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The primary objective of this research was to identify the root cause of limited slip differential (LSD) NVH. The study examined the significance of different oils and additives that make up the lubrication mix in the axle. The impacts of gear marking compound type, friction modifier type, gear marking compound level, friction modifier level, reaction plate surface finish roughness, and friction material type were studied using Taguchi's Design of Experiment. Eaton's Vertical Friction Tester (VFT), a sub-system level test stand, was used to measure the performance characteristics of the clutch pack and oil mix. Sequential approximation and cumulative analysis methodologies were used to analyze test data where NVH was beyond the measurement capacity of the test stand. The DOE analysis showed that the type of gear marking compound used to set the ring gear mesh during axle build had the most significant influence on NVH levels.

Journal bearings are machine elements designed to produce smooth (low friction) motion between solid surfaces in relative motion and to generate a load support for mechanical components. In a Journal bearing, the entire load is carried by a thin film of fluid present between the rotating and the non-rotating elements. The thickness of the film is very sensitive to ambient temperature, radial clearance and misalignment. Though these parameters are difficult to control, it is important to consider these as noises while designing the Journal bearing. When noises in the design space are very strong, the conventional DOE and RSM methods suppress the effect of control factors and render them irrelevant in the design process. This leads to overdesigning the product, which in turn adds more cost. The main objective of this work is to design a bearing, which is insensitive to noises at each stage of the product life cycle.

The objective of this paper is to provide a robust design solution for a Jet pump which is used for fuel removal from an Active Drain Liquid Trap (ADLT). This jet pump can work for both Gasoline and Diesel based automobiles. The major focus area of this paper, is improvement in the robustness of Jet pump performance parameters, such as motive flow and induced flow. A design study for such a two fuel application was first initiated using Taguchi's robust design approach. In order to reduce the inventory complexity and cost, a common design possibility was then addressed. Two approaches for robust design have been discussed, namely the Taguchi Methodology (Orthogonal Cross Array based design) and the Dual RSM (Response Surface Methodology) Technique. Results show that the Dual RSM provides improved performance with reduced variation, as compared to Taguchi's approach.

The primary objective of this study was to provide an efficient system solution for the removal of fuel from an Active Drain Liquid Trap (ADLT), used in automotive vent systems; using a Jet Pump. The Voice of Customer was collected and analyzed. The two major focus areas identified were - improvement in robustness of Jet Pump performance and maximization of induced flow. Robust design of such a Jet Pump was carried out using Taguchi's Orthogonal Crossed Array based parameter design, through computer simulation. Two Jet Pumps were designed for Gasoline based vehicles; one with the conventional approach and the other with the robust design approach. Both were put on a field trial, integral with the vent system. The robust design showed a tremendous improvement in performance over the conventional design, due to the elimination of cavitation and insensitivity to noises.