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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.

The present work compares the tribological properties of ZnO (Zinc Oxide) nanoparticle based lubricant with ZDDP (zinc dialkyl dithiophosphate) based lubricant. The nanolubricant was prepared by mixing the nanoparticles in base oil followed by ultrasonification and ZDDP based lubricant was prepared by mixing ZDDP and stirring with base oil. Base oil used was mineral base oil. Both the lubricants were tested at three different temperatures, loads and roughness values. The test was carried out on AISI 52100 steel samples prepared by wire cutting and were grinded to three different levels of surface roughness. Friction and wear tests were performed using a reciprocating sliding tribo-tester at three different loads and temperatures. Taguchi orthogonal array was used to reduce the number of experiments. SEM, EDS and AFM analysis were carried out to study the surface wear phenomenon.

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.

Lithium (Li)-based batteries have wide applications in the everyday gadgets. Li-based batteries have prominent usage in the automotive sector. All the major OEMs for manufacturing hybrid electric vehicles (HEVs) and electric vehicles (EVs) use only Li batteries and are still going to continue for the next decades. However, during the operation of these batteries, they are susceptible to environmental and battery factors. The amount of charge currently taken in or out influences the internal resistance and temperature of the battery. Therefore, the amount of heat generated by the Li-ion batteries during operation is critical for designing a cost-effective and efficient thermal management system (TMS) for HEVs and EVs.

Design and simulation analysis of braking system for ATV is carried out with the assistance of Ansys and MATLAB. Heat generated increases the temperature of the disc brake at the rubbing surface resulting in thermal stresses in the components of the braking system. Static, structural, thermal, computational flow dynamics, vibrational & fatigue behavior of ventilated brake disc rotor, hub and upright are analyzed. Stainless Steel, SS-410 material configuration has been considered for disc brake rotor and results obtained are analyzed in terms of performance, longevity and efficiency. Braking efficiency and stopping distance curve are analyzed from their characteristics plot. Vibrational behavior, structural behavior, thermal behavior, performance efficiency, flow behavior of ventilated disc brake rotor can be easily depicted with respect to bump and droop during acceleration, high climb and maneuverability. Ventilated disc brake Rotor with outer diameter of 220 mm is used.

This paper demonstrates the sloshing phenomena of a cylindrical tank with and without baffles. The main objective of this study is to design baffles of different configurations to reduce sloshing in a cylindrical tank partially filled with gasoil-liquid subjected to only longitudinal acceleration and deceleration. Two different baffle designs have been introduced in the present study. A 3-D transient analysis of a cylindrical tank was carried out using ANSYS-FLUENT with and without baffles. Volume of Fluid (VOF) method was used to study the free surface profile of the fluid in the considered tank. Pressure distribution, velocity distribution and force distribution have been studied in the present study. It has been observed that the new design of baffle was able to reduce sloshing effectively.

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.

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.

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.

A shock absorber endurance test for an automobile that was supposed to resist at least 200,000 load cycles but failed to meet the statutory fatigue limit was under examination. This is due to the breakdown of the assembly that holds the shock absorber shims. This failure occurred due to Fretting fatigue. A design improvement is being introduced to avoid fretting fatigue on the shock absorber shim assembly. FEA is used to investigate the shim assembly in order to locate the stress zone. After adding more shims to the piston, fatigue life was significantly improved. The damping forces were unaffected by the fundamental solution that was applied to make this improvement.

Suspension system of a vehicle plays an important role to carefully control motion of the wheel throughout the travel. The vertical and the lateral dynamics (ride and handling) is affected by the unsprung-to-sprung mass ratio. Lower value of this mass ratio leads to enhanced performance of the car. To optimize the unsprung mass of the car, design of control arm plate is optimized with Aluminum material and Carbon fibre reinforced composite control arms framework are used to achieve high stiffness to weight ratio. These leads to increase in overall power to weight ratio of the car which helps to deliver maximum performance to the wheels. Through analysis of real-life working conditions of the entire steering knuckle assembly in ACP pre- post ANSYS 18.1 with the defined boundary conditions, equivalent stress and total deformations are obtained. Based on the results, geometrical topology of the control arms plates is further optimized.

The drastic technological advancements in the field of autonomous vehicles and connected cars lead to substantial progression in the commercial values of automobile industries. However, these advancements force the Original Equipment Manufacturers (OEMs) to shift from feedback-based reactive business analysis to operational-data based predictive analysis thereby enhancing both the customer satisfaction as well as business opportunities. The operational data is nothing but the parameters obtained from several parts of an automobile during its operation such as, temperature in radiator, viscosity of the engine oil and force applied over the brake disk. These operational data are gathered using several sensors implanted in different parts of an automobile and are continuously transmitted to backend computers to develop Digital Twin, which is a virtual model of the physical automobile.

A Formula Student race car is a car designed and manufactured for speed, performance, and competition. For a car to have high speed and performance, their parts also need to be lighter with being able to sustain the dynamically occurring stresses. Effective braking is a crucial factor which determines the performance of the car. This paper focuses on designing a brake caliper on the basis of calculations done with respect to a Formula Student race car, selecting a material which is of low density but with higher strength which can be easily manufactured with low cost and analyzing the design. Further, the manufactured part is also tested statically to ensure proper working before being tested on an actual formula student race car. The caliper is again tested dynamically, where the caliper is mounted on rear wheels of the car. To ensure proper working, brake pressure sensors are being mounted which also helps to validate the calculations.

This paper describes the design of a novel pneumatic gear shifting system to replace the existing gear stick manual shifting system for ease of the driver while shifting gears. The aim of this work is to have a semi-automatic shifting (pneumatic shifting) removing the need for the driver clutch operation. The system consists of a solenoid valve, CO2 gas-pressurized cylinder, double-acting cylinder, and single-acting cylinder. On basis of the signal received the gear needs to be changed, the shifter opens or closes a magnetic valve assembly. The solenoid valve allows the compressed air into the piston that comes from a pressurized cylinder, in order to create the effect of shifting gears. The pedal shifter and buttons are used to shift the gears. The pedal shifter was designed by using a 3-D printing technique using PLA material. The microcontroller used is ATMEGA-328 in this system. There are three switches, one for upshift, downshift, and clutch respectively.

The final drivetrain ratio is an essential part of a vehicle. It is responsible for providing the desired torque to overcome obstacles while maintaining the speed and acceleration of a vehicle. A vehicle must have an optimum gear ratio to obtain the desired velocity and acceleration. To achieve this, four different approaches were used considering the input parameters of a BAJA All-Terrain Vehicle (ATV). The traction received from the ground is calculated and plotted against velocity on different terrains. Further, a drivetrain was modeled in Simulink to obtain different parameters like vehicle speed, acceleration, and wheel slip. A range of gear ratios was obtained by following a similar trend of vehicle parameters that were best suited for improving vehicle performance. Graphs were plotted to compare the effect of various vehicle parameters, and an optimum gear ratio was obtained.

A Powertrain is one of the major sources of excitation of a vehicle vibration and noise in off highway vehicles. It typically has a significant contribution in whole vehicle NVH characteristics. The structure borne energy of the powertrain is transmitted to the chassis and rest of the vehicle through powertrain mounts. Hence, it is of prime importance to design an effective powertrain mounting system in such a way that it will reduce vehicle vibrations to improve vehicle NVH as well as ride comfort, resulting in an effective vibration isolation system and ensuring long service life. In this paper, a newly developed an analytical tool for effective design of isolation system is discussed. For this model, powertrain is considered as a six degree-of-freedom system. Analytical calculations are implemented to find optimum mount design parameters i.e. stiffness, orientation and position of isolators to meet desired NVH targets.

Permanent magnet brushed DC (PMBDC) motors are mostly preferred in many automotive applications because of better power density and easier control. Five different automotive applications such as electric parking brake (EPB), power seat, power window, sunroof drive, and tire air pump are chosen and discussed in this paper. A step-by-step electromagnetic analysis is carried out for all the designed models. Low-cost ferrite-based magnets are used for cost reduction keeping the efficiency as high above 77% in all the models. Comparison on performance and cost are discussed in the conclusion section.

In lieu of the drastic growth of the vehicle population, there is a huge consumption of fossil fuels and mineral oils for mobility. This leads to depletion in fossil fuels and mineral oils which are the by-products of petroleum. These fossil fuels can’t sustain for a long period of time because of its toxicity. In order to reduce the usage of existing mineral oil for lubrication, a source of non-edible oil from Jatropha curcus is processed as jatropha methyl ester (JME). It is holding high viscosity, density and easy blend with base oil. In this current work, the wear resistance of the lubricating oil is enhanced by the addition of nano-copper oxide particle blend with the base oil. The emission performance and tribological behavior have been experimentally tested in 98.2CC two-stroke air cooled engine. The 20% of JME blend with CuO nano particle provides better emission performance and wear characteristics than the other combination of blends.

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).

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.