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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
This project introduced a brand-new tire size 245/90R16 for the first time globally in the 16-inch tube-type category, designed specifically for commercial vehicles with Vehicles 8.5T -12T gross vehicle weight (GVW). The main goal was to create a compact vehicle that can carry more payload, reduce overall weight, and improve fuel efficiency with use of rear single tyre instead of twin tyre in 8.5T. This helps customers lower their operating costs and improve vehicle performance, especially on narrow roads. The new tire supports high load capacities: up to 2300 kg for single tire use and 2180 kg for dual tire fitment. It enables a new type of vehicle to be developed an 8.5-ton GVW vehicle with rear single tires offering better payload capacity without increasing the size of the vehicle. By using this new tire, the kerb weight of the vehicle is reduced, which increases the payload and helps improve fuel economy. This helps lower the cost of the vehicle by optimizing surrounding
Pawar, Dhondiram DnyandeoShaikh, MatinAmbekar, Prasad
This paper presents a comprehensive survey and data collection study on the adaptability of Camera Monitoring Systems (CMS) for passenger vehicles. With the growing demand for enhanced safety, automation, and driver assistance technologies, Camera Monitoring Systems (CMS) has emerged as a key component in modern automotive design. This study aims to explore the current state of camera-based monitoring in passenger vehicles, focusing on their adaptability through survey data collection of various driving population and analysis. This paper evaluates the acceptance of CMS configurations in replacement to conventional rear-view mirrors through Position of Monitor, Clarity, CMS Adaptiveness to eyes, Comfort while turning, Merging into moving traffic, Monitoring Rear Traffic, while Getting Out of Car, while Overtaking, Coverage Area and Overall Acceptance. The findings offer valuable insights for manufacturers, engineers, and researchers working toward the evolution of intelligent vehicle
Sinha, AnkitTambolkar, Sonali AmeyaBelavadi Venkataramaiah, ShamsundaraKauffmann, Maximilian
Automobile emissions refer to the gases and particles released into the atmosphere by vehicles during their operation. These emissions contribute to environmental pollution and have an impact on human physiology and environment. This paper assimilates findings from a comprehensive research study examining tyre wear and its Indian perspective. Tyre wear understood as a factor affecting road safety, environmental health, and economic sustainability. The study identifies factors affecting tyre wear and provides overview regarding tyre wear generation in India, encompassing road infrastructure, vehicle characteristics, driving patterns, and environmental factors. Moreover, it examines the adverse effects of these particles on human health, such as respiratory ailments and cardiovascular diseases, as well as their impact on ecosystems. This paper delves measures to measure tyre wear and safeguard both environmental and public health. It also covers the tyre wear measurement methodologies to
Joshi, AmolKhairatkar, VyankateshBelavadi Venkataramaiah, Shamsundara
The adoption of flex-fuel vehicles (FFVs) in India presents a significant opportunity to reduce dependence on fossil fuels, lower greenhouse gas emissions, and ensure compliance with the country’s evolving emission norms. This paper explores the key aspects of flex-fuel technology in the context of Indian four-wheeler regulations, particularly Bharat Stage VI and potential future emission norms. The study begins with an overview of flex-fuel technology, detailing its advantages and associated challenges. A critical focus is placed on blend identification techniques, which play a vital role in optimizing combustion efficiency and ensuring seamless transitions between different ethanol-gasoline blends. Furthermore, the impact of ethanol blending on various fuel properties is examined, including changes in energy content, latent heat of vaporization, octane number rating, and stoichiometric air-fuel ratio. These factors significantly influence engine performance and emission
Balasubramanian, KarthickKR, PrabhakarKallahallii Somu, Santhosh Kumar
Customers in off-highway industry are increasingly seeking high-performance capabilities for their tractors due to increasing penetration of mechanisation and labour scarcity. One effective solution to achieve enhanced performance is turbocharging of engines, while meeting emission and highly dynamic transient response of tractor field applications. The process of selecting and validating a suitable turbocharger for tractor field application suitability is significantly time and resources consuming activity due to extensive testbed and field trials. This study focuses on the selection of turbocharger for tractor engines through analytical calculations to freeze key parameters like lambda, boost pressure ratio & temperature within boundaries of exhaust temperature and turbo efficiency maps to deliver best field transient performance and fuel consumption. The selected parameters are further validated under real-world transient operating conditions, involving tractors and their implements
Kumar, Harish KumarRawat, SaurabhDogra, DaljitSinghSingh, SachleenSingh, Amarinder
As vehicles are becoming more complex, maintaining the effectiveness of safety critical systems like adaptive cruise control, lane keep assist, electronic breaking and airbag deployment extends far beyond the initial design and manufacturing. In the automotive industry these safety systems must perform reliably over the years under varying environmental conditions. This paper examines the critical role of periodic maintenance in sustaining the long-term safety and functional integrity of these systems throughout the lifecycle. As per the latest data from the Ministry of Road Transport and Highways (MoRTH), in 2022, India reported a total of 4.61 lakh road accidents, resulting in 1.68 lakh fatalities and 4.43 lakh injuries. The number of fatalities could have been reduced by the intervention of periodic services and monitoring the health of safety critical systems. While periodic maintenance has contributed to long term safety of the vehicles, there are a lot of vehicles on the road
HN, Sufiyan AhmedKhan, FurqanSrinivas, Dheeraj
As urban population continues to grow, the safety of Vulnerable Road Users (VRUs) particularly in the presence of Heavy Good Vehicles (HGVs) has emerged as a critical concern. Research indicates that VRUs are at a 50% higher risk of fatal injury in collisions involving HGVs compared to passenger cars. To address this issue, this study proposes a novel pedestrian protection system that integrates LiDAR (Light Detection and Ranging) technology with a reusable airbag system to mitigate the severity of collisions. The proposed solution adopts a twofold approach for enhancing VRU protection in scenarios involving HGVs. In both approaches, LiDAR sensors are used to generate a real-time 3D model of the vehicle’s surroundings, enabling accurate VRU detection and predictive collision analysis. Scenario 1: When vehicle speed exceeds the first threshold and a collision is unavoidable, the onboard ECU activates front lid actuators, extending the vehicle's front lid which can be retracted back to
Patil, UdaySriharsha, ViswanathPillai, Rajiv
Severe rear-impact collisions can cause significant intrusion into the occupant compartment when the structural integrity of the rear survival space is insufficient. Intrusion patterns are influenced by impact configuration—underride, in-line, or override—with underride collisions channeling forces below the beltline through the rear wheels as a primary load path. This force concentration rapidly propels the rear seat-pan forward, contacting the rearward-rotating front seatback. The resulting bottoming-out phenomenon produces a forward impulse that amplifies loading on the front occupant’s upper torso, increasing the risk of thoracic injury even when the head is properly supported by the head restraint. This study analyzes a real-world rear-impact collision that resulted in fatal thoracic injuries to the driver, attributed to the interaction between the driver’s seatback and the forward-moving rear seat pan. A vehicle-to-vehicle crash test was conducted to replicate similar intrusion
Thorbole, Chandrashekhar
Virtual Reality technology is emerging as a transformative solution in the manufacturing industry. It offers significant advantages over traditional tools like Tecnomatix Process Simulate in assembly & ergonomic simulations. Analysis using PS is time-consuming and lacks real-time human interaction as it relies on detailed modelling and sequential workflows, which will delay the identification of assembly no-build conditions and ergonomic issues. This paper evaluates the time and the cost-saving potential of VR in assembly processes and explores its role in minimizing the need for physical prototypes across various stages of vehicle development. VR provides interactive environments, enabling interaction with 3D models and real-time collaboration with various teams across the globe. This leads to faster identification of assembly process flaws, quicker iteration cycles, and a reduced need for physical prototypes in the station development process for the lines. VR allows individuals to
Nagendran, Rakesh Kumar
Twist beam suspensions are widely utilised in passenger vehicles because of their simplicity and cost-efficiency, yet they provide engineers with a complex challenge as their performance depends entirely upon the structural properties of the beam itself. Traditional methodologies rely on the generation of Modal Neutral Files (MNF) based upon vehicle dynamics requirements and packaging constraints, which is a highly time-consuming process that starts failing to fulfil the demands of a market where development times are being exponentially reduced. Besides this, part of flexible body’s real behaviour might be lost in the process of converting multibody models into parametric ones, which, in turn, presents difficulties in modifying compliant-related items. Thanks to a novel approach followed jointly by Applus+ IDIADA & Mahindra, quick identification and optimisation of key tuneable items is achieved by employing a hybrid solution that combines full flexible and FE elements in Hexagon
Osorio, Alejandro GarcíaPrabhakara Rao, VageeshAsthana, ShivamRasal, Shraddhesh
With increased deterioration of road conditions worldwide, automotive OEMs face significant challenges in ensuring the durability of structural components. The tyre being the primary point of contact with the road is expected to endure harshest of impacts while maintaining the other performance functions such as Ride & Handling, Rolling resistance, Braking. Thus, it is considered as the most challenging component in terms of design optimization for durability. The current development method relies on physical testing of initial samples, followed by iterative construction changes to meet durability requirements, often giving trade-off in Ride & Handling performance. To overcome these challenges, a frugal simulation-based methodology has been developed for predicting tyre curb impact durability before vehicle-level testing so that corrective action can be taken during the design stage.
Sundaramoorthy, RagasruobanLenka, Visweswara
In recent days, cabin variants in the tractor are preferred by the farmers for the Coziness and longer field hour operation with less fatigue. Noise perceived by customer is the most important factor taken into account during the design stage, as it’s directly linked with operator’s comfort. Observed noise levels has to be within the defined limits as per national/international standards Overall cabin noise levels is contributed by the structure borne noise below 630 Hz. Structure borne noise is the noise typically radiated by the door, roof, windshield, floor, fender and structure assembly due to the engine excitation through the transmission housings and backstories. This paper depicts the process of tractor cabin structure borne noise prediction in the virtual environment. Firstly, Engine bearing loads and axle bearings has been extracted in the virtual stage from the vehicle level driveline model using commercially available MBD software. The finite element (FE) model of the cabin
Qunasekaran, PandiyanayagamK, SomasundaramChavan, Amit
Today due to time to market requirements, Original Equipment Manufacturers (OEM) prefers platform modularity for Product Development in Automotive Domain. Money and time being main constraint we need to focus on single platform which can give flavors of different category just by changing Ride height and Tyre and some extra tunable. Taking this as challenge still tyre development for new variant demands lot of time and iterations which can lead to delays in time to market. This study provides a virtual development process using driver in loop Simulator and Multi body dynamics simulation which are real time capable and integrating physical tire models. The proposed alteration introduces ride height changes, weight distribution changes, and center of gravity changes from existing vehicle design. The proposed new vehicle variant also introduces tire change from highway terrain type to all-terrain type as it was intended to deliver some off-roading capabilities, thereby vehicle dynamics
Shrivastava, ApoorvAsthana, Shivam
The handling of a vehicle is crucial to the perception of its dynamic characteristics, such as comfort, stability, composure, sportiness, and precision. Kinematics and Elasto-kinematics, also known as Kinematics and Compliance (K&C), form the basis of an automobile's handling characteristics. Kinematics focuses on the movement of suspension components, including wheels, axles, and linkages, and how these movements relate to the vehicle's body motion. Compliance refers to the suspension's ability to deform under load, primarily due to the flexibility of springs, bushings, and other elastic components. Elastomer bushings, as flexible elements in the kinematic chain, significantly impact K&C and require a detailed study. Suspension bush stiffness is typically measured through static and dynamic tests, in various directions – radial, axial, torsional, etc. Tests involve applying a force or torque and measuring the resulting deflection and/or rotation. These measurements are used to
Avhad, Anish
In the rapidly evolving and highly competitive automotive industry, manufacturers are under immense pressure to bring products to market quickly while meeting customer expectations. As a result, optimizing the product development timeline has become essential. Structural integrity analysis for chassis and suspension systems lies in the accurate acquisition of operational load spectra, conventionally executed through Road Load Data Acquisition (RLDA) on instrumented vehicles subjected to proving ground excitation. At this point, RLDA is mainly used for final validation and fine-tuning. If any performance shortfalls, such as premature component failure or durability issues, are discovered, they often trigger design revisions, prototype rework, and additional testing. This study proposes a Virtual Road Load Data Acquisition (vRLDA) methodology employing a high-fidelity full-vehicle multibody dynamic (MBD) representation developed in Adams Car. The system is parameterized and uses high
Goli, Naga Aswani KumarPrasad, Tej Pratap
Final design choices are frequently made early in the product development cycle in the fiercely competitive automotive sector. However, because of manufacturing tolerances design tolerances stiffness element fitment and other noise factors physical prototypes might show variations from nominal specifications. Significant performance differences (correlation gaps) between the digital twin representation produced during the design phase and real-world performance may result from these deviations. Measuring every system parameter repeatedly to take these variations into account can be expensive and impractical. The goal of this study is to identify important system parameters from system characteristic data produced by controlled dynamic testing to close the gap between digital and physical models. Dynamic load cases are carried out with a 4-poster test rig where vehicle responses are captured under controlled circumstances at different suspension locations. An ideal set of digital model
Verma, Rahul RanjanGoli, Naga Aswani KumarPrasad, Tej Pratap
With the inevitable shift of automotive industry towards E-mobility and mandatory fuel efficiency targets, there is a need to evaluate the energy losses in the vehicle & identify potential areas of improvement. Energy losses are calculated for different components in the corner module system of a passenger car. Contribution of losses (resistances) from respective component are depicted using simple analytical models. Potential energy saving improvements were identified and analyzed basis emerging technologies in respective areas.
Raghatate, Kumar ShreyasVedartham, RaghavendraKhanger, RakeshBisht, Arun
Vehicle dynamics is a vital area of automotive engineering that focuses on analyzing how a vehicle responds to driver inputs and external factors like road conditions and environmental influences. Achieving optimal performance, safety, and ride comfort requires a detailed understanding of longitudinal, lateral, and vertical dynamic behavior. The objective of this paper is to develop and validate the model of a concept Race car and evaluate its vehicle dynamics behavior using IPG CarMaker, a high-fidelity virtual testing environment widely used in industry. The model incorporates a range of vehicle parameters, including suspension parameters like spring and damper characteristics, mass distribution, tire properties and powertrain parameters. The performance evaluation is done as per standard guidelines, including Constant Radius turn test, Sine Steer test and other standard tests like Acceleration, Braking along with Ride and Comfort classification. The key parameters that are
Agrewale, Mohammad Rafiq B.Vaish, Ujjwal
The present disclosure is about combating Thermal runaway in Electric, Plug-in Hybrids and mild hybrid vehicles. This paper comprises of high-Voltage Battery pack containing Battery cells electrically coupled with Shape Memory Alloy along with Busbars. These connectors (Shape Memory Alloy) are programmed to operate in two states: First to electrically connect the cells with the busbars, second to disconnect the individual cells from electric connection beyond the threshold temperature. This mechanism enables the Battery cells to rapidly prevent the Battery from the Thermal runaway event which is caused from the cell level ensuring the Battery safety mechanically. Additionally, the Battery pack includes the cell monitoring system and Battery Monitoring System to enhance the above invention with regards to the safety of the vehicle. This configuration is implementable and retrofittable into existing battery systems, offering a robust solution to the challenges posed by prolonged vehicle
Reginald, RiniRout, SaswatVENKATESH, MuthukrishnanChauhan, Ashish JitendraSelvaraj, Elayanila
Electric motor benchmarking is often constrained by limited availability of motor-specific data, particularly when dealing with commercially available or third-party electric motors. This paper presents a streamlined and scalable methodology for characterizing unknown E-Motors using a configurable universal inverter platform. The proposed approach is specifically designed for OEMs and Tier 1 suppliers seeking to evaluate performance metrics such as torque accuracy, peak and continuous capability, efficiency, and control behavior—without prior access to key motor parameters or simulation data. A central challenge in this context is the stepwise electromagnetic characterization required to determine the phase current needed for accurate speed and torque control, especially under a Maximum Torque per Ampere (MTPA) or Maximum Torque per Watt (MTPW) strategy. As this requirement is highly dependent on the motor’s topology and electromagnetic properties, most conventional approaches rely on
Kanya, BenjaminDuchi, FrancescoRavi, Abhishek
Occupant Safety systems are usually developed using anthropomorphic test devices (ATDs), such as the Hybrid III, THOR-50M, ES-2, and WorldSID. However, in compliance with NCAP and regulatory guidelines, these ATDs are designed for specific crash scenarios, typically frontal and side impacts involving upright occupants. As vehicles evolve (e.g., autonomous layouts, diverse occupant populations), ATDs are proving increasingly inadequate for capturing real-world injury mechanisms. This has led to the adoption of computational Human Body Models (HBMs), such as the Global Human Body Models Consortium (GHBMC) and Total Human Model for Safety (THUMS), which offer superior anatomical fidelity, variable anthropometry, active muscle behaviour modelling, and improved postural flexibility. HBMs can predict internal injuries that ATDs cannot, making them valuable tools for future vehicle safety development. This study uses a sled CAE simulation environment to analyze the kinematics of the HBMs
Raj, PavanRao, GuruprakashPendurthi, Chaitanya SagarNehe, VaibhavChavan, Avinash
The objective of the present study is to examine trends in occupant kinematics and injuries during side impact tests carried out on vehicle models over the period of time. Head, shoulder, torso, spine, and pelvis kinematic responses are analysed for driver dummy in high speed side impacts for vehicle model years, MY2016-2024. Side impact test data from the tests conducted at The Automotive Research Association of India (ARAI) is examined for MY2016-2024. The test procedure is as specified in AIS099 or UNECE R95, wherein a 950kg moving deformable barrier (MDB) impacts the side of stationary vehicle at 50km/hr. An Instrumented 50th percentile male EUROSID-2 Anthropomorphic Test Device is positioned in the driver seat on the impacting side. Occupant kinematic data, including head accelerations, Head Injury Criterion (HIC15), Torso deflections at thorax and abdominal ribs, spine accelerations at T12 vertebra, and pelvis accelerations are evaluated and compared. The “peak” and “time to
Mishra, SatishBorse, TanmayKulkarni, DileepMahajan, Rahul
This study focuses on enhancing energy efficiency in electric vehicle (EV) thermal management systems through the development and optimization of control logic. A full vehicle thermal management system (VTMS) was modeled using GT-Suite software, incorporating subsystems such as the high voltage battery (HVB), Electric powertrain (EPT), and an 8-zone cabin. Thermal models were validated with experimental data to ensure accurate representation of key dynamics, including coolant to cell heat transfer, cell-to-ambient heat dissipation, and internal heat generation. Control strategies were devised for Active Grille Shutter (AGS) and radiator fan operations, targeting both cabin cooling and EPT thermal regulation. Energy consumption was optimized by balancing aerodynamic drag, fan power, and compressor power across various driving conditions. A novel series cooling logic was also developed to improve HVB thermal management during mild ambient conditions. Simulation results demonstrate
Chothave, AbhijeetKumar, DipeshGummadi, GopakishoreKhan, ParvejThiyagarajan, RajeshPandey, RishabhS, AnanthAnugu, AnilMulamalla, SarveshwarGangwar, Adarsh