www.autotechreview.com October 2014 | Volume 3 | Issue 10 NOW, ALSO AVAILABLE ON It’s on 14 INTERVIEW Ravindra Pisharody, Executive Director, CV Business Unit, Tata Motors 18 TECHNOLOGY FORESIGHT Trends In Lightweighting of BEVs: A Review of Strategies – Part II 60 NEW VEHICLE Maruti Suzuki Ciaz – Setting The Sedan Gameplan on Track PISTONS & RINGS — DRIVING EFFICIENCY IN ENGINES POWERED BY MM Auto_New_ with new logo.indd 1 24-04-2014 10:11:38 EDITORIAL VOTE OF CONFIDENCE Dear Reader, The past fortnight has been one of historic firsts! India achieved what no other nation in the world had managed to in their first attempts – the Mars Orbiter Mission (MOM) or ‘Mangalyaan’, as it was named, entered the Martian orbit in its first attempt, giving the Indian Space Research Organisation (ISRO) a place in global space history. The success of Mangalyaan is a huge vote of confidence to the Indian space community, considering it was an acutely complex mission. What makes this an incredible feat is also the fact that this has been the least expensive space mission to Mars in recent times. Consider the numbers: India spent just $ 74 mn as against the US National Aeronautics and Space Administration’s $ 671 mn – a staggering one-ninth of what the US spent! To put things in perspective, Mangalyaan cost a quarter less than the money spent to make the 2013 science fiction thriller, Gravity. Even Prime Minister Narendra Modi, in his speech at the Madison Square Garden, New York recently, said in a light hearted manner that the per km cost to Mars was cheaper than a km worth of an auto-rickshaw ride in India. The other most remarkable thing about Mangalyaan’s success is that it was made entirely with home-grown Indian technologies. A lot of technologies were reused from ISRO’s past missions. Many experts acknowledged the fact that the cheap indigenous technology came out of sheer necessity. That, in fact, has been a mantra with the Indian industry – a manufacturing philosophy that has resulted in many successes across industries. The Indian industry has come to be known for its frugal approach to manufacturing. There are myriad examples in the automotive industry as well, be it in terms of products or processes. The Mangalyaan mission is no mean engineering feat. The ISRO should now expect the world to queue up to not just use its expertise, but to learn prudence in engineering and innovation. In fact, it should offer tremendous boost to the entire Indian engineering community, which has strong global credentials already. This is yet another feather in India’s engineering cap. DEEPANGSHU DEV SARMAH Editor-in-Chief New Delhi, October 2014 @deepangshu autotechreview.com October 2014 Volume 3 | Issue 10 1 COVER STORY PISTONS & RINGS — DRIVING EFFICIENCY IN ENGINES 24, 30, 36, 42 | The demand for more at less is a term well understood by automotive engineers, as efficiency and power continue to become a common offering now. Pistons and rings, which to the naked eye haven’t changed much over the decades, have undergone a phenomenal change in reality. They’re lighter, yet stronger and engineers continue to push the boundaries further as you read this. Keeping in mind their critical role for any engine, Auto Tech Review, in this issue, takes a look at the technical developments taking place in this space. GUEST COMMENTARY 12 Driverless Cars: Truly ‘Auto’mobile RAJEEV SINGH, Partner and Head of Automobile Sector, KPMG in India INTERVIEW 14 “2015-16 Could See Recovery of The Indian Automotive Industry” Ravindra Pisharody, Executive Director, CV Business Unit, Tata Motors 2 CONTENTS NEWS COVER STORY 4 Interactions 24 System Comparison of Steel & 54 Volkswagen Polo GT – All-Round 7 Events Aluminium Pistons for PC Functional Capability 10 News Diesel Engines Simon Schneider, Kai Schreer, SHOPFLOOR Holger Ehnis, Stefan Spangenberg TECHNOLOGY FORESIGHT 56 Continental Automotive – Aiming 30 Lower Friction Losses with Market-Specific Localisation 18 Trends In Lightweighting Of Bevs: New Piston Ring Coating A Review Of Strategies – Part II Marcus Kennedy, Steffen Hoppe, NEW VEHICLE Suresh Babu Muttana, Rakesh Kumar Dey, Johannes Esser Arghya Sardar 60 Maruti Suzuki Ciaz – Setting The 36 Gas-Lubricated Mechanical Face Rings Sedan Gameplan on Track For CO2 Reduction Sören Neuberger, Eberhard Bock, DECODING TECHNOLOGY Habil. Werner Haas, Klaus Lang 64 Pistons & Rings – Prime Movers 42 Aspects of Piston Material Choice Arun Jaura for Diesel Engines Arnd Baberg, Marcus Freidhager, Harald Mergler, Klaus Schmidt OTHERS 01 Editorial TECHNOLOGY 03 Imprint 46 Greater Efficiency Thanks to Mild Hybrid Integrated Approach Friedrich, Thomas Knorr, Sven Hager, Markus Kneissler 52 Battery Show Votes In Favour of A Lithium-Ion Future FOLLOW US ON @autotechreview1 COVER FIGURE © Goruppa/iStockphoto.com IMPRINT Editorial & Business Office: Editor-in-Chief: Deepangshu Dev Sarmah Publisher & Managing Director: Springer India Pvt Ltd [email protected] / @deepangshu Sanjiv Goswami 7th Floor | Vijaya Building | 17, Barakhamba Road Assistant Editor: Arpit Mahendra For Editorial Contribution, write to the Editor-in-Chief at New Delhi – 110001 | India [email protected] / @arpitmahendra3 [email protected] + 91 11 4575 5888 (P) | +91 11 4575 5889 (F) Senior Correspondent: Naveen Arul (Bangalore) For Advertisements, write to Manager – Sales at Auto Tech Review (ATR) is a monthly magazine focussed on automotive technology, and appears 12 times a year. 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[email protected] [email protected] ©2013, Auto Tech Review Manager – Events: Chanakya Mehta [email protected] Sr. Designer /Photographer: Bharat Bhushan Upadhyay [email protected] autotechreview October 2014 Volume 3 | Issue 10 3 INTERACTION MICHELIN, PTC MICHELIN | MATERIAL USAGE TO CHANGE, NOT COMPOSITION Reduce, Reuse, Recycle and Renewable. In line about the question of shifting the load from one with the idea of Reduce, Michelin is making con- natural source to another. Aimon’s response to it stant efforts to develop lighter tyres, which last was that with the growing demand for tyres, the longer as well, said Aimon. Making these tyres a need for “natural rubber”, i.e. polyisoprene-based catalyst for higher fuel-efficiency, in tandem with elastomer will continue to grow in the long-term. the mentioned initiatives, leads to reduction in It is hence necessary to find additional supply consumption of natural resources. Reuse covers possibilities for it where the Hevea (type of rubber the actions of repairing, re-grooving and recap- tree) can grow. A diversification is also necessary ping, all of which lead to longer use of tyres and to find additional capacities in the long-term for lower consumption of rubber. Recycle and Renew- bio-based polyisoprene. As a matter of fact, sug- able, as their name suggests ensure that materi- ar-based polyisoprene will not replace Hevea- als aren’t wasted, leading to a controlled usage of based polyisoprene in the future, but it will be an new materials. additional source for polyisoprene, he added. In order to further improve its approach to green FUTURE ACTIONS credentials, Michelin had recently announced the Depleting natural reserves, impact on human acquisition of a significant minority stake in Sym- health and a changing climate are some of the The magnitude of raw material consumption by bioFCell, a France-based developer of fuel-cell key reasons forcing industries to innovate envi- the global tyre industry is huge, clearly reflected technology. Through this partnership, Michelin will ronmentally-friendly products and production pro- by these spectacular numbers. Globally, the in- be able to help the fuel-cell company in putting cesses. One key automotive component, which dustry consumes about 32 mn tonnes of raw ma- its plans in industrial production, while it stands uses considerable amount of natural resources, is terial, of which India presently accounts for about to benefit from an increased role in developing the tyre with about 75 % of it made from fossil- 1.8 mn tonnes only. In the long-term though, sustainable mobility, Aimon said. Michelin itself is based raw materials. And this has been a subject India’s consumption will increase to about 4 %. no stranger to the fuel-cell technology and has of research for most tyre makers today. We recent- Looking at such constantly-increasing demand, been actively working on it since a long time. ly spoke to Dominique Aimon, Vice-President, it’s imperative that each gram of rubber is used in Technical & Scientific Communication, Michelin the best way possible, noted Aimon. One such ini- FUTURE OF TYRES to understand the work being done by Michelin in tiative is the Tire Recycling Project (TREC), which order to lower the burden of tyres on nature. enables manufacture of new tyres from raw mate- There are numerous experiments being done by rials sourced from used tyres. Two methods, which tyre makers across the globe in pursuit of a better 4R STRATEGY achieve 100 % recycling of tyres, are TREC Re- tyre on all accounts. Some of these involve usage generation and TREC Alcohol Recycling Program.