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Rapidly changing emission and fuel efficiency regulations are pushing the design optimization boundaries further in the Indian car market which is already a very cost conscious. Fuel economy can be improved by reducing moving parts friction and weight optimization. Driveline or Transmission power losses are major factor in overall efficiency of rotating parts in a vehicle. Transmission efficiency can be improved by using low viscosity oil, reducing oil quantity and reducing churning losses in car transmission. Changes like low viscosity and reduced oil volume give rise to challenges like compromised lubrication and durability of rotating parts. This further leads to extended design cycles for launching new cars with better transmission efficiency and fuel economy into the market. Design cycle time can be reduced by using CFD simulation for oil flow validation in the early design stage.

Clutch actuation system in manual transmission is one of the key systems of power-train with which driver interacts frequently. Therefore its load and travel feeling are important to customer. Clutch actuation system consists of clutch pedal assembly, flexible cable mounted on body panel, and clutch release arm/ shaft assembly inside transmission unit assembly. Clutch pedal load, travel and engagement point are important parameters to specify the actuation feeling while designing the clutch actuation system. Validation of actual values is being done at proto vehicle testing stage, as final output calculation may not be accurate due to dependency on variables difficult to estimate. To overcome these difficulties a virtual dynamic model of the entire clutch actuation mechanism has been created in MBD software. Model input factors are based on actual testing results to improve the accuracy. The model predicts the clutch pedal load and travel values for a given set of vehicle inputs.