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To meet the latest trends in internal combustion engines pertaining efficiency, emissions and durability, downsizing of the engine has become the key focus area. This paper describes about a robust, reliable and an integrated approach used in design and development of state of art high power density/ high speed engine developed from the concept, which can be adopted for passenger car and LCV application. A three-cylinder, 1.5 liter displacement diesel engine, fully balanced is being designed with an objective to produce 115kW @ 4200 rpm, delivering a specific power output over 75 kW/liter, which is at par with a contemporary class of specification in it. In the first stage, a derated version of 75 kW (50 kW/liter) with Euro-IV and Euro-V specifications is targeted aiming at smaller car and light motor vehicle segment and a prime-mover for hybrid application.

Modern vehicles are designed for quiet interior with lower engine and exhaust noise levels. Under such circumstances, gear whine and rattle become one of the significant contributors towards in-cab noise, besides wind and road noise. Present paper deals with dynamic analysis, simulation and validation of the transmission system model for observed gear whine inside the cabin of a passenger car during its running condition. The exercise included development of an accurate numerical model to enable prediction of noise transmission from automatic gearbox to cabin structure. Experimental Modal Testing (EMT) of automatic transmission and suspension components, Multibody simulation of automatic transmission and Finite Element Analysis (FEA) of components and subassemblies followed by component and system level response correlations were carried out. Detailed methodology adopted for the exercise is discussed in the paper.

Performance and emission tests have to be carried out on range of engines having wide applications and varied specifications. In this context situation compels to adopt critical measures and revamp the methodologies in the area of design and development / matching of cardon shafts, rubber couplings and development of test bed systems for testing of single / two cylinder engines. Considering this need, a new strategic design approach has been formulated, which have reduced cost, loss of time and serious damages. This paper outlines a modern and practical approach used along with in-house available tools for controlling various dynamic behavioral issues involved. Redesign of shafts and couplings is done based on the comprehensive mass elastic data obtained from variety of engines. Apart from conventional torsional and bending vibration theories, FE and experimental tools are used to understand the modal behavior of engine coupled systems.