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Technical Paper

High Durable PU Metallic Monocoat system for tractor sheet metal application.

2019-11-21
2019-28-2541
In sheet metal painting for various applications like Tractor, Automobile, most attractive coating is metallic paints and it is widely applied using 3 coats 2 bake or 3 coat 1 bake technology. Both options, results in high energy consumption, higher production throughput time & lower productivity in manufacturing process. During various brainstorming & sustainable initiatives, paint application process was identified for alternative thinking to reduce burden on environment & save energy. Various other industry benchmarking & field performance requirement studies helped us identify the critical to quality parameters. We worked jointly with supplier to develop mono-coat system without compromising the performance & aesthetical properties. This results in achieving better productivity, elimination of two paint layers, substantial reduction in volatile organic content, elimination of one baking cycle and energy saving.
Technical Paper

MOLD IN COLOR DIAMOND WHITE ASA MATERIAL FOR AUTOMOTIVE EXTERIOR APPLICATION

2019-11-21
2019-28-2562
In this paper, mold in color diamond white ASA material has been explored for front bumper grill, fender arch extension and hinge cover applications. Other than aesthetic requirements, these parts have precise fitment requirement under sun load condition in real world usage profile. Structural durability of the design was validated by virtual engineering. Part design and material combinations with better tooling design iterations were analysed by using mold flow analysis. Complete product performances were validated for predefined key test metrics such as structural durability, thermal aging, cold impact, scratch resistance, and weathering criteria. This part met required specification. This mold in color ASA material-based parts has various benefits such as environmentally friendly manufacturing by eliminating environmental issues of coating, easily recycled, and faster part production because intended color achieved in one step during molding.
Technical Paper

NEXT GENERATION POWER DISTRIBUTION UNIT IN WIRING HARNESS

2019-11-21
2019-28-2571
Keywords – Miniaturization, Low Profile (LP) Relays, Low Profile (LP) Fuses, Fuse box, Wiring Harness Research and/or Engineering Questions/Objective With the exponential advancement in technological features of automobile’s EE architecture, designing of power distribution unit becomes complex and challenging. Due to the increase in the number of features, the overall weight of power distribution unit increases and thereby affecting the overall system cost and fuel economy. The scope of this document is to scale down the weight and space of the power distribution unit without compromising with the current performance. Methodology Miniaturization involves replacing the mini fuses and J-case fuses with LP mini and LP J-case fuses respectively. The transition doesn’t involve any tooling modification and hence saves the tooling cost.
Technical Paper

Development of a Graphical User Interface (GUI) Based Tool for Vehicle Dynamics Evaluation

2019-11-21
2019-28-2397
Title Development of a Graphical User Interface (GUI) Based Tool for Vehicle Dynamics Evaluation Authors Mr. Shubham Kedia, Dr. Divyanshu Joshi, Dr. Muthiah Saravanan Mahindra Research Valley, Mahindra & Mahindra, Chennai Objective Objective metrics for evaluation of major vehicle dynamics performance attributes i.e. ride, handling and steering are required to compare, validate and optimize dynamic behavior of vehicles. Some of these objective metrics are recommended and defined by ISO and SAE, which involve data processing, statistical analysis and complex mathematical operations on acquired data, through simulations or experimental testing. Due to the complexity of operations and volume of data, evaluation is often time consuming and tedious. Process automation using existing tools such as MS Excel, nCode, Siemens LMS, etc. includes several limitations and challenges, which make it cumbersome to implement.
Technical Paper

A Study on the Effect of Steering Input Frequency on Transient Lateral Dynamics of Four-Wheeled Passenger Vehicles

2019-01-09
2019-26-0070
Vehicle lateral dynamic response parameters such as yaw velocity, lateral acceleration, roll angle, etc. depend on the nature of steering input. Response parameters vary with the amplitude and frequency of steering input. This paper deals with developing insights into the effect of steering input frequency on transient handling dynamics. For the purpose two SUV segment vehicles with similar curb weight are considered. Vehicles are given pulse inputs of the amplitudes corresponding to 4 m/s2 steady state lateral acceleration and target speeds of 80 kmph and 100 kmph, as recommended in ISO 7401:2011. Steering inputs are executed using a Steering Robot (ABD SR30). Lateral transient dynamic response gains as well as natural frequencies of yaw are studied for 0-2 Hz input frequencies. Several insights are developed, adding to the understanding of transient lateral dynamics and its relationship with steering input.
Technical Paper

A Test Methodology for Vehicle Wind Noise Reduction and Acoustic Quality Improvement

2019-01-09
2019-26-0216
Aeroacoustics of vehicles is becoming an important design criterion as it directly affects passenger’s comfort. The wind noise at highway speeds (>80 KMPH) is a critical quality concern under normal and crosswind conditions and dominant factor in assessing acoustic comfort of the vehicle. Wind noise is caused by the vortex air flow around a vehicle body and air leakage through the sealing gaps of attached parts. This majorly contributes to high frequency noise (>250 Hz). Accurate identification and control of noise sources and leakage paths result in improved acoustic comfort of the vehicle. In this paper, aero-acoustic quality characteristics of validation prototype vehicle are studied. The major wind noise sources and leakage paths in the vehicle are identified through in-house blower set up in the semi anechoic room. The overall wind noise level and articulation index of vehicle at various speeds are determined through on- road measurements.
Technical Paper

Novel, Compact and Light Weight Plenum Assembly for Automobiles

2017-07-10
2017-28-1924
Plenum is the part located between the front windshield and the bonnet of an automobile . It is primarily used as an air inlet to the HVAC during fresh air mode operation. It’s secondary functions include water drainage, aesthetic cover to hide the gap between windshield to bonnet, concealing wiper motors and mechanisms etc. The plenum consists mainly two sub parts viz. upper plenum and lower plenum. Conventional plenum design which is found in majority of global OEMs employ a plastic upper plenum and a metal lower plenum which spans across the entire width of engine compartment. This conventional lower plenum is bulky, consumes more packaging space and has more weight. In this paper, we propose a novel design for the plenum lower to overcome above mentioned limitations of the conventional design. This novel design employs a dry and wet box concept for its working and is made up of complete plastic material.
Technical Paper

Optimizing OSRVM Package for Maximizing In-vehicle Visibility

2015-09-29
2015-01-2837
Overall in-vehicle visibility is considered as a key safety parameter essentially mandated due to the increasing traffic scenario as seen in developing countries. Driver side bottom corner visibility is one such parameter primarily defined by A-pillar bottom and outside rear-view mirror (OSRVM). While defining the OSRVM package requirements such as size, position and regulatory aspects, it is also vital to consider other influencing parameters such as position of pillars, waist-line height, and Instrument panel which affect the in-vehicle visibility. This study explains the various package considerations, methods to optimize OSRVM position, shape and housing design in order to maximize the in-vehicle visibility considering the road and traffic conditions. A detailed study on in-vehicle visibility impacted by OSRVM packaging explained and had been verified for the results.
Technical Paper

Optimization of Vehicle Electrical Energy Consumption

2015-09-29
2015-01-2882
This paper focuses on optimizing the electrical energy consumption of vehicle. By introduction three concepts. 1) Innovative speed control logic for radiator fan motor according to vehicle speed and air flow through radiator. 2) Introducing regeneration of energy from radiator fan motor while free running and deceleration of vehicle. 3) Using BLDC motors (generation mode and motoring mode) in radiator and blower motors. About 50 % of total electrical energy consumption of vehicle is contributed by radiator fan motor and blower motor (proven data by performing alternator charge balance test during NEDC cycle). By introducing above three concepts, 50 % electrical energy consumption can be reduced to 25 - 30 %, which gives more than 3.5 % fuel economy improvement and more than 10 gmCO2 reduction per kilometer. Further reduction in conducted emission at motor level, soft starting for radiator fan and blower motor and elimination of high inrush current.
Technical Paper

Sealing Prediction and Improvement at Cylinder Head & Block Interface under Thermo-Mechanical Loading involving Multi- Layer Steel Gasket

2015-04-14
2015-01-1743
An inadequate sealing of the combustion chamber gasket interface may have severe consequences on both the performance & emission of an engine. In this investigation, both the distribution of the contact pressure on the gasket and the stresses of the cylinder head at different loading conditions are explored and improved by modifying the design. A single cylinder gasoline engine cylinder head assembly has been analyzed by means of an uncoupled FEM simulation to find the sealing pressure of the multi-layer steel (MLS) gasket, strength & deformation of the components involved. The thermal loads are computed separately from CFD simulations of cylinder head assembly. The cylinder head assembly consisting of head, blocks, liner, cam shaft holder, bolts, gaskets, valve guides & valve seats, is one of the most complicated sub-assembly of an IC engine.
Technical Paper

Vinyl Ester Based SMC Material for Automotive Oil Sump Application

2015-04-14
2015-01-0718
This paper describes vinyl ester based SMC (Sheet molding composite) material for oil sump part in automotive application. This sheet moulding composite is a ready to mould glass-fibre reinforced vinyl ester material primarily used in compression moulding process. This vinyl ester resin is compounded with glass fibre to meet the product functional requirements. Oil sump is a structural component under bonnet that forms the bottommost part of the crankcase and also contain the engine oil before and after it has been circulated through the engine. Generally, metals are preferred material for this application. In this paper, fibre filled vinyl ester based thermoset resin (SMC) material has been explored for oil sump application. They possess excellent properties in terms of tensile strength, modulus, impact strength, dimensional stability, high/low temperature resistance and oil resistance.
Technical Paper

Eco-Friendly Recycled PET (Polyethylene Terephthalate) Material for Automotive Canopy Strip Application

2015-04-14
2015-01-1304
This paper describes the suitability of recycled polyethylene terephthalate (RPET) material for canopy strip in a commercial vehicle. The material described in this paper is a PET compound recycled from used PET bottles and reinforced with glass fibers so as to meet the product's functional requirements. The application described in this paper is a Canopy strip which is a structural exterior plastic part. Canopy strip acts as a structural frame to hold the Vinyl canopy in both sides of the vehicle. Functionally, the part demands a material with adequate mechanical and thermal properties. Generally, PET bottles are thrown after use thereby creating land pollution. PET being inert takes an extremely long time to degrade thereby occupying huge amount of space in landfills and directly affecting rain water percolation. This work focused on recycling the PET bottles and compounding them suitably so as convert them into useful automotive parts.
Technical Paper

Design For Affordability -Composite Running Board

2015-01-14
2015-26-0070
Light weighting is the Current trends in automotive to achieve better fuel economy which helps for meeting fuel economy standards & to offset the higher fuel prices. Thus there is a need to develop composite running board which is light weight & structurally sound enough to meet the performance. The present paper provides a composite running board assembly for an automobile. The running board assembly includes a board, an insert body and a plurality of brackets. Upon stepping of a passenger on the board, the board transfers load on the insert body which subsequently transfers the load to the plurality of brackets thus facilitating even distribution of the load on the automobile body. This paper also put lights on the use of improved TRIZ application - an approach to inventive problem solving for designing highly affordable & light weight running board. The cost & weight reduction achieved with innovative design is about 40 % & 35 % comparing to existing cost & weight.
Technical Paper

Systematic Approach to Design Hand Controlled Parking Brake System for Passenger Car

2015-01-14
2015-26-0078
This paper is an attempt to compile a systematic approach which can be easily incorporated in the product development system used in the design and development of parking brake systems for passenger cars having rear drum brakes, which in turn can effectively reduce the lead time and give improved performance. The vehicle GVW, percentage gradient and maximum effort limits (as per IS 11852 - Part 3), tire and drum brake specifications were taken as front loading. This data is used for target setting of functional and engineering parameters, such as lever pull effort, lever ratio and angular travel of lever. Design calculations were performed to obtain theoretical values of critical parameters like lever effort and travel. The comparison between target and theoretical values give the initial confidence to the system engineer. Further, the outcome was taken to conceptualize the hard points of lever on vehicle for ergonomics.
Technical Paper

Experiences in Cold Start Optimization of a Multi-Purpose Vehicle Equipped with 2.2L Common Rail Diesel Engine

2011-04-12
2011-01-0124
High speed diesel engines are difficult to start in cold conditions (at subzero temperature) because the cylinder head and cylinder block absorbs heat of compression and thus preventing ignition due to the high surface to volume ratio. Also the coolant and the engine oil become viscous at subzero temperature and make the condition unfavorable for starting. Combustion optimization along with the help of a heating aid can make these engines to start quickly without any engine misbehavior. Cold startability is the ability of an engine to start within a specified time and continue to run without any malfunctioning. Combustion instability will lead to the misfiring of the engine unless it is calibrated properly. The European countries are subjected to a minimum temperature of -20°C to -25°C. So the intention of this work is to optimize the cold startability of Mahindra's Multi-Purpose Vehicle (MPV) up to -25°C which is to be sold in European countries.
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