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In the recent years, reduction of new product development time is the major challenge for all auto manufacturers to sustain in the stiff competition. Durability evaluation is one of the most time consuming element in New Product Development (NPD) process. Finding a generic solution for commonly faced design issues is a key factor for dramatic reduction in evaluation time. Testing time reduction can be achieved by breaking down the evaluation into subsystem level and component level instead of complete vehicle. But the maximum time reduction can be achieved only through durability evaluation at material / process level. This type of evaluation yields a generic solution, which results in establishing all-purpose design and material selection criteria during initial stage of development. By adopting this technique, separate evaluation of vehicles/ subsystems for improvements in material, welding, process etc. can be avoided.

Brake system is one of the most important safety related sub systems for any automobile. This requires all auto majors to put more effort in design optimization of brake system and exhaustive evaluation for the same. On-road evaluation of brakes is time consuming process and has other shortfalls like unsafe riding conditions, less repeatability, limitation of brake input force, speed, less control in test conditions, requirement of special track etc. Normal lab testing for brake system has several drawbacks like imprecise inertia simulation, more testing time, uncontrolled test environment, partial system level evaluation, huge rotating mass which may lead to unsafe operating conditions, frequent maintenance, etc. This paper describes about the methodology adopted, efforts involved and results obtained by developing an accelerated evaluation system for brakes as a complete sub system in laboratory.

Automotive manufacturers today are faced with the challenge of producing high quality products in a short time. In such a competitive environment, higher reliability gives competitive edge to the manufacturers. However, higher reliability involves increased durability testing on their part, which leads to an increase in development time and cost. Therefore, it becomes imperative to re-look the existing test standards as against the actual customer usage conditions thereby optimizing the testing time and the development costs. With that goal in mind, this paper elaborates the procedure used for establishing a correlation between three structural durability test rigs and customer usage on the road. Two different approaches were adopted to arrive at a final correlation between the structural test rigs and the customer usage on the road. The first approach arrives at a one to one correlation based on the failure modes of different components observed on each of the test rigs and in field.

A methodology is presented to obtain loads coming on the handle bar of a motorcycle of one model and calculating generic loads from the same for all other motorcycle models. The handle bar of a motorcycle of model M1 was instrumented with strain gages and calibrated for vertical and horizontal loads. The instrumented handle bar was assembled on the vehicle and data was collected on the test rig in laboratory. The vertical and horizontal loads acting on the handle bar, on test rig was obtained based on the calibration performed. The loads thus obtained are for a particular motorcycle model M1 and is dependent on the wheel loads of that motorcycle. These loads were converted into generic load cases, which are applicable for all models of motorcycles. The generalized loads thus generated were used in predicting the fatigue life of handle bar of a different motorcycle model (M2) using FE analysis and MSC fatigue.