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In rubber industry, different techniques are used to enhance durability. This paper gives complete design, development and testing methodology of rubber bush in which pre-compression of rubber is used to enhance rubber bush life. In bogie suspension, axle to torque rod join is critical as it has to transfer lateral and longitudinal load with flexibility. This makes challenging to design joint which need to carry more than 6 ton load and having flexibility of more than 10 degree articulation. In this torque rod to axle joint called as End bush, compressed rubber is used to carry high load with flexibility. Other possible material for bush can be brass bush which able to carry high load however not able to give high flexibility Design and finite element calculations are done to design pre-compression and rubber volume to get desired strength and stiffness to carry required load with flexibility.

Products from the developed western countries are brought to India by different manufacturers. It is needed to look at the different aspects of the vehicles like performance parameters, structural stability, serviceability etc, as the requirement of the local market differ vastly from those requirement of the original markets. Indian market condition demands the vehicle suitable for taking the abuse load on the rough roads as the road conditions in the mofussil area and country side are bad. This paper describes the definition and validation of the carryover products, to suit the Indian conditions by using different techniques, to reduce time to market. This paper describes the creation of accelerated endurance test cycle for a mini truck which is representative of Indian customer usage of 120,000 km. Relative damage method is used for correlation of proving ground (track) with customer usage pattern on selected channels.

Light commercial vehicles are extension of three wheelers due to their need for simplicity and load carrying capacity. Smaller vehicle being simpler, have engine mounted at the rear. This give an added advantage in term of simple and light weight design and thus cost effective and have low engine noise and vibration in cabin. In many of the light commercial vehicles, which have been downsized from the bigger vehicles like trucks, have the aggregates designs similar to those of trucks like the drive line extending from the mid engine to rear axle having integral differential. The axle carries the leaf springs for giving robust look as well the load carrying capacity. In the new rear suspension design of the light commercial vehicle, advantage of the mid position engine concept and rear engine concept have been captured. This paper is discusses the design philosophy and the packaging of the same along with criteria for design.

In India, demand for three wheelers with low noise is increasing among the customers thereby the noise reduction of three wheelers is necessary. In order to overcome the demand in the market, manufactures are giving more importance to noise levels at passenger ear level and driver ear level. In test vehicle it was found that engine is the main noise source, biggest challenge was to reduce noise transfer from engine compartment to passenger and driver ear. In three wheelers it is more difficult as there is no close cabin. This paper main objective is to reduce noise levels at driver and passenger ear level. The objective and subjective evaluations of both vehicles were carried out to identify the levels at driver ear level and passenger ear level. First task was to find out noise sources in engine. Most dominating noise source was tappet and flywheel area. Modifications were done on tappet cover and flywheel cover to reduce noise levels.

In the era of low cost product, enormous pressure to keep product development cost and time as low as possible. Durability verification and validation always consume big amount of product development cost and time. This paper gives low cost and quick, durability virtual verification which can be tested by running vehicle on track to check correlation. In this low cost durability verification, maximum stress levels on Frame and Cabin are generated analytically at all hot spot location based on finite element inertia relief analysis. Basic input load data is acquired by running proto type vehicle on track. Mathematical loading spectrum (Range Vs Cycle-Cumulative frequency distribution) for track is evaluated from acquired data. Stress spectrums are generated analytically for all hot spot locations based on mathematical load spectrum. Analytically component S-N curve for frame, cabin components with different slops [1,2] is generated based on material ultimate tensile stress values.