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Development, optimization and calibration of diesel engine parameters have become extremely complex, because the recent technology engines have too many parameters and their interactions, which play significant role in controlling emissions. To reduce development time and cost, a systems approach to engine optimization is possible through an effective Design of Experiment (DoE). Various steps were devised like setting measurable target quantity & customer demands, parameter evaluation & screening, fractional factorial - orthogonal array design, experimentation, evolving objective/merit function, analysis, determination of optimum combinations and success run for validation. A naturally aspirated DI diesel engine is optimized using DoE for optimum performance and minimum emissions.

Six-seater three-wheelers have gained popularity among the commuters especially for their point to point low fares and better frequency compared to Municipal buses. However, pressure is mounting from all the quarters to ban these vehicles or to drive them out of the municipal limits. These vehicles with maximum loading capacity of 550 kg employ diesel engines which emit high soot & particulate matter or 2-stroke petrol engines which emit carbon monoxide as high as 13 g/km and hydrocarbon as high as 8 g/km, alarmingly high above the 1996 emission norms of 6.75 g/km CO and 5.40 g/km HC. Also the noise levels were higher. Considering the above threat, the authors had taken up the challenge to investigate and curb the pollution by employing high durability metallic catalytic converters.

Today's automotive exhaust systems are developed to deliver minimum noise, emissions and maximum durability based on the legislative and performance requirements. In addition, they must also meet requirements of packaging, safety, flow rates, lower system restriction, high temperature compatibility, corrosion resistance, easy serviceability and cost effectiveness. These challenging requirements cannot be met effectively without a systems approach. The exhaust system development process starts with selection of design methodology and evolution of checklists for system design specifications and definition of targets. System design specifications are elaborated with reference to performance, durability, legislation, installation, manufacturing / assembly / service considerations, etc. Checklists for exhaust system clearance and design review are given.

In this work a simple 1-D model for the macro kinetic conversion behaviour of a commercial automotive Three-way-exhaust catalyst for a Turbocharged DI-Gasoline-Engine is realized using GT-Power. A detailed reaction kinetic model to predict the activity of the commercial three way catalyst has been adopted from Young-Deuk [1], considering all possible reactions in the catalytic converter based upon the Langmuir-Hinshelwood mechanism. 1D model was later modified for the laboratory scale catalyst and validated against synthetic gas test bench data.

An open wheeled open cockpit racing-car with Maruti 800 BS III MPFI engine was designed and built for the SUPRA SAE INDIA 2011 student competition by ARAI academy students. The car won the best engineering design award and second in CAE category. The key focus was to build a car with superior safety and comfort. This work discusses in detail about the design, analysis and validation of the primary structure of the car which includes chassis and impact attenuator. This paper will serve as a reference to the future students who are participating in supra competition. A review of supra sae rules relating to chassis is used to develop realistic parameters. Based on the weight distribution calculations and the hard points the chassis is designed, modelled using cad tool and simulated for longitudinal acceleration, lateral acceleration, braking condition, braking with one circuit failure, bending stiffness and Torsional stiffness using finite element analysis.

India already has the highest concentration of megacities and urban growth continues. Together with an increasing need for individual mobility in particular, the Indian market demands new vehicle concepts. German lower-Saxony research centre of Automotive Engineering (NFF) and The Automotive Research Association of India (ARAI) together with representatives from the automotive industry develop a research roadmap to satisfy the future demand for metropolitan cars.

A global shift towards a greener and low carbon footprint will require noteworthy improvements in the manner in which energy is being produced and utilized. With the boom in passenger vehicle market in automotive industry, the transformation into systems which are more cost effective and fuel efficient, are apparently the need of the hour. Among the ‘Clean’ technologies, Hybrid Electric Vehicles (HEV) are on the top of the list of options. The paper presents in detail the survey of relevant prospects of HEV in the Indian market and how the Indian OEMs have responded to this opportunity. Series, parallel, parallel electric assist and combined hybrid electric systems are evaluated and the viable solutions are proposed. A broad study has been conducted on the various strategies and methodologies for implementation through the HEV. It also elucidates the design criteria and optimization techniques with reference to the relevant driving cycles.

To improve the performance and durability of two stroke engines, pressure, volume and temperature of crankcase are the important parameters which need optimisation. The paper investigates these scavenge parameters of a small two stroke engine with a view to alleviate its thermal conditions. Investigation of the pressure histories have been done with reference to pressure fluctuations, backflow, Kadenacy effect, list approximation, ring sticking, engine seizure, crankcase volume, crankcase temperature, cylinder barrel temperature, engine speed and physical parameters of the engine. By reducing the crankcase volume by 11 %, the maximum torque has increased by 11 % and shifted from 3000 RPM to 4000 RPM. The maximum power at 6000 RPM has increased by 12 %. Crankcase volume of 2 to 2.5 times the cylinder displacement is considered to be suitable.

Today's automotive Air Intake Systems are developed to deliver maximum filtration efficiency, maximum dust holding capacity and maximum service interval range based on engine performance and reliability requirements. It must also meet requirements of packaging, higher flow rates, lower pressure drop, lower noise, better fuel economy, increased vehicle speed/acceleration, high temperature compatibility, corrosion resistance, easy serviceability and cost effectiveness. It requires a well-behaved uniform flow with minimum temperature rise and pressure drop across the system. The air intake system should be installed such that no water ingress or water traces are found during the water wading test. These challenging requirements cannot be met effectively without a systems approach. The Air Intake System development process starts with selection of design methodology and evolution of checklists for System Design Specifications (SDS) and definition of targets.

Application of Diesel Particulate Filter (DPF) will become necessary for trapping diesel particulate matter especially with stringent Emission Legislation of Euro IV and beyond. While developing a DPF, conflicting requirements like low-pressure drop, high thermal durability, high compressive strength, high trapping efficiency and practical regeneration needs to be considered. This paper focuses on the development and optimization of cost effective ceramic based DPFs for a diesel utility vehicle. The effect of DPF diameter, length, cell density and wall thickness on the pressure drop in fresh as well as soot laden conditions are evaluated, based on which the final size of DPF is determined. Special attention to substrate making, coating, canning, temperature and pressure feedback is given. Strategies for DPF regeneration like catalyzed and additive regeneration are evaluated.

More powerful and faster vehicles have increased the load on the conventional brake system, which lead to lower brake system life particularly that of brake liners. This is not only due to higher braking speed but also due to the frequent brake applications especially in city driving and downhill conditions with heavy loads. In order to deal with excessive heat released, which results from continuous braking during repetitive braking operation, it is essential that there must be some system to share the load of service brakes. This is achieved by use of auxiliary brakes like exhaust brakes, which shares the total braking force leading to better vehicle safety. This paper reviews the requirements, design considerations and design verification of exhaust brake developed for light commercial diesel vehicle. Electrical circuit, vacuum circuits and fuel cut-off system required for exhaust brake application are designed. Accelerator and brake controlled exhaust brake system are evaluated.

Biodiesel is an alternate fuel for diesel consisting of the alkyl monoester of fatty acids derived from vegetable oils. The most usual method to transform oil into biodiesel is transesterification which can be carried out using different catalyst. Jatropha is second generation oil which is non edible and can be use for producing biodiesel. The first part is to expel oil from jatropha seeds. There are different types of expelling methods such as mechanical extraction, solvent extraction and enzymatic extraction. The study was conducted with hand driven mechanical expeller which is most conventional way of extracting oil from seeds with mechanical efficiency of 60-80% for single pass. The study includes various combinations of parameters like seed treatment, sun drying, pre-heating, soaking at different temperatures and different de-hulling compositions.