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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
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
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
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
This paper presents a comprehensive numerical methodology for simulating the coupled process-structure behavior of short glass fiber-reinforced, injection-molded thermoplastics. The approach integrates elastoplastic and anisotropic material characteristics using three engineering tools: Moldflow, Digimat, and ABAQUS. It accounts for fiber orientation and injection molding defects, linking to thermo-mechanical performance. This method enables accurate virtual modeling of real-time injection-molded components by transferring anisotropic data from Moldflow to ABAQUS. In this study, short fiber orientation and potential injection molding defects such as weld lines and residual stresses are discussed using Moldflow simulation. Besides, Digimat is employed as an interface tool to facilitate the transfer of Moldflow simulation results, namely fiber orientation and material behavior in the allied configurations directly into ABAQUS. This integration enables the evaluation of thermo-mechanical
T, KalingaYanamadala, Dharma TejaMattupalli, VenkataChirravuri, BhaskaraMiller, Ronald
Unlike internal combustion engine (IC Engine) vehicles, the rapidly growing electric vehicle (EV) market demands tyres with superior yet often conflicting performance characteristics. The increased weight of EVs, due to their heavy batteries, necessitates robust tyres with reinforcement and higher inflation pressure. Conversely, increased wear due to higher initial torque and the need for lower rolling resistance to extend range, combined with the requirement for better grip for improved handling, call for advanced compound and tread pattern designs. EV tyres need to be stiffer, lighter, and low hysteresis, making it very hard to reduce low-frequency (20-200 Hz) interior noise that was previously masked by engine noise. This study investigates the low-frequency (20-200 Hz) structural-borne interior noise performance of EV tyres using both experimental and simulation tools. By wisely tuning the tyre's stiffness, mass, and damping properties, the necessary noise targets can be achieved
Subbian, JaiganeshM, Saravanan
Electric Vehicles (EV) are embedded with increased software algorithms coupled with several physical systems. It demands the efficacy of components which are linked together to build a system. The digital models reviewed in this paper are at system-level and full vehicle-level, comprising many components and control design, analysis, and optimization. Systems pertaining to each functionality such as, A/C (Air Conditioning) loop, E-Powertrain (Electric Powertrain), HEVC (Hybrid Electric Vehicle Controller), Cooling system, Battery Management System (BMS), Vehicle control system etc. together make an ‘Integrated Digital Vehicle.’ Fidelity of Intersystem co-simulation [AMESIM + SIMULINK] is key to validating thermal and energy strategies. This paper elucidates the correlation of Digital Vehicle compared to Test for Thermal Strategy in different driving scenarios and Energy management. Validation of Digital vehicle with 52kWh, 40kWh High Voltage Battery for Intercity Travel of Customer
Sarapalli Ramachandran, RaghuveeranSrinivasan, RangarajanSaravanan, VivekDutta, SouhamPichon, MartinLeclerc, CedricGuemene, Alexis-Scott
The rapid adoption of connected vehicle technologies and advanced driver assistance systems (ADAS) necessitates robust security mechanisms capable of identifying and mitigating sophisticated cyber threats in real-time. Traditional signature-based intrusion detection systems (IDS) are often inadequate in addressing the dynamic and evolving nature of automotive cybersecurity threats, particularly in modern vehicle networks like Controller Area Network (CAN), CAN with Flexible Data-Rate (CAN-FD), and Automotive Ethernet. This research introduces a novel Real-time Intrusion Detection System utilizing advanced Machine Learning (ML) techniques designed specifically for automotive network environments. The proposed IDS framework employs supervised and unsupervised ML algorithms, including anomaly detection, behavioral analytics, and predictive threat modeling, to achieve high accuracy and rapid threat identification capabilities. Through extensive testing in simulated and actual vehicle
Chaudhary lng, VikashDesai, ManojChatterjee, Avik
In the automotive industry, external aerodynamic evaluations in digital environments are commonly conducted using simplified, large box tunnels with vehicle being static. These approaches are computationally efficient and ensure faster turnaround time. To closely replicate physical wind tunnel testing or real-world conditions, these simulations are often augmented with moving ground and rolling tire configurations. While such setups provide valuable directional feedback for aerodynamic drag improvements, they frequently exhibit significant discrepancies when compared to physical wind tunnel test data. It is observed that key factors such as wind tunnel blockage effects, boundary layer suctions, when not properly accounted for, distort the local flow field dynamics and introduce errors in the simulations. With OEMs aiming to accelerate time-to-market for new vehicle launches, many aspire to minimize reliance on physical testing and maximize use of digital methods for design sign-off
Sharma, Sandeep KumarChalipat, SujitMaiyya, Sandeep
This study focuses on the effect of door seal compression prediction and its impact on structure borne NVH in trucks. Customer perception of vibrations are envisaged as quality criteria. It is necessary to determine the contribution of seal stiffness due to seal compression under closed condition of the door rather than considering stiffness of the door seal under uncompressed conditions. The dynamic stiffness of door seal is determined from analysis of non-linear type. The simulations are built using the Mooney - Rivlin model. The parameters influencing the compression of door seals in both two – dimension and three – dimension, are identified from the analysis. This involves contemplating the appropriate seal mounted boundary condition on the body and the door of the vehicle. The stiffness after compression of seal is extracted from this non-linear analysis which is further used to obtain the vibration modes for the doors in the truck cabin. As a part of next step, the compressed
L, KavyaRamanathan, Vijay
With growing significance of electric vehicles (EVs), their powertrains – while naturally quieter than internal combustion engine (ICE) powertrains – pose new NVH (Noise, Vibration, Harshness) challenges. These are triggered mainly from high-frequency disturbances caused by electric motors and gear interactions. Isolation of such excitations is essential for securing cabin refinement and customer expectations for acoustic comfort. This paper offers a simulation-based approach to optimal placement of the electric drive unit (EDU), which houses the electric motor and gearbox, with the objective of reducing vibration transfer to the chassis of the vehicle. The methodology explores the effect of spatial mount repositioning under actual dynamic load conditions through multibody dynamics (MBD) modeling and integrated optimizer using advanced multibody dynamics simulation software – Virtual Dynamics. The suggested workflow helps in effective investigation of mount positioning within packaging
Shah, SwapnilMane, PrashantBack, ArthurEmran, Ashraf
Born Electric SUVs is gaining immense popularity due to enhanced ride and handling characteristics, advanced tech features elevating both performance and customer experience to an elite standard. Due to the platform constraints, the vehicle adopts a Front Wheel Drive (FWD) layout with a rear twist beam configuration, housing the electric motor at the front to deliver drive torque directly to the front wheels. Torque steer is a phenomenon often found in FWD cars, which is unsettling to driver where the steering wheel could be pulled hard to one side when there is aggressive throttle input potentially leading to deviation of the vehicle from its desired path. In contrast to internal combustion engines (ICEs), electric motors provide an instantaneous torque, something that can worsen torque steer if not well addressed. However, torque steer remains a key concern, with high torque output of electric motors especially for a front wheel drive vehicle. This paper introduces a methodology to
Prabhakara Rao, VageeshWankhade, KrishnaThakur, PragyeshRasal, ShraddheshAsthana, Shivam
Nowadays, digital instrument clusters and modern infotainment systems are crucial parts of cars that improve the user experience and offer vital information. It is essential to guarantee the quality and dependability of these systems, particularly in light of safety regulations such as ISO 26262. Nevertheless, current testing approaches frequently depend on manual labor, which is laborious, prone to mistakes, and challenging to scale, particularly in agile development settings. This study presents a two-phase framework that uses machine learning (ML), computer vision (CV), and image processing techniques to automate the testing of infotainment and digital cluster systems. The NVIDIA Jetson Orin Nano Developer Kit and high-resolution cameras are used in Phase 1's open loop testing setup to record visual data from infotainment and instrument cluster displays. Without requiring input from the system being tested, this phase concentrates on both static and dynamic user interface analysis
Lad, Rakesh PramodMehrotra, SoumyaMishra, Arvind
Brake response time in truck air brake systems is crucial for ensuring safety and operational efficiency. This paper details the development of a simulation model aimed at fulfilling all regulatory requirements for brake response time, as well as serving as a tool for stopping distance calculations. The actual pneumatic circuit, including brake valves, relay valves, brake chambers, and plumbing have been replicated. The aim is to use 1D simulations to predict the response time compliance during the pressurizing phase (when brakes are applied) of the brake system. A mathematical model is developed using a commercially available 1D simulation tool. This model employs a lumped parameter approach for the pneumatic components, with governing equations derived from compressible flow theory and empirical valve flow characteristics. The simulation outcomes provide detailed response time and pressure build-up profiles. Validation against 201 vehicle test cases showed 96% of simulations within
Kumbar, PrafulMurugesan, KarthikShannon, Rick
The objective of this study was to examine the effect of Correlated Colour Temperature (CCT) of automotive LED headlamps on driver’s visibility and comfort during night driving. The experiment was conducted on different headlamps having different correlated colour temperatures ranging from 5000K to 6500K in laboratory. Further study was conducted involving participants of different age group and genders for understanding their perception to identify objects when observed in light of different LED headlamps with different CCTs. Studies have shown that both Correlated Colour Temperature and illumination level affect driver’s alertness and performance. Further study required on headlamps with automatically varying CCT to get better solution on driver’s visibility and safety.
Patil, Mahendra G.Kirve, JyotiParlikar, Padmakumar
The purpose of this report is to identify systematic approach of formation of India specific automotive database matrix. At first the paper reviews the practices used to prepare automotive dataset catalogue with established pattern to showcase automotive dataset from which appropriate data clusters can be picked up judiciously in order to train ADAS algorithms. The work applies this framework which helps to establish strategy to build a grid in which Indian automotive dataset can be contoured and selection of serviceable data bunches can be picked. This would make sure prompt selection of database aiming model training with valid input. This serves the purpose of implementation and evaluation of varied ADAS levels in India which insist upon good quality of distinguished dataset pertaining to Indian scenarios. The paper describes the approach with the example of AEB scenarios and present appropriate matrix readiness comprising of relevant data objects excluding unnecessary junk data
Behere, Sayali RajendraKarle, ManishKarle, Ujjwala
The need for energy is ever increasing, though the dependency on renewable energy have increased, it is not sufficient to cater the demand. India is one of fastest developing country which depends on coal 55% for its total energy need. To achieve coal digging & transportation an underground mining vehicle has gained high importance. Underground mine environment is inherently dangerous due to various factors, including explosive and toxic gases, dust, and the potential for collapses. Thereby vehicles running in coal mines requires extreme safety features to safeguard its operator & coal mine workers. In India the Directorate General of Mines Safety (DGMS) under Government of India circulates notification to Manager of Coal and Metalliferous Mines & OEM, concerned about the minimum safety evaluations to be taken care for the mining trucks. It has been observed that there are significant inconsistencies in design practices for mining vehicles, with the presence of multiple, unverified
Babar, SagarAkbar Badusha, A
An optimal engine lubrication system, encompassing engine oil and an oil cooler, is critical for thermal management and minimizing frictional losses. This system ensures adequate lubrication and cooling of engine components, thereby maintaining optimal performance. This study investigates the implications of oil cooler removal in a 45HP inline engine tractor. Various validation trials were conducted, including high ambient temperature tests under worst-case conditions, high coolant temperature scenarios, and a rigorous tractor killer test. In the latter, the tractor underwent 100 hours of operation on a PTO bench at maximum engine RPMs. Despite an observable increase in lubricant oil temperature during these tests, the tractor did not exhibit any component seizure or failure. The findings aim to determine whether the inclusion of an oil cooler is essential for the engine's operational reliability. This research offers valuable guidance for optimizing hardware selection and cost
Gupta, DeepakKumar, PankajSingh, ManjinderSingh, GagandeepKumar, MunishSingh, HarpreetSingh, Maninder
With the increasing connectivity of modern vehicles, cybersecurity threats have become a critical concern. Intrusion Detection Systems (IDS) play a vital role in securing in-vehicle networks and embedded vehicle computers from malicious attacks. This presentation shares about an IDS framework designed specifically for POSIX-based operating systems used in vehicle computers, leveraging system-level monitoring, anomaly detection, and signature-based methods to identify potential security breaches. The proposed IDS integrates lightweight behavioral analysis to ensure minimal computational overhead while effectively detecting unauthorized access, privilege escalation, communication interface monitoring etc. By employing a combination of rule-based and OS datapoints, the system enhances threat detection accuracy without compromising real-time performance. Practical series deployments demonstrate the effectiveness of this approach in mitigating cyber threats in automotive environments
Shukla, SiddharthChatterjee lng, Avik
The proliferation of connectivity features (V2X, OTA updates, diagnostics) in modern two-wheelers significantly expands the attack surface, demanding robust security measures. However, the anticipated arrival of quantum computers threatens to break widely deployed publickey cryptography (RSA, ECC), rendering current security protocols obsolete. This paper addresses the critical need for quantum-resistant security in the automotive domain, specifically focusing on the unique challenges of two-wheeler embedded systems. This work presents an original analytical and experimental evaluation of implementing selected Post-Quantum Cryptography (PQC) algorithms, primarily focusing on NIST PQC standardization candidates (e.g., lattice-based KEMs/signatures like Kyber/Dilithium), on microcontroller platforms representative of those used in two-wheeler Electronic Control Units (ECUs) - typically ARM Cortex-M series devices characterized by limited computational power, memory (RAM/ROM), and strict
Mishra, Abhigyan
Determination of part tolerances for reduced variation in suspension level performance by using Multi-objective Robust Design Optimization (MORDO) The car industry is very competitive, and companies need to satisfy their customers to keep or grow their market share. It’s important for car makers to build affordable cars that provide a good driving experience, comfort for passengers, and safety for everyone. Suspension systems are very important for how a vehicle rides, handles, and stays stable, and they directly affect how driving feels. If parts are not positioned correctly, it can really impact how well a vehicle works. As a result, suggested limits for where suspension parts are placed are given to prevent issues with Kinematics and Compliance (K&C) properties. So, designing parts with the right tolerances is very important in making vehicles. It helps lower production costs and keeps the vehicle's performance consistent. This paper shows a step-by-step method to find the strongest
Pathak, JugalGanesh, Lingadalu
After the implementation of BS-VI emission standards, effective exhaust after-treatment has become critical in minimizing harmful emissions from diesel engines. One significant challenge is the accumulation of hydrocarbons (HC) in the Diesel Oxidation Catalyst (DOC). Certain hydrocarbons may adsorb onto the catalyst surface yet remain unreactive, leading to potential operational inefficiencies. This phenomenon necessitates the desorption of unreactive hydrocarbons to allow space for more reactive species, thereby enhancing oxidation efficiency and overall catalyst performance. The process of desorption (DeSorb) is vital to maintaining the balance of reactive hydrocarbons within the DOC. When a vehicle is idling, unburnt fuel produces hydrocarbons that accumulate in the DOC. Upon acceleration, these hydrocarbons can lead to an uncontrolled rise in temperature, resulting in DOC push-out, catalyst damage, and downstream impacts on the Diesel Particulate Filter (DPF). To mitigate these
K, SabareeswaranK K, Uthira Ramya BalaRaju, ManikandanK J, RamkumarYS, Ananthkumar
Requirement for Construction Equipment Vehicles (CEVs) in India is continuously growing as India being fastest growing country in the world in terms of Infrastructure. The technology in the automotive industry is evolving rapidly in recent times. Thus, with the development of new technologies, the challenges are also ever-increasing from an Electromagnetic Interference, Susceptibility (EMI/EMC) and Safety perspective. Recently CEVs include various types of machines including Compactor, Wheel Loader, Crane, Paver, Truck Crane, Cement Mixer etc. EMC requirements of all these types are internationally governed by ISO 13766-1, 2. This paper provides insights about various considerations to be taken during EMC Tests of each type of machines. It also includes guidelines related to antenna positioning, reference point calculations, Narrow Band and Broad band considerations. It will also provide general EMC guidelines and precautions related to component selection and placement along with
Yeola, MayurShinde, Avinash
Meeting the stringent emissions norms of CEV stage V for medium BMEP engines, CI engines present significant challenges. These stringent norms call for a highly efficient DPF. With the increasing demands for high-performance DPFs, the issue of soot accumulation and cleaning presents significant hurdles for DPF longevity. This paper explores the potential of passive DPF regeneration, which leverages naturally occurring exhaust gas conditions to oxidize accumulated soot, offering a promising approach to minimize fuel penalty and system complexity compared to active regeneration methods. The study investigates engine calibration techniques aimed at enhancing passive regeneration performance, emphasizing the optimization of thermal management strategies to sustain DPF temperatures within the passive regeneration range. Furthermore, the paper aims to expand the applicability of passive regeneration across diverse engine loads common in off-highway applications with effective passive
Saxena, HarshitGandhi, NareshLokare, PrasadShinde, PrashantPatil, AjitRaut, Ashish