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Gearbox and driveline durability is always been a sensitive subject from both end user and manufacturer’s point of view. Since powertrain is heart of vehicle, naturally it is expected to long last and perform satisfactorily for the entire vehicle life. Sometimes the driveline aggregates especially gearbox might face some issues because of various factors, but this is distinctively noted by the driver since it is one of the important touch point of the vehicle. The gear slippage is a very typical phenomenon observed in automotive gearbox. The issue of gear slippage is very sensitive because it leads to compromising safety of the driver, also it deteriorates gear shift quality and thereby performance of the vehicle. Generally, gear slippage is not observed during end of line testing or during early kilometers of vehicle. It is observed after some thousand kilometers, that to initially gear slippage is not observed consistently and that’s why it is difficult to identify at early stage.

With Continuous increase in demand to reduce weight is forcing Automotive Designers towards finding ways to explore new materials for the Engine components. Currently, Aluminum, Thermoplastics and Composites are widely used in Engine application. This paper examines the potential of a Magnesium alloy Front Cover designed to replace the Cast iron Front Cover in a Light duty Diesel engine. In presented study, a Cast iron Engine front cover is re-designed for Magnesium alloy and components developed. Further Magnesium alloy component tested at vehicle level and it has been demonstrated that a magnesium alloy Front cover can achieve key functional requirements such as Structural durability, Sealing, NVH, while providing substantial Weight saving.

Success of the vehicle in the market depends on comfort provided while usage, which also include level of noise, vibration and harshness (NVH). In order to achieve good cabin comfort, the NVH levels have to be as low as possible. Powertrain is main source of NVH issues on vehicle and typically mounted on vehicle using rubber isolators. The dynamic characteristics of rubber isolators play vital role in reducing the vibrations transfer from powertrain to vehicle structure while operation and during dynamic conditions. Traditionally, isolators are manufactured using Natural Rubber (NR) to meet functional requirements which include vibration isolation and durability. At times either of above requirements has to be compromised or sacrificed due to the limitation in compounding process and other practical problems involved with manufacturing of rubber parts.

As revealed from J. D. Power surveys, today most vehicle owners consider perceived quality as a direct indicator of the vehicle build quality and durability. [5] The problem has become more prominent and noticeable in recent times, due to the desire for reduced cost, reduced weight targets, aesthetic demands, and crash requirements. The performance of the door assembly when subjected to an abuse load of sag and over opening is one such perceived quality indicator which gives the customer the first impression about the engineering and build quality of the vehicle. Door hinge inclination and hinge contact flushness tolerance are the major design parameters affecting this performance. Although these are an important design parameter, the precise quantification of the effect of these design parameters on door performance under abuse loading has remained somewhat elusive.

Durability of an exhaust system of an automobile is vital to its overall performance as well as customer satisfaction. Existing CAE approach involves simplified modelling & approximations and hence, offers a good scope to model critical details that have a definite bearing on the reliability of its prediction. In this work, an attempt has been made to capture all details such as effect of bolt pre-load on the rubber bushes/isolators, actual 3D model of the rubber bushes/isolators, material property based on measured load-deflection characteristics of the rubber bushes/isolators & contact interactions of mating surfaces that were apparently missing in the existing approach. All such modelling enhancements were incorporated in the model, which was then solved using non-linear solution technique.

OEMs are seeking to develop vehicle light weighting strategies that will allow them to meet weight and fuel economy targets hence increasingly shifting their focus towards incorporating lighter material solutions at mass produced scales. Composites are seen by automotive manufacturers as the solution to lightweight vehicles without affecting their performance. More and more parts are made of short fiber reinforced plastics (SFRP) as well as continuous fiber composites. However, replacing metals by composites requires a new design approach and a clear understanding of the composite behavior. This paradigm however requires a dedicated tool for composite design in order to take into account the specific composite behavior. Traditional design tools are not able to state accurately the composite material behavior and sometime leading to use high safety of factors and lack of confidence in the design.

Emission norms across the world are getting more and more stringent day by day, in pursuit of saving the mother Earth. Automotive industry is quick to respond to this huge challenge. One solution lies in making the vehicles lighter. That's why scope of the lightweight materials is more and more realized and explored during the last decade. One of the front runners in the lightweight material is Carbon Fiber Reinforced Polymer (CFRP). CFRP comes with own challenges in its understanding, designing and engineering. For effective use of the CFRP material, from a design and mass point of view, it has to be optimized in such a way that every section and layup is utilized to its maximum potential. Current paper demonstrates the multi-step optimization approach used in a design and development of car hood. Initial assessment of the hood showed that few attributes were falling short of the requirement targets, and could only be achieved with a mass penalty.