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The objective of the research is to develop a lightweight yet stiff, 2 piston fixed brake caliper which can be used in formula student race car. To make a race car, its components need to be lighter. To stop a car with minimum stopping distance, it needs to have a sophisticated braking system with well-designed components. The designing of the caliper is carried out on the Altair Inspire software. The topology optimisation algorithm is used to minimise the weight of the caliper without compromising the stiffness. The structural analysis is also carried out on the Altair Inspire. The caliper is also tested for fatigue failure using Ansys.

Oxygenated fuels like biodiesel and ethanol possess prominent characteristics as an alternative fuel for diesel engines. However, these fuels are corrosive in nature and hygroscopic. This might results in material incompatibility with the fuel supply system of an automobile. The filter consists of a filter membrane that that traps the contaminants from the fuel and prevents them from entering into the combustion chamber. The operational hours of the filter membrane depend on the quality of fuel employed. The conventional filter is designed for fossil diesel operation and hence the filter life might degrade earlier in the case of oxygenated fuels like biodiesel or ethanol. The proposed work focuses on the impact of oxygenated fuels, viz. karanja and ethanol blended karanja biodiesel on the filter membrane and its flow characteristics. Two tests, pressure difference and contaminant retention test are carried out in accordance with Japanese standard D1617:1998.

The radiator as heat exchanger plays a very significant role in an engine cooling system by maintaining the coolant at an optimum temperature. The present study aims at improving the performance of an automobile radiator by using nano-coolants. Nano-scale particles have been tested and proven to have enhanced thermal conductivity than their bulk counterparts due to their increased surface area-to-volume ratio. Thus the nanoparticles dispersed in the base fluids called nanofluids are used as a radiator coolant to improve the performance of the radiator. Aluminum oxide (Al2O3)-based nanofluid at 0.04%, 0.08%, 0.15% by volume concentrations is used in two different base fluids, one being water and the other ethylene glycol (30%) (EG)-water mixture. Coolant is supplied at three different inlet temperatures at 40°C, 50°C, and 60°C and at five different flow rates ranging from 2 L/min to 6 L/min at an interval of 1 L/min.

Due to the depletion of fossil fuels and excessive air pollution, the world is moving towards electric vehicles. Usage of electric vehicles avoids the global warming and safeguard the earth. Batteries are the primary source of electricity for electric vehicles which generates lot of heat during its operation. Now a days, firing accidents of electric vehicles on roads are frequent. One of the most significant systems to avoid this fire accident is thermal management system. Effective thermal management of high-power density battery is essential for battery’s performance, life, and safety. Components that are used for the thermal management are to be as efficient as possible to achieve effective cooling of batteries. Direct Liquid Cooling has received lot of interest in recent years. A non-conductive dielectric fluid is used to submerge the battery cells. As the fluid is dielectric, the direct contact with the cell surfaces will not be tend to short circuit the battery.

The cross flow design of a radiator and its heat transfer and temperature drop was simulated then validated by using a data acquisition system during both static and dynamic running conditions of a Formula SAE car. The data acquisition system simulated and validated the radiator's cross flow design and heat transfer, as well as the temperature drop, under static and dynamic conditions in a car. The optimal radiator design determines the engine's operating temperature and the desired temperature drop gain through proper design of the inner core, number of fins and tubes, and radiator material. The purpose of a properly designed radiator is to prevent the combustion engine from heating up above its operating temperature [1]. The radiator's design is based on the operating temperature of the CBR 600RR engine. The highest temperature recorded was around 105°C, and in the worst case scenario, it can reach 110°C.

The present study discusses the effects of engine combustion, performance and emission features of methanol-gasoline blend fired lean burn Spark Ignition (SI) engine. Performance features such as Brake Power (BP), Brake Specific Fuel Consumption (BSFC), Brake Thermal Efficiency (BTE), tail pipe emissions namely Hydrocarbon (HC), Carbon Monoxide (CO), Nitrogen Oxide (NO), Carbon di Oxide (CO2) and combustion characteristics viz. in-cylinder pressure, Heat Release Rate (HRR), Cumulative Heat Release (CHR) and variation of mean effective pressure were measured and compared with that of neat gasoline. Experiments were conducted on a modified sole cylinder four-stroke compression engine (Kirloskar TAF1) to operate as SI engine with a compression ratio of 10.5:1. A new manifold injection system and ignition system were developed by replacing the fuel injection pump and injector.

A compression ring may be a metal seal between the pistons and cylinder walls in a combustion chamber of Internal combustion engine, the important function of the compression ring is to cover the combustion area in order that there’s no movement of gases from the engine chamber to the crank case area. Supportive heat transmission from the piston to the cylinder wall helps in achieving the specified power exerted at the piston crown and efficiency of an engine. This compression ring is continuously subjected to friction and wear. To overcome or decrease the wear and tear it’s coated with certain materials which rises the lifetime of the ring. In this project we are using Chrome and Moly coated piston rings. The Coating thickness were measured using Image Analyzer. The Pin-on-Disk (POD) testing machine used to find the wear and tear rate of Chrome and Moly coated piston rings.

Nickel based superalloys have a wide range of applications due to high mechanical strength at high temperatures, fracture toughness and resistance to corrosion. However, because of their outstanding properties, it is considered as the difficult to machine materials. Inconel alloy X-750 is used extensively in rocket-engine thrust chambers. Airframe applications include thrust reversers and hot-air ducting systems along with large pressure vessels are formed from Inconel alloy X-750. Moreover, the comparative analysis of machinability aspect using coated carbide inserts is reported few. The current study explains the machinability investigation on Inconel alloy X-750 superalloys using coated carbides. To collect the experimental data, the L16 experimental design plan is used to experiment with a machining length of 40 mm.

In the fabrication of parts in auto and aero segments, the use of ceramic (SiCp, Al2O3p) reinforces aluminum alloy found to be increased than that of steel and cast iron. This matrix-reinforced alloy has a high strength to weight ratio along with higher modulus and hardness, the lower thermal coefficient of expansion, and improved tribological properties. To this extent, this paper investigates the turning characteristics and optimization study of newly developed metal matrix composites by the addition of both hard ceramic SiCp and soft stable lubricant molybdenum disulfide (MoS2p). The samples such as Sample 1: AlSi10Mg/3SiCp, Sample 2: AlSi10Mg/2MoS2p and Sample 3: AlSi10Mg/3SiCp /2MoS2p are prepared using the automated stir-casting machine. The particles are observed to be uniformly distributed in the composite. After density and hardness measurement, the samples are subjected to machining, and the responses are optimized by using response surface method.

In the present paper, to predict the process relation between laser-assisted machining parameters and machinability characteristics, statistical models are formulated by employing surface response methodology along with artificial neural network. Machining parameters such as speed of cut; the rate of feed; along with the power of laser are taken as model input variables. For developing confidence limit in collected raw experimental data, the full factorial experimental design was applied to cutting force; surface roughness; along with flank wear. Response surface method (RSM) with the least square method is used to develop the theoretical equation. Furthermore, artificial neural network method has been done to model the laser-assisted machining process. Then, both the models (RSM and ANN) are compared for accuracy regarding root mean square error (RMSE); model predicted error (MPE) along with the coefficient of determination (R2).

Epoxy carbon fiber composite materials are known for their light weight and high performance. They can be effective substitutes for commonly used materials for making drive shafts. Fiber orientation angle plays a major role in determining such a drive shaft’s responses. The responses considered in this paper are critical buckling torque, fundamental natural frequency and total deformation. A drive shaft made of epoxy carbon unidirectional prepreg is generated using ANSYS 18.0 ACP Composite Prepost. The objective of this paper is to determine an optimal configuration of fiber orientation angles for four, five and six-layered epoxy carbon drive shaft which tends to increase critical buckling torque and fundamental natural frequency while decreasing the total deformation. The optimal configuration which satisfies this objective for the three responses is identified by Minitab 17 statistical software.

This paper summarizes the research work incorporated in the exploration of the potential of swirling in CI Engine and designing of a new mechanism, particularly at inlet, to deliver it to improve the in-cylinder air characteristics to eventually improve mixing and combustion process to improve the engine performance. The research is concentrated on the measures to be done on engine geometry so as to not only deliver advantage to any specific fuel. According to the CI combustion theory, better engine performance may be achieved with Higher Viscous Fuel by improving the in-cylinder air-fuel mixing by increasing the swirl (rotation of air view from top of the cylinder) and tumble (rotation of air view from front of the cylinder) of in-cylinder air inside the fuel-injected region. The proposed inlet component is embedded with airfoil and is suitably designed after being iterated from four steps.

The heat losses through exhaust gases and the engine coolant contribute significantly towards reduction in thermal efficiency of an Internal Combustion (IC) engine. This largely impacts the fuel economy and power output. Waste Heat Recovery (WHR) has proven to be an effective method of overcoming these challenges. A Rankine cycle is a reverse refrigeration cycle that circulates a working fluid through the four basic components namely the pump, evaporator, turbine and condenser. It is a popular WHR approach in automotive applications with varying levels of success in the past. As the heat transfer capability in organic working fluids is greater than the conventionally used inorganic fluids, the former is used to capture maximum waste heat from low grade heat sources such as the automobile engine. A dual-loop Organic Rankine Cycle (ORC) is proposed for a heavy duty IC Engine with working fluids R245fa and R236fa for the High Temperature (HT) and Low Temperature (LT) loops respectively.

Increasing advancement in automotive technologies ensures that many more lightweight metals become added to the automotive components for the purpose of light weighting and passenger safety. The accidents are unexpected incidents most drivers cannot be avoided that trouble situation. Crash studies are among the most essential methods for enhancing automobile safety features. Crash simulations are attempting to replicate the circumstances of the initial crash. Frontal crashes are responsible for occupant injuries and fatalities 42% of accidents occur on frontal crash. This paper aims at studying the frontal collision of a passenger car frame for frontal crashes based on numerical simulation of a 35 MPH. The structure has been designed to replicate a frontal collision into some kind of inflexible shield at a speed of 15.6 m/s (56 km/h). The vehicle’s exterior body is designed by CATIA V5 R20 along with two material properties to our design.

Today manufacturing industries have become more competitive and to survive, industries should be capable of accommodating the sudden market change. The conventional manufacturing systems like Dedicated Manufacturing Lines (DMLs) can produce high volume of product but difficult to cater to varying product types. On the other hand, Flexible Manufacturing System (FMS) is capable of handling product variety but not suited for mass production, The Reconfigurable Manufacturing System (RMS) gives the advantage of both the system, as it has the capability to adjust to both high volume requirement and product variety, and it able to upgrade to new process technology with minimal effort. In this work the reconfiguration is carried out in machine and system level. At machine level, a new inspection machine is proposed which can be used for multiple products with minimal adjustments and a special drilling and bore tool is suggested to reduce the cycle time and ramp up time when product changes.

Considerable weight of an automobile is constituted by the engine and there is scope for improvement in fuel efficiency and emission control through optimization of weight in the engine. In this work, AlSi10Mg alloy produced by the direct metal laser sintering (DMLS) is suggested for engine application which is a lightweight aluminum alloy. Mechanical properties like tensile strength, compressive strength, and hardness of both cast and DMLS manufactured alloy are compared followed by analysis of SEM images of tensile test fractured surfaces. Reciprocating wear test is carried out for one lakh cycles at 125°C temperature with SAE 40 grade oil as lubricant. Co-efficient of friction (COF), wear rate of the cast and DMLS manufactured samples are compared. Wear patterns are analyzed using SEM images of the wear tracks.

Various research regarding new types of fabrication and modifications of Aluminium alloy to improve the existing properties are going on. The wide range application of aluminium alloy is in aerospace and Automobile Industries. The demand for this material improved by mechanical properties with little to zero increment in weight. The current work is based on the fabrication of hybrid aluminium metal matrix composites with the addition of TiC (Titanium Carbide) and Al2O3 (Aluminium Oxide) reinforcement particle using stir casting technique. Three types of hybrid composite samples were prepared based on the weight percentage 5% Al2O3+0% TiC (sample-1), 8% Al2O3 + 12% TiC (sample-2), 20% Al2O3+15% TiC (sample-3). The objective of the study is to analyze the mechanical and corrosion properties of the hybrid composite with the influence of the reinforcement and varying the weight fraction of the particles.

Inconel 600 is a face-centered cubic structure and nickel-chromium alloy. Alloy 600 has good resistance to oxidation, corrosion-resistant, excellent mechanical properties, and good creep rupture strength at a higher temperature. Alloy 600 is used in heat treating, phenol condensers, chemical and food processing, soap manufacture, vegetable, and fatty acid vessels. In this context, the present paper investigates the machinability characteristics of Alloy 600 under dry environment. Also, the parametric effect of cutting speed, feed rate, and cutting depth on the force, surface roughness, and tool wear is carried out using 3-Dimensional surface and 1-Dimensional plots. The optimal parameters are determined systematically based on Taguchi-desirability analysis with turned with TiAlN coated carbide insert. From the graphical analysis of collected data, the low rate of feed and moderate cutting for roughness and cutting force and average feed rate for tool wear with low cutting depth.

Inconel 718 has excellent material properties, corrosion, and oxidation property among the nickel based superalloy. This property makes it suitable for producing components operating under extreme environments subjected to pressure and heat. The present study aims to examine the machinability comparison under dry and MQL turning of Inconel 718. The secondary aim is to report the sustainable machining on Inconel 718. Dry and MQL (Minimum Quantity Lubrication) experiments are carried out on Inconel 718 alloy based on Taguchi’s designed L16 orthogonal array. The cutting tools are an advanced coated cutting tool and uncoated tool. The levels of turning parameters are varied at 70, 120, 170 and 220 m/min of turning speed, 0.1, 0.15, 0.2 and 0.25 mm/rev of feed rate and 0.3, 0.4, 0.5 and 0.6 mm of cutting depth. The cutting forces, surface roughness, flank wear, and chip morphology are taken for the current investigation. The factor effect on output responses is studied using 2D plots.

Inconel 825 is nickel (Ni)-iron (Fe)-chromium (Cr) alloy with additions of copper (Cu), molybdenum (Mo), and titanium (Ti). The alloy has excellent resistance to corrosion and is often the most cost-effective alloy in sulphuric acid piping vessels and chemical process equipment. No attempt of applying MQL with three nanofluids was reported conferring to the works accessed. The present study is focused on evaluating the effect of the addition of three nanoparticles (CuO, Al2O3, and CNT) in vegetable oil applied by MQL mode during turning of Inconel 825 with coated carbide tool. Cutting force, surface roughness, and tool wear are evaluated. The results showed that the addition of nCNT substantially improved the machining performance and smaller flank the tool edge, while the adhesion and abrasion are observed as wear mechanism and better results are obtained at 0.5% of nCNT+ vegetable oil to produce the lowest values.