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In the automotive industry, the electric vehicle is the new era, and companies are committed to reducing carbon emissions by electrification of their vehicles. In the development of electric vehicles, the battery is the central power source for all the parts of the vehicle. Usually, it is placed under the body because of its size and mass. So, it is important to protect battery cells from leakage and damage from obstacles. For on-road electric vehicles, speed bumps are one of the crucial obstacles. This paper investigates and analyses the protection of battery pack systems in electric vehicles while encountering speed bump profiles at different speeds. During the physical test on a speed bump, there is a possibility of bump hit on the battery pack system and it is necessary to ensure the structural safety of the battery pack systems. In this study, CAE method has been developed to validate the battery pack system in the event of a speed bump crossing.

In a passenger car, suspension link bushings, engine and transmission mount bushings and bump-stops are made of elastomeric materials, to maximize the durability and comfort. Thus, deformation behavior of rubber and its durability is important for product design and development. In virtual engineering, simulating rubber fatigue is a complex exercise, since it needs right modeling strategy and coupon based testing material data. Principal stretches based Ogden model is used to characterize the hyper elastic deformation behavior of natural rubber. Fatigue crack growth approach used here for the fatigue analysis. Engine torque strut mount is used to control the engine and transmission fore aft motion and it is connected between body and Powertrain (PT) system. Powertrain events are predominant for damage contribution to mount failure. So, it is important to predict fatigue life of mount elastomer bushing under Powertrain loading.

Instrument Panel (IP) in a vehicle has multiple attachment brackets that hold various modules, sensors, speakers, switches etc., and one such bracket is the Voltage Stabilizer Module (VSM) bracket. This bracket holding both VSM and Inverter Module (IM). These brackets are more vulnerable to vibration loads which are random in nature, that occur during customer usage of vehicles on the roads or during vehicle testing on Proving ground. During the design of the VSM bracket, the vibration loads should be considered for the evaluation of structural performance of this bracket. The objective of this study is to predict the stress and fatigue life of the VSM bracket while subjected to random vibration load. Virtual simulations are used to evaluate the stress and fatigue life of the bracket. Random response analysis is performed to find the strength of the bracket and vibration fatigue simulation is performed to predict the life of the bracket.

Structural durability of automotive components is one of the key requirements in design and development of today’s automobiles. Virtual simulations are used to estimate component durability to save the cost and time required to build the components and testing. The objective of this work is to find the service life of automotive HVAC pipe assembly by calculating cumulative fatigue life for operation under actual powertrain load conditions. Modal transient response analysis is performed with the measured powertrain load time history. Strain based fatigue life analysis is carried out using modal superposition method (MSM). The estimated fatigue life was compared with the physical test results. This paper also explains the root cause of low fatigue life on pipe assembly and provide the solution.

The objective of this work is to find cumulative fatigue damage of the truck cabin caused by proving ground data. Stresses in the cabin are derived by finite element analysis using inertia relief method. Multi body simulation software ADAMS was used to obtain the load history at cabin attachment points using measured proving ground data as input. The fatigue damage of the truck cabin was estimated by linear super position method with static results and load history. The calculated numerical fatigue damage results were compared with physical test results and correlated.

Evaluation of vehicle structural durability is one of the key requirements in design and development process of commercial vehicles. Computer simulations are used to estimate vehicle durability because of its cost advantage and reduction in lead time to launch the product. The objective of this work is to find the service life of the passenger commercial vehicle (Bus) by calculating cumulative fatigue life in operation under actual road conditions. Chassis and superstructure were considered for this exercise. Measured road load data at vehicle wheel centers were used for performing multi-body simulation in ADAMS to extract load histories at attachment points. Modal transient response analysis is performed using MSC-Nastran with the extracted load time history. Strain based fatigue life analysis is carried out in MSC-Fatigue using modal superposition method (MSM). The estimated chassis and superstructure fatigue life is compared with the physical test results.

Truck chassis assembly forms the structural backbone of a heavy commercial vehicle. The main function of the truck chassis is to support the aggregate components and payload acting on it during operating conditions. The chassis is subjected to vertical loading (Bump), fore and aft loading (braking and acceleration), lateral loading (Cornering) and torsional loading (Articulation). Out of the above load cases, the vertical load (bump load) decides the maximum load carrying capacity of the chassis when the vehicle traverses uneven surfaces. This paper explains the importance of theoretical bending stress calculation of truck frame side member (FSM) subjected to vertical load which will help the designer to arrive at the major section of FSM during initial stage of the design. Different concept proposals of FSM can be evaluated using these calculations quickly.