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This specification covers a corrosion-resistant steel in the form of investment castings homogenized and solution and precipitation heat treated to 180 ksi (1241 MPa) tensile strength.
AMS F Corrosion and Heat Resistant Alloys Committee
In automotive engineering, understanding driving behavior is crucial for decision on specifications of future system designs. This study introduces an innovative approach to modeling driving behavior using Graph Attention Networks (GATs). By leveraging spatial relationships encoded in H3 indices, a graph-based model constructed, which captures dependencies between various vehicle operational parameters and their operational regions using H3 indices. The model utilizes CAN signal features such as speed, fuel efficiency, engine temperature, and categorical identifiers of vehicle type and sub-type. Additionally, regional indices are incorporated to enrich the contextual information. The GAT model processes these heterogeneous features, learning to identify patterns indicative of driving behavior. This approach offers several significant advantages. Firstly, it enhances the accuracy of driving behavior modeling by effectively capturing the complex spatial and operational dependencies
Salunke, Omkar
In a conventional powertrain driven by Internal combustion (IC) engines, various sensors are used to monitor engine performance and emissions. Along with physical sensors, virtual sensors or modelled values of key parameters play an important role for enabling various diagnostics strategies and engine monitoring. Conventional strategies for modelling incorporate the use of regression models, map-based models and physics-based models which have few drawbacks in terms of accuracy and model calibrations efforts. Data driven models or neural networks have fairly better accuracy and reliability for estimating complex parameters. Representing the neural network with a mathematics-based model would help to eliminate drawbacks associated with conventional modelling approach. The proposed methodology uses artificial intelligence technique called artificial neural network (ANN) for estimation of temperature at turbine inlet (TTI) in typical diesel engine. The data driven model is built in Python
Jagtap, Virendra ShashikantShejwal, SanketMitra, Partha
Public transport electrification is going to play a massive role in India’s COP26 pledge to achieve net zero emissions by 2070. India plans to electrify 800,000 buses in a push towards 30% EV penetration by 2030. Further encouraged by government incentives under National Electric Bus Program (NEBP), e-Bus market is expected to grow at a CAGR of ~86% annually over the next 5 years. With most OEMs going for fleet electrification for reducing CO2 emissions and to cater to growing demand in Indian cities for cleaner public transport, improving powertrain efficiency and performance of state-of-the-art e-Buses is a natural progression of e-mobility sector development in India. The first step in designing powertrain for an electric city bus is to determine the motor(s) size and transmission specifications (number of gears, gear ratios etc.). Complications arise due to a wider and non-linear operation range of eBus. This study focuses on powertrain optimization for a medium duty electric city
Sandhu, RoubleChen, BichengEmran, AshrafXia, FeihongLin, XiaoBerry, Sushil
The application of AI/ML techniques to predict truck endgate bolt loosening represents a major innovation for the automotive industry, aligning with the principles of Industry 4.0. Traditional physical testing methods are both expensive and time-consuming, often identifying issues late in the development process and necessitating costly design changes and prototype builds. By harnessing AI/ML, manufacturers can now analyze endgate slam and bolt preload data to accurately forecast potential bolt loosening issues. This predictive capability not only enhances quality and safety standards but also significantly reduces the costs associated with tooling and builds. The AI/ML tool described in this paper can simulate a variety of load conditions and predict bolt loosening with over 90% accuracy, considering factors such as changes in loads, bolt diameters, washer sizes, and unexpected masses added to the endgate. It provides valuable design insights, such as recommending optimal bolt
Sivakrishna, MasaniDas, MahatSingh, AbhinavKarra, ManasaShienh, GurpreetLuebke, Amy
With the advent of digital displays in driver cabins in commercial vehicles, drivers are being offered many features that convey some useful or critical information to drivers or prompt the driver to act. Due to the availability of a vast number of features, drivers face decision fatigue in choosing the appropriate features. Many are unaware of all available functionalities displayed in the Human Machine Interface (HMI) System, leading to a bare minimum usage or complete neglect of helpful features. This not only affects driving efficiency but also increases cognitive load, especially in complex driving scenarios. To alleviate the fatigue faced by drivers and to reduce the induced lethargy to choose appropriate features, we propose an AI driven recommendation agent/system that helps the driver choose the features. Instead of manually choosing between multiple settings, the driver can simply activate the recommendation mode, allowing the system to optimize selections dynamically. The
K, SunilDhoot, Disha
Electric vehicles (EVs) are the cornerstone of sustainable transportation, but their performance and component longevity are heavily influenced by driving behaviors. This study proposes a comprehensive analytical framework to assess how different driving styles affect the operational health of key EV components such as the battery pack, motor, and DC-DC converter. Various driving styles such as aggressive, moderate, and economical are discriminated against using dynamic vehicle operation signatures including acceleration and braking intensity, turning profiles, and load variations. These behavioral patterns are reflected in the electrical responses, namely current and voltage waveforms across power electronic systems. By analyzing these electrical signatures, a range of KPIs can be estimated for each component, offering insights into their operational stress and degradation trends. Experimental analysis using real-time EV datasets validates the framework’s ability to predict and
Deole, KaushikKumar, PankajHivarkar, Umesh
The rapid development of science and technology has impacted on the human lifestyle. The automotive industry plays a crucial role as travel is an integral part of human lifestyle. This indeed has increased the need and demand for automotive domain to step ahead with technology and innovations. Especially, related to ADAS features and AI/ML based algorithms to provide comfort, safety, and many other factors for the consumers. The busy life of human beings has shown an increased rate of many health-related issues like stress, anxiety, heart attacks, blood pressure and so on. The existing system in vehicles detects health emergency and triggers SOS to the emergency service center. However, several catastrophic events occur due to delayed information, thus there is a need for a proactive solution that combines technology and human safety. In this work, we have investigated the different methods which detect the health issues of occupants in a vehicle by monitoring their stress level, heart
Eswarappa, AshaNagaraj, ChaitraMudassir, Syed
In area of modern manufacturing, ensuring product quality and minimizing defects are utmost important for maintaining competitive advantage and customer satisfaction. This paper presents an innovative approach to detect defect by leveraging Artificial Intelligence (AI) models trained using Computer-Aided Design (CAD) data. Traditional defect detection methods often rely on physical inspection, which can be time-consuming and prone to human error. The conventional method of developing an AI model requires a physical part data, By utilizing CAD data, the time to develop an AI model and implementing it to production line station can be saved drastically. This approach involves the use of AI algorithms trained on CAD models to detect and classify defects in real-time. The field trial results demonstrate the effectiveness of this approach in various industrial applications, highlighting its potential to revolutionize defect detection in manufacturing.
Kulkarni, Prasad RameshSahu, DilipJoshi, ChandrashekharKhatavkar, AkshayPoddar, ShivaniDeep, Amar
This work focuses on the prediction of Trimmed Body Noise Transfer Function (NTF) using Glazed BIW (body in white) structural model characteristics by leveraging Machine Learning (ML) technique. Inputs such as Glazed BIW (GBIW) attachment dynamic stiffness, Body Panel Vibration Transfer Functions (VTF) and Driver Ear level NTFs are employed to predict Trimmed Body NTF for a particular hard point. An iterative process of performing design modifications on the BIW to verify its effect on BIW performance and therefore on Trimmed body NTF is undertaken. BIW geometric parameters are varied in an organized manner to generate hundreds of data points at GBIW level which are provided as input to the train the ML model to predict the trimmed body level NTF. The outcome provides crucial insights of how the trimmed body NTF is closely related to the GBIW design characteristics. This ML approach of predicting trimmed body NTF based on GBIW characteristics provides critical insight about GBIW design
Kulkarni, Prasad RameshBijwe, VilasKulkarni, ShirishSahu, DilipInamdar, Pushpak
ISO/SAE 21434 emphasizes comprehensive cybersecurity risk management throughout the automotive lifecycle. However, specific guidance on validating cybersecurity measures at the production level remains limited. This paper addresses the gap in production-stage validation, particularly after End-of-Line (EOL) flashing, which includes configurations of security hardware and software protection (e.g., hardware register configuration, Debug and P-flash password settings etc.) Current automotive cybersecurity validation methods, despite adherence to ISO/SAE 21434, lack specific procedures for the production stage. The existing system-level validation using the ASPICE V-model (e.g., SWE.6, SYS.5) does not ensure the integrity and functionality of cybersecurity features in the final manufactured unit post-EOL flashing. This gap poses a risk of vulnerabilities being introduced during the EOL process, compromising critical security measures. To mitigate the cybersecurity risks in production
Chakraborty, SuchetaKulanthaisamy, NagarajanSankar, Ganesh
In agricultural tractors, braking actuation is usually done through control linkages consisting of a series of connected four-bar linkages with multiple pivots from the pedal to the brake pads. The quality of force transmission is critical as it directly affects the braking performance of the tractor. Forces measured at the end of the control linkage or brake pull rod often show deviation from theoretical values based on mechanical advantage calculations. This is due to various factors such as linkage transmission angle, elasticity, and friction losses in joints. A standardized simulation method needs to be developed and validated to predict the losses in the control linkage system. In this paper, the author proposes a simulation approach using multi-body dynamics, which includes contribution factors such as transmission angle, linkage elasticity, and friction in joints. MBS models for brake linkage systems for three different tractors were developed with flex bodies using ADAMS/View
Subbaiyan, Prasanna BalajiNizampatnam, BalaramakrishnaRedkar, DineshArun, GK, VinothR, SengottuPaulraj, Lemuel
The Mahindra XUV 3XO is a compact SUV, the first-generation of which was introduced in 2018. This paper explores some of the challenges entailed in developing the subsequent generation of this successful product, maintaining exterior design cues while at the same time improving its aerodynamic efficiency. A development approach is outlined that made use of both CFD simulation and Coastdown testing at MSPT (Mahindra SUV proving track). Drag coefficient improvement of 40 counts (1 count = 0.001 Cd) can be obtained for the best vehicle exterior configuration by paying particular attention to: AGS development to limit the drag due to cooling airflow into the engine compartment Front wheel deflector optimization Mid underbody cover development (beside the LH & RH side skirting) Wheel Rim optimization In this paper we have analyzed the impact of these design changes on the aerodynamic flow field, Pressure plots and consequently drag development over the vehicle length is highlighted. An
Vihan, Nikhil
A primary focus of an automotive architecture development is to efficiently distribute the mass, energy, and stiffness throughout the body structure. The car body structure is integrated with load carrying members, pillar structures, panels, and joints. These structural members play a significant role in meeting the body in white (BIW) performance within weight targets. The initial development stage of the vehicle architecture has a flexibility to change the sections and joints as compared to the later stages. An effective utilization of the primary stage of the design will minimize the efforts during the later stage of the performance improvements. One of the critical performance metrics of the BIW is noise vibration and harshness (NVH). For better NVH performance, the BIW must meet certain stiffness and mass requirement that is specific to the vehicle configuration and type. A good design strategy of the section parameters of structural members along with stiffer joints will assist
Senthilkumar, VibeeshRaghuvanshi, JayeshkumarLakshe, Shailesh
Addressing the challenge of optimal strain gauge placement on complex structural joints and pipes, this research introduces a novel methodology combining strategic gauge configurations with numerical optimization techniques. Traditional methods often struggle to accurately capture combined loading states and real-world complexities, leading to measurement errors and flawed structural assessments [9]. For intricate joints, a looping strain gauge configuration is proposed to comprehensively capture both bending and torsional effects, preventing the bypassing of applied loads. A calibration technique is used to create strain distribution matrices and access structural behavior under different loading conditions. Optimization algorithms are then applied to identify gauge placements that yield well-conditioned matrices, minimizing measurement errors and enhancing data reliability. This approach offers a cost-effective solution by reducing the number of gauges required for accurate stress
Shingate, UttamYadav, DnyaneshwarDeshpande, Onkar
Improving transaxle efficiency is vital for enhancing the overall performance and energy economy of electric vehicles. This study presents a systematic approach to minimizing power losses in a single-speed, two-stage reduction e-transaxle (standalone) by implementing a series of component-level design optimizations. The investigation begins with the replacement of conventional transmission oil with a next-generation low-viscosity transmission fluid. By adopting a lower-viscosity lubricant, the internal fluid resistance is reduced, leading to lower churning losses and improved efficiency across a wide range of operating conditions. Following this, attention is directed toward refining the gear macro-geometry to create a gear set with reduced power losses. This involves adjustments to parameters such as module, helix angle, pressure angle, and tooth count, along with the introduction of a positive profile shift. These modifications improve the contact pattern, lower sliding friction, and
Agrawal, DeveshBhardwaj, AbhishekBhandari, Kiran Kamlakar
The present work demonstrates a transient Fluid-Structure-Interaction (FSI) based numerical methodology for estimation of aerodynamic-induced flutter of the rear bumper of a Sports Utility Vehicle (SUV). Finite Volume Method (FVM) based High-fidelity transient full vehicle aerodynamic simulations were conducted for the estimation of the transient aerodynamic load. Subsequently, by mapping this transient aero load onto the surface of the rear bumper, Finite Element Method (FEM) based dynamic structural simulations were performed to predict its response. The results obtained through simulations were then compared against experimental wind tunnel test data of a prototype car with modified bumper for the specific test-case. The pressure and the time series data of rear bumper deflection were captured at multiple probe locations from wind tunnel experiments at 140 and 200 kmph. The distribution of pressure on the rear surfaces of the car was well captured by the aerodynamic simulation at
Choudhury, SatyajitYenugu, SrinivasaWalia, RajatZander, DanielGullapalli, AtchyutBalan, ArunAstik, Pritesh
In autonomous vehicles, it is vital for the vehicle to drive in a manner that ensures the driver is comfortable and has confidence in the system, which ensures he does not feel compelled to intervene or take control of the vehicle. The system must consider environmental factors and other aspects to provide the driver with a comfortable and stress-free drive. In this regard, the road friction coefficient, which quantifies the grip experienced by the tire on a road, is a critical parameter to be considered by several comfort and safety functions. An inaccurate estimation of road friction coefficient can lead to discomfort in worst case safety risks for the driver, as the system would be over or underestimating the tire’s grip on the road and this alters the vehicle’s response to control inputs. In the context of Advanced Driver Assistance Systems (ADAS), dynamically estimating the road friction coefficient can significantly improve the safety and comfort of driving functions. However
Rangarajan, RishiSukumar Rajammal, Prem KumarSingh, Akshay PratapKumaravel, Sujeeth SelvamKop, AnandBharadwaj, Pavan
Air suction in a naturally aspirated engine is a crucial influencing parameter to dictate the specific fuel consumption and emissions. For a multi-cylinder engine, a turbocharger can well address this issue. However, due to the lack of availability of continuous exhaust energy pulses, in a single or two-cylinder engine, the usage of turbocharger is not recommended. A supercharger solution comes handy in this regard for a single or two-cylinder engine. In this exercise, we explore the possibility of the usage of a positive displacement type supercharger, to enhance the air flow rate of a single cylinder, naturally aspirated, diesel engine for genset application, operating at 1500 rpm. The supercharger parametric 3D CAD model has been prepared in Creo, with three design parameters i.e. (a) Generating radius, (b) depth of blower and (c) clearance between lobes & lobe and casing. The optimum roots blower design is expected to fulfil the target boost pressure, power consumption and
Satre, Santosh DadasahebMukherjee, NaliniRajput, SurendraNene, Devendra
There is rapidly increasing advancement in Connectivity, Autonomous, Subscription and Electrification features in vehicles which are being developed. These trends have resulted in an increase in attack surface and security risks on vehicles. To handle these growing risks, it has become important to include passive security systems such as Intrusion detection systems (IDS) which can detect successful or possible attempts of intrusion into vehicle systems compromising their security. In vehicles based on Zonal Architecture, two types of IDS can be implemented, Network based IDS (NIDS) and Host Based IDS (HIDS). The NIDS is implemented in Gateway Electronic Control Unit (ECU) and can monitor multiple networks connected to Gateway, whereas the HIDS usually monitors one single host ECU. Extensive research material is available on NIDS for CAN Networks. For example, the CAN Network in a vehicle is monitored for various abnormal behaviours such as increased busload and invalid signal values
E L, Nanda KumarMutagi, MeghaSonnad, PreetiSharma, Dhiraj
Ambient light reflecting off internal components of the car, specifically the Head-Up Display (HUD), creates unwanted reflections on the Windshield. These reflections can obscure the driver's field of view, potentially compromising safety and reducing visual comfort. The extent of this obscuration is influenced by geometrical factors such as the angle of the HUD and the curvature of the Windshield, which need to be analyzed and managed. The primary motivation is to improve driver safety and visual comfort. This is driven by the need to address the negative impact of ambient light reflecting off Head-Up Displays (HUDs), which can impair visibility through the Windshield. There is a need for tools and methods to address this issue proactively during the vehicle design phase. This study employs a tool-based modeling method to trace the pathways of ambient light from its source, reflecting off the HUD, and onto the Windshield using a dimensional modeling tool. It focuses on: Geometrical
Muchchandi, VinodAkula, Satya JayanthMahindrakar, PramodG S, Sharath
Fleet owners often encounter significant logistical and financial problems when dealing with battery packs of different ages and conditions. The standard industry practice is to replace old batteries with identical new ones. This process is inefficient because it costs a lot, creates too much inventory, and eliminates battery packs that are still useful too soon. The problem worsens when manufacturers stop making older battery models, which can force a vehicle to retire early. This paper puts forward a framework for mixing different types of battery packs to deliver the performance needed for a vehicle’s mission. We show how this works in three everyday service situations: 1) Repair, when a single damaged pack needs replacing; 2) Life Extension, where aged packs are combined with newer ones to meet mission range; and 3) Performance Restoration, which uses next-gen packs when the original parts are obsolete. The study shows that a vehicle can complete its required missions by
Nair, Sandeep R.Ravichandran, Balu PrashanthHallberg, Linus
In today’s fast paced and competitive automotive market, meeting the customer’s expectation is the key to any OEM. This has led to development of downsized high performance engines with refinement as an important deliverable. However developing such high output engines do come with challenges of refinement, especially higher torsional vibrations leading to transmission noise issues. Hence, it becomes important to isolate the transmission system from these high torsional vibration input. To address this, one of the most common method is to adopt Dual Mass flywheel (DMF) as this component dampens torsional vibrations and isolates the transmission unit from the same. While Dual Mass Flywheel assemblies do great job in protecting the transmission units by not allowing the oscillations to pass through them, they do have their own natural resonance frequency band close to the engine idle (low) engine speeds, which must be avoided for a continuous operation otherwise it may lead to Dual Mass
Raiker, Rajanviswanatha, Hosur CJadhav, AashishJain, OjaseJadhav, Marisha
The Ministry of Road Transport and Highways (MoRTH), Government of India, has established BHARAT NCAP to provide a fair, meaningful, and objective assessment of the crash safety performance of cars. This program evaluates vehicles across three key areas, including Child Occupant Protection (COP). A critical component of the COP assessment involves dynamic testing using Q-series child dummies representing a 1½-year-old (Q1.5) and a 3-year-old child (Q3). As per the BHARAT NCAP protocol, these dummies are placed in the second-row outboard seating position within Child Restraint Systems (CRSs) and subjected to two primary dynamic impact tests: Offset Deformable Barrier (ODB) conducted at a speed of 64 km/hr. and Mobile Deformable Barrier (MDB) Side Impact tests conducted at 50 km/hr. The dynamic assessment of these child dummies is primarily focused on the head, neck, and chest regions to evaluate the effectiveness of the CRSs and overall vehicle safety system in protecting young
Khopekar, MariaLakshminarayana, ApoorvaMohan, PradeepKurkuri, Mahendra