Index Issue 2012-2013

1) Mobile Medical Unit (MMU)

2) Mobile Computer Van (MCV)

3) Development of CAE Methodology for NVH Prediction of Automotive Door

4) ARAI – Partner of Choice for Safe Journey of Indian Railways

5) Advanced Engine Transient Dyno Emission Test Facilities with Altitude Simulation

6) Head Restraint Performance Test Rig

7) Validation of Component and Sub-system of Vehicles by Vibration Testing

8) Ph.D. Program Jointly Run by ARAI and VITU

9) BIS and NABL Accredited Tyre Testing Facility at ARAI

10) ABS Performance Tests for Two Wheelers as per IS 14664-2010, ECE R 78 & GTR-3

11) Digital Library @ ARAI

12) Multi Axis Simulation Testing (MAST) System

13) Development of Energy Absorbing Rear Under-Run Protection Device (RUPD) for Commercial

Vehicles

14) Web based Platform for Homologation and Regulations – A New Service by ARAI

15) Design and Development of Radiator Fan for Automotive Application

16) Forging Process Optimization using Computer Simulation

Mobile Medical Unit (MMU)

Vehicle Evaluation Lab (VEL) worked on a specialized project with NRHM (National Rural Health Mission) for State Health Society (SHS) to support health care delivery system in rural area by improving infrastructure, critical manpower, committed health care delivery system and improving health care implementation through a medical van in remote and rural areas with hand in hand consultancy with ARAI. SHS, Maharashtra entered into an agreement with ARAI for a turnkey project to procure 40 MMUs with prescribed specifications. The role of ARAI included the following:

Study the requirements and necessary specifications from SHS desired to have for MMUs.

Provide all technical expertise to finalize layout, technical specifications and design of MMUs.

Carry out market survey and studies to provide necessary inputs to SHS.

Evaluate bids and recommend most responsive and suitable bidder for lower offer.

Prepare and execute agreement between SHS and body builder.

Inspect process of manufacturing of MMUs in 3 stages.

Stage 1: Body builder built MMU as per the approved design provided by ARAI. Inspection team inspected the design and layout of a prototype MMU and reported to the body builder for proposed modifications in the prototype.

Stage 2: ARAI inspected all 40 MMUs during manufacturing process. Inspection was carried out in two stages. First inspection was at the body paneling stage of MMUs and other was when the MMU was fully ready for delivery.

Stage 3: ARAI further carried out inspection of all MMUs within 6 months to one year from the date of delivery of Individual MMU. ARAI will also submit a report to SHS on the status of working and functioning of MMUs.

ARAI recently completed this project and all these 40 medical mobile units have been handed over to respective districts of Maharashtra by the SHS.

Photographs of MMU

Right Hand Side View Left Hand Side View

Doctor Cabin and Examination Table Doctor Cabin and Storage Box

Nurse Cabin and Pathology Area DG Set System Controls

Mobile Computer Van (MCV)

ARAI has executed a turnkey consultancy project for Pune Zillah Parishad (Pune ZP). Scope of

project encompassed design of Mobile Computer Vans (MCVs) as per specific requirement and

intended technical specifications. The role played by ARAI in this exercise is as listed below :

Finalisation of design

Finalisation of inside layout and interiors

Finalisation of technical specification

Selection and procurement of vehicle chassis

Finalisation of body builder

Supervision in three stages of body building of MCVs

Stage 1: Inspection of design and layout of prototype MCV provided by the body

builder, verification with the specifications and suggest modifications in the prototype.

Stage 2: Inspection of all MCVs during manufacturing process. The activity was carried

out in two stages. One was at the initial paneling stage of body building of MCVs and the

other was at the final stage when the MCVs were ready for dispatch.

Stage 3: Inspection of all MCVs in a given span of operation of Individual MCV and

submit report on verification of working and functioning of MCVs, to Pune ZP.

Selection and procurement of laptops and LCD projector

Registration of vehicle and

Post-delivery inspection after six months

Finalization of vehicle specifications was considered w.r.t body structure, exterior paneling, interior

paneling, flooring, doors, windows, seats, chairs, paints, locks, insulation, front show, side dickeys,

fire extinguishers, wiring harness, master switch, buzzer, fans, DG set and other fitments. Vehicle

Evaluation Lab has executed this project and handed over all three mobile computer vans to

Pune Zilla Parishad.

Photographs of Mobile Computer Van (MCV)

Front Right View Rear Right View

Front Left View Rear View with Step Entry

Internal View - front to rear Internal view – rear to front with laptops

Development of CAE Methodology for NVH Prediction of Automotive Door

ARAI has developed a methodology to predict vibration (Mode shape, Inertance and vibration transfer

function) and noise characteristics (Noise transfer function) of the door assembled to car body. This is based on

the results of a number of CAE projects carried out along with experimental validation.

This methodology enables:

To understand physics of Door to develop Modeling methodology to implement in CAE model.

To understand mechanism of modes of Test and CAE.

To improve mode shapes and frequencies of CAE results to correlate with Test Results.

To improve modeling methodology of CAE Model to predict vibration characteristics to determine

several potential area which affect vibration characteristics of door.

To achieve Correlation of CAE results within 5% accuracy with the test.

Similar methodology can be used for other automotive components and sub-systems for accurate and

reliable prediction of NVH behavior in early stage of product development.

Figure: Comparison of Mode shape CAE and Test

ARAI – Partner of Choice for Safe Journey of Indian Railways

Prototype Crashworthy LHB GS Coach Crash Test at RDSO

Research Designs & Standards Organization (RDSO) of Indian Railways recently conducted crash test of the

prototype LHB (Linke Hoffman Bausch) General Second Class coach at its Lucknow headquarters. Passive

Safety Lab of ARAI was awarded the contract for instrumentation, data acquisition, high speed photography, data

retrieval and data analysis along with general test execution.

The test was conducted to study the behavior of LHB coaches which are built by Rail Coach Factory,

Kapurthala. At present, LHB Coaches are used in premium trains such as Rajdhani, Shatabdi and Duranto

Express. An LHB GS Coach weighing 46 tons impacted with stationary flat platen wagon of 110 tons of weight at

43 km/hr. Four high speed cameras and multiple accelerometers mounted on the coach and wagon recorded the

test. The test was witnessed by senior members of Railway Board, Mr. Keshav Chandra, member (mechanical)

and RDSO Director General, Mr. V Ramachandran.

Previously, RDSO had used services of TTCI Inc., USA and ARA Inc. USA for execution of such test in 2005.

ARAI was selected for conducting the test based on its expertise in conduct of automotive crash tests

and vast experience in data acquisition and analysis.

ARAI has unique facilities such as portable Electronically Controlled Vehicle (ECV) Crash system, supporting

infrastructure such as multiple High Speed Cameras, On-board data acquisition system and vast expertise in

data acquisition which can be utilized by interested organizations to execute special types of tests at ARAI or at

customer’s end. ARAI has already conducted ECV controlled guided vehicle tests with security systems

at customer’s end.

Advanced Engine Transient Dyno Emission Test Facilities with Altitude Simulation

With emerging new vehicle technologies, the current and future vehicles have very low pollutant concentration in their exhaust. To certify such advanced technology vehicles for Type Approval and Conformity of Production (COP) as per present and future emission legislations, new generation emission equipment with better accuracy, repeatability and reliability is required. Hence state-of-the-art emission equipments, which can measure very low concentrations of emissions, are set up in the emission laboratory. Also to ensure the accuracy of measurement the ambient air parameters like Pressure, temperature, humidity are tightly controlled.

Recently we have established engine test facility with transient dynamometer and CVS, full flow dilution tunnel and dilute emission measurement bench. This facility is suitable for testing as per Euro IV, Euro V, EPA for automotive engines and Stage III B, Stage IV, EPA Tier 4 for non road engines. This facility is suitable for Diesel, gasoline, CNG engines and blends.

Test facility is equipped with:

1.Transient dynamometers (2 nos.) with Peripherals

1. Transient Dynamometer:-

Maximum Power Range 220 kW @ 2200 - 4500 rpm

Maximum Torque Range 960Nm @ 1000 – 2200 rpm

Maximum Dyno Speed 8000

2. Transient Dynamometer:-

Maximum Power Range 500 kW @ 1600 - 3200 rpm

Maximum Torque Range 3000Nm @ 800 – 1600 rpm

Maximum Dyno Speed 8000

3. Exhaust Gas Analysis System:-

CO (L) NDIR Analyser Range 50 to 5000 ppm

THC HFID Analyser Range 10 to 5000 ppmC

CH4/ THC HFID Analyser Range 10 to 5000 ppmC

NO/ NOx HCLD Analyser Range 10 to 5000 ppm

CO2 NDIR Analyser Range 0.5 to 6% Vol

O2 PMD Analyser Range 0 to 25% Vol

NH3 HCLD Analyser Range 10 to 1000 ppm

4. Full Flow Particulate Measurement System with CVS:-

Constant Volume Sampler 120 m3/min

Full flow dilution tunnel diameter ɸ 18”

Secondary dilution tunnel diameter ɸ 5”

Filter Holder Size ɸ 47mm & ɸ70mm

Other salient features:

Inertia Simulation & Acquisition for use for vehicle simulation

Combustion Air handling unit with high Altitude Simulation facility up to 80 kPa required for EPA certification.

Silencer Simulation Valve to simulate vehicle exhaust back pressure

Intercooler with boost pressure adjustment to simulate vehicle intercooler

Blow-by meter, lambda meter, oil conditioning unit

Combustion analysis system

Angle Encoder

Engine Docking Trolley

Laser Tool Engine Alignment

Head Restraint Performance Test Rig

Head Restraint Performance Test Rig designed as per FMVSS 202a, ECE R 17, IS 15546 regulatory and non-

regulatory requirements is installed and commissioned at ARAI.

Seats, seat belts, seat belt anchorages, etc. are safety critical items for the passenger in case of sudden

acceleration / deceleration and accidents.

Head restraints are integral and adjustable parts of automotive seats. The main purpose is to limit rearward

displacement of an adult occupant’s head in relation to his torso in order to reduce danger of injury to the cervical

vertebrae in the event of an accident and during rear impact crashes.

Whiplash is one of the most common and annoying types of injuries in motor vehicle rear impact crashes.

Whiplash injury is defined as “an acceleration-deceleration mechanism of energy transferred to the neck usually as a result of a motor vehicle crash.” In the most common form of whiplash, crash forces jerk occupant's head rearward, past the top of the seatback, twisting and injuring the neck. Observations

Whiplash is common after traffic collisions

Whiplash develops mild to severe pain and disability

Poor medical recovery due to high levels of pain and / or disability

Medical costs associated with the condition are substantial

Logical response to this problem is to effectively raise seatback and prevent excessive rearward motion of head. Head restraints serve the purpose of extending the seatback. There are adjustable restraints attached to the seatback and can be moved up or down to suit the occupant. Also, there are integral restraints of fixed height and usually homogeneous part of seatback. About Test Rig

Six long stroke servo-hydraulic actuators with standard SAE back / head forms and dedicated PC based

controller with loading profile editor and post processing software for reports with graphs.

Independent 3 loading stations to do test on all types of automotive front facing seats having single, two and

three head restraints.

12 DOF movement through servo-electric motors to position individual loading stations based on seat

mounting.

With this new rig, ARAI can carry out head rest performance test and seat back strength tests as per regulatory and non-regulatory requirements.

Head Restraint Performance Test Rig

Validation of Component and Sub-system of Vehicles by Vibration Testing Vibration testing is an important part of automotive product development. Vibration testing is a useful tool for simulating various failure modes in the laboratory as it can reproduce both road and engine excitations. The objective of testing is to bring service vibration conditions in the laboratory. In order to comply with the latest market product development needs, it is to be tested under various conditions of vibration, temperature and humidity. Vibration testing involves determination of resonance frequency, sine sweep test within the specified frequency bandwidth, random and shock testing. Power Spectral Density (PSD) is very good representation of random vibration data. Hence some test calls for testing with PSD as input. Structural Dynamics Lab (SDL) of ARAI provides various facilities to cater to the need of vibration testing. This testing is required for various components and sub-assemblies of vehicle in all categories that vary in value of payload, frequency of testing and vibration values. We have different facilities to address this need of customer.

1) Uniaxial Servo-Hydraulic test facility (consisting of X and Y direction slip table and Z direction servo-hydraulic actuator and controller arrangement)

2) X, Y and Z axis Electro Dynamic Shaker test facility integrated with climatic chamber Servo Hydraulic Facility is in operation for last 20 years. Over the years, SDL has handled and completed number of projects in vibration field like seat assembly, radiator assembly, fuel tank assembly, dash board, car front, rear bumpers, etc. using servo-hydraulic facility. Recently 6000 kgf Electro Dynamic Shaker is installed with 8 m3 capacity large climatic chamber for thermal and vibration simulation. This test set up provides X, Y and Z axis vibration testing at different environmental conditions without need to disturbing mounting of component similar to in-service mounting.

6000 kgf Large Electro Dynamic Shaker

8 m

3 Climatic Chamber

Combined ED shaker and chamber test facility is an effective platform that can be used for wide range of components. This is a value addition to existing single axis vibration test. Typically this system can be used for validation of components like –

Seat assembly testing

Radiator assembly testing

Spare wheel carrier assembly testing

Instrumented panel testing

Automotive instrument modules

Battery carrier assembly Fuel tank assembly

The facility is backed up with existing expertise at SDL in the area of road load data acquisition and analysis, laboratory simulation, fatigue life analysis, accelerated durability testing program, etc. Brief specifications of the test systems are as follows :

6000 kgf Large Electro Dynamic Shaker

Sr. No. Parameters Capacity

1 Z direction Maximum 300 kg payload

Useful frequency range 5 Hz to 300 Hz

8 ‘g’ maximum acceleration with max 200 kg pay load on platform

2 X and Y direction Maximum 217 kg payload

Useful frequency range 5 to 2000 Hz

‘9 ‘g’ maximum acceleration with max 260 kg pay load on platform

3 Displacement Peak ± 25 mm

4 Capabilities Vibration Control, Data Management, Signal Analysis

8 m3 Large Environmental Chamber

1 Chamber inside size 2200 mm X 2200 mm X 1800 mm height

2 Temperature range with - 60°C to 180°C

3 Humidity control range 10% to 95% RH

Ph.D. Program to be jointly Run by ARAI and VITU

ARAI and VIT University have signed Memorandum of Understanding to jointly run Ph.D. program facilitating

working professionals to acquire doctorate while in job. The course will commence from Academic Year 2013-14.

ARAI and VITU will conduct written tests as well as interviews for admission to the doctorate course. Selected

candidates will be given admissions based on their merit. Doctoral Committee will suggest four subjects for

completion and getting credit points. This would be in the form of 5-day PIPs, where one of the compulsory

subjects would be Research Methodology. The candidate would be required to do the project at the place of work

and submit the thesis pending completion of 3 years from the date of registration. There is a provision for full

time students also.

BIS and NABL Accredited Tyre Testing Facility at ARAI Tyre industry has always been an integral part of the auto industry, which has seen vast growth with the development of automobiles. India has emerged as one of the most competitive tyre markets, due to easy availability of natural rubber, which is the most important raw material and production facilities at par with global standards. India has always been inclined towards globalization and tyre industry has not been different. This is evident from the shift of the industry to radial tyres from the diagonal ply ones. In recent times, liking towards tubeless tyres as compared to tube type ones has been observed. The importance of applied research and setting up of well-equipped laboratories in technology upgradation has been realized. Technology upgradation stems from adapting global technology and developing it to suit the Indian conditions and utilization pattern. Performance of tyres is critical in determining their influence on the ride, handling and safety of cars, commercial vehicles and aeroplanes. Steering, acceleration and braking actions are transmitted to the road through tyres in quite often adverse conditions. Ultimately they are the only point of contact with the ground and means by which a vehicle remains controllable. It is required to recognize the importance and legislative demands for accurate testing to certify tyres for use on the vehicles.

In India, tyre as a component is covered under Rule 95 of Central Motor Vehicle Rules (CMVR). According to Government of India’s Notification# S.O. 2953(E) dated 19th November 2009(base) and S.O. 1057(E), dated 11th May 2011 (amendment), all types of pneumatic tyres and tubes for automotive vehicles should meet Indian standards (IS) and should have ISI marking from 19th November 2010. Vision To establish a Centre of Excellence for tyre testing, which would assist Indian tyre industry and auto industry in

development of tyre technology, by offering services of homologation testing initially and grow towards delivering R&D services in tyre performance testing, tyre - road vehicle interaction dynamics, tyre technology adaptability to Indian environmental and road conditions and safety. Objectives

To provide state-of-the-art facility for tyres and wheels homologation activity.

Establishing vehicle dynamics team with active participation of tyre test laboratory and structural laboratory

Correlation of free rolling, steady state and dynamic forces on tyres in the laboratory and outdoor track tests.

CO2 emissions estimation of tyres.

Tyre noise measurement and optimization.

Increasing tyre life -measures and practices.

Take up projects targeted towards development of tyre technology to adapt Indian environmental and road conditions.

Present Facilities

Two station load – speed performance / endurance test facility for passenger and commercial vehicle tyres. Testing can be conducted up to 100 kN as a function of load and speed of 350 km/h with a camber angle of ± 4°. Transient data can be monitored and observed on the machine, which is computer controlled.

Bead unseating testing facility for passenger car tyres (3000 kg capacity).

Plunger test / tyre strength test facility for passenger car tyres and commercial vehicle tyres (10000 kg capacity)

Tyre Dimension verification test.

Bureau of Indian Standards (BIS) and NABL (ISO 17025) Recognition ARAI’s tyre testing facility is recognized by Bureau of Indian Standards (BIS) and NABL (ISO 17025). With these accreditations / certifications, ARAI undertakes testing and certification of tyres for BIS for ISI marking.

Facility Upgradation - Phase I Multi-station Endurance Test Rig for Tyre Endurance Test: Multi-station endurance test machine dedicated to endurance testing of passenger car tyres provides quality service to the automotive and tyre industry in a shorter lead time. Facility Upgradation - Phase II Rolling resistance test rig to estimate coefficient of rolling resistance passenger cars and commercial vehicles. New ECE Regulation ECE 117 specifies requirements for tyre rolling resistance and labeling of the same is mandatory in European countries. This development has emerged since the relation of fuel economy and rolling resistance was established. Facility Upgradation - Phase III (Planned) Apart from meeting the homologation requirements for automotive wheels and tyres, ARAI is planning to establish centre of excellence that can support Indian tyre manufacturer in developing advanced products in order to compete with the global players.

ABS Performance Testing of Two Wheelers as per IS 14664-2010, ECE R 78 & GTR-3 With the improvement of disc brake systems and new technologies such as Anti-lock Braking Systems (ABS) and Combined Braking Systems (CBS), modern motorcycles are equipped with very sophisticated and effective braking systems. Vehicle Evaluation Laboratory (VEL) of ARAI has recently introduced new service of carrying out performance evaluation of Anti-lock Braking Systems on two-wheelers by using state-of-the-art instrumentation. These tests are carried out as per the test prescriptions in IS:14664-2010 (Automotive Vehicles-Performance requirement and Testing Procedure for braking systems of Two and Three Wheeled Motor Vehicle). With this expertise developed at VEL, ABS performance tests can also be conducted as per the specifications prescribed in ECE R 78 and Global Technical Regulation GTR-3, for export requirements.

Instrumentation Aspects High precision instruments required for testing to meet the requirement of the Standard are selected for use. Following high precision instruments are employed for carrying out tests :

1. V-Box 2. Hand force meter 3. Foot pedal force meter 4. Wheel speed pick up sensor 5. Triggers 6. Weather station

Expert riders at VEL are fully equipped with riding gears and safety gadgets necessary for the tests.

Figure 1: Photographs illustrating fitment of outriggers for testing

The two-wheeler on test needs to be fitted with appropriately designed out-riggers and instruments for data

acquisition. Out-riggers are well-constructed keeping in view overall safety requirements of the rider, vehicle spin or

loss of control during testing. The out-riggers are designed so that they do not interfere during normal riding of

vehicle.

Test Procedure

The following trails are conducted in various road surface conditions having different peak braking co-efficients

(pbc) and vehicle conditions.

Figure 2 : Photograph illustrating transition test from low friction surface to high friction surface

Data Acquisition and Analysis Parameters acquired, after conducting trails as per requisite standards can be precisely analyzed. Following figure indicates sample data acquired during the tests. Such tests can also be performed at VEL as development assignment necessary for finalizing specifications of braking system.

Figure 3 : Sample data acquired during test

Digital Library @ ARAI

Digital Library (Institutional Repository) of ARAI, Pune is developed to capture, organize, preserve and disseminate

research publications of ARAI. It includes ARAI Update, Automotive Abstracts, Conference Proceedings, SIAT

Keynote Papers, SIAT Technical Papers, Seminar Papers, Technical Papers published by ARAI employees, news

related to ARAI and Open Access Books. Apart from these collections, Digital Library also provides links of

available online resources like SAE Digital Library, Patent Search, Daily News, etc. ARAI digital library contains

1500 digital items.

The Digital Library is created using DSpace Open Source software developed by Massachusetts Institute of

Technology & Hewlett-Packard Labs, USA. There are multiple levels of searches including basic, advanced and

keyword search facilities. Users can search and retrieve the documents using search bars provided on the

homepage or can browse using author, title, subject and dates.

The objective of Digital Library is to preserve original research documents of ARAI in digital format leading to

concise Knowledge Management and improve library services by providing qualitative and quantitative resource

sharing to the user with minimum time.

ARAI Executives can have access directly on their desktop through Intranet, whereas Industry Professionals can

access by personally visiting ARAI Knowledge Centre.

Multi Axis Simulation Testing (MAST) System

Working closely with the Automotive Industry for development and validation of components, aggregates and full vehicle by fatigue analysis, durability testing, laboratory simulation, failure analysis and optimization, Structural Dynamics Laboratory (SDL) of ARAI has demonstrated its competency in the area of laboratory simulation and multi axis simulation. Over the years, SDL has handled and completed number of projects like four / six poster simulation, multi axis road load simulation using dedicated set-ups like MTS 329 and road load simulation of chassis using 22 channel custom test rig, validation of components like cabin, chassis attachment components, radiator, etc. on custom built multi axis simulator. Further, it gives pleasure to announce introduction of 6 degree of freedom Multi Axis Simulation Testing (MAST) system. MAST systems are the best method of quickly conducting durability tests on vehicle components and sub-systems. Target data required for MAST system can easily be measured using traditional road load data

acquisition on the component or adjacent to the component, on the proving ground or roads. Instrumented component or sub-assembly is then mounted on the table and simulated to achieve target data measured in multi direction.

The MAST system is the effective platform that can be used for wide range of components. This is a value addition to the existing single axis vibration test. Typically this system can be used for validation of components like

Seat

Radiator

Engine Mount

Instrumented Panel The facility is backed up with available expertise of SDL in the area of road load data acquisition and analysis, laboratory simulation, fatigue life analysis, accelerated durability testing program, etc. Broad specifications of the MAST system are as given below :

Movements: 6 DOF; Vertical, Longitudinal, Lateral, Roll, Pitch, Yaw.

Max Load Capacity: 650kg.

Table Size : 1.5m X 2m

Peak to Peak Acceleration Vertical: 5g; Longitudinal4g; Lateral: 4g.

Movements: Roll: 9deg; Pitch: 9deg; Yaw: 9deg.

Frequency : 40Hz Installation of Hexapod MAST System with the Environmental Chamber is planned in near future.

Development of Energy Absorbing Rear Under-Run Protection Device (RUPD) for Commercial Vehicles

Rear under-run protection device is essentially designed to prevent car from being under-run underneath heavy vehicle in the event of crash. In the absence of RUPD, in an under-run accident, truck-bed can penetrate up to the driver compartment causing serious fatal injuries to the car-passengers. It also causes damage to the heavy vehicle. An increasing number of cases involving vehicles crashing into the rear of heavy vehicles have prompted implementation of IS 15812:2005 governing installation of rear under-run protection devices on commercial vehicles. Structural Dynamics Lab (SDL) of ARAI has successfully developed Energy Absorbing Rear Under-run Protection Device (RUPD) for Commercial Vehicles with Dow Automotive India, meeting the latest requirements of IS and ECE. This is a value addition developed product with respect to present RUPDs.

Under-run collisions

The rate of fatalities is high in this kind of crash because truck bed and chassis can penetrate car passenger compartment, hitting its occupants at the head and chest level.

In this case, all the modern developments in automotive safety technology like airbags, seat belts and energy absorption capability of the car by crushing are virtually worthless.

Energy Absorbing Rear Under-run Protection Device for Commercial Vehicles

Benefits

Universal BAR design: the device can be fitted on different vehicles of same category Higher energy absorption: the device absorb more energy than conventional designs even while offering

significantly lower weight Design readiness for higher load requirements: in upcoming UPD regulations

Web based Platform for Homologation and Regulations – A New Service by ARAI ARAI’s customer-base is spread over across the globe and is expanding day-by-day. In order to effectively serve our global customers in the areas of Homologation and Regulations, we have recently re-designed our website and enhanced our web-based services. Considerable information / knowledge related to Homologation and Regulations activities is already disseminated through ARAI website (www.araiindia.com) and our customers are extensively using it. With the rapid growth of the Automotive Industry, need is now felt to expand the scope to cover modular web-based on-line transactions, which will result into mutual benefit. This initiative has direct link to two of our Business Perspectives, viz. “Improving Internal Processes” and “Customer Focus”.

Technical teams at our Homologation Management & Regulations and Information Technology Management Divisions have recently developed these application modules. The modules are built on web based knowledge and information exchange platform for our Homologation and Regulations customers. These modules are :

Documentation for Electronic Type Approval of Vehicle (DELTA) and tracking status of the same

Giving access to the manufacturer for his own archival of TA certificates

Regular updates on CMVR, access to published and draft Automotive Industry Standards (AIS)

Proceedings of national committees, like AISC, CMVR-TSC

India’s participation in UN ECE WP.29 activities

Advice on specific technical queries related to Homologation or Regulations

We have pleasure to announce launch of these modules in the form of new services with effect from 1st April 2013. The services will be open for subscription to vehicle / system / component manufacturers, test agencies, general user, etc. as appropriate. Brief description of the modules is as given below:

Homologation

DELTA Application TA Certificates CMVR Handbook

Facility for Vehicle Manufacturers to

upload applications for Type Approval as per CMVR and online tracking of

ongoing cases Charges: Nil Subscription: Restricted to ARAI’s Type Approval Customers.

Availability of Archived Data of previous TA certificates through

controlled access Charges: Yes Subscription: Restricted to only ARAI’s Type Approval Customers.

Contains information about Indian homologation for Automotive Vehicles, Components, Generator Sets, CEVs,

Agricultural Tractors, etc. Charges: Yes Subscription: Open to all.

Expert Advice

FAQ

Advice from ARAI experts on Homologation can be sought

Charges: Yes Subscription: Open to all.

A bank of frequently asked questions and answers related to Homologation is available to the user. Charges: Nil Subscription: Open to all.

Regulations

Automotive Industry

Standards (AIS) AISC/CMVR-TSC/SCOE

Committees WP.29 Working Groups

ARAI publishes automotive safety

standards on behalf of AISC

(Automotive Industry Standards

Committee). Subscriber can access

these AIS standards and their

working drafts

Charges: Nil

Subscription: Open to all.

Agenda, Minutes and other

documents related to meetings of 3

national level committees are

available under this service.

Charges: Yes

Subscription: Restricted to only

member organizations/ associations

India participates in 6 working groups

under WP.29, a world body under UN-

ECE. Subscriber can access the

documents of these working groups.

Charges: Nil

Subscription: Restricted to only

members of India- Working Groups.

Expert Advice

FAQ

Advice on Regulations can be sought from

ARAI experts

Charges: Yes

Subscription: Open to all.

A bank of frequently asked questions and answers

related to Regulations is available to the user.

Charges: Nil Subscription: Open to all.

Design and Development of Radiator Fan for Automotive Application Cooling fans are required to provide air flow for engine cooling, air conditioning compressor fluid cooling and charged air cooling. Designing of a cooling fan to suit the environment, in which it is placed in the vehicle can reduce the energy required for its operation. Picking an off-the-shelf design may not always be the right solution when an optimized design is the end target. Also, traditional method of trial and error is time consuming and expensive. Thus, it is required to have methodology developed for generating blade profile for the given functional requirements by eliminating the process of trial and error. CAE Lab of ARAI has developed a methodology for design and development of radiator cooling fan for Automotive application. The methodology has been validated by establishing good correlation between experimental and computational results. This methodology facilitates shorter product development cycle and cost saving in prototype manufacturing. The salient features of this methodology are:

Generation of initial blade profile for the given functional requirements using Axial Fan Design software developed in-house. The Fan Design Software packages complex airflow concepts, airfoil behavior and design expertise to provide a cost effective powerful design solution. The software provides an optimal initial design with minimal interactive effort, in least possible time, through the simplest of methods.

Preparation of CAD model and CFD analysis of initial design to predict fan performance in terms of Airflow, Pressure Rise and Power Consumption

Parametric Optimization of initial fan design using CFD to meet functional requirements.

Preparation of Rapid Prototype model of the optimized fan design and testing to evaluate the performance.

Fine tuning of final fan geometry to meet the functional requirements and Validation with the experiments. Few sponsored projects are completed using this approach with the capability and know-how gained to meet the cooling fan design and development requirements. Using this methodology, we have developed fan designs reporting up to 13% improvement in the static efficiency in the entire operating range as compared to their existing design.

Fig 1: Correlation of Experimental and Computational Results

Fig 2: Optimized Geometry of Cooling Fan Design

Fig 3: Pressure Contours and Velocity Vectors on Cooling Fan

Forging Process Optimization using Computer Simulation By conventional practices, development of forging process for any new component requires many shop floor trials to arrive at optimum process, including initial billet dimensions. However, with the help of reliable computer simulation tools, it is now possible to optimize complete forging process and billet dimensions with minimum or no shop floor trials. This saves considerable time, efforts and cost. Also, simulation gives good insight about potential results due to variations in process parameters and helps reveal possible forging defects which then can be corrected before start of production. Similarly forging process simulation tools can help optimize the existing forging processes to increase the yield, make it more energy efficient and eliminate defects. Thus, computer simulation is an important tool to design effective and innovative forging processes offering advantages of reduced number of shop floor trials, increased productivity, reduction in operation cost, reduction in flash wastage, increased profitability, etc. ARAI-Forging Industry Division at Chakan, Pune (ARAI-FID) has one such reliable software, Forge2011, with dedicated workstations and 16 Core Cluster computing infrastructure along with other modeling and pre / post processing software tools like Unigraphics, Pro-Engineer, Autodesk Inventor, HyperWorks, UGNX – Nastran. With these facilities, ARAI-FID has successfully developed forging processes for new forging components and has also optimized existing forging processes. The case study given here demonstrates how computer simulation can optimize conventional manufacturing process and resolve most of the manufacturing defects in design stage itself. Case Study: Optimisation of forging process for a Circular Flange In the conventional forging process, a circular flange was getting forged in 2 stages after heating, i.e. blocker using hammer followed by a combined operation of trimming/piercing/drawing using hydraulic press. This process was having different forging defects at both the stages, viz. under-filling in blocker stage and undesired curvature forming and tearing in combined operation. Additionally reduced tool life was also a problem.

The first step chosen in the methodology was to simulate existing forging process and validate simulation process. Inputs required for simulation were initial billet size, material details, thermal details, die design, forging equipment details, lubrication details, etc. Fig. 1 and Fig. 2 show the simulation results that captured the under-filling during blocker stage and tearing and undesired curvature forming during combined operation similar to actual forging process. This validated the simulation process adopted.

Fig 1: Under-filling defect predicted by simulation process

Fig 2: Tearing and undesired curvature forming predicted by simulation process

Detailed study was carried out to understand the possible reasons for these defects. Modifying existing forging process was a challenging job, which requires knowledge of die design and understanding of forging process. In blocker stage it was observed that more material was gathering towards the centre of flange than filling the corners indicating improper design of dies. It was also observed that initial billet size was inadequate for complete filling. Number of iterative simulations were carried out to find the appropriate die shape by changing draft angles, inclinations, fillets, curvatures, etc. and to find optimum billet size for blocker stage to eliminate the defect of under-filling. Billet was changed from rectangular cross section to cylindrical. Fig 3. shows no under-filling after blocker stage by using modified die design. Also no forging defects, viz. folds, cracks, etc. were observed after blocker stage.

Fig 3: No under-filling for modified dies at blocker stage

In the combined operation (trimming / piercing / drawing), it was observed that less amount of material was getting pierced from central area of component and more amount of diametrical variation was made to get required inner diameter in final component. Due to this die design, more amount of material was flowing outside the area of interest (i.e. waste of material). It was also observed that no proper curvatures were provided on punch causing stress concentration in hub area (as shown in Fig. 2B), which was the cause of initiation of cracks and tearing of component. It also caused die wear and hence less tool life. The punch of combined operation was modified by giving proper fillets and curvatures to minimize the generation of stress concentration and give proper path to material to flow with minimum travel of punch. Fig. 4. shows the forging defects of tearing and undesired curvatures

removed after combined operation. As shown in Fig. 5 there was considerable reduction (almost 1/3

rd) in the press

load requirement because of new die design for combined operation stage which will improve the tool life.

Fig 4: No tearing and undesired curvature after combined operation

Fig 5: Press Load for actual and modified die design for combined operation

Shop-floor trials were carried out using modified dies as per the new designs and no defects were observed in the

modified process. Machining requirement after combined operation was also reduced considerably.

Conclusion

Computer simulation could capture the defects in the existing forging process.

Simulation results gave insight about the forging process and it enabled to find possible reasons for the

defects.

Optimum billet shape and modified die designs were arrived at by iterative computer simulations.

All the forging defects were removed using the modified forging process.

Because of modified process, press load was reduced considerably (@ 1/3rd) and hence improved tool life.

Results of the simulation were validated by shop-floor trials.

The entire exercise of computer simulation helped to arrive at optimum forging process with no forging

defects which gave benefits of reduction in time, cost, energy consumption, waste and improved product

quality.

Shrikant R Marathe, Director, ARAI director@araiindia.com

The Automotive Research Association of India Survey No. 102, Vetal Hill, Off Paud Road, Kothrud, Pune 411 038 (India)

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