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Electric passenger car with floor battery usually have its front boot space empty and the space is used as additional luggage storage. This space can be utilized to capture the wind energy and generate electricity. Based on this, the objective of this work is to perform an aerodynamic analysis of an electric passenger car using wind turbine placed at the front. Initially the aerodynamic analysis of a basic electric car model is performed and further simulated using wind turbines and aerodynamic add-on-devices. The simulation is carried-out using ANSYS Fluent tool. Based on the simulation result, scaled down optimized model is fabricated and tested in wind tunnel for validation. The result shows reduction of drag coefficient by 5.9%.

Any change is vehicle exterior design, affects the aerodynamics characteristic. Generally different types of roof racks are attached on passenger vehicles to carry luggage which affects aerodynamic drag. The objective of this work is to perform aerodynamic analysis of ground vehicle with roof rack to investigate the change in drag coefficient. First, the aerodynamic analysis of a baseline passenger car model is performed with and without generic benchmarked roof rack at 100 kmph. Further analysis is carried out with different new designs of roof racks. Based on simulation result, a scaled down prototype model is fabricated and validated by using a wind tunnel test for optimum suitable case. The modelling of the vehicle is done in CATIA tool and simulation is carried out by using ANSYS Fluent.

In high speed race cars, aerodynamics is an important aspect for determining performance and stability of vehicle. It is mainly influenced by front and rear wings. Active aerodynamics consist of any type of movable wing element that change their position based on operating conditions of the vehicle to have better performance and handling. In this work, front and rear wings are designed for race car prototype of race car. The high down force aerofoil profiles have been used for design of front and rear wing. The first aerodynamic analysis has been performed on baseline model without wings using CFD tool. For investigation, parameters considered are angle of attack in the range of 0-18° for front as well as rear wing at different test speeds of 60, 80, 100 and 120 kmph. The simulation is carried out by using ANSYS Fluent. The simulation results show significant improvement in vehicle performance and handling parameters.

Active aerodynamics can be defined as the concept of reducing drag by making real-time changes to certain devices such that it modifies the airflow around a vehicle. Using such devices also have the added advantages of improving ergonomics and performance along with aesthetics. A significant reduction in fuel consumption can also be seen when using such devices. The objective of this work is to reduce drag acting on a passenger car using the concept of active aerodynamics with grill shutters and air dams. First, analysis has been carried out on a baseline passenger car and further simulated using active grill shutters and air dams for vehicle speed ranging from 60 kmph to 120 kmph, with each active device open from 0° to 90°. The optimized model is then validated for a scaled down prototype in a wind tunnel at 80kmph. Vehicle has been modelled using SolidWorks tool and the simulation has been carried out using ANSYS Fluent.

Forging is a metal forming process involving shaping of metal by the application of compressive forces using hammer or press. Forging load of equipment is an important function of forging process and the prediction of the same is essential for selection of appropriate equipment. In this study a hot forging material i.e. 42CrMo4 steel is selected which is used in automotive components like axle, crank shaft. Hot forging experiments at 750°C are carried out on cylindrical specimens of aspect ratio 0.75 and 1.5 with true height strain (ln (ho/hf)) of 0.6. Forging load for the experiments is calculated using slab and upper bound deformation models as well as Metal forming simulation using commercially available FEA software. The upper bound models with 30% deviation from the simulation results are found to be more accurate compared to the slab models.

FEA based simulations are extensively used in automotive industry for improving the product design and reducing the time taken for design and prototyping. FEA based simulations require material data as an input in form of material models. Most commonly used material models for simulation of metallic materials are elastic models and elasto-plastic models, which provide very good correlation till ultimate tensile strength (UTS). For simulation beyond UTS value, elasto-plastic material model has to be used along with material model considering the damage accumulation post UTS. For crash like event in automotive crash, required material models should consider the effect of various stress state conditions (Triaxiality) and strain rate sensitivity of materials along with damage accumulation. In LS Dyna solver, MAT_ADD_EROSION material model (GISSMO) along with MAT_024 is widely used for these applications.

An open wheeled open cockpit high speed car with 800 CC MPFI engine was developed validated and run at 105 kmph. The key focus was to build a car with superior aerodynamic characteristics especially in terms of drag. This work discusses in detail about the design and simulation of car using CFD package followed by Wind Tunnel testing. The design of high speed car starts with design of seat according to the ergonomics of the driver followed by the space frame. Based on the space frame designed, the body panels are sketched and CAD model is developed. The CAD model is imported in CFD package for virtual testing and validated through wind tunnel results. For this 1:3 scale model was manufactured using Rapid Prototyping.

Gerotor pump is a positive displacement pump unit which is widely used for lubrication in on-road and off-road engine applications. This paper is focused on Gerotor pump design competency established at ARAI comprising of design of inner and outer rotors, suction & delivery ports, optimizing inlet and outlet diameters & its position, development of methodology to calculate oil flow rate, volumetric efficiency, mechanical efficiency & slippage. The finalization of design is followed by CFD of Gerotor pump to optimize the pressure and flow pulsation. A trochoidal profile is used to design the inner and outer rotors and its conjugate profile are realized by a set of equations using a method based on the theory of gearing. Suction and delivery port is analytically designed based on the same design parameters of the trochoidal profile.

Hydrogen Internal Combustion Engine (H2ICE) has hydrogen gas storage system and is operated at very low temperature before it enters the combustion chamber. The effect of hydrogen on steel materials is detrimental because of hydrogen embrittlement. Forged steel parts are used in engine specifically valve. The goal of the work is to analyze the outcome of low temperature i.e. 35 °C to -30 °C on three types of forged steel materials i.e. 40Cr4, 42CrMo4 and EN8 and assess any potential changes in their properties due to ductile to brittle transition. Charpy impact test is widely used to determine the temperature at which a material shifts from exhibiting ductile behavior to brittle behavior. This transition is critical for understanding the safety and reliability of steel components, as brittle fracture can lead to catastrophic failures.

Role of wheel and underbody aerodynamics of vehicle in the formation of drag forces is detrimental to the fuel (energy) consumption during the course of operation at high velocities. This paper deals with the CFD simulation of the flow around the wheels of a bus with different wheel housing arrangements. Based on benchmarking, a model of a bus is selected and analysis is performed. The aerodynamic drag coefficient is obtained and turbulence around wheels is observed using ANSYS Fluent CFD simulation for different combinations of wheel-housing- at the front wheels, at the rear wheels and both in the front and rear wheels. The drag force is recorded and corresponding influence on energy consumption of a bus is evaluated mathematically. A comparison is drawn between energy consumption of bus body without wheel housing and bus body with wheel housing. The result shows a significant reduction in drag coefficient and fuel consumption.

With emission norms getting more and more stringent, the trend is shifting towards electric and hybrid vehicles. Electric motor replaces engine as the prime mover in these vehicles. Though these vehicles are quieter compared to their engine counterpart, they exhibit certain annoying sound quality perception. There is no standard methodology to predict the noise levels of these motors. Electric motor noise comprises of mainly three sources viz., Aerodynamic, Electromagnetic and Mechanical. A methodology has been developed to predict two major noise sources of electric motor out of the three above viz. Mechanical and Aerodynamic noise. These two noise sources are responsible for the tonal noise in an electric motor. Aerodynamic noise arises most often around the fan, or in the vicinity of the machine that behaves like a fan. This noise is predominant at higher motor speed and also in electric vehicle due to higher speed fluctuation.

This paper presents a methodology for predicting thermal comfort inside Midibus cabin with an objective to modify the Heating, Ventilation and Air Conditioning (HVAC) duct design and parametric optimization in order to have improved thermal comfort of occupant. For this purpose the bus cavity is extracted from baseline CAD model including fully seated manikins with various seating positions. Solar Load has been considered in the computational model and passenger heat load is considered as per BSR/ASHRAE 55-1992R standard. CFD simulation predicted the air temperature and velocity distribution inside passenger cabin of the baseline model. The experimental measurements have been carried out as per the guidelines set in APTA-BT-RP-003-07 standard. The results obtained from CFD and Experimental test were analysed as per EVS EN ISO7730 standard and calculated occupant comfort in terms of thermal comfort parameters like Predicted Mean Vote (PMV) and Predicted Percentage Dissatisfied (PPD).

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.

Nickel electroplating is commonly used with substrates including steel, aluminum, plastic and zinc die-cast parts because of its high resistance to temperature, corrosion and wear in harsh conditions. To further enhance its tribological and mechanical properties, research works are going on to produce nano-reinforced composites of Ni with various ceramic and rare earth oxides like CeO2, ZrSiO4, SiC, TiO2, etc. The aim of present work is synthesis and characterization of Ni films and Ni based TiO2 nano-composite coating processed by pulse co-electrodeposition technique. Also, to investigate the various properties such as mechanical, wear and corrosion resistance, conductivity & thermal stability of Ni-TiO2 nanocomposites electrodeposited on steel substrate, especially the effects of the amount of nanosized TiO2 particles in Ni-TiO2 nanocomposites.

Virtual modeling of engine and predicting the performance and emissions is now becoming an essential step in engine development for off-road application due to the flexibility in tuning of the combustion parameters and requirement of shorter development times. This paper presents an approach where the test bed calibration time is reduced using virtual techniques, such as 1D thermodynamic simulation and 3D CFD combustion simulation for 4 cylinders TCIC engine complying with Stage IIIA emission norms. 1D thermodynamic simulation has played an important role in the early stage development of an engine for selection of engine sub systems like turbocharger, manifolds, EGR system, valve timings etc. The application of 1D Simulation tool for combustion system development, focusing on NOx emissions for an off road multicylinder mechanical injection diesel engine is discussed.