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Growing demands for fuel efficient vehicles and reducing air pollution leads to light weighting of vehicles. Using optimum combination of high strength steel and lightweight aluminum alloy in the automotive structures may be answer to the problem. Joining of these two dissimilar metals have several issues related to techniques and reliability that need to be addressed for efficient mass production. There are several joining techniques used for dissimilar metals out of which Cold Metal transfer (CMT) is one of the methods. As simulation is an integral part of product design, development of CAE methodology for joining of dissimilar metals using CMT is necessary. This paper includes investigation on various modeling methods of welded joint developed using CMT process. Numbers of lap shear specimen were tested experimentally and results were compared with simulation. Based on correlation, most suited modeling technique was adopted.

Automotive Industry Standard (AIS)-031 specifies the requirement of strength of large passenger vehicles in case of rollover. In India the certificate is granted after the successful completion of rollover test of the vehicle as per AIS-031. Complete vehicle is used for rollover test in which the vehicle is tilted laterally in the ditch of 800 mm. Such tests with complete vehicle are costly and unaffordable to small bus body builders. So according to Annex 2 of AIS-031, manufacture can carryout rollover on body sections of the vehicle. This is an equivalent approval method which is less costly compared to rollover test on complete vehicle. It requires detailed study of superstructure and selection of weakest body sections from the given superstructure of bus, which in turn requires mass and energy calculation of body section. For doing rollover analysis using body section, bus is selected which has already passed a full-rollover test.

With ever-increasing concern for the occupant safety, it is desirable that the design of truck cab should meet the safety requirements specified in ECE R-29. The cab must be designed in such a way that, sufficient survival space to be guaranteed in the event of accident for the safety of the driver and co-driver. It was found that there are some areas, which are not covered by the standard or the standard is not very clear. This paper discusses about the practical problems incurred during implementation of the standard in Indian scenario and also suggests possible practical solutions.

Buses are commonly used mode of transport in less motorized countries. With growth in economy, the numbers of buses have increased tremendously both in rural and urban areas. With increased number of buses, the issue of safety of passengers and the crew assumes special importance. A large number of bus accidents involve rollovers and falling into ditches or downhill sides. Therefore, the structural integrity of buses is critically important. In order to provide buses with minimal rollover resistant superstructure, Economic Commission for Europe, Regulation Number 66 (ECE R - 66) was issued in the early eighties. Type approval can be granted on the basis of rollover test on complete vehicle or body section or pendulum test on body section or by calculations. This paper includes the numerical simulation of rollover test of a full bus body according to ECE R-66. It also includes similar simulation of a representative bus section and validation with the experimental rollover test.