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Advanced Non-linear topology optimization methods have been addressed as the most promising techniques for light weight and performance design of Powertrain structures. The theoretical achievements are obtained both mechanically and mathematically. Nowadays, the great challenge lies in solving more complicated engineering design problems with multidisciplinary objectives or complex structural systems. The purpose of this paper is to provide a forum to present new developments in structural Non-linear topology optimization. The advantage of the proposed method is that structural optimization on irregular design domains can be carried out easily. Furthermore, this method integrates the stress analysis and the boundary evolution within the framework of finite element methods. In this paper, mainly focused on the Commercial Vehicles Powertrain component i.e. Transmission Housing.

A propeller shaft is a mechanical component of drive train that connects transmission to drive wheels/axle with the goal to transfer rotation and torque. It is used when the direct connection between transmission and drive axle is not possible due to large distance between their respective assigned design spaces. In commercial vehicles especially in heavy duty (GVW/GCW>15 tons) a single piece propeller shaft is seldom used due to its inherent disadvantages and therefore, most if not all, of the setups consists of multiple pieces of propeller shaft which are directly mounted on to frame cross members with the help of mounting brackets. As such the mounting bracket assembly undergoes various dynamic and static loading conditions and should be able to withstand these loads. This paper will focus on the FEA analysis of propeller shaft mounting assembly system. Furthermore, these results will be correlated with physical tests results collected from test rig and physical vehicle testing.

The existing head cover is having external oil and blow by separation unit, which is not only costlier but also complex and leads to increase in overall height of engine which was difficult to integrate in new variants of vehicles. A new head cover has been designed with internal baffle type oil and blow by separation system to ensure efficient separation and proper packaging of the system in new variants. The new system has been finalized after 26 DOE’s of different wire mesh sizes and different baffle plate size and positions. The final system has two bowl shaped separation unit with wire mesh, two cup type oil separation passages and one baffle plate for separating blow by. The system works on condensation and gravity method. The blow by is guided through a well-defined passage integrated in aluminum cylinder head cover itself. The passage angle is maintained to ensure minimum oil flow with blow by.

Three on the tree, four on the floor. The gear change mechanism is a component that is too often taken for granted but it is one of the more important features of the vehicle. It must be quick and smooth in action, efficient and totally reliable. Modern driving conditions demand that the driver makes frequent gear changes and a mechanism that is temperamental or inaccurate can be both frustrating and dangerous as well as physically tiring. The gear changing mechanism starts, quite obviously, with the gear lever. Most stem from the fact that a gear lever must move in two planes, forward and back and then from side to side to move across the gear "gate". A good many drivers think of gear changing as one simple action. This is more a tribute to the design of gear changing mechanisms than a reality. There are multiple gear selector mechanisms that are available for use in commercial vehicle industry.