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For the validation of a new design of a wheel, the conventional fatigue tests may not be entirely sufficient. They may give us the success or failure, but they may not help us any further in improving the design. Experimental Stress Analysis (ESA) is becoming increasingly crucial for the validation of any new design of the wheel. One can know the exact stresses acting at a point on the wheel during its operation with the help of ESA, making it very helpful for further upgradation in design. However, requirement of a prototype makes the validation process laborious, costly and time consuming. Finite Element Method (FEM) has evolved as a resourceful tool for analyzing various components under a variety of operating conditions. It is being used not only to predict the critical points bearing the highest stress in a wheel, but also to predict its fatigue life. However, it is still not very reliable due to its deviation from the ESA observations.

Manufacturing processes play a major role not only in the attainment of high product quality, but also in the reduction of manufacturing and consequently also product costs. In manufacturing industries tools used are of major importance in this respect, as it is very expensive and critical in the process since it is tool dominant process and their job to convert products or components. In mass productions, wear and chipping of tools is inevitable. Hence reconditioning of tools play vital role since it is not possible to discard the tools for minor damages or flaw, as the tool cost is very high and expensive. However there are variables to consider geometry, material, defect and coating all play a part in driving the decision to recondition a tool. The processes generally used for reconditioning of tools are welding overlays, grinding, machining and using it for next applicable size etc.

For more than a decade there is a progressive demand for fuel efficient and high specific power output engines. Optimization of engine cooling and thermal management is one of the important activities in engine design and development. In the present paper an effort has been made to simulate the heat transfer modes of cylinder block and head for a present 4-stroke air-cooled motorcycle engine. Two and three-dimensional decoupled and conjugate heat transfer analysis has been done with commercially available computational fluid dynamics (CFD) codes. Experimental results are also presented. A complete simulation model has been developed and CFD techniques have been applied to design and optimize air cooling surfaces of cylinder head and block, for an air cooled motorcycle engine. The two dimensional analysis is an easy and fast method to predict fin surface temperature, heat transfer co-efficient and flow velocity.