Client

Hindalco,
India

Industry

Automobile,
Electric Vehicles

Challenge

The client has developed a new Aluminum alloy and intends to manufacture extrudable motor housing for 2-wheeler EVs, replacing the existing die-cast housing design. The new Aluminum alloy offers better thermal properties allowing a thermally efficient motor housing for the user. A thermally efficient motor housing can help improve its efficiency, extend its life and prevent issues such as overheating, which can lead to thermal stress, insulation degradation, and reduced torque and power output.

 

Timetooth was given the challenging assignment of designing and developing motor housing conforming to or exceeding the structural and performance requirements of the baseline motor housing design.

Service Area

Turnkey New
Product
Development

Timeline

August 2021 to September 2022

Based on the simulation results, prototype manufacturing was carried out with controlled GD & T in conformance with the client’s rigorous quality standards.

Key Engineering Solutions

1. Modal Analysis was performed to determine the different mode shapes and their respective natural frequencies.

2. Linear static analysis was conducted for analyzing the structural strength and rigidity.

3. The effect of random vibration on structure was evaluated by PSD analysis. Thermal effect was analysed using CFD analysis.

Solutions

Timetooth commenced the project by developing design ideas modifying the baseline design. The client’s in-house acceptance criteria were studied, and various virtual validation tests were planned. Timetooth leveraged FE analysis to evaluate the designs. Modal Analysis was performed to determine the different mode shapes and their respective natural frequencies. Linear static analysis was conducted for analyzing the structural strength and rigidity. The effect of random vibration on structure was evaluated by PSD analysis. Subsequently thermal effect was analysed using CFD.

Based on the simulation results, prototype manufacturing was carried out with controlled GD & T in conformance with the client’s rigorous quality standards. Physical testing of the prototype was executed at the client site. The prototype cleared the structural acceptance criteria of the tests.

Key Highlights

ROI for the client

High-Performance Product was developed in a record time.

Excellent Correlation (90+) between virtual and physical results.