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Ride is considered to be one of the crucial criterion for evaluating the performance of a vehicle. Automobile industry is striving for improvement in designs to provide superior passenger comfort in Commercial vehicles segment. In Industry, Quarter-car model has been used for years to study the vehicle’s ride dynamics. But due to lower DOF involved in quarter car, the output accuracy is somewhat compromised. This paper aims in development of a 7 DOF full-car Model to perform the ride- comfort analysis for Light Duty 4*2 Commercial Bus using MATLAB Simulink which can be used to tune the suspension design to meet the required ride-comfort criteria. Firstly, experimental data and Physical Parameters are collected by performing Practical Test on commercial Bus on different road profiles. Secondly, a Full Car Mathematical Model with 7 DOF has been developed for a bus using MATLAB Simulink R2018a.

Particulate matter is one of the major pollutant responsible for deteriorating air quality, particularly in urban centers. Information on contributing sources with the share from different sources is a first and one of the important steps in controlling pollution. Diverse sources, anthropogenic as well as natural, like industries, transport, domestic burning, construction, wind-blown dust, road dust contribute to particulate matter pollution. Receptor modeling is a scientific method which is utilized for assessment of the contribution of various sources based on chemical characteristics of particulate matter sources and ambient air particulate matter. Representative data of fractions of various chemical species in the particulate matter from the different sources i.e. source fingerprint is an essential input for the receptor modeling approach.

Last decade has been era of environmental awareness. Various programs have launched for making devices and appliances eco-friendly. This initiative has lead automobile industry toward hybridization and now total electrification of vehicles. As electric motor is being added to automobile as a prime mover, due to high frequency vibrations along with higher torque electric motor needs to be isolated properly & carefully as this vibration can damage other automobile parts. Dynamic response of electric motor is different from response of IC engines, so use of engine mounting design method may not be suitable for designing mounting system for electric motor. First, both 4- point and 3- point mounting system are considered for analytical and experimental investigation of force and displacement transmissibility. Position and orientation of elastomeric mounts plays important role in design of mounting system for electric motor.

To enhance the crashworthiness of electric vehicles, designing the optimized and safer battery pack is very essential. The deformed battery cell can result in catastrophic events like thermal runaway and thus it becomes crucial to study the mechanical response of battery cell. The goal of the research is to experimentally investigate the effect of mechanical deformation on Lithium-ion battery cell. The paper thoroughly studies the phenomenon of short circuiting at the time of failure. Various experiments are carried on 18650 cylindrical cells (NCA chemistry) under custom designed fume hood. The setup captures the failure modes of battery cell. The loading conditions have been designed considering the very possible physical conditions during crash event. The study has been done for radial compression, semicircular indentation, hemispherical indentation, flat circular indentation and case of three-point bending.

NVH has gained importance in the field of earth moving equipment due to the demand of quieter machines and stringent in-cab as well as exterior noise emission norms. Several parts of the world have adopted strict legislation on noise emission by earth moving equipment, but many countries have not adopted any regulations till date. The aim of this study is to help governing bodies as well as machine manufacturers in adopting simple yet accurate testing method for compactor machine. The study consists of directivity analysis, noise source identification, noise source ranking and 4-point microphone position sound power evaluation method applied to compactors with wide range of engine power ratings. All the tests in 4-point method and directivity analysis were performed under stationary as well as dynamic conditions.

Design of real time active controls for structural dynamics problems requires a very precise mathematical model, to closely determine the system dynamic behavior, under virtual simulation. The finite element models can somehow be used as a mathematical model but due to complex shape/structure of the component, the size of discrete models resulting from finite element analysis is usually very large, causing the virtual simulation to be extremely computationally intensive and time consuming, also the boundary conditions applied are not very scalable, making the system deviate from its real dynamic behavior. Thus, this paper deals with the design of a Model Order Reduction technique, using orthogonal decomposition of system matrices, which can be used for creating accurate low-order dynamic model with scalable boundary conditions.

Electric Vehicles (EVs), with its inherent advantage of zero tailpipe emissions, are gaining importance because of aggressive push from government not only to reduce air pollution but also to reduce dependency of fossil fuel. EVs and necessary charging infrastructure along with ‘connected’ technology is redefining mobility. Considering the fast growing EV market, it becomes important for an EV Powertrain Architect to design and develop a powertrain solution having low engineering efforts and satisfying business, market and regulatory requirements at a competitive price. This paper presents a compact, flexible, convenient and smart featured simulation tool for an EV Powertrain Architect for estimating the specifications of key powertrain components such as traction battery and electric motor. The proposed tool takes into consideration the end-user as well as the regulatory requirements of range, maximum speed, acceleration and gradeability.

CNG has recently seen increased penetration within the automotive industry. Due to recent sanctions on diesel fuelled vehicles, manufactures have again shifted their attention to natural gas as a suitable alternative. Turbocharging of SI engines has seen widespread application due to its benefit in terms of engine downsizing and increasing engine performance [1]. This paper discusses the methodology involved in development of a multi cylinder turbocharged natural gas engine from an existing diesel engine. Various parameters such as valve timing, intake volume, runner length, etc. were studied using 1D simulation tool GT power and based on their results an optimized configuration was selected and a proto engine was built. Electronic throttle body was used to give better transient performance and emission control. Turbocharger selection and its location plays a critical role.

Passive safety regulations specify minimum safety performance requirements of vehicle in terms of protecting its occupants and other road users in accident scenarios. Currently for majority cases, the compliance of vehicle design to passive safety regulations is assessed through physical testing. With increased number of products and more comprehensive passive safety requirements, the complexity of certification is getting challenged due to high cost involved in prototype parts and the market pressures for early product introduction through reduced product development timelines. One of the ways for addressing this challenge is to promote CAE based certification of vehicle designs for regulatory compliance. Since accuracy of CAE predictions have improved over a period of time, such an approach is accepted for few regulations like ECE-R 66/01, AIS069 etc which involves only loadings of the structures.

In the pioneering sectors of design and development, industries are looking for computer integrated solutions for product development; especially in aerospace industries where the demands for reduction in the development cycles and prototyping iterations. Generative design and topology optimization are the recent tools for achieving the desired design solutions. Topology optimization aims to find an ideal structural configuration within the given design domain with various constraints, objectives, and boundary conditions. In this study, topology optimization is used as a design tool in the development phase of a component. An efficient methodology is developed based on topology optimization for regeneration of a tertiary components. The topology optimization approach used in this research is divided into three main stages: modelling, optimization and regeneration.

An excellent physical and mechanical property makes Aluminium (Al) alloy suitable alternative lightweight materials against steel and cast iron in automotive components. ICME is a computational tool, which integrates the materials information to engineering product performance analysis. MatCalc is ICME tool, which follows the chain rule of process, microstructure, property and performance relationship in materials development. This paper reports the development of Al 6061-T6 propeller shaft through forging process and the materials and process model of the Al yoke is simulated using MatCalc simulation software. Finite element analysis method is used for designing of Al 6061-T6 propeller shaft. The forged Al yoke is solutionized at temperature 550°C for 1 hr followed by artificial ageing at temperature 180°C for 16 hrs to improve the hardness and strength of the yoke.

This work is a part of program on “Development of High Performance DI, 3 Cylinder CRDI Diesel Engine to meet Euro-IV/V Emission Norms focused on automotive passenger car application purpose. This is a 3 Cylinder, TCIC engine designed for combustion pressure of 160 bar max for first stage which is being upgraded to 200 bar max in the second stage. Cylinder Head design is a part of complicated configuration whose construction and principal dimensions are dependent on the size of inlet and exhaust valves, fuel injectors positioning and mounting, port layout and swirl and shape of combustion chambers. The cylinder head of a direct-injection diesel engine has to perform many functions. It has to bring charge air to the cylinder and exhaust gas from the cylinder, with minimum pumping loss and required swirl and other properties of charge motion.

This work is a part of program on “Development of High Power Density DI, Diesel Engine to Meet US EPA - Tier III Emission norms for off highway and Genset application purpose. This is a 4 Cylinder, TCIC engine delivering 165 Hp @ 2500 rpm. BMEP at max torque comes to be 18 bar giving max cylinder firing pressure of 160 bar. Engine block is a most vital component which has to serve various functions all together. Also design of block for such a high BMEP levels, demands to give a different design strategy required for development of High Performance Engines. In order to reduce overall production cost, several constraints are imposed on design of new block. Design of block is carried out within several design, assembly and manufacturing constraints such as maintain a specific cylinder centre distance, integral oil cooler in the engine block, re-location of camshaft and FIE positions, incorporation of various accessories viz. steering pump, Air Compressor etc.

Diesel powered electric generators are used in a variety of applications, such as emergency back-up power, temporary primary power at industrial facilities, etc. As regulatory and customer requirements demand quieter designs, special attention is given to the design of acoustic enclosures to balance the need of noise control with other performance criteria like ventilation and physical protection. In the present work, Statistical Energy Analysis (SEA) approach augmented by experimental inputs is used to carry out Vibro-acoustic analysis of an enclosure for higher capacity Diesel generator set. The exterior sound radiated from an enclosed generator is predicted and further enclosure is optimized for an improved sound-suppression. The airborne sources such as engine, alternator, radiator fan and exhaust are modelled explicitly using experimental noise source characterization. Structure borne inputs are also captured in the test for improving modelling accuracy.

The paper discusses the methodology for measuring the sound absorption of sound package materials in a different sizes of reverberation chambers. The large reverberation chamber is based on test methods and requirements as per ASTM C423 and ISO 354 standards. Both the test standards are similar and recommend a reverberation chamber volume of at least 125 m3 and 200 m3 respectively for sound absorption measurements from 100 Hz to 5000 Hz. The test sample size requirements are from 5.5 to 6.7 m2 as per ASTM C423 and 10 to 12 m2 as per ISO 354. In the automotive sector passenger car, heavy truck, and commercial vehicle, the parts that are used are much smaller in size than the size prescribed in both the standards. The requirement is to study the critical parameters such as the chamber volume, sample size, reverberation time and cut-off frequency etc. which are affecting the sound absorption property of acoustic material.

Sound Quality (SQ) of brake and clutch pedal assembly plays an important role in contributing to vehicle interior noise and perception of sound. Quiet operation of brake and clutch units also reflects the vehicle built and material quality. Noise emitted from these sub-assemblies has to meet certain acceptance criteria as per different OEM requirements. Not much work has been carried on this over the years to characterize and quantify the same. An attempt has been made in this paper to study the sound quality of brake and clutch pedal assemblies at component level and validate the same by identifying the parameters affecting SQ. Effect on noise at different environmental conditions was studied with typical operating cycles in a hemi-anechoic chamber. The effect of sensor switches integrated within the clutch and brake pedal on sound quality is analyzed. It is found that the operating characteristics of switches drives the noise and SQ.

With the announcement, as per draft notification GSR 187 (E) dated 19th Feb 2016 issued by MoRTH (Ministry of Road Transport and Highways), on vehicle emission standards to leapfrog from BS IV to BS VI by 2020, diesel engines would be greatly facing challenges to meet the stringent emission requirements of 90% reduction in PM and 50% reduction in NOx emissions simultaneously. Up to BS IV, in-cylinder strategies utilizing higher fuel injection pressure, higher intake boost, lower to moderate EGR, optimized combustion chamber design and lower intake manifold temperature would be sufficient. But meeting emission levels at BS VI levels would require a combination of both in-cylinder combustion control and after treatment system [1]. However, unlike Europe and US markets where wide spread adoption of after treatment solution is viable, for Indian market it would be impeded by infrastructure availability, system cost and cost of ownership.

The present research deals with study of pongamia oil methyl ester as a lubricant by blending with anti-wear additive ZDDP. The experimental work carried in this work aims to investigates the friction and wear characteristics by blending zinc diakyldithio phosphates (ZDDP) with pongamia oil methyl ester as lubricant under various loading conditions and temperatures. The coefficient of friction and wear scar depth were determined using pongamia biodiesel blended with 0.3%, 0.6% and 1 % ZDDP by concentration through high frequency reciprocating wear testing machine for 2 h duration. The reciprocating wear tests were performed on an engine liner-piston ring contact under the loads of 40 N, 60 N and 80 N for 2 h duration at temperatures of 100°C, 125°C 150° C with 10 Hz oscillation frequency. The addition of ZDDP with pongamia biodiesel showed marginal reduction in friction coefficient and wear scar depth under all loads and temperatures.

The infliction of rigorous emission norms across the world has made the automobile industry to focus and dwell upon researches to reduce the emissions from internal combustion engines, namely diesel engines. Variation in fuel injection timing has better influence on reduction of engine exhaust emissions. This papers deals with the variation of fuel injection timing along with fuel injection pressure numerically on a 4 stroke, single cylinder, and direct injection diesel engine running at full load condition using CONVERGE CFD tool. As the piston and bowl geometry considered in this work is symmetric, only 60 degree sector of the piston cylinder assembly is considered for numerical simulation over complete 360 degree model.

Thermal management is one of the most challenging and innovative aspects of the automotive industry. The efficiency of the vehicle cooling framework unequivocally relies upon the air stream through the radiator core. Significant advances in thermal management are being embraced in the field of radiator material and coolant. The radiator shouldn't be exclusively credited for the reliable cooling of the engine. There are other auto parts that play an essential role in keeping engine temperature at a manageable level. The fan-shroud assembly is an important component of the cooling system. While the fan is responsible for drawing in air, the fan shroud's job is to ensure uniform air distribution to the radiator core. By assisting airflow in the engine compartment the fan shroud helps in dismissing excess heat from the engine. This assembly also prevents the recirculation of heated air through the cooling fan.