Static and Nonlinear Finite Element Analysis of Engine Assembly

	FE Model of entire engine was built including contacts boundary conditions in a great details
	Analysis was performed for Pretension, Structural & Thermal loading conditions
	Maximum stress levels and areas of stress concentrations were predicted
	Gasket degree of sealing and bore distortion prediction were the key points
	Water Jacket analysis was performed using CFD and Heat Transfer Coefficients (HTC) were predicted for the engine assembly. The results were used for predicting thermal stresses

Engine Assembly Structural Optimization for Low Noise Radiation

	Design considerations were given to NVH aspects at the initial stage
	Preparation of Acoustic meshed model of engine, unit force velocity prediction and engine side wall panel contribution were some of the key points
	Base Sound Power Level (SWL) reduction of 4 dB(A) was achieved with 3% increase in the total engine mass

Design of Silencer for better acoustic performance

	Design optimization was carried out using integrated FE and CFD approach
	Established silencer design methodology
	With the new design, Insertion Loss(IL) was increased by 5-6 dB(A) without affecting Back pressure(BP) and minimal change in overall dimensions of silencer
	Pass by noise level was reduced by 1 dB(A)

Bus Structure Evaluation for Rollover, Strength and Durability as per ECE-R 66 /AIS-031

	FE Model of entire bus was built along with assigned Non-linear material data which was generated by experimental testing
	Material and Joint modeling technique used for rollover analysis was validated by component level testing
	C.G. of bus was determined by experimental method
	Rollover analysis and testing was carried out as per ECE- R 66 to check the strength of the superstructure
	Structural strength determination of bus under braking and cornering load
	Fatigue life of bus was predicted for a given road input data by using MBD, FEM and Fatigue life prediction code

Evaluation of Truck Cab to meet ECE R 29/AIS 029

	FE Model of entire truck cab was built along with assigned Non-linear material data which was generated by experimental testing
	Frontal Impact Test, Roof Strength Test and Rear Wall Strength analysis and was carried out as per ECE R 29 to check the strength of the cab.
	Simulation results were validated by experimental testing.
	Structural modifications were carried out to meet the regulatory requirements.

Bus Structure Joint simulation and Experimental Validation

	The critical joints get tested experimentally to generate the quasi-static load-deflection characteristics
	Same joints get simulated to validate the material properties and connections.
	Good correlation between experimental and simulated load – deflection results

	Detailed Seat modeling using MADYMO
	Extraction of contact characteristics from explicit Non-linear simulation
	Extraction of seat back stiffness from explicit Non-linear simulation
	Application of crash pulse to belted and unbelted dummies
	Evaluation of dummy behavior and injury values as per FMVSS 208

Water Jacket Optimization for effective Cooling

	Extraction of water core from head & block, preparation of meshed model
	Heat transfer analysis in 3D CFD code Fluent at maximum power condition
	Prediction of Heat Transfer Coefficients (HTC) at coolant wall interface at head, block, intake & exhaust port
	Identification of hot spots and region of flow separation which leads to pressure drop
	Mapped the heat transfer coefficients at the coolant-wall interface on the FEA mesh to predict the metal temperatures and thermal stresses further