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This paper focuses on reducing abnormal noise originating from suspension when driving on rough road at the speed of 20 kmph. The test vehicle is a front wheel driven monocoque SUV powered by four cylinder engine. Cabin noise levels are higher between 100 to 800 Hz. Vibration levels are measured on front and rear suspension components, front and rear subframe, subframe connections on body to identify the noise source locations. Since the noise levels are dominant only in certain rough patches at very narrow band of time, wavelet analysis is used for problematic frequency identification. Based on wavelet analysis, it is identified that the vibration levels are dominant on front lower control arm (LCA) due to inferior isolation performance. The dynamic stiffness of LCA bushes is reduced by ~ 30% to improve the isolator performance which reduced the noise levels by ~ 2 dB (A).

Without the masking effect of a combustion engine, noise from the road is much more prominent in electric vehicles (EV) and has become the dominant source of noise for drivers and passengers. Road noise however is a complex problem. Unlike engine noise, which comes from a single, well-defined source, road noise finds its origins in the road-to-tire contact. This means that there are typically 4 sources (assuming a 4-wheel vehicle) which are influenced by the roughness and profile of the road as well as the compliance of the tires. From an engineering point of view it’s easy to appreciate the added complexity compared to engine noise. In addition to the engineering complexity, there is also a supplier-OEM relationship that comes into play. Most OEMs do not manufacture their own tires and may even have multiple tire suppliers for the same vehicle. This brings on another set of complications.

Customer expectations for cabin tractors from comfort perspective has grown multifold in the recent years. Cabin noise and vibration is one of the crucial parameter which drives comfort feel for the customer. This would enable customer to remain comfortable during long working hours. Moreover, Cabin Tractors with lesser noise levels found to have better acceptance by Customers all over the world. The Nebraska reports studied for US based tractor shows evolution of trend of cabin noise in 100-150hp tractors in last couple of decades. Undoubtedly, tractor manufacturers have put lot of efforts towards meeting legislation demand & stringent customer requirements for European and US market. This paper presents the work carried out for investigating major contributing factors affecting tractor cabin Noise & Vibration for an existing 75HP tractor.

High strength aluminium alloys are an ideal material in the automotive sector leading to a significant weight reduction and enhancement in product safety. In recent past extensive development in the field of high strength steel and aluminium was undertaken. This development has been propelled due to demand for light weight automotive parts. The high strength to weight ratio possessed by Al alloy helps in reducing the total weight of the vehicle without effecting the overall performance, thereby increasing the fuel economy and reducing the carbon emission level. Joining of high strength aluminium alloy is critical to develop durable automotive products. Joining of high strength aluminium alloy for mass production in automobile industry is a challenging task. Laser welding is recognized as an advanced process to join materials with a laser beam of high-power, high-energy density.

Light weight and Robust manufacturing technologies are always needed for transformation drive to the Automotive industry for next-generation vehicles with better Power to weight ratio. Innovations and process developments in materials and manufacturing processes are key to this light weighting transformation. Aluminium material has been widely used for this light weighting opportunities. However aluminium joining techniques, quality and poor consistency are limiting this transformation. This technical paper represents one of such case, where the part is made up of Aluminium through conventional casting route which affected laser weld quality due to poor casting soundness. This experiment explains in detail about the importance of Casting soundness for Laser weld Quality, Penetration, Strength etc., and the product consistency.

Electric vehicles are much quieter than IC engine powered vehicles due to less mechanical components and absence of combustion. The lower cabin noise in electric vehicles make customers sensitive to even small disturbance in vehicle. Road boom noise is one of the major concerns to which the customers are sensitive in electric vehicles. The test vehicle is a front wheel driven compact SUV powered by electric motor. In normal plain road, noise levels are acceptable but when the vehicle has been driven on coarse road, the boom noise is perceived, and the levels are objectionable. Multi reference Transfer path Analysis (MTPA) is conducted to identify the path through which maximum forces are entering the body. Based on MTPA, modifications are proposed on the suspension bushes and the noise levels were assessed.

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