-Sandeep Kumar Shukla
  • Technical Paper
  • 2019-28-2542
To be published on 2019-11-21 by SAE International in United States
Plastics are prone to photo oxidative and thermal oxidative degradation under usage conditions due to their chemical nature. From sustainability and cost standpoint, there is an increasing focus on Mold-In-Color (MIC) plastic materials. Simultaneously customer’s expectations on the perceived quality of these MIC parts has been increasing with attractive color and glossy appearance. A study was conducted to analyze the product quality and durability aspects over a prolonged exposure to accelerated weathering condition. Material selected for this study were injection molded specimens of ABS and PC/ABS used in automotive passenger vehicles. Comparative analysis was conducted before and after weathering exposure at defined intervals by using the various tools like Fourier Transform infra-red spectrometer (FTIR), thermogravimetric analyzer (TGA) and universal testing machine (UTM), Izod impact tester, dynamic mechanical analyzer (DMA) to understand the impact on their chemical and mechanical properties. This study will be useful in understanding material behavior, durability, performance and product quality.
 

LIGHT WEIGHTING OF ADDITIVE MANUFACTURED PARTS FOR AUTOMOTIVE PRODUCTION APPLICATIONS THROUGH TOPOLOGY OPTIMIZATION TECHNIQUES

General Motors Technical Center India-Abhijith Naik, T Sujan, Suraj Desai, Saravanakumar Shanmugam
  • Technical Paper
  • 2019-28-2544
To be published on 2019-11-21 by SAE International in United States
Rapidly enhancing engineering techniques to manufacture components in quick turnaround time have gained importance in recent time. Manufacturing strategies like Additive Manufacturing (AM) are a key enabler for achieving them. Unlike traditional manufacturing techniques such as injection molding, casting etc., AM unites advanced materials, machines, and software which will be critical for Industry 4.0. Successful application of AM involves a specific combination and understanding of these three key elements. In this paper the AM approach used is Fused Deposition Modelling (FDM). Since material costs contribute to 60% of the overall FDM costs, it becomes a necessity to optimize the material consumption of the produced parts. This paper reports case studies of 3D printed parts used in an Automobile plant’s production aids, which utilize computational methods(CAE), topology optimization and FDM constrains (build directions) to manufacture the part in the most optimal way. These methodologies were used to validate the current operating conditions, optimize the design, increase the stiffness of the original part and reduce the material costs. The newly optimized designs were verified by successfully passing…
 

Industry 4.0 in Agriculture

John Deere India Pvt, Ltd.-Vishal Eknath Kirve
  • Technical Paper
  • 2019-28-2442
To be published on 2019-11-21 by SAE International in United States
In recent times, there has been an enormous shift towards automation in Auto as well as Agriculture Industry. Farming is playing an important role in the survival of world. Currently, agricultural industry is facing several challenges. These challenges can be reduced or removed by using automation in the agricultural tools and techniques. Industry 4.0 is the industrial fourth revolution which focused on automations in manufacturing technologies such as cyber physical systems, Internet of Things, artificial intelligence and cloud and cognitive computing. The development and improvement of the connectivity between agricultural tools is leading to significant progress in the agricultural practices. Advancement and automation of the technologies with Internet of Things (IoT), replacing traditional agricultural methodologies which causes wide range of improvements in the fields. The main purpose of this paper is focused on the review of basic concept of Industry 4.0, the number of new tools and techniques used by smart agriculture for the improvement in the fields and the list of benefits of smart agricultural solutions. Smart Agriculture is using advanced technologies such as…
 

Future hybrid Vehicles with advanced 48V electrified drive train technology to reduce Co2 emission

Mercedes-Benz R&D India Pvt Ltd-Chandrakant Palve, Pushkaraj Tilak
  • Technical Paper
  • 2019-28-2487
To be published on 2019-11-21 by SAE International in United States
Future hybrid vehicles with advanced 48V electrified drive train technology to reduce CO2 emission. Chandrakant Palve* Pushkaraj Tilak * * Mercedes-Benz Research & Development India Pvt. Ltd. Bangalore. India. Key Words: 48V, CO2, P3 Hybrid, Electrified powertrain, AMT, emission, shift comfort, motor Research and/or Engineering Questions/Objective Global automotive industry is putting effort in moving from conventional powertrain technology to hybrid & electric powertrains. This efforts plays a vital role to achieve cleaner environment, improved performance, reduced fossil-fuel dependency, low noise for meeting regulatory & customer requirements. Automotive industry is facing a challenge of meeting stringent CO2 emission targets of 95g & 175g per kilometer for passenger cars & light commercial vehicles respectively. 48V is an important stepping stone in this direction. By taking motivation from this strategic challenge, advanced 48V P3 electrified powertrain technology has been proposed. The objective of this research is a novel electrified powertrain which offers Dual Clutch Transmission (DCT) level of shift comfort in combine with CO2 benefit without additional cost and weight penalty. Methodology The present study describes a unique…
 

MOLD IN COLOR DIAMOND WHITE ASA MATERIAL FOR AUTOMOTIVE EXTERIOR APPLICATION

Mahindra & Mahindra Ltd-Karthik Govindaraj, K V Balaji, Murukesan Vimalathithan, Gandhi Samir, Ladhe Rajesh
  • Technical Paper
  • 2019-28-2562
To be published on 2019-11-21 by SAE International in United States
In this paper, mold in color diamond white ASA material has been explored for front bumper grill, fender arch extension and hinge cover applications. Other than aesthetic requirements, these parts have precise fitment requirement under sun load condition in real world usage profile. Structural durability of the design was validated by virtual engineering. Part design and material combinations with better tooling design iterations were analysed by using mold flow analysis. Complete product performances were validated for predefined key test metrics such as structural durability, thermal aging, cold impact, scratch resistance, and weathering criteria. This part met required specification. This mold in color ASA material-based parts has various benefits such as environmentally friendly manufacturing by eliminating environmental issues of coating, easily recycled, and faster part production because intended color achieved in one step during molding. Also, it lowers overall production energy footprint, less scrap with no secondary painting, and lower final part cost by eliminating secondary operations.