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Kakria S.,Thapar University | Sriharsha I.,Maruti Suzuki India Ltd | Wagh M.,Maruti Suzuki India Ltd
SAE Technical Papers | Year: 2015

Suspension and chassis play a vital role in the structural performance of an off-road vehicle. The paper focuses on Computer Aided Engineering (CAE) modeling and simulation study of an All Terrain Vehicle (ATV) structure to analyze its static and dynamic behavior. An integrated MBD-FEA approach used for analysis purpose has been presented. In the study, a Multi Body Dynamic (MBD) model of the ATV suspension system is built using ADAMS/Car. The effect of change in suspension hardpoints on suspension characteristics has been analyzed by carrying out Design of Experiment (DOE) study using ADAMS/Insight. This is done to minimize roll, camber and kingpin angle variation during vertical wheel travel, thus increasing stability of the vehicle under rough road conditions. This helps in optimizing the front and rear suspension geometry of ATV. The Finite Element (FE) model of ATV chassis is prepared to check its structural integrity. The input loads at body attachment points for FE model are taken from MBD suspension bench test analysis. The input loads for impact analysis are calculated analytically. Since safety of driver depends on structural strength and robustness of chassis, it is important to evaluate the design for all possible load cases (viz., bench and impact loads). Necessary countermeasures are taken in the structure based on stress response. Finally, various tests like double lane change, constant radius cornering and sine input are performed on full vehicle MBD model to predict its handling characteristics. This includes the steady state (understeer/oversteer behavior and roll angle) and transient (vehicle response-time lag) response. Various road profiles generated virtually in ADAMS/Car are further helpful in understanding the dynamic behavior. The process methodology depicted in this paper is useful in design and development of ATV for SAE BAJA event. It provides an important feedback regarding vehicle structure during design phase itself well before actual prototype is built. Copyright © 2015 SAE International and Copyright © SAEINDIA.


Kumar Reddy J.S.,Maruti Suzuki India Ltd
SAE Technical Papers | Year: 2015

Bumper opening area projected on condenser to total condenser core area is referred to as condenser opening area. The condenser opening area plays a vital role in A/C Performance of vehicle particularly during idling and initial cooling of vehicle. This paper presents detail study on effects of condenser opening area on A/C performance. Based on theory, the effect of condenser opening area is studied and it is validated by experimental results. Depending on these results an optimum value of condenser opening area required for best A/C performance is concluded. Copyright © 2015 SAE International.


Gosain A.,Maruti Suzuki India Ltd | Ravindran M.,Maruti Suzuki India Ltd
SAE Technical Papers | Year: 2010

One of the most common NVH refinement areas of a vehicle is the cabin booming noise. The current study discusses the improvement of the low frequency booming noise in the cabin of a small passenger car. The practice of reinforcing experimental evaluation results with the extensive use of computer aided engineering tools in the development process is presented in this paper. The structural changes executed in the vehicle, to reduce noise contribution, are iterated and optimized using simulation and validated using experimental analysis methods like operational modal analysis, linear frequency response functions and actual run-up measurements. Additionally, the interesting variation of the NVH characteristics of a vehicle due to the changeover from a 4-cylinder inline to a 3-cylinder inline powertrain, while inheriting the similar body structure, is discussed in this study. Copyright © 2010 SAE International.


Kumari S.,Maruti Suzuki India Ltd.
SAE Technical Papers | Year: 2013

In automotive seating system, seat upholstery quality has an important role in defining the overall quality and aesthetics of vehicle interiors. Technical textiles for seating system used in automotive applications are generally categorized into woven or knitted type. An automotive textile material is a composite material made up of three layers; base fabric (top layer), foam (middle layer) and scrim (bottom layer) as shown in Fig. 1. There are many challenges to be overcome during development of fabric e.g. mechanical, physical and aesthetic issues have an impact on overall seat quality, appearance and performance. These issues get highlighted during testing, which takes place during development stage of fabric. The concerns mentioned above are found in automotive textiles in both woven and knitted types of fabrics sourced from different manufacturing set-ups. This paper focuses on identification of problems during testing, followed by root cause analysis. In technical textiles, design of the fabric, its structure and finishing plays a significant role in ascertaining overall property of the fabric, either enhancing or deteriorating it. In this paper, parameters affecting different properties were studied and evaluated. Major parameters considered are: 1Construction of fabric2Material GSM3Density of lamination foamFigure 1Layers of Automotive Seat Covering Fabric. Copyright © 2013 SAE International and Copyright © 2013 SIAT, India.


This article brings a practical analysis for determination of gravity center in unsymmetrical three dimensional bodies practically and graphically. The gravitational center of an object is the point from which if suspended, the object remains stable at all times, this is also called as center of mass of the object, or the theoretical point at which the entire weight of the object is assumed to be concentrated. In certain tests, the Center of Gravity (CG) of the Seat is required to be known, for load application. The CG is the point at which a SEAT would balance if it were possible to suspend it at that point. This paper deals with use of applied engineering and theoretical calculations to ascertain the CG of First and Second Row seats (individual and bench type). In this case the center of gravity location is expressed in units of length along each of three axes (X, Y and Z). Load balance equation is used to calculate the CG of the seat. Relevant equation as given in Eqn. 1. (1) The performance and design criteria of seat systems require that the seat should be lighter for reduced fuel consumption while still meeting the safety requirement for seat including headrests and seat back static and dynamic structural performance. Other safety requirements for the seat are the seat belt anchorage, luggage retention capability, child seat anchorage and top tether requirements as defined by pertinent regulation. Copyright © 2013 SAE International and Copyright © 2013 SIAT, India.


Yadav K.,Maruti Suzuki India Ltd | Thakur R.,Maruti Suzuki India Ltd
SAE Technical Papers | Year: 2016

Hood is the closure provided in the frontal portion of the vehicle for covering the engine room. Any component disposed in the frontal portion of the vehicle becomes important because of aesthetic as well as regulatory requirements. Introduction of new regulations like pedestrian protection brings new challenges for the original equipment manufacturers and the governing authorities. Introduction of Pedestrian Protection regulation, a recent development in the automotive industry, has thrown several questions in front of original equipment manufacturers. This work explains the procedure to address such question and the learning associated with it. With an attempt to comply Pedestrian regulation, following were the major challenges: 1Common Platform and Engine2High Hood Styling3Limited freedom to increase vehicle front overhang4Location of hood switch With above mentioned constraints, a team of design, evaluation and testing set forth its aim to make the Hood system pedestrian headform compliant while giving priority to styling and common platform. Also the location of safety device, hood switch, can't be changed which becomes a major constraint in reducing the HIC values as the gap required for energy absorption was not available between hood and member hood lock. This paper presents all the facets and the outcomes of this important activity. Final design corroboration was done at Physical testing laboratory. The scope of this work lies in the application of the learning obtained during the activity for future deployment on various models. Copyright © 2016 SAE International.


Kulshrestha A.,Maruti Suzuki India Ltd. | Rawat N.,Maruti Suzuki India Ltd.
SAE Technical Papers | Year: 2015

During the conceptualization of vehicle, it is big challenge for automotive manufacturer to design a vehicle which has an excellent aesthetic looks as well as meet the stringent vehicle regulations. In the vehicle styling, bumper plays an important role in deciding of the contemporary looks of the vehicle. To improve customer satisfaction, it is important to design a bumper which provides feeling and sense of durability. In addition, bumper should sustain low-speed impact and protects the peripheral components such as parking lights, headlamps, hood, back door and safety related installed equipments like Rear parking camera, parking sensors, etc. Bumper should be dent resistant and be able to regain its original shape on removal of the applied load. An elegant design of bumper should be light weight with high strength. This paper explains about a new CAE methodology developed to simulate the real life loading condition of bumper and to calculate the deformation in the bumper. Physical testing is being conducted to validate the design. On the basis of CAE and test correlation results, an optimized design of bumper is developed which not only meets the vehicle regulations but also saves significant weight and cost. Copyright © 2015 SAE International and Copyright © SAEINDIA.


Ranjith Kumar T.R.,Maruti Suzuki India Ltd | Yadav A.N.,Maruti Suzuki India Ltd
SAE Technical Papers | Year: 2016

Presently, lot of research is going on, to improve the thermal efficiency and there by the Fuel Economy of vehicles. Increasing the compression ratio to improve on the performance is an option. The compression ratio is a factor that influences the performance characteristics and FE of internal combustion engines. When targeting high output levels at low engine speeds, undesired combustion events called pre-ignition can occur. These pre-ignition events are typically accompanied by very high cylinder peak pressures which can lead to severe damage of engine component. The application engineer needs to optimize this undesired combustion event. This paper describes a systematic application developed to reduce pre-ignition. A case study was done to identify the pre-ignition phenomenon by using in-cylinder measurement. The paper also explains how air, fuel, injection angle and spark can help to avoid pre-ignition. Copyright © 2016 SAE International.


Bayani S.,Maruti Suzuki India Ltd
SAE Technical Papers | Year: 2011

Vehicle hood experiences impact loading once it is dropped freely from a specific height. This phenomenon is known as Hood Slam (HS). HS induces damage to the components of the hood and front end module. This damage accumulates over the vehicle lifetime and may lead to failure. In a traditional design process, the durability performance of the hood and front end module is evaluated by conducting an impact test. It is, however, very costly and time-consuming to achieve a statistical-based confidence. This paper presents the CAE methodology that intends to replace the physical test and predict the durability performance of the hood and front end module early in the design cycle. The precise capturing of the time dependent contact conditions between the different components of the closing mechanism is essential in simulating the load transfer between the hood and the body. The body-hood contact sequence brings about a variable deformation of the bump stops, due to the curbed movement of the hood and the resulting modal oscillations of the hood itself. This CAE method demonstrate simplistic modeling of latch to capture precisely all the phases in hood slam event. Predefined initial rotational velocity is applied on the hood and the dynamic response of the structure is studied over a period of time. The impact loading causes local deformation and stress concentration, which may become potential failure spots. The stress time history from the impact simulation is used to evaluate the fatigue life of the component. FEA results are correlated with the physical test results. This paper explains the benefit of CAE technology to the vehicle closures development. Copyright © 2011 SAE International and Copyright © 2011 SIAT, India.


Noise generated in the driveline is mainly transferred inside the passenger cabin through air (air borne noise) and through the vehicle body structure, engine mounts, cables etc. Source of the noise generation in the vehicle is mainly through the engine fluctuation (engine combustion excitations). Any change in the engine characteristics results in the change in passenger cabin noise. Also, influence of the vehicle body structure due to change in material properties also affects the NVH performance. This technical paper explains the effect of change in engine characteristics as well as change in the transfer path (material property) on the NVH performance of the gearbox and subsequently the NVH performance of vehicle. Copyright © 2015 SAE International and Copyright © SAEINDIA.

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