K A LYA N I P O W E R T R A I N LT D.

Emerging as the fastest growing leader

in end-to-end solutions for clients
across the globe
 KALYANI POWERTRAIN LTD.

AN OVERVIEW

Technically strong
State-of-the-art Part of
Design & State-of-the-art
Proto Esteemed
Development Testing facility
Solution
Manufacturing Kalyani Group
unit
provider

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PA R T O F T H E R E N O W N E D K A LYA N I G R O U P

STEEL MAKING
Kalyani Steels Ltd.
Saarloha Advanced Materials Pvt. Ltd.

FORGING & RESEARCH &

MACHINING DEVELOPMENT

Bharat Forge Ltd. Kalyani Center for Technology &

Kalyani Technoforge Ltd. Innovation
CDP Bharat Forge GmbH Kalyani Center for Manufacturing &
Bharat Forge Daun GmbH Innovation
Bharat Forge Aluminiumtechnik AUTO COMPONENTS & Kalyani Powertrain Ltd.
RENEWABLE ENERGY
Bharat Forge Kilsta AB

INMET Technology Solutions

Kalyani Additives
Kalyani Maxion Wheels
Automotive Axles Ltd.

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OUR SOLUTIONS
FROM IDEA TO PRODUCTION
SYSTEM INTEGRATION

DEVELOPMENT
PROCESSES DESIGN CAE / FEA ANALYSIS

CUSTOMER
REQUIREMENTS &
CONCEPT

MANUFACTURING
READINESS &
PROCESSES PRODUCTION RAPID PROTOTYPE
SUPPORT MANUFACTURING

TESTING & VALIDATION

Our solutions include all above offerings as an end-to end solution or individual solutions as
required.
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D E S I G N C A PA B I L I T I E S
SOFTWARE CAPABILITIES

CAD Softwares Gear Design Software

DESIGN CALCULATIONS

Gear Sizing tool RLD to Durability cycles conversion tool Spline Calculations

Note :Images quality reduced to maintain confidentiality,

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C A E C A PA B I L I T I E S
CAPABILITIES OVERVIEW

Passenger Car Off road E-Truck Construction Equipment / Agri

IC Engine EV

• Truck chassis FEA analysis

• Weight optimization of differential housing
• Cross member FEA analysis
• DC-DC converter thermal analysis
• Shock tower nonlinear FEA analysis
• Gear box durability & NVH
• Rear spindle design
• Differential cage strength analysis
• Knuckle FEA analysis
• Differential cage fatigue calculation
• Steel to Al conversion – sub-frame
CAE RESOURCES OVERVIEW

HPC CLUSTER

ABAQUS STAR CCM+

CORES 36

HYPERMESH 2 INTEL XEONRO

NASTRAN PROCESSOR
E5-2696V3

256 GB RAM
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C A E C A PA B I L I T I E S

E-Axle design & development

E-Axle design & development

• Concept design
• FEA analysis
• 3D /2D drawing release
• Prototype manufacturing

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C A E C A PA B I L I T I E S

E-Axle design & development

CAE verification for following load cases:

• Vertical impact
• Braking
• Cornering
• Combined loading
• Fatigue life evaluation

Vertical impact deformation results Braking loading simulation results

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C A E C A PA B I L I T I E S

E-Axle design & development

Combined loading results:

Fatigue life evaluation

Highest stress location Software: FEMFAT

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C A E C A PA B I L I T I E S
BIW STATIC AND DYNAMIC STIFFNESS EVALUATION

• Static bending & torsion stiffness evaluation

• Modal analysis

• FRF analysis at attachment points to evaluate

dynamic stiffness

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C A E C A PA B I L I T I E S

Vehicle Body Engineering

Structural integrity:
Strength / stiffness (bending/torsion) of BIW
BIW durability
Door sag, permanent set evaluation
Denting performance evaluation of Door

NVH:
Dynamic stiffness evaluation at attachment points
Acoustic cavity simulation

Crash:
Typical activities
Full vehicle model build
Conversion of crash models to NVH

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C A E C A PA B I L I T I E S
SHOCK TOWER NON LINEAR FEA ANALYSIS

SHOCK TOWER DESIGN: ALUMINIUM CASTING

FEA ANALYSIS DETAILS: Material non-linear analysis

LOADING: Pothole Braking

Pothole cornering
Ultimate Vertical
Oblique Curb Strike
Jounce loading

TARGETS:
Stresses < UTS

VON MISES STRESS RESULTS

POTHOLE BRAKING SOLVER: ABAQUS JOUNCE LOADING

The design meets stress targets

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C A E C A PA B I L I T I E S
CROSS MEMBER FEA ANALYSIS

E-DRIVE CROSS MEMBER

CROSS MEMBER DESIGN: Aluminium casting

FEA ANALYSIS DETAILS: Material non-linear analysis

LOADING:
• 8KPH Front Bumper
• Max Forward Engine Torque and rebound
• Max Forward Engine Torque and Left Cornering
• Vertical and Lateral Right Loading

TARGETS:
Stresses < UTS

The design meets stress targets

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C A E C A PA B I L I T I E S
REAR SPINDLE DESIGN OF SUV
CAE LOAD CASES
DESIGN ENVELOPE CAE SIMULATION RESULTS
(24 LOAD CASES)

Deliverables:
• Optimized design which meets design targets
• Material spec & HT finalization
• Drawing release
• Design validation plan
• Testing
• Production drawing release

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C A E C A PA B I L I T I E S
TRUCK CHASSIS FEA ANALYSIS

E-Truck Chassis design optimization:

• Achieved weight reduction of 50 Kg
• Concept design
• Quick FEA analysis
• 3D /2D drawing release

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C A E C A PA B I L I T I E S
TRUCK CHASSIS FEA ANALYSIS

FEA ANALYSIS DETAILS:

Linear static analysis

Load cases:
• Longitudinal
• Lateral
• Vertical
Targets:
Stresses < UTS

VERTICAL LOADING RESULTS

CHASSIS BEV MOUNTING BRACKET COMPRESSOR MOUNTING BRACKET

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C A E C A PA B I L I T I E S
TRUCK CHASSIS FEA ANALYSIS – COMPRESSOR MOUNTING BRACKET

BASELINE DESIGN DESIGN ITERATIONS

OPTIMIZED DESIGN

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C A E C A PA B I L I T I E S
CAE EVALUATION OF KNUCKLE OF SUV

Knuckle design CAE simulation results

Deliverables:
• Optimized design of knuckle which meets stress
targets

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C A E C A PA B I L I T I E S
STEEL TO ALUMINUM CONVERSION – SUBFRAME OF SUV

STEEL (STAMPING) DESIGN DESIGN ITERATIONS (MATERIAL – AL)

ITERATION 1

ITERATION 2

OBJECTIVE: Improve modal performance of Al casting design to match closely with stamping
design

RESULT SUMMARY: Iteration 2 design met the requirements.

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C A E C A PA B I L I T I E S
TOPOLOGY OPTIMIZATION OF DIFFERENTIAL CAGE
DESIGN SPACE TOPOLOGY OPTIMIZATION RESULTS
DESIGN SPACE THE MATERIAL (IN BLUE)
(GREEN) CAN BE REDUCED

OPTIMIZED ASSEMBLY MODEL

THE OPTIMIZED MODEL MEETS STRESS TARGETS.

SOLVER: ABAQUS

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C A E C A PA B I L I T I E S

Laser welding simulation

Steel to Cast iron laser welding

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C A E C A PA B I L I T I E S
Laser welding simulation

CAE Simulation: Steel to Cast iron laser welding – Welding simulation in Simufact

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C A E C A PA B I L I T I E S
Laser welding simulation

Test set up: Pull out test Test set up: Torsion test

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Oil flow simulation

Objective: Optimization of passages of oil catcher tray to meet oil flow

requirement at bearings
oil catcher tray

Concept design

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Oil flow simulation

Start of simulation Results at 0.2 sec Results at 1 sec

Results at 2 sec Results at 4 sec Results at 5 sec

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C A E C A PA B I L I T I E S
GEARBOX HOUSING STRENGTH ANALYSIS

LOADS & BOUNDARY CONDITIONS:

MOUNT
CONSTRAINT
• Housings are fixed at both
mount locations & bearing
reaction forces are applied at
bearing locations.

SOLVER: ABAQUS

BOLT PRETENSION TORQUE LOAD

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C A E C A PA B I L I T I E S
GEARBOX HOUSING MODAL ANALYSIS

FREQUENCY MODE_01= 441 HZ FREQUENCY MODE_02= 475 HZ

SOLVER: ABAQUS

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C A E C A PA B I L I T I E S
DIFFERENTIAL CAGE STRENGTH ANALYSIS

LOAD CASES: Assembly loads, Ring gear loads

SOLVER: Abaqus (contact nonlinearity)

SOLVER: ABAQUS

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C A E C A PA B I L I T I E S
DC-DC CONVERTER THERMAL ANALYSIS

CONCEPT & PROTO

CAD CAE DEVELOPMENT
DESIGN TESTING

SOLVER: ANSYS/FLUENT
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T E S T I N G C A PA B I L I T I E S
TESTING & VALIDATION SOFTWARE CAPABILITIES

With NVH module

TESTING SETUPS
Output LH
motor/Dyno

Test piece

Input motor/Dyno Output RH

Motor LH Test piece
motor/Dyno Motor RH

Drive shafts

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T E S T I N G C A PA B I L I T I E S
TESTING & VALIDATION CAPABILITIES
Torque in Nm

Speed in rpm

Torque in Nm
Speed in rpm
Time in sec
Torque in Nm

Speed in rpm

Time in sec

LUBRICATION TEST
Time in sec

DURABILITY TEST SYNCHRO TEST

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 W i t h K A LYA N I P O W E R T R A I N
experience unmatched excellence

Thank you

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