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Mobility Engineering DECEMBER 2013 MOBILITY FIRST ENGINEERING ISSUE AUTOMOTIVE, AEROSPACE, OFF-HIGHWAY A quarterly publication of and SIMCOMVEC Preview Safe, green, and connected Low-cost Datsuns from Chennai New surface engineering technologies Q&A with Mahindra & Mahindra’s Executive Director & President E-mobility in India MX150™ Interconnects HIGH-PERFORMANCE INTERCONNECT TECHNOLOGY FOR TOMORROW’S AUTOMOTIVE INNOVATION Leveraging our expertise in interconnect For standard and custom solutions that enable technology, Molex is powering the future of the innovation and enhance the on-board experience, Connected Vehicle segment with the MX150™ turn to Molex. We’re committed to automotive interconnect system. Offering a reduced package innovation — from the inside out. size, it is ideal for SAE- and ISO-style wire in single- and dual-row configurations up to 22.0A. See how we can enhance your designs: molex.com/me/mx150.html CONTENTSVolume 1, Number 1 Features 46 Technologies for safe, green, and connected vehicles 69 Metals make a comeback SIMCOMVEC PREVIEW AEROSPACE MATERIALS SIMCOMVEC 2013 will feature 40 technical sessions, an A look at how new metallic and hybrid materials are exhibition, and a ride-and-drive. competing with carbon composites for a continuing role in aerospace manufacturing. 47 Q&A with Dr. Pawan Goenka INTERVIEW 74 High hopes or just dreaming? The Executive Director & President – Automotive & Farm AIRCRAFT Equipment Sectors, Mahindra & Mahindra Ltd. answers A look at how Asia’s aircraft manufacturers are trying to questions on a range of subjects such as auto fuel efficiency, break into new markets to challenge the status quo. emissions, alternative fuels, safety, telematics, manufacturing, and sustainability. 79 Sensitive to safety OFF-HIGHWAY ELECTRONICS A growing number of digital sensors are among the tools 50 Advances in surface engineering being used to make sure failures are rare and injuries are MATERIALS Newer materials with improved properties can enhance the even more infrequent. properties of the working surfaces of cylinder components for the demands of increased temperatures, pressures, and 83 Simulating off-highway hybrids corrosive atmospheres and still satisfy performance and life OFF-HIGHWAY ELECTRONICS | SIMULATION requirements. With customers squeezed by fuel costs, off-highway OEMs are showing some interest in developing hybrid equipment. CAE simulation tools are needed because of lack of 54 E-mobility opportunities in experience with such devices. Their functional complexity the Indian ecosphere requires control system simulation throughout their lives. AUTOMOTIVE ELECTRIFICATION The Prime Minister of India in January 2013 unveiled the National Mission on Electric Mobility and formed a National Board of Electric Mobility to fast track e-mobility for India Cover through industry-government partnerships. The U-2523 T heavy commercial truck is one of the 56 Building cars From Legos latest offerings from Ashok AUTOMOTIVE DESIGN & MANUFACTURING Leyland, the event sponsor of The new Nissan/Renault plant for new low-cost Datsun cars SIMCOMVEC, the joint effort in Chennai provides an opportunity to explore a tale of two from SAEINDIA and SAE modular system approaches. International (see page 46). 60 Mobility in 21st Century India STUDENT PERSPECTIVE India’s rapidly growing population has made transportation systems unable to effectively keep up with demand, losing the country untold man hours and wasting money. 64 Low-cost instrument clusters AUTOMOTIVE INTERIORS A Delphi expert proposes a design strategy to help overcome challenges for manufacturability of automotive displays suited for emerging markets. follow us @SAEAutoMag MOBILITY ENGINEERING DECEMBER 2013 1 CONTENTS Departments 4 Editorial 24 Testing new materials and technology for the aerospace industry AEROSPACE PROPULSION | Mobility Engineering to address transportation MATERIALS challenges 27 Why VW is anticipating trouble ahead 6 Focus AUTOMOTIVE ELECTRONICS Welcome to the first issue of Mobility Engineering 29 A touch of simplicity in the cockpit AEROSPACE AVIONICS 8 Messages from Industry SAEINDIA evolves with Mobility Engineering 30 CGT’s new coverstock exceeds 40% sustainable content AUTOMOTIVE INTERIORS 10 SAEINDIA News 32 Lightweight carbon-fiber and SMC body panels under 10 Update on Virtual SUPRA SAEINDIA development AUTOMOTIVE BODY 10 SAEINDIA and membership 35 Grede offers iron as lightweighting option 11 Virtual Baja-2014 qualifying TRUCK MATERIALS 38 Federal-Mogul upgrades simulation and testing to 12 Industry News meet engine downsizing AUTOMOTIVE SIMULATION 12 Ashok Leyland sells Detroit-based testing and 40 Modeling and simulating hydraulic circuits engineering company OFF-HIGHWAY HYDRAULICS | SIMULATION 12 Tata Steel to build ultra-modern furnace to make 43 Fine-tuning vibro-acoustic countermeasures in a aerospace steels turboprop aircraft AEROSPACE TESTING 12 Mahindra Aerospace opens new aerostructures facility in Bangalore 87 Global Vehicles 14 Relan forms joint venture with Toyota Boshoku 87 Kubota goes deluxe with two new models for its M-Series 14 VECV produces Euro 6 engines at technologically advanced Indian plant 88 Scania employs simulation to produce customer-specific vehicles 14 Dana supplies axles for new M&M platform 90 Doosan DX140LCR excavator features reduced 16 Tech Report tail swing 16 GM’s new 1.0-L turbocharged triple aims for 90 ABB ‘flash charges’ electric bus in 15 s benchmark NVH AUTOMOTIVE POWERTRAIN 92 Deere’s 2014 8R tractors get more powerful 18 The case for alternative fuels AUTOMOTIVE ENERGY and a new cab 20 Energy recovery choices for commercial vehicles 94 2014 Sprinter gets upgrades in growing TRUCK POWERTRAIN | ENERGY commercial van segment 22 Customers get fast payback from extra cost of Cat 96 Q&A hybrid excavator OFF-HIGHWAY ENERGY Finding common ground among automotive, aerospace, and CV electronics © SAEINDIA and SAE INTERNATIONAL reserves all rights . No part of this publication and/or website may be reproduced, stored in a retrieval system or transmitted in any form without prior written permission of the Publisher. Permission is only deemed valid if approval is in writing. SAEINDIA and SAE International buys all rights to contributions, text and images, unless previously agreed to in writing. In case of address/addressee not found, return to SAE INDIA, No 1/17Ceebros Arcade, 3rd Cross, Kasturba Nagar, Chennai -600 020. Telefax: 91-44-2441-1904, Phone: 91-44-4215 2280. Published by : SAEINDIA, 1/17, 3rd Cross, Kasturba Nagar, Adyar, Chennai – 600 020. Printed at : Hi-tech Offset Private Ltd., 11, Srinivasa Nagar Main Road, Koyambedu, Chennai – 600 107. 2 DECEMBER 2013 MOBILITY ENGINEERING COMSOL 4.3b Now Available! www.comsol.co.in/4.3b MULTIBODY DYNAMICS: A swashplate mechanism is used to control the orientation of helicopter rotor blades. Verify and optimize your designs with COMSOL Multiphysics.® Multiphysics tools let you build simulations that accurately replicate the important characteristics of your designs. The key is the ability to include all physical effects that exist in the real world. To learn more about COMSOL Multiphysics, visit www.comsol.co.in/introvideo Product Suite COMSOL Multiphysics ELECTRICAL FLUID MULTIPURPOSE INTERFACING AC/DC Module CFD Module Optimization Module LiveLink™ for MATLAB® RF Module Microfluidics Module Material Library LiveLink™ for Excel® Wave Optics Module Subsurface Flow Module Particle Tracing Module CAD Import Module MEMS Module Pipe Flow Module ECAD Import Module Plasma Module Molecular Flow Module LiveLink™ for SolidWorks® Semiconductor Module LiveLink™ for SpaceClaim® CHEMICAL LiveLink™ for Inventor® MECHANICAL Chemical Reaction Engineering Module LiveLink™ for AutoCAD® Heat Transfer Module Batteries & Fuel Cells Module LiveLink™ for Creo™ Parametric Structural Mechanics Module Electrodeposition Module LiveLink™ for Pro/ENGINEER® Nonlinear Structural Materials Module Corrosion Module LiveLink™ for Solid Edge® Geomechanics Module Electrochemistry Module File Import for CATIA® V5 Fatigue Module Multibody Dynamics Module Acoustics Module © Copyright 2013 COMSOL. COMSOL, COMSOL Multiphysics, Capture the Concept, COMSOL Desktop, and LiveLink are either registered trademarks or trademarks of COMSOL AB. All other trademarks are the property of their respective owners, and COMSOL AB and its subsidiaries and products are not affiliated with, endorsed by, sponsored by, or supported by those trademark owners. For a list of such trademark owners, see http://www.comsol.co.in/tm EDITORIAL EDITORIAL Kevin Jost Editorial Director [email protected] Asit Barma SAE India Editor Mobility Engineering to address transportation C V Raman ED, MSIL [email protected] challenges Arun Jaura SAEINDIA and SAE International have big plans VEC 2013 combines the 8th SAEINDIA Inter- VP, SAEINDIA [email protected] for our Indian members and the Indian transpor- national Mobility Conference with the inaugural Bala Bharadvaj tation engineering community. This new maga- Commercial Vehicle Engineering Congress India, MD, Boeing R & T [email protected] zine, Mobility Engineering, and the industry and is being held at the Chennai Trade Centre Mathew Abraham show where it launches, SIMCOMVEC 2013, are over 4-7 December 2013. Forty technical ses- Sr. GM, Mahindra [email protected] the prime evidence. sions will examine critical topics for the on-road Nitin Ranade This issue of Mobility Engineering will be the and off-road engineering community. VP, Mahindra
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