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					                                                                                                                                                                                                                                            8/13/2012


                                                  Engine CAE DVP - mHawk Diesel 2Cyl. 34 kW for MPV HT application
Sr.                             Analysis                                                  Analysis Description
No     (System) DVP        Activities/Projects                                                                                                                           Results &
                                                                                                                                                              Modeling                Report   Remark
           Item           Related to the DVP                                                                                                                             Iterations
                                                          BOM                        Load                          BC                      Output
                                   Item
1     Bore distortion     Strength analysis of    Cylinder head,          Assembly load:                  Crankcase is fixed at   (1) Stress
      test                Cylinder head and       Crankcase, valve        (1) Bolt preload                the centre bearing      (2) Gasket pressure
                          crankcase for           seat, valve guides,     (2) Interference loads          and nodes on            distribution
                          assembly load           valve, cylinder head    (valve seat - cyl head, valve   crankcase skirt to      (3) Bore distortion
                                                  bolts, gasket, liner,   guide -cyl head)                avoid rigid body        (4) Cylinder head
                                                  crankshaft (beam)       (3) Injector load               motion                  deformation

2     Cold firing test    Strength analysis of    Cylinder head,          (1) Assembly load               Crankcase is fixed at   (1) Stress
                          Cylinder head and       Crankcase, valve        (2) Gas load on cylinder        the centre bearing      (2) Gasket pressure
                          crankcase - cold        seat, valve guides,     head and crankcase              and nodes on            distribution
                          firing                  valve, cylinder head    (3) Reaction force on           crankcase skirt to      (3) Bore distortion
                                                  bolts, gasket, liner,   crankshaft                      avoid rigid body        (4) Cylinder head
                                                  crankshaft (beam)                                       motion                  deformation


3                         Thermal strength        Cylinder head,          (1) Assembly load               -                       (1) Stress
                          analysis                Crankcase, valve        (2) Temperature on gas                                  (2) Temperature
                                                  seat, valve guides,     side and water sides                                    distribution through each
                                                  valve, cylinder head    obtained by CFD analysis                                component
                                                  bolts, gasket, liner,
                                                  crankshaft (beam)
                          Strength analysis of    Cylinder head,          (1) Assembly load               Crankcase is fixed at   (1) Stress
                          Cylinder head and       Crankcase, valve        (2) Gas load on cylinder        the centre bearing      (2) Gasket pressure
                          crankcase - hot         seat, valve guides,     head and crankcase and          and nodes on            distribution
                          firing                  valve, cylinder head    reaction force on crankshaft    crankcase skirt to      (3) Bore distortion
       Engine full load                           bolts, gasket, liner,   (3) Thermal load                avoid rigid body        (4) Cylinder head
       endurance test                             crankshaft (beam)                                       motion                  deformation


                          Fatigue life safety     Cylinder head and       Stress data from ABAQUS --------------                  Safety factor w.r.t
                          factor calculation in   Crankcase               stress analysis. The                                    endurance limit
                          FALANCS                                         Assembly and thermal
                                                                          loading conditions are used
                                                                          for mean stresses and the
                                                                          gas firing loading is used
                                                                          for the pulsating stresses.

    4 Engine full load Strength analysis of Crankcase, bearing            (1) Bolt preload (2) Gas        Top deck of             (1) Stress
      endurance test main bearing wall       cap, bolts, bearing          load (3) Shell crush            crankcase is fixed      (2) Deformation
                                             shells and part of
                                             crankshaft between
                                             two walls.
    5                  Fatigue life safety   Crankcase                    Stress data from ABAQUS -                               Safety factor w.r.t
                                                                                                                                                                                               25.05.09
                       factor calculation in                              stress analysis. The bolt                               endurance limit
                       FALANCS                                            load and shell crush loading
                                                                          conditions are used for
                                                                          mean stress. Gas load
                                                                          stresses are used as
                                                                          pulsating stresses.


                                                                                                                                                                                                          Mahindra & Mahindra Ltd,A.S,/CAE/page 1 of 3
                                                                                                                                                                                        25.05.09

                                                                                                                                                                                                                                     8/13/2012

Sr.                             Analysis                                                Analysis Description
No      (System) DVP       Activities/Projects                                                                                                                    Results &
                                                                                                                                                       Modeling                Report   Remark
            Item          Related to the DVP                                                                                                                      Iterations
                                                       BOM                        Load                       BC                   Output
                                   Item
6                         Strength analysis of Connecting rod, cap, (1) Bolt preload (2) Gas       (1) Fix centre of rod (1) Stress
                          connecting rod       crank pin, piston pin, load (3) Inertia load (4)    and both pins during (2) Deformation
                                               bearing shells at      Shell crush                  bolt loading and shell
                                               small and big end,                                  crush (2) Fix
                                               bolt                                                crankpin during
                                                                                                   inertia and gas load
7       Engine full load Fatigue life safety    Connecting rod and     Stress data from ABAQUS --------------              Safety factor w.r.t
        endurance test factor calculation in    cap                    stress analysis. The bolt                           endurance limit
                         FALANCS                                       load and shell crush loading
                                                                       conditions are used for
                                                                       mean stress. The Gas and
                                                                       Inertia loading are used for
                                                                       the pulsating stresses.

     8 Torsional          Crankshaft            Crankshaft, flywheel, (1) Gas pressure over           Crankcase is fixed   (1) Torsion vibration
       Vibration test     multibody dynamic     ring gear, damper     operating speed range                                amplitude
                          (MBD) simulation in   pulley hub and ring,                                                       (2) Safety factors
                          Excite                TVD (Torsional                                                             (3) Cyclic speed
                                                vibration damper),                                                         irregularity (Max angular
                                                clutch mass and                                                            speed - Min angular
                                                inertia, part of                                                           speed)/Mean speed
                                                crankcase including                                                        (4) Torsional stress
                                                bearings                                                                   amplitude
                                                                                                                           (5) Bearing and crankpin
                                                                                                                           Loads & moments



     9 Engine full load   Crankshaft Dynamic Crankshaft, flywheel, (1) Dynamic excitations     Enforced motion is          Dynamic stresses
       endurance test     Stress analysis (FE ring gear, damper    (displacements) from excite applied. Hence no
                          Based)              pulley hub and ring, are used for the analysis   constraints
                                              TVD, clutch mass
                                              and inertia, part of
                                              crankcase including
                                              bearings

10 Vibration test         EGR System Modal EGR system                  ----------------------------123 and two rotations   Frequency and mode                                           01.05.09
                          Analysis         including Intake and                                    @ the axes              shape
                                           Exhaust manifolds                                       perpendicular to bolt
                                                                                                   axis - at the bolting
                                                                                                   locations
11     Engine over load EGR System              EGR system             10 g load                   123 and two rotations   Displacement and stress
             test       Strength Analysis       including Intake and                               @ the axes                                                                           25.05.09
                                                Exhaust manifolds                                  perpendicular to bolt
                                                                                                   axis - at the bolting
                                                                                                   locations
                          EGR System            EGR system             Measured Accelerations at Two rotations @ the       Displacement and stress
                          Transient analysis    including Intake and   mounting locations in X, Y, axes perpendicular to
                                                Exhaust manifolds      Z directions                bolt axis - at the
                                                                                                   bolting locations




                                                                                                                                                                                                   Mahindra & Mahindra Ltd,A.S,/CAE/page 2 of 3
           test


                                                                                                                                                                                                                                                8/13/2012

Sr.                         Analysis                                                   Analysis Description
No    (System) DVP    Activities/Projects                                                                                                                         Results &
                                                                                                                                                       Modeling                Report              Remark
          Item        Related to the DVP                                                                                                                          Iterations
                                                  BOM                            Load                          BC                     Output
                              Item
                      Safety factor       EGR system                 Transient load                  -------                 Safety factor w.r.t
                                          including Intake and                                                               endurance limit
                                          Exhaust manifolds


12 Vibration test     Modal analysis of     A/C Compressor       ----------------------------        123 and two rotations   Natural frequencies and
                      Front Cover           casing, Front Cover,                                     @ the axes              mode shapes
                                            Compressor mass                                          perpendicular to bolt                                                              05.05.09
                                            and inertia                                              axis - at the bolting
                                                                                                     locations
13 Engine over load Strength analysis of A/C Compressor              (1) Belt load (2) 10g load is   123 and two rotations   principal stress
   test             Front Cover          casing, Front Cover,        applied based on the            @ the axes
                                         Compressor mass             direction of first mode (3)     perpendicular to bolt
                                         and inertia                 Combined load                   axis - at the bolting
                                                                                                     locations
                      Front Cover           A/C Compressor           Measured Accelerations at       Two rotations @ the     Displacement and stress
                      Transient analysis    casing, Front Cover,     mounting locations in X, Y,     axes perpendicular to                                                                         05.05.09
                                            Compressor mass          Z directions                    bolt axis - at the
                                            and inertia                                              bolting locations
                      Safety factor         Front cover              (1)Belt Load as mean load       -------                 Safety factor w.r.t
                                                                     (2)Transient load as                                    endurance limit
                                                                     fluctuating load

14 Vibration test     Modal analysis of   Alternator Mounting ---------------------------- 123 and two rotations             Natural frequencies and
                      Alternator mounting bracket, Compressor                              @ the axes                        mode shapes
                      bracket             mass and inertia                                 perpendicular to bolt                                                                        05.05.09
                                                                                           axis - at the bolting
                                                                                           locations
15 Engine over load Strength analysis of Alternator Mounting (1) Belt load (2) 10g load is 123 and two rotations             principal stress
   test             Alternator mounting bracket, Compressor applied based on the           @ the axes
                    bracket              mass and inertia    direction of first mode (3)   perpendicular to bolt
                                                             Combined load                 axis - at the bolting
                                                                                           locations
                    Alternator mounting Alternator Mounting Measured Accelerations at Two rotations @ the                    Displacement and stress
                    bracket Transient    bracket, Compressor mounting locations in X, Y, axes perpendicular to
                                                                                                                                                                                                   05.05.09
                    analysis             mass and inertia    Z directions                  bolt axis - at the
                                                                                           bolting locations

                      Safety factor         Alternator Mounting      (1)Belt Load as mean load -------                       Safety factor w.r.t
                                            bracket                  (2)Transient load as                                    endurance limit
                                                                     fluctuating load


                                                                                                                                                                                                   25.05.09




                                                                                                                                                                                                              Mahindra & Mahindra Ltd,A.S,/CAE/page 3 of 3

				
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