Power Cylinder components (Piston, Cylinder Bore, Piston Pin, Piston Rings) experience some of the most challenges operating conditions during the engine operations with transient temperatures reaching over 1000 Deg. C and pressures often reaching 200 bar, careful assessment of the power cylinder components can greatly improve the fuel efficiency, peak power, oil consumptions and emissions. 1000s of man hours of engineering analysis experience to verify the power cylinder component designs at Cummins using FEA, Multi-body Dynamic Analysis and Coupled Physics simulations provide a great edge to solve the future powertrain challenges.

(image source: www.jastor.org)

System level multi-body simulations can provide quick design improvement guidelines as well as system validation during the concept design and the design finalization stage. With the experience of 1000s of man hours of multi-body dynamic analysis on IC Engine Power Cylinders, Valve trains and crankshafts at Cummins using MBD tools like AVL, GT and CASE provides strong expertise to solve the system simulation challenges using Multi-Body Dynamic Analysis

Assessing the structural integrity of the large engineering structures pose various engineering, computational and project management challenges. Experience with global engineering companies like GE Transportation and Cummins provided a vital experience of devising the analysis approach that suits the scale of the model and accuracy requirements, handling computational complexity and ensuring the delivery within project scope, schedule and budget

(image source: http://paarsun.com/en/dbr/)

Many product change or modification projects require careful redesign of the packaging structure requiring various considerations like fitment, aesthetics, assembly, accessibility, heat and noise dissipation. Valuable experience of 3.0L Diesel Engine packaging at Tata Motors and Locomotive Power Electronics Component packaging at GE Transportation set the stage for more contribution in design of more complex engineering assemblies.

(image source: https://www.b-parts.com/en/store/products/83145/engine-tata-safari-42_fd-30-d-4x4-1998/)

Developing capable FEA team requires years of experience and careful nurturement from the experts. Capability development effort can be greatly reduced by expert FEA trainers. Years of work as a Corporate trainer at ANSYS provided a vital experience of training technical teams of multi-national engineering companies like Cummins, GE Healthcare, MAN Energy Solutions, Siemens, John Deere, Sulzer, Reliance, CEAT and L&T Valves.

Failure of components in the testing stage or to matter worse after customer delivery stage result in huge warranty costs, possible litigations and rework. Failure analysis requires careful study of operating conditions during failure and a comprehensive analysis of component from design to materials and quality to manufacturing or assembly processes. Stringent time lines are routine in failure analysis projects. Experience of failure analysis of accessory mounting bracket in Tata Motors, Eddy Current Brake Resistors at GE and Piston Pin, After Cooler, Piston Ring and Pistons in Cummins has developed the much required expertise to systematically handle the failure analysis projects.

(image source: https://www.ms-motorservice.com/en/technipedia/post/piston-pin-fractures/)