Automotive Research Association of India
Research Institute of the Automotive Industry with the Ministry of Heavy Industries & Public Enterprises, Govt. of India
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Effective use of CAE in Engine Design
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

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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)

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CAE at work for Making Vehicles Safer
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.

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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

Simulation of Occupant Behavior during Frontal Impact
Objective : To carry out a sled test simulation using Occupant Safety Software MADYMO to evaluate the behavior and injuries of passengers during frontal impact of a bus.

  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
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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
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