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An automobile door is a complex module, which consists of various fixed and movable subassemblies and components. Parameters such as safety, vehicle dynamics, aesthetic and strength are critical while designing the door assembly. Apart from the above, the design of door trim should minimize BSR (buzz squeak and rattle) at vehicle running conditions. Stiffness is one of the key engineering requirements which if not optimized will result in higher BSR levels and failure of the door trim components. In this study, more importance is given to optimize the stiffness of door trim. As per DVP (design verification and planning) standards of the OEMs, the range of deflection for the plastic trim parts is defined considering the conditions, comfort level and location of use. If stiffness is higher than the requirement, the door trim plastic parts are harder and will violate the quality and safety norms. If it is lower, then trim parts will not meet the functional requirements and safety norms.

The Charge Air Cooler (CAC) is designed to cool the charge air after being boosted by the Turbocharger. In order to maintain the optimum temperature and to further improve the charge air density entering to the engine the CAC is used. This makes the combustion more efficient and better engine performance and fuel economy. The performance of the CAC is highly affected by the plumbing lines which transport the compressed charge air from turbocharger to the intake manifold of the Engine. It consists of tube, hose, duct and resonator. Designing the optimum CAC plumbing lines with lesser pressure drop is the major requirement of the CAC system considering the complex packaging. In such scenarios, one-dimensional (1D) simulation is a good way to compute the pressure drop for faster and economical solution.