Case Study: Tata Consultancy Services achieves 40% front-axle weight reduction with ANSYS

India-Based Auto OEM Reduces Front Axle Weight by 40% with ANSYS

Tata Consultancy Services (TCS) worked with International Auto, Ltd. to redesign the front axle of a commercial tractor. The challenge was to deliver a new axle that matched the existing design’s strength and reliability while achieving a substantial weight reduction; TCS relied on ANSYS finite element analysis software (ANSYS Mechanical) to drive the virtual testing and design evaluation.

ANSYS was used to run a geometric model through 13 certification load cases (drop, impact, torture, worst-load, etc.), allowing TCS to pinpoint high-stress areas and evaluate five proposed designs from Unigraphics CAD. Using ANSYS Mechanical the team selected a U-box with extender configuration that reduced axle weight by approximately 40%, kept displacements negligible, limited stress increases to about 15%, and cut manufacturing costs through less welding and smaller components—delivering measurable material and production savings.

Tata Consultancy Services

Dilip K. Mahanty

Group Leader of the Design & Analysis Center