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In the modern automotive sector, durability and reliability are the most common terms. Customers are expecting a highly reliable product but at low cost. Any product that fails within its useful life leads to customer dissatisfaction and affects the reputation of the OEM. To eradicate this, all automotive components undergo stringent validation protocol, either in proving ground or in lab. This paper tails on developing an accelerated lab test methodology for NRS leaf spring bracket by simulating field failure. Initially, potential failure causes for spring bracket were analyzed. Road load data was then acquired at proving ground and customer site to evaluate the damage on the spring bracket. To simulate the field failure, lab test facility was developed, reproducing similar boundary conditions as in vehicle.

Due to the emerging technologies and globalization, expectations of the customers on commercial vehicles are getting increased over the period. It is an important duty of an OEM to deliver a perfectly configured product to suit the customer requirements. When it comes to configuration of a vehicle, engine power is one of the key factors which indicate the performance of that vehicle. There is a tough competition between every OEM to increase the engine power for enhancing the overall operational performance. One method to increase power is to improve its volumetric efficiency. This is achieved with help of turbocharger and Charge Air Cooler (CAC). CAC improves volumetric efficiency by increasing intake air-charge density. Any failure on CAC leads to lower the volumetric efficiency and increase in turbocharger loading. This paper deals with the validation of CAC assembly using different test conditions by analyzing potential failure modes against the field issues.

In the modern automotive sector, durability and reliability are two terms of utmost importance and relevance. The ever improving standards and cut throat competition has led to customers expecting highly reliable products at low costs. Any product that fails within its useful life leads to customer dissatisfaction and affects the OEM’s reputation. To eradicate this, all automotive components undergo stringent validation protocol, either in proving ground or in lab. Multipurpose bracket is one of the most important and critical aggregate in the vehicle assembly. It encompasses various mounting components such as FUPD bracket, steering mounting bracket, front spring front bracket, cab mount bracket, cab tilt cylinder mounting bracket, front cross member, footstep bracket and bumper. All these components experience various degrees of vibration and fatigue during its running period.

In the emerging commercial vehicle sector, it is very essential to give a product to customer, which is very reliable and less prone to the failures to make the product successful in the market. In order to make it possible, the product is to be validated to replicate the exact field conditions, where it is going to be operated. Lab testing plays a vital role in reproducing the field conditions in order to reduce the lead time in overall product life cycle development process. This paper deals with the design and fabrication of the steering column slip endurance test rig. This rig is capable of generating wear on the steering column splines coating which predominantly leads to failure of steering column. The data acquired from Proving Ground (PG) was analyzed and block cycles were generated with help of data analyzing tools.