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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
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
This study presents an integrated vehicle dynamics framework combining a 12-degree-of-freedom full vehicle model with advanced control strategies to enhance both ride comfort and handling stability. Unlike simplified models, it incorporates linear and nonlinear tire characteristics to simulate real-world dynamic behavior with higher accuracy. An active roll control system using rear suspension actuators is developed to mitigate excessive body roll and yaw instability during cornering and maneuvers. A co-simulation environment is established by coupling MATLAB/Simulink-based control algorithms with high-fidelity multibody dynamics modeled in ADAMS Car, enabling precise, real-time interaction between control logic and vehicle response. The model is calibrated and validated against data from an instrumented test vehicle, ensuring practical relevance. Simulation results show significant reductions in roll angle, yaw rate deviation, and lateral acceleration, highlighting the effectiveness
Duraikannu, DineshDumpala, Gangi Reddi
This study presents a comprehensive 1D simulation approach of an automotive solenoid-based diesel fuel injector and a common rail injection system for a marine engine using Simcenter AMESim. The injector model was developed to analyse the injection rate and total injected fuel at various solenoid actuation durations (1.2 ms and 2.0 ms) and common rail pressures. The experimental results from a well-established research study are used for validating the simulation results of the solenoid-based injector. Overall error in total fuel injected ranges from -6.14 percent to 1.93 percent, while timing errors for the start of injection vary from 1.7° crank angle (CA) to 0.08° CA and the end of injection from 2.8° CA to 0.20° CA at 1200 rpm demonstrating strong agreement at higher rail pressures (above 1000 bar) and solenoid actuation times. Building on this validated injector model, a detailed marine common rail system was developed incorporating key hydraulic components: a check valve to
Bhoware, YashPise, UdaySaha, DiptaGaikwad, Nilesh
The clutch is a mechanical device that connects and disconnects engine power to the drivetrain through the clutch disc and cover assemblies. The disc, with friction material linings is mounted on the transmission shaft, transmits power when clamped between the flywheel and cover assembly. During operation, wear occurs due to speed differences and slippage between the engine and transmission. Clutch performance is evaluated under repeat restart conditions on steep gradients to assess thermal durability and reliability in commercial vehicles. The repeat restart test on a 12% gradient replicates truck launches under full load, where excessive slippage generates heat that may lead to friction material wear or failure if critical temperature limits are exceeded. To address the high cost and time of physical testing, a 1D thermal simulation was developed using GT Suite. The model replicates 90 repeat vehicle launches on a 12% gradient in first gear, integrating driver inputs and drive cycles
Munisamy, SathishkumarChollangi, DamodarMane, Sudhir
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 the evolving landscape of the automotive industry, this study presents an innovative approach to developing digital twins for driver profiles, establishing a standardized and scalable procedure for collecting and analyzing driving data on a global scale. The proposed methodology centers on the development of a robust cloud infrastructure, including Data Lake and associated services, designed for efficient storage and processing of large volumes of data from multiple markets and vehicle types. The research introduces an adaptable procedure for data collection campaigns, applicable to diverse global markets and encompassing a wide range of vehicles, from internal combustion engines to electric and hybrid models. A key feature of this approach is the establishment of advanced data decoding protocols, enabling precise interpretation of CAN network information from vehicles of different manufacturers and models, even when the CAN structure is not previously known. The study defines
Arturo, RubioMarín Saltó, AnnaDiaz, FranciscoOlivencia, Sergio
Passenger cars are subjected to extensive conditions ranging from driving through wet roads, water puddles, icy roads, and rain. This can affect the performance of different parts over time, one such aspect is the vehicle corrosion, whose impact is felt on a wide spectrum from aesthetics to safety due to loss of material. The general condition for corrosion mainly requires electrolyte to be present on the metal surface, which is transported through self-soiling and foreign soiling. Vehicle soiling is an important aspect for vehicle design. Amongst the many aspects of vehicle soiling, one important aspect is the prediction of water accumulation that enables prediction of corrosion sensitive regions in the vehicle. Power train components like Engine, transmission and corresponding wiring harness are at highest risk of water-wetting, As the vehicle drives through the water puddle the components are not just wet by the direct inflow of water but also by water being splashed by moving
Shukrey, SarthakPattankar, RohanYenugu, Srinivasa
High power and torque density electric motor is finding increasing demands in modern-day electric and hybrid vehicles because of compact and light-weight designs. These high-performance requirements are achieved by increasing the current flow, strengthening the magnetic field as well as downsizing the motor dimensions and hence can lead to multiple failure modes if not designed properly. Higher current flow results in increased magnitude of losses within the motor components such as ohmic loss, iron loss, hysteresis loss and mechanical losses. All these localized losses contribute to higher operating temperature and temperature gradient that can act as a catalyst to several modes of failure. Hence, accurate prediction of temperature distribution across the motor components is very crucial to come up with a robust and durable motor design. A common approach of predicting component temperature is by assuming bulk losses for lamination stack, hairpin and magnets. This approach might be
Munshi, Irshad AhmedElango, GokulKarmakar, NilankanPrasad, Praveen
Automotive headlamps in Battery Electric Vehicles (BEVs) are exposed to a wide range of environmental and operational conditions that influence their thermal behaviour. Factors such as solar radiation, ambient temperature, lighting features, and nearby heat sources can significantly impact headlamp temperatures, potentially leading to issues like condensation, material degradation, and reduced optical performance. Accurate thermal modelling using Computational Fluid Dynamics (CFD) is essential during the design phase, but its effectiveness depends heavily on the fidelity of boundary conditions, which are often based on internal combustion engine (ICE) vehicle data. This study investigates the thermal behaviour of BEV headlamps under real-world conditions, focusing on parking and charging scenarios. Temperature measurements were taken at various locations on the lens and housing of a Jaguar I-Pace using thermocouples. The results show that lighting features, particularly the high beam
Nangunuri, Vishnu TejaKapadia, VatsalKovacs, GaborAhmad, Waqas
Today, passenger car makers around the world are striving to meet the increasing demand for fuel economy, high performance, and silent engines. Corporate Average Fuel Economy (CAFE) regulations implemented in India to improve the fuel efficiency of a manufacturer's fleet of vehicles. CAFE goal is to reduce fuel consumption and, by extension, the emissions that contribute to climate change. CNG (Compressed Natural Gas) engines offer several advantages that help manufacturers meet and exceed these standards. The demand for CNG vehicles has surged exponentially in recent years, CNG engine better Fuel efficiency and advantage in CAFÉ norms make good case for OEM & Customer to use more CNG vehicle. CNG is dry fuel compared to gasoline. These dry fuels lack lubricating properties, unlike conventional fuels like petrol, diesel and biofuels, which are wet and liquid. Consequently, the operations and failures associated with these fuels differ. The materials and designs of engine parts, such as
Poonia, SanjayKumar, ChandanSharma, ShailenderKhan, PrasenjitBhat, AnoopP, PrasathNeb, Ashish
Refined NVH performance of a vehicle is a mark of premium quality. Achieving the desired NVH performance in different vehicle operating conditions is always a Herculean task and early stage “CAE design recommendations” play crucial role in overall vehicle design development. This becomes tougher when the program is very much cost, weight and timeline sensitive. This paper explores simulation approach for addressing a major noise issue for a vehicle running at a constant speed on a rough road. While working on any issue, the first and the most critical step is to identify the exact root cause of the issue. Hence, we propose a detailed full vehicle level “contribution analysis (CA) + transfer path analysis (TPA)” methodology (everything done through the simulation) and then go for the design recommendations to improve the performance. We used road excitation power spectral density (PSD) as the input at all the four wheels (spindle locations) calculated through MBD software. The first
Mahajani, MihirNascimento, FabioAdinarayana Reddy, KodidelaMatyal, MahanteshTenagi, IrappaSardar, Chenna
The pressing global need for de-fossilization of the transport sector, especially within the heavy-duty segment, has intensified the exploration of alternative clean fuels. In this context, methanol gained traction due to their renewable production pathways, carbon-neutrality, and are being highly promoted by the Indian government to reduce CO2 emissions. Dual direct injection compression ignition (DDICI) is an effective combustion strategy to use methanol in heavy-duty engines, which combines the advantage of high-efficiency compression ignition with the clean-burning potential of methanol. In contrast to spark-ignited premixed methanol engines, this strategy involves a diffusion combustion of the methanol flame, thereby eliminating knocking and enabling running with high compression ratios. This experimental and numerical study presents a comprehensive investigation into the DDICI strategy using methanol as primary fuel and diesel as a pilot for ignition assistance. The work
Singh, InderpalDhongde, AvnishRaut PhD, AnkitGüdden, ArneEmran, AshrafBerry, Sushil
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
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
The Government of India has mandated biofuel blending in automotive fuels to reduce crude oil imports and support the national economy. As part of this initiative, Oil Marketing Companies (OMCs) have begun nationwide blending of E20 fuel (20% ethanol in petrol). Ethanol supply is expected to exceed demand by the end of 2025 due to initiatives like the Pradhan Mantri JI-VAN Yojana. Alternative applications for ethanol are being explored; one promising approach is its use as a co-blend with diesel fuel (ED blends). However, ethanol’s low cetane number and poor lubricity pose challenges for direct use in diesel engines without modifications. ED blends demonstrated reduced emissions while maintaining performance comparable to conventional diesel. To further address concerns related to materials compatibility of ED blends with fuel system components, particularly plastomers that may impact engine durability, a detailed study was conducted using elastomers such as FVMQ, FKM, HNBR, and NBR in
Johnpeter, Justin PChakrahari, KiranChakradhar, MayaArora, AjayPrakash, ShantiPokhriyal, Naveen Kumar
Identification of renewable and sustainable energy solutions remains a key focus area for the engine designers of the modern world. An avenue of research and development is being vastly dedicated to propelling engines using alternate fuels. The chemistry of these alternate fuels is in general much simpler than fossil fuels, like diesel and gasoline. One such promising and easily available alternate fuel is compressed natural gas (CNG). In this work, a 3-cylinder, 3-liter naturally aspirated air-cooled diesel engine from the off-highway tractor application is converted into a CNG Diesel Dual fuel (CNG-DDF) engine. Part throttle performance test shows the higher NMHC and CO emissions in CNG-DDF mode which have been controlled by an oxidation catalyst in C1 8-mode emission test. A comparative performance shows that the thermal efficiency is up to 2% lower with CNG-DDF with respect to diesel. However, it has shown the benefit of 44% in Particulate Matter, while retaining the same NOx
Choudhary, VasuMukherjee, NaliniKumar, SanjeevTripathi, AyushNene, Devendra
Ammonia has emerged as a promising alternative fuel for transportation because of its high energy density (NH3 has more hydrogen than propane in a similar size tank), simple and carbon-free combustion, and potential to produce sustainably. This paper investigates the feasibility of using ammonia as fuel for internal combustion engines (ICE) and fuel cells in automotive applications. In many ways, ammonia captures these benefits by being produced from renewable energies and having the potential to reduce reliance on fossil fuels. There are significant drawbacks of ammonia however, such as its decreased energy content per unit volume, NOx emissions potential, and necessary engine adaptations. This paper discusses the combustion characteristics of ammonia and how it functions in typical ICE's as well as new fuel cell technology, and the necessary infrastructure to produce, store, and distribute ammonia for automotive applications. The study compares operations to conventional fuels
Jadhav, AjinkyaBandyopadhyay, DebjyotiSutar, Prasanna SSonawane, Shailesh BalkrishnaRairikar, Sandeep DThipse, Sukrut S
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
Higher latent heat of vaporization of ethanol deteriorates low ambient temperature starting of engines with ethanol blended fuels. In case of flex fuel vehicles, cold starting becomes very critical on account of higher ethanol content. This case study highlights how pivot table based analytics were effectively employed to enhance engine start strategy during the development of small commercial vehicle running on E20 and E85 fuel blends. The approach showcases how structured data interpretation can significantly support development work in Flex Fuel calibration. The analysis is focused on various critical engine start events such as first crank success, failure to start, battery voltage behavior, and post-start stability across a range of coolant temperatures, particularly below 20°C. Real world test data was categorized using data analysis based on parameters such as crank RPM, battery voltage during cranking, fuel, phase detection status, throttle input, and spark advance, and start
Undre, ShrikantKulkarni, DeepakThonge, RavindraUpadhyay, RajdipKanchan, Shubham
India being highly populated and developing country, the demand for various alternative fuel is increasing drastically. It is driven by the need to reduce dependency on traditional fossil fuels & reduce impact on environmental issues like Greenhouse gas, emissions & pollution. The potential options, CNG (Compressed Natural Gas) & Biodiesel, are becoming increasingly popular and important. Biodiesel, a renewable fuel which is produced from waste materials & crops which grown repeatedly & easily available while CNG is more sustainable than diesel as natural gas is a cleaner-burning fossil fuel in comparison to coal or oil. This paper will focus on comparison between basic properties of Diesel, CNG & Biodiesel. In this study will also focus on survey of various Government initiatives, policies & infrastructural development which are evolving to encourage the usage of CNG & Biodiesel. These fuels are emerging as promising alternative contenders to traditional diesel. It has the potential
Bondada, NanditaBaruah, LabanyaMokhadkar, Rahul
This paper compares carbon dioxide, carbon monoxide, methane, and oxides of nitrogen emissions from medium and heavy-duty buses using diesel, diesel-hybrid, and CNG powertrains. Comparisons are made using results from chassis dynamometer-based tests with driving cycles intended to simulate a wide range of operating conditions. Tail pipe emissions are measured by diluting the vehicle’s exhaust in a full-scale dilution tunnel by mixing with conditioned air. Samples are drawn through probes of raw exhaust, diluted exhaust and measured using laboratory grade emission analyzers. Fuel consumption of diesel is measured using a weighing scale, while a gas flow meter is used for measuring CNG consumption. Experimental data from 19 buses tested on a chassis dynamometer over the last 8 years has been analyzed and a comparison of results from similar buses with the differently fueled powertrains is presented. Based on these test results, it is shown that replacing diesel engines with CNG engines
Iyer, Suresh
In a developing country like India, the growing energy demand across all sectors underscores the urgent need for clean, sustainable, and efficient energy alternatives. Hydrogen stands out as a promising fuel, offering virtually zero emissions and helping to reduce greenhouse gas (GHG) emissions, which directly contributes to mitigating global warming, ensuring a cleaner environment, and lowering dependency on fossil fuels. In line with Sustainable Development Goal 7 (SDG 7), which seeks to guarantee that everyone has access to modern, cheap, and sustainable energy, hydrogen is well-positioned to be a major player in India's energy transformation. However, hydrogen has unique properties such as its wide flammability range, high reactivity, and high energy content present significant challenges in terms of safety, particularly in its storage, transportation, and usage. Improper handling or inadequate safety measures can lead to hazardous incidents, making robust testing, certification
Pawar, YuvrajDekate, Ajay DinkarThipse, SBelavadi Venkataramaiah, Shamsundara
India’s commitment to carbon neutrality is significantly shaping the future architecture of commercial vehicle powertrains. While the use of CO₂-free technologies such as battery-electric drivetrains has already been successfully demonstrated across various applications, challenges related to limited range and the lack of high-power charging infrastructure continue to hinder widespread adoption, particularly for productivity-critical commercial vehicles. This has shifted the spotlight toward sustainable fuels, which offer the advantage of fast refueling times. Among these, hydrogen internal combustion engines (H₂ ICE) have gained increasing attention in recent years. In regions such as the European Union, the primary motivation for hydrogen is CO₂ reduction. In contrast, for markets like India, hydrogen also presents a strategic opportunity for reducing dependency on fossil fuel imports. Over the past four years, multiple performance and emission development projects across various H
Arnberger, AntonDanninger, AloisMannsberger, StefanBreitegger, Bernhard