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Offering the most fuel efficient cars to the customer is the biggest challenge for entire auto industry. Increasing engine efficiency and reducing the emissions with higher power is the best way to delight the customers. The demands for high power and better performance have resulted in progressive higher loading on internal components, and are putting challenge for the engine designers and analysts. It is required to discover and implement the most efficient analysis processes to ensure better durability, improved thermal performance and sealing ability of gasket in the main parts of engine during early design phase with keeping focus on development cost. This paper shows the integrated approach of CFD and structural analysis considering the thermal loading and higher cylinder pressures. The study focuses on the evaluation of Gasoline engine component durability and ensuring the gasket sealing during early design stage to reduce the prototyping cost and time.

Water Wading refers to the situation where a car is moving through relatively deep water at low speed. The challenges of an automotive Original Equipment Manufacturer (OEM) is to integrate the functional parts like bumper, bumper grille, engine undercover, intake system etc., to enhance the vehicle quality and performance. One of the challenges in vehicle front end and engine room design is to prevent water entry into the air intake system during wading. If significant amount of water enter the air intake, some of the water could subsequently enter the engine cylinder, which would damage the critical components within the engine beyond repair. In general practice wading tests have been carried out during proto stage of vehicle development program to ensure vehicle performance. However a Computational Fluid Dynamics (CFD) method for carrying out water wading calculations early during the development phase offers reduction in development cost and time for a new vehicle.