Introduction
The fuel consumption of a commercial truck is very much influenced by its aerodynamic performance. The greater the drag resistance, the greater is the fuel consumption. Therefore, it is very important to design the truck to minimize drag.

There can be few challenges such as

• Large model size required that high end computation hardware be used.
• Design modifications needed to be selected to minimize manufacturing difficulty and cost.

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Introduction
The vital ergonomic aspect of any cabin design is the thermal comfort of passengers especially the driver. The passenger should not experience high temperature variance when the air conditioning is switched on. The velocity of air coming out of an automotive AC unit decides the comfort level of the passengers. To achieve target velocities inside the cabin efficiently and effectively, CFD helps interior system cabin designers greatly.

There can be few challenges such as

• Air cavity volume extraction.
• Customizing the variant models for different vane positions and blower speed.

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Introduction
Crankcase/ Engine block is one of the most critical components of Powertrain assembly. Due to varying combustion pressures inside cylinder bores, the crankcase is subjected to dynamic loads. This fluctuation in the pressure causes variation in reactions at the crankshaft’s main bearings which leads to High Cycle Fatigue (HCF) failures at bearing fillets in the crankcase.

There can be few challenges such as

• Expertise requirements in FEA, CFD, Multi Body Simulations and Fatigue.
• High level of non-linearities.
• Requirement of High-Performance cluster due to the large size of model (no. of degrees of freedom ~15 Mil).

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Introduction
An exhaust system is subjected to extreme thermal load cycles. The variation of thermal loads might lead to thermal fatigue failure of components of exhaust system. It is very important to evaluate thermal fatigue life of the exhaust system.

There can be few challenges such as

• Expertise requirements in FEA, CFD, and Fatigue (multi- Physics expertise in Fluid Mechanics, Heat Transfer, Structural Mechanics).
• High level of non-linearities.
• Co-relation of CFD results with Test data.

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Introduction
Due to the inclusion of EGR, the intake side heats up a lot and an heat exchanger is required to reduce the temperatures of exhaust gas from getting re circulated to intake manifolds. In the proposed simulation, brazing of an EGR cooler was failing because of thermal loads and CAE was implemented to optimize design to avoid failure.

There can be few challenges such as

• Expertise requirements interlinking CFD - FEA.
• High level of non-linearities.
• Space constraints in underhood region to optimize design of EGR cooler.

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Introduction
There are no analytical methods for Vibration Design and system designers have to depend on test data to meet ‘Warranty Life’ criteria In this scenario, Power Spectral Density (PSD) simulation assists designer to predict failure locations and durability for vibration loads much in advance before real life test. In current scenario, a seating system with suspensions for an off-highway vehicle was simulated for Vibration failures.

There can be few challenges such as

• CAE – Physical Test co-relation.
• Modeling of seat suspension/ damping components for different operating frequencies.
• Precise conversion of time domain data into frequency domain data.

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Introduction
Seating systems are required to pass a good number of tests as per different standards like FMVSS, ECE, AIS. Now most of the seating suppliers are implementing CAE techniques to simulate different mandatory test setups to shorten Design cycles with cost advantage. Passenger Seats are subjected to various static and dynamic loads. The seats need to sustain these loads and meet the standard test requirements. The Head Restraint Performance (HRP) test is one of the critical tests as the neck injuries are the most frequently reported form of injuries.

There can be few challenges such as

• Manufacturing and cost constrain during optimization.
• High level of non- linearities/ Modeling of foam material.
• Test co-relation due to variation in material properties in different lots.

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Introduction
Engine cooling a vital parameter in Engine/ Powertrain design. The designing of the engine coolant in circuit becomes challenging due to thermal requirements and space constraints in the under-hood region.

There can be few challenges such as

• Modelling and calibration of porous region for complicated sub-assemblies (e.g. filters).
• Modelling of Boiling phenomenon.
• Use of advanced hardware to simulate fairly good sized CFD model.

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Introduction
As part of a comprehensive plan for reducing the serious risk of rollover crashes, death and serious injury in crashes, Roof Crush analysis becomes an important element in the Vehicle Body Design. The roof and structural parts should be able to sustain such loads and also meet the standard test requirements.

There can be few challenges such as

• Design optimization considering all Standard test requirements.
• Management of a FE assembly with good no. of parts.
• Developing a lean FE model which can accommodate part level changes in different variants in design cycle.

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Introduction
The crankshaft is one of the most critical part of Powertrain system. It is subjected to highly varying dynamic loads and precise estimation of Fatigue life is highly critical subject.

There can be few challenges such as

• Defining loading conditions (firing pressure, engine load conditions).
• Modelling different joints in cranktrain system.

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Introduction
To demonstrate possibility of automation in CFD simulation using scripting language, Iterate Hot-cold transformation of turbomachinery to create cold shape by subtracting deformations from hot shape definitions analysis is considered.

There can be few challenges such as

• Blade shape determination is crucial since even small discrepancies affect blade tip clearances, flow angles and performance.
• Forced response of aeroelastic flutter and acoustic noise level analysis require accurate blade operating shape.

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Introduction
Electronic components have become an essential part of a vehicle. Their number and complexity have risen greatly. Thus the measurement of their EMC to avoid electronic faults forms a vital analysis, especially for electric or hybrid vehicles.

There can be few challenges such as

• High voltage systems and flow of high currents feeding the drive train.
• Large conductive surfaces of the car body.
• EMC risk management.

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