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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.


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.

Employing natural plant based fiber in interior automotive parts for cost & weight benefit

Vivekanandhan-Vivekanandhan Venkatesan Balaguru
  • Technical Paper
  • 2019-28-2559
To be published on 2019-11-21 by SAE International in United States
The Automotive industry is in ever more need for a lesser weight car due to progressively stringent emission norms and the demand of customer to have better mileage. It can be a gargantuan challenge for automotive manufacturers to search for lesser weight material to meet both customers as well as regulatory norms. But in some cases such lower weight material can increase the cost and adding a expensive material which increases overall cost to a price sensitive market like India is not favorable. One such solution is using the indigenous plant fiber (Jute) in combination with propylene (PP) to make Interior plastics components. Jute a vegetable fiber also referred to as "the golden fiber" has high tensile strength, low extensibility and is well established in fabric, packing, agriculture, construction industries. The biodegradable Jute lesser weight & abundance (India is the leading manufacturer of the Jute) can be utilized in making automobile trim parts in India. Through this paper we will have insight of the natural fiber based plastic components the benefits (lesser weight, Less GSM…

Investigation of Dry sliding Wear behavior of AA8011 reinforced with Zirconium Oxide and Aluminium Oxide Hybrid Composites processed through Multi direction forging

Sri Krishna College of Engg. and Tech.-Sathishkumar Kuppuraj, Soundararajan Ranganathan, Sathishkumar Aruchamy, Shanthosh Gopal
  • Technical Paper
  • 2019-28-0057
To be published on 2019-10-11 by SAE International in United States
The present work focused on fabricating hybrid composites of AA8011 with reinforcement particles of Zr2O3 and Al2O3 was taken equal (5wt%) weight percentage respectively. The hybrid composites were casted in square shape (50x50x50 mm size) under the optimal stir casted process parametric condition, further it was taken for forging process. The prepared three samples were induced for uni-direction (x), bi- direction (x and y) and multi direction (x,y and z) forging route and the response of micro hardness of 68,81 and 96 VHN were obtained due to microstructural phase changes with uniform distribution of particles in the matrix. Further the forged hybrid composites were investigated for tribological tests under dry sliding condition in a Pin-on-Disc tribometer apparatus by varying the load of 5,10,15,20 N and by adjusting the sliding speed as 200, 450 and 800 rpm respectively. The outcomes uncovered all the samples that the wear rate increments with increase in load and coefficient of friction shows decrement at most extreme load conditions. Wear rate increases with increase in sliding speed and coefficient of friction…

Experimental Investigation of High Speed Turning Of ASTM A510 Alloy in Micro Turning Process Parameters and Its Validation through Ranking Algorithm

SRM Institute Of Science And Technology-Sundar Singh Sivam Sundarlingam Paramasivam, Durai Kumaran, Krishnaswamy Saravanan, Raj Rajendran
Tishk International University-Ganesh Babu Loganathan
  • Technical Paper
  • 2019-28-0071
To be published on 2019-10-11 by SAE International in United States
There is a growing demand for industrial products with increased number of functions and of reduced dimensions and part features in sub millimeter scale in parts and Assembly. Micro-machining is the most basic technology for the production of such miniature parts and components. In this study, a number of turning operations were performed in micro conditions i.e. Micro Process parameters to achieve the best response for the benefits of industries at very high Spindle Speed (3000,3500,4000 Rpm), Feed ( 20,40,80 µm/s), Depth of Cut (0.2,0.4,0.8 µm) and Tool Nose Radius (,1.2 mm ). At a wide range of Input Process Variables, the variations in Surface Quality, Material Removal Rate, Energy Consumption and Tool wear were investigated. After completion of Experimental to develop optimization strategy for given set of input parameter combination for better response using combined Taguchi and Grey Relational Analysis (GRA). So this Model would be beneficial for manufacturing a micro parts for better maximum product accuracy and improve the productivity

Design of Light Weight Footstep Using Continuous Glass Fiber Reinforced Plastic Brackets

Mahindra & Mahindra, Ltd.-Praveen Kumar, Vivek KV Shenoy, Ashish Kumar Sahu, Srivatsa Sriperumbudur, Anton Kumanan, K V Balaji
  • Technical Paper
  • 2019-28-0172
To be published on 2019-10-11 by SAE International in United States
Objective Utility or Off-road vehicles are characterized with their higher ground clearances. Higher ground clearance of vehicle requires the vehicle to have footsteps for easy entry and exit of passengers from the vehicle. A typical foot step construction consists of structural steel brackets with an Aluminium or plastic top panel. Conventional steel construction is heavier to meet weight bearing capacity and durability requirements. Our objective of this work is to explore lightweight materials which can meet these performance requirements with a lighter construction. We chose to study the continuous glass fiber reinforced plastic as an alternative to the metal construction. Methodology The continuous glass fibers in the PP matrix improves the material strength due to high strength to weight ratio. The strength of the matrix increases depending on the fiber length in the matrix. This technology uses twin screw extrusion and plunger type injection to retain the fiber length in the molded part which helps the part to bear higher loads depending upon the aspect ratio of fibers in the matrix. We have produced test…

Design of energy absorbing plastic brackets to meet rear crash regulation ECE R42

Automotive & Industrial Sales-Pushparaj Arumugam
Automotive CAE-Devendra Sankla
  • Technical Paper
  • 2019-28-0041
To be published on 2019-10-11 by SAE International in United States
ECE R 42 uniform is a provision concerning the approval of vehicles with regard to their front and rear protective devices. Invention of low speed impact plastic brackets is related to rear bumper impact as per ECE R42 at a vehicle speed of 2.5 KMPH. Current bumper collision system uses several separate components assembled together. These components include a soft energy absorber which must go through iterative design and testing process which results in a comparatively high material cost. The invention involves the design of an energy dissipating method in slow speed rear impact with use of plastic brackets. The impact energy during the crash is controlled using innovative initial and secondary crash zones. The initial pendulum impact is on the bumper mounting sheet metal bracket which absorbs part of the energy. The proposed bracket design is capable to absorb the low speed impact energy during crash without the use of any additional parts. The bracket geometry is designed for maximum energy absorption during collapse. The design is also optimized to reduce the size of…

A Case Study on the Importance of Implementing an Obsolescence Material Management in an Aerospace Manufacturing Supplier Industry Environment

GITAM School of Technology-Mani Rathinam Rajamani, Eshwaraiah Punna
  • Technical Paper
  • 2019-28-0145
To be published on 2019-10-11 by SAE International in United States
Obsolescence Material management plays an important and vital role in today’s modern Aerospace manufacturing, Aerospace Maintenance, Repair and Overhaul industry as well as Aerospace Distributors. Aerospace vehicles have a considerable longer product life-cycle when compared to any other consumer goods like automobile and electronics industry. With the advent of new, disruptive technologies, many sources and supplies of materials including COTS and Standard catalogue parts, components and goods, which are widely used in an Aerospace manufacturing environment, are diminishing at a considerable rate and thus result in their obsolescence before the end disposal of the product life cycle. It is one of the leading causes to the sale of counterfeit and fraudulent parts and components, which can result in considerable deterioration of Quality and Cost to Customer. This technical paper emphasizes on the need for implementation of an effective Obsolescence management framework which an Aerospace company can follow through defining, deploying and sustaining Obsolescence Management through Policy, Procedures, Process and People methodology to be followed at manufacturing, maintenance and to identify proactively, notify and mitigate the…

Study of Mechanical Properties and Multi Response Optimization of Process Parameter for Showing Signs of Improvement Product Quality in Drilling of Alsi7cu4 Utilizing GRA in Taguchi Method

SRM Institute Of Science And Technology-Sundar Singh Sivam Sundarlingam Paramasivam, Krishnaswamy Saravanan, Durai Kumaran, Raj Rajendran
TISHIK University-Ganesh Babu Loganathan
  • Technical Paper
  • 2019-28-0058
To be published on 2019-10-11 by SAE International in United States
Showing and streamlining of cutting parameters are a champion among the most essential components in drilling processes. This examination displays the change of drilling procedures parameters on AlSi7Cu4 made by Gravity Die Casting and with replies in light of OA with Taughi GRA and ANOVA. The effects of alloying parts were bear on the Chemical Composition, microstructures, mechanical property, Hardness, X-Ray and S Das response is particularly analyzed. Motivations on the progression of Drilling parameters using the Taguchi strategy to obtain slightest surface Roughness (Ra), Circularity Error, Burr size and Thrust Force. Different Drilling preliminaries were coordinated using the L9 OA on CNC Milling machine. The examinations were accomplished on AlSi7Cu4 composite piece cutting tool of an ISO 460.1-1140-034A0-XM GC3 of 12 mm measurement with Tool 140 degrees, used all through the preliminary work under dry cutting conditions. The central and participation effect of the data factors on the foreseen responses are analyzed. The foreseen regards and estimated regards are really close. The given system could be utilized to pick the level of infiltrating constraints.…

Optimization of Machining Process Parameters for Minimizing the Waste Stream response through Multi-Objective Optimization

SRM Institute of Science and Technology-Sundar Singh Sivam Sundarlingam Paramasivam, Krishnaswamy Saravanan, Durai Kumaran, Raj Rajendran, Harish Sriram
Tishk International University-Ganesh Babu Loganathan
  • Technical Paper
  • 2019-28-0062
To be published on 2019-10-11 by SAE International in United States
During the delivering of an item, any material created moreover to a definitive item will be named as waste. The waste produced in light of machining could be a notable conservation worry for creators. The shape and condition of waste streams created, and their transportation components divergence with the strategy utilized and also shift among the technique. The effect in view of each waste stream differs as well. This examination reports a machining strategy includes the procedure of material to give a completed or a semi-completed item. This is frequently done by misapplication tools, totaling, machines and distinctive data sources that are appropriate to the strategy. The procedures thought of for the point of this work includes machining of material manipulation devices to give parts and items. The yield of the technique incorporates the item and increase the waste streams. The waste streams will be in the form of Chips, Energy usage, and Worn cutting tools and Operating time. TOPSIS and ANNOVA was acclimated gauge the chief essential Cutting speed, Feed rate, Depth of Cut…