Benchmarking

BENCHMARKING

Problem Definition

To Compare the physical Vibration test results and arrive at a Finite Element Model which matches the Physical test results. Using this as reference, the customer wants to run reliable tests using the simulation technique. The main requirement is the achieve complete NVH analysis of the BIW along with the cross-members. This would include a variety of different steps such as 3D scanning, reverse engineering, vibration testing, CAE analysis, material testing, obtaining data regarding the mechanical properties of each part after material testing, and finally BOM has to be prepared.

Scope of work

The Scope of work that we had accepted includes
•Full Vehicle Teardown & Teardown documentation
•Stagewise 3D Scanning with necessary referencing for part level scanning & alignment.
•Creation of Level wise Bill of Materials to correlate sub assembly modeling & Assemblydocumentation, Material composition analysis & Grade identification, Suggestion of Alternatematerials, Correlation of Grade physical properties with actually measured properties on critical parts.

Tools Used for specific activities

The tools used during this process were :

1.COMET L3D blue light scanner : Scanning is the process of capturing a multiple number ofpoints from the surface of the part and forming point cloud data which later after processing is used asan STL file to do reverse engineering(CAD modeling).
2.Geomagic Design-X 3D software : This software is used for reverse engineering. With the help ofthis software a cad model is prepared from the STL file.
3.Solid Works : This software is used for assembly alignment.
4.Mechanical tools such as grinding machine, drilling machine, gas cutter, hammer, chisel, etc.
5.Vibration testing equipment kit.
6.Spectrometer : This machine is used for material testing(chemical composition).
7.Universal Testing Machine : This machine is used to obtain the value for tensile strength, yieldstrength, and elongation.
8.Total Materia : This tool is used to obtained the grade of the material according to their chemicalcomposition as well as the mechanical properties of the material.

Procedure

1. 3D scanning of car in assembly position

The first step of this project is 3D scanning which involves a series of steps such as:
• Cleaning of the car.
• Pasting target stickers on the surface of the car, which are used as references for scanning.

• After sticker pasting is done, white powder is sprayed on the car which aids in the scanning of the surface of the car.

• Then the scanning of the full car is done.

Before Scanning

After Scanning

2. Tear Down

• After the scanning of the full car in assembly position, the car was torn down to BIW level. Once again, it has to be scanned in BIW condition with cross members.

3. Scanning of BIW with cross members

• Next, the scanning is done for BIW with cross members. This is done for the inner surface, the outer surface, and the underbody surface of the car.

4. Scanning of BIW without cross members

• The area which is covered by cross-members and not scanned is now scanned after the removal of the cross-members. This completes the scanning of the BIW in assembly position.

5. Scanning of individual cross-members

• When the cross-members are removed from the assembly they are not fully scanned. This way, each cross-member can get scanned individually after it gets removed from the BIW.

6. NVH testing

• Actual NVH testing is performed to authenticate the accuracy of the simulation results.

7. Tear down of BIW to individual parts

• After the BIW and cross-members were completely scanned, the BIW and each of the cross-members were torn down into individual parts.
  • While removing each individual part the thickness, weight, and different types of weldments (spot weld(2T &3T), laser weld, arc weld and plug weld) is noted down for each part.
  • BIW parts are segregated into seven different sub-assemblies which are :
  Side outer LHS panel assembly, Side outer RHS panel assembly, Roof assembly, Dash and Cowl panel assembly, Rear panel assembly, Floor assembly and Engine compartment assembly.
  • Cross-members are segregated into five different sub-assemblies :
  Front bumper guard assembly, Rear bumper guard assembly, Front suspension cross-member assembly, Rear suspension cross-member assembly, and Instrument panel assembly.

8. Scanning of individual parts

• The individual part that gets dismantled from the BIW or cross-members assembly. The individual part then gets scanned which aids us in individual part modeling.

9. Cad modeling

• BIW cad modeling is done assembly-wise such that all the parts and sub-assemblies are perfectly assembled considering the actual thicknesses and the thickness directions.
  • All the parts are model and it is shown bellow as outer panels, inner panels and underbody panels which also includes floor panels. Similar to BIW, cross-members also get modeled taking care of all the procedure followed in modeling during BIW.
  • All the five cross-members are modeled and shown below :

10. Material testing

• Material testing is done for getting the chemical composition for all the individual parts of BIW and cross-members. The machine used for getting chemical composition is Spectrometer.
  • With the chemical composition the materials is segregate into different grades. This is done with the help of a tool called “Total Materia”.
  • During the process of Material analysis, we identified thirty different grades in this vehicle.

11. Tensile testing

• This testing is done to get the tensile strength, yield strength and elongation percentage.
  • This testing is done for each grade and the machine used to do this is Universal Testing Machine.

CASE STUDY FOR BENCHMARKING TO BUY A PERFECT CAR FOR FAMILY

CASE

Mr. D.S. Pughazhyendhii lives in a crowded city and needs a big car for his family as well as daily commute to office. He needs car to travel to Madurai from Bangalore once in a month. He has a budget of 8 - 10 lakh on road.

OBJECTIVE

Benchmarking the vehicles in markets according to cutomer's needs.

STUDY

According to customer's need it would be best for him to go for compact SUV as it is a class of small sports utility vehicle bigger than the mini SUVs but smaller than mid sized SUVs. As compact SUVs are taller than the hatchbacks and the sedans, you sit at a higher height. This helps you get a better view of the road. This is advantageous especially in crowded areas, where negotiating through other road users gets a bit tricky. In comparison, it gets a bit tough to make your way through traffic in a typical low slung hatchback or sedan. A height advantage lets you have a better view of your surroundings. So the compact SUV would be a better option for the cutomer as he has to use it for dauly commute in a crowded city Bangalore.

BENCHMARKING OF VARIOUS COMPACT SUVs IN MARKET

Following are the compact SUVs selected for benchmarking as per famous brands in India:

1. Ford EcoSport 8/10

The Ford EcoSport is fresh from a makeover and is all the better for it. The talking point is the completely redone cabin that also gets the latest of features, while the revised suspension improves comfort too. As ever, the EcoSport remains good to drive with tidy handling and a peppy diesel engine. There are a lot of variants on offer but the tempting top version with class-leading safety kit like 6 airbags breaches the Rs 10 lakh mark.
For EcoSport diesel prices:
1.5l Diesel Ambiente MT Rs 8.42 lakh
1.5l Diesel Trend MT Rs 9.16 lakh
1.5l Diesel Trend+ MT Rs 9.56 lakh
1.5l Diesel Titanium MT Rs 9.99 lakh
1.5l Diesel Signature MT Rs 10.99 lakh
1.5l Diesel Titanium+ MT Rs 11.04 lakh
1.5l Diesel S MT Rs 11.89 lakh

2. Tata Nexon 8/10

The attractive Tata Nexon is definitely the value for money proposition in this segment. And, the keen pricing and eye-catching styling are not the only things that make this Tata tempting. Its diesel engine is capable, there’s a good balance between ride and handling and the cabin space is surprisingly roomy. There’s also plenty of kit on offer. Fit and finish though largely good, could be better, though.
Tata Nexon diesel prices:
Nexon XE diesel Rs 7.19 lakh
Nexon XM diesel Rs 7.84 lakh
Nexon XT diesel Rs 8.40 lakh
Nexon XZ diesel Rs 8.99 lakh
Nexon XZ+ diesel Rs 9.69 lakh

3. Maruti Suzuki Vitara Brezza 7/10

Maruti’s compact SUV is a sales champion and that’s because like other big-selling Marutis, the Vitara Brezza too gets the basics right - it’s efficient, reliable and fairly well priced. The Maruti Suzuki Vitara Brezza scores well on practicality too but the package is not perfect. The noisy 90hp 1.3-litre diesel motor feels outdated and, though punchy, lacks bottom-end grunt.
Vitara Brezza prices:
Vitara Brezza LDi Rs 7.521 lakh
Vitara Brezza VDi Rs 8.04 lakh
Vitara Brezza ZDi Rs 8.82 lakh
Vitara Brezza ZDi+ Rs 9.77 lakh

4. Renault Duster 85PS 7/10

The Renault Duster might be past its prime now but it still makes for a compelling SUV buy in the well-priced 85hp, diesel guise. The engine is very tractable and performance is actually more than acceptable. The Duster also feels tough and rugged and ride quality is very impressive. Where the Duster loses out is in the cabin, which doesn’t feel special enough and equipment levels are also down compared to similar-priced SUVs.

Renault Duster 85PS prices:
Standard Rs 8.95 lakh
RXE Rs 9.09 lakh
RXS Rs 9.95 lakh
RXZ Rs 10.89 lakh

5. Mahindra TUV300 6/10

Unlike the three monocoque-bodied SUVs above, the Mahindra TUV300 is built on a hardier ladder frame chassis, and correspondingly feels that little bit more rugged too. The cabin is quite spacious too though comfort isn’t the best; the rear-most jump seats take the seat count up to seven but are best left unused. A bouncy ride, mediocre performance and high price also mark the Mahindra SUV down.
TUV300 prices:
T4+ Rs 8.26 lakh
T6+ Rs 8.83 lakh
T8 Rs 9.54 lakh
T10 Rs 9.99 lakh

After comparisons of cars from various points of view I would recommend "TATA NEXON " for these reasons:

• It is the only and first car indigeniously built car in India with Five start rating from EURO NCAP.
• Tata nexon has a big beefy look which makes it to look like range rover. Its color and stylish look make it unique from others.
• Tata has introduced IRA connected car technology which can be connected through a sim in android and will give signal when car goes 3 meters away from its location.
• Nexon also has Xpress cooling function which cools down the temperature insdide car in just 8 minutes with certain conditions.
• Nexon provides AC vents both in front and rear for passengers with two speed adjustments. Although it is not very suitable for three adults at back but a child upto 15 years can come in middle comfortably.
• Nexon provides big Boot space of 350 litres and can accommodate large amount of things.
• It has provided maximum 31 utility spaces inside where travellers can keep their things easily.
• Nexon comes with good ground clearance of 209 mm which makes it to drive very easily on rough and bumpy surfaces.

I hope Mr. D.S. Pughazhyendhii will have a safe, happy rides and will enjoy the Nexon journey.