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Motorcycles are a preferred means of transportation in most of the countries due to its economic factor and ease in travelling. Rider comfort is an important aspect while designing a vehicle. Rider comfort is often compromised by unwanted vibrations experienced at human interface points also called as tactile points. These unwanted vibrations also affect rider’s motorcycle control and overall health. There are two major source of vibrations in a motorcycle that is engine & road inputs. In current study, a method is being explored to predict engine induced vibrations. Engine induced vibrations at various locations are simulated through multi body dynamics (MBD) and finite element (FE) simulation methods at vehicle level. Motorcycle model comprising of engine, frame and subassemblies are modeled in FE tool and then condensed to be used in MBD tool. Piston assembly, connecting rod, bearings and engine mounts are modeled in MBD tool.

Automotive steering wheels, which play an important role as a human machine interface, are evolving over time with numerous integrations and innovations. Thermoplastic steering wheel, one of the innovations in recent times, offers significant reduction in mass along with part integration and styling flexibility and is an excellent replacement to traditional metal armature steering wheels. Typical steering wheels need to meet many performance requirements before they enter production. With the advancement of computational mechanics and increase in computational capabilities, it has become much easier to evaluate and optimize steering wheel performance in different ways. Instead of manufacturing and running prototype tests, steering wheel designs can be modeled and optimized virtually in various scenarios using standard finite element analysis technique, thus facilitating faster development cycle.

Automotive OEM's are looking for innovative material solutions that will help them to reduce weight, thereby reduce carbon footprint. One such emerging area to meet this objective is glazing, where traditionally glass is used as the material. Polycarbonate which is an engineering thermoplastic has the potential to replace glass, providing 30 to 40% of weight saving. Two shot injection compression process is primarily adopted for manufacture of these large complex polycarbonate-glazing panels, in order to reduce residual stresses and clamp force. This involves combination of two processes, first the injection compression of clear panel and second overmolding of black out portion with integral features. Prediction of deformation of these molded large panels is a critical parameter for successful replacement of glass. A novel prediction methodology to address this critical parameter is discussed along with comparison of results with experimentation.

Automotive industry is looking for weight out options to increase the fuel efficiency of automobiles. Thermoplastics usage is increasing to reduce the dead weight of different automotive components. Traditional steering wheel can be replaced with thermoplastic to make it lighter without compromising its performance requirements. Thermoplastic steering wheel offers overall reduction in cost as well as significant reduction in mass. In addition, thermoplastic steering wheel also offers part integration and styling flexibility. As steering wheel has to meet variety of loading criteria (vibration, static loading, dynamic loading and fatigue), the overall design is a multi objective optimization process. Major challenges of thermoplastic steering wheel are to design the effective model for any particular wheel geometry domain defined by OEM's (Original Equipment Manufacturer) styling studios.

This paper describes a methodology to prototype and validate thermoplastic energy absorbers in a broad range of vehicle geometries. The objective of this prototype tool designed with quick prototype methodology is to achieve ready PC/PBT energy absorber designs for pedestrian testing. Generic vehicle models were used to finalize the energy absorber design features. The prototype tool was designed from optimized energy absorber designs that meet pedestrian performance in low packaging space, typically 45–60 mm. A set of prototype tools is being built to match different beam heights and packaging spaces. The tool has also the functionality of achieving different thickness and different design features using the latest manufacturing technologies. A full energy absorber can be built from individual lobes over the width of the car. The finalized design combined with ‘quick prototyping’ methodology was used to finalize the mold design, which can cater to a wide range of vehicle geometries.