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Assessment of cooling performance in the design stage of vehicle allows a reduction in the number of needed prototypes and reduces the overall design cycle time. Frontend cooling and thermal management play an essential role in the early stages of commercial vehicle design. Sufficient airflow needs to be available for adequate cooling of the under-hood components. The amount of air mass flow depends on the under-hood geometry details, positioning and size of the grilles, fan operation and the positioning of the other components. Thermal performance depends on the selection of heat exchanger. This paper describes the effects of several design actions on engine cooling performance of a commercial vehicle with the help of Computational Fluid Dynamics (CFD) simulation tool Fluent™. Front of vehicle design is captured in detailed FE model, considering front bumper, grille, cabin, cargo and surrounding under-hood and underbody components.

Paper explains conversion of existing drum brake system to disc brake system with complete digital validation at structural as well as thermal level to make sure First Time Right Design before physical part development. To provide leverage to quick design, modification and selection of brake system according to vehicle configuration, a virtual computational fluid dynamics (CFD) simulation process is developed and validated with test results. Temperature variation over brake drum and disc in internal standard braking cycle is measured virtually and correlated with test results. Also Fade testing criteria’s were considered during CFD analysis. This up gradation is must considering technology enhancement trend and safety in automotive segment. In current competitive market scenario and as per customer requirements, front disc brake module is becoming necessary not only for passenger segment but also for commercial segment vehicle.