Design of Light weight spoiler for efficient aerodynamic performance of a vehicle 2019-28-0003
The spoiler is an aesthetic as well as functional part fitted on the vehicles to increase the vehicle appeal and improve vehicle aerodynamics. The improvement of aerodynamics performance of the vehicle at higher speeds is achieved by reducing the overall vehicle coefficient of drag. This helps in better handling and improved fuel efficiency of the vehicle thus contributing to development of a greener vehicle. In this paper, the main focus is to reduce overall vehicle coefficient of drag, reduce the spoiler weight and improve the vehicle appeal thereby increase the customer appeal. Six-sigma design methodology (Define-Measure-Analyze-Design-Verify) and tools were used to arrive at the optimum solution for the stated objectives.
QFD is used for converting the customer requirements into engineering parameters which define the final product. The QFD inputs are then used to define the critical to quality parameters (CTQ) for the spoiler. CTQ parameters were further drilled down to derive the engineering parameters and their relationship to CTQ values established using the correlation methods. Coefficient of drag value of 0.41 compared to the baseline value of 0.43 was achieved improving 5% vehicle drag and fuel efficiency in theoretical terms. Design and development of 2.5mm thickness for the blow molded aesthetic part reduced the weight by at least 15% compared to similar Mahindra products. Six sigma methods can also be effectively used to design a product by optimizing the parameters without compromising the customer needs.