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Improving the aerodynamic drag level of semi-trailers will contribute largely to reduce the fuel consumption and the emissions of harmful gases of heavy duty vehicles. The final step in product validation of aerodynamic drag reduction devices is often conducting fuel savings test during operational activities. During an operational test, data is gathered for a period when the vehicle is not equipped with an aerodynamic device and consequently for a period with the device equipped. A simple fuel consumption comparison between the periods does not give the desired accurate result as the operating conditions are different for the control and test period. In an attempt to take these varying conditions into account, the average fuel consumption per ride is modeled as a linear function of several independent variables: the wind conditions, the outside temperature, the humidity, the payload, the road inclination and the presence of the drag reduction device.

Small commercial vehicles (SCVs) are the drivers of a major part of India’s indirect economy, providing the most efficient means of transport. With the introduction of BS-VI norms, some major overhauls have been done to the SCV models to meet BS VI norms in challenging timeline for early market entry. This forced to automotive designers towards challenge of cost competitiveness as well as refinement level to survive in this competitive market. This paper explains the systematic approach used to overcome challenges of higher tactile vibrations, higher in-cab noise because of BS VI requirement in 2 cycle engine required for small commercial vehicle. The solutions were need to be worked out without compromising the other performance attributes like total cost of ownership, fuel economy, ease of servicing and cost effectiveness.

This paper presents a simple diagnostic tool / method to identify the causes of variations in measured backlash between the ring gear and its planets in a hub reduction axle. This tool can identify the influence of the parameters such as ring gear ovality / eccentricity with respect to hub axis, accuracy of planet pinion bore position on bell-housing-carrier with respect to hub axis and hub play. This tool eliminates the need of complex and time consuming measurement methods to identify these individual parameters.

The bake hardening effect depends on three parameters i.e. pre-straining, paint baking temperature and paint baking time. The combined effect of all these parameters results into the increase in yield strength, called the “baking effect”. This paper explains the individual effects of these parameters on the baking value. Tensile test were carried out for the 495 samples baked at baking temperature from 140°C to 250°C with differential baking time of 10, 15, 20, 25 and 30 minutes and differential pre-straining of 2%, 3% and 5%. The differences of yield strength between the unbaked and baked sample were calculated and the increase in yield strength was noted. After these laboratory trials 800 numbers of door outer panels of a small truck were formed and finish painted. The increment in yield strength after component forming and painting was determined by taking tensile samples from three different locations of 5 painted doors.

In automotive design and development, there are different stages for product design. In this fast changing scenario product design, digital verification of design (CAE), physical validation of the product and launching of the same in short time is important in product development life cycle of any new generation vehicle. This paper proposes a new approach towards development of a green-field platform for commercial vehicles by improving reliability of CAE and thereby reducing the need for prototype testing and hence shortening development cycle and costs - we call it “Hybrid Mule”. This Hybrid Mule has complete design intent under-body and engine-house while upper-body is made of simple representative tubular space frame. FRP skin panels are attached to this space frame to create a safe environment for test-driver. FRP skin also provides early feel of styling in running condition and evaluates basic ergonomics and visibility.