Integration of Clutch Housing and Transmission Housing in Light-Duty Trucks for Powertrain Downsizing using Simulation Tools and Experimentally Validated 2021-26-0376

Downsizing and Light weighting is the latest trend in the automotive industry to achieve more fuel efficient, compact and cost effective design of vehicles. Powertrain components compromise of more than 45% of the total vehicle weight. Automakers are putting significant efforts to reduce the weight of power train components. Integrated design of aluminum Engine Head and Intake manifold has been successfully implemented.

Now currently we have identified the gear box housings for downsizing in light duty trucks i.e. Existing light duty trucks Cast Iron transmission. This design has been successfully modified with integrated clutch housing and transmission housing, using lightweight aluminum as the new material, using simulation tools. This lead to weight savings of up to 30% and cost savings of 20-25% as compared to existing cast iron designs. Using an integrated design reduces the assembly cost, makes the design more compact and gives better weight balance.

From an emissions perspective, it is estimated that every 50 Kg of weight reduced from an average 1,500 Kg vehicle cuts CO2 emissions by 4 ~ 5 grams. This feat is achieved using simulation tools and experimental verification in three steps. First step is comparing the stiffness values of existing cast iron design with the new aluminum integrated design, step two is to optimize the design using topology optimization tool to achieve the most optimum weight of the housing. Step three is to analyses the housings strength in static, dynamic and fatigue loading conditions. The same is being backed by conducting experimental verification and these results has been correlated with the simulation results. The stiffness tests at the test rig have been successfully completed and the stiffness vales have matched with 98% accuracy with the CAE simulation results. The same housing is checked with RLDA tests and has been successfully completed all the requirements. Accelerated Endurance Test is also done on the vehicle with new housing to verify the design in running conditions as well.

The FE simulation tools have helped us in selecting the right parameters for the design and ensure first time right design at the development phase. For future this can be implemented on light duty buses as well. The design and ensure first time right design at the development phase.