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Brake drum in commercial vehicles is very important aggregate contributing towards major weight in brake system module. The main function of brake drum is to dissipate kinetic energy of vehicle into thermal energy, as a results in braking operation major load comes on brake drum. Hence this is very critical component for vehicle safety and stability [1]. Objective of this paper is to increase the pay load, which is utmost important parameter for commercial vehicle end customers. To achieve the light weighing target, alternate materials such as Spheroidal graphite iron (SGI) has been evaluated for development of brake drum. Many critical parameters in terms of reliability, safety and durability, thickness of hub, wheel loading, heat generation on drum, manufacturing and assembly process are taken into consideration. The sensitivity of these parameters is studied for optimum design, could be chosen complying each other’s values.

To compete with the current market trends there is always a need to arrive at a cost effective and light weight designs, hence the need for upgrading the existing/proven integral connecting rod to fracture split connecting rod. This technique provides gains as weight reduction and consequently reducing noise and vibration due to the decrease of the oscillating mass from the system. Using the proposed fracture split connecting rod, it is estimated that cost savings of up to 10%, reduction in weight and better fatigue performance (25% - 30%) can be achieved. For this, we have used simulation tools to reduce number of physical tests and thereby achieving considerable reduction in design and development time and cost. High carbon alloy steel used for manufacturing fracture split connecting rod and it doesn’t require additional heat treatment after hot forging.