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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 today’s market, faster product development without compromising durability is essential. Durability assessment ensures a vehicle maintains structural integrity under normal and extreme conditions. Achieving this requires effective Road Load Data Acquisition, integrated with robust design practices and efficient validation processes. However, physical RLDA is time-consuming and costly, as it depends on prototype vehicles that are often available only in the later development stages. Failures identified during these late-stage tests can delay the product launch significantly. This study presents a full digital methodology of fatigue life estimation for suspension aggregates. A study has been demonstrated on Rear Twist Beam component of rear suspension. The approach integrates the digital RLDA methodology presented in literature and finite element analysis simulation process, enabling durability assessments entirely within the virtual domain. This approach demonstrates how digital RLDA
Kokare, SanjayDwivedi, SushilSiddiqui, ArshadIqbal, Shoaib
Existing ICE Mid and Heavy commercial vehicles in the Indian and international market are recording a large number of mishaps due to blind spots and non-accessibility of the driver to the opposite side mirror in real-time driving. Non-driver side rear view mirror adjustment creates the need for the driver to get down and adjust the mirror manually/get support from the co-passenger. The paper proposes a solution for a Microcontroller-based compact mirror adjustment system, which will run with minimal economy and highest efficiency. This will assist drivers in aesthetically and safely monitoring of mirror to check on specific blind spots in day conditions This will reduce the prone accidents due to non-visibility by approximately 30%, ensuring enhanced road safety and driver comfort. The Indian commercial vehicle segment needs this solution to be implemented when we look at the rate of increasing demand and also accident rates.
Jambagi, Vaibhavi VyankateshGangvekar, OnkarBhandari, Kiran Kamlakar
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
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
In last two decades, Farm customer expectation on cabin comfort has been increased multifold. To provide the best-in-class customer experience in terms of comfort without adding cost and weight is bigger challenge for all NVH Engineers. It is evident from literature survey that cabin tractors with better comfort is well accepted by customers in US and European Market. Apart from engine excitation, customer has become more sensitive to customer-actuated-accessory noises due to overall reduction in cabin noise in last 2 decades. This paper presents the study conducted on HVAC blower noise in 30HP cabin tractor. Tactile vibrations and cabin noise is not acceptable when AC is switched on due to low frequency modulating nature in frequency range of ~65Hz and 130Hz. The investigation is carried out systematically considering each component of Source-Path-Receiver model. HVAC blower unit as source is diagnosed in detail to understand root cause. Strong dominance of first order of blower been
K, SomasundaramChavan, Amit
Calibration of measuring instruments is of utmost importance in the field of metrology. It is a mandatory pre-requisite for establishing the fidelity of the measurements as well as to lend confidence. Even more critical is the requirement for the master equipment deployed to calibrate the devices in use. This entails that high accuracy needs to be guaranteed in the calibration process, and that the uncertainty be quantified precisely. The widely used conventional least squares polynomial regression formulation for load cell calibration is based on the non-normalized residual, which is the difference between the measured and master values. The nature of this formulation is such that it imparts more weightage on measured values at higher ranges resulting in good accuracy. However, there is a limitation of this same formulation that results in lesser accurate fit at lower values especially if the instrument is to be used in operation over a wide range including lower ranges of the
S Thipse, Yogesh
This paper presents an innovative in-lab accelerated testing approach for chassis-mounted components, with a particular focus on the cooling module of commercial vehicles. The proposed method simulates real-time data acquired from field operations and replicates all critical chassis modes, including torsion. Additionally, real-time coolant circulation at specified pressure and temperature maintenance are feasible during durability testing, enhancing the realism of the test environment. The cooling modules, comprising the radiator, intercooler, and charge air cooler (CAC), often experience failures due to various multi-axial inputs and chassis modes. This paper introduces an innovative methodology for replicating field conditions in the lab, utilizing seven servo-hydraulic actuators to simulate multi-axial inputs. The accuracy of in-lab simulation for the acceleration levels at input and response locations of the cooling module exceeds 90%. This makes it a preferred choice for test
V Dhage, YogeshSatale, Sunil
Heavy tipper vehicles are primarily utilized for transporting ores and construction materials. These vehicles often operate in challenging locations, such as mining sites, riverbeds, and stone quarries, where the roads are unpaved and characterized by highly uneven elevations in both the longitudinal and lateral directions of vehicle travel. During the unloading process, the tipper bodies are raised to significant heights, which increases the vehicle's centre of gravity, particularly if the payload material does not discharge quickly. Such conditions can lead to tipper rollover accidents, causing severe damage to life and substantial vehicle breakdowns. To analyse this issue, a study is conducted on the vehicle design parameters affecting the rollover stability of a 35-ton GVW tipper using multi-body simulations in ADAMS software. The tilt table test was simulated to determine the table angle at which wheel lift occurs. Initially, simulations are performed with the rigid body model
Vichare, Chaitanya AshokPatil, SudhirGupta, Amit
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
With the expansion of compressed natural gas (CNG) filling station in India, bi-fuel vehicles are gaining popularity in recent times. Bi-fuel engine runs on more than one fuel, say in both CNG and petrol. Hence, the engine must be optimized in both the fuel modes for performance and emissions. However, due to the inherent differences in combustion characteristics: ignition dynamics and fuel properties, they pose a significant challenge in case of detection of misfires. Misfires are caused because of faulty injection systems and ignition systems and incorrect fuel mixture. Accurate detection is essential as misfires deteriorate the catalysts performance and may impacts emission. Misfires (or engine roughness) is calculated from engine crankshaft speed signal. In this study, the effectiveness of crankshaft-based misfires detection method, comparison of misfire signals magnitude in bi-fuel modes and practices developed for accurate detection of misfires is presented.
Thiyagarajan, AbhinavN, GobalakrishnanR, Hema
Driver-in-the-Loop (DIL) simulators have become crucial tools across automotive, aerospace, and maritime industries in enabling the evaluation of design concepts, testing of critical scenarios and provision of effective training in virtual environments. With the diverse applications of DIL simulators highlighting their significance in vehicle dynamics assessment, Advanced Driver Assistance Systems (ADAS) and autonomous vehicle development, testing of complex control systems is crucial for vehicle safety. By examining the current landscape of DIL simulator use cases, this paper critically focuses on Virtual Validation of ADAS algorithms by testing of repeatable scenarios and effect on driver response time through virtual stimuli of acoustic and optical warnings generated during simulation. To receive appropriate feedback from the driver, industrial grade actuators were integrated with a real-time controller, a high-performance workstation and simulation software called Virtual Test
Sharma, ChinmayaBhagat, AjinkyaKale, Jyoti GaneshKarle, Ujjwala
Nowadays, vehicle enthusiasts often vary the driving patterns, from high-speed driving to off-roading. This leads to a continuous increase in demand for four-wheel drive (4WD) vehicles. A 4WD vehicle have better traction control with enhanced stability. The performance and reliability of 4WD vehicles at high speeds are significantly influenced by driveline stiffness and natural frequency, which are largely affected by the propeller shaft and transfer case. This study focuses on the design optimization of the transfer case and the propeller shafts to enhance the vehicle performance at high speeds. The analysis begins with a comprehensive study of factors affecting the power transfer path, transfer case stiffness, and critical frequency, including material properties, propeller shaft geometry, and different boundary conditions. Advanced computational methods are employed to model the dynamic behavior of the powertrain, identifying the natural frequency of the transfer case and propeller
Kumar, SarveshYadav, SahdevS, ManickarajaSanjay, LKanagaraj, PothirajJain, Saurabh KumarDeole, Subodh M
As the brain and the core of the electric powertrain, the traction inverter is an essential part of electric vehicles (EVs). It controls the power conversion from DC to AC between the electric motor and the high-voltage battery to enable effective propulsion and regenerative braking. Strong and scalable inverter testing solutions are becoming more essential as EV adoption rises, particularly in developing nations like India. In India, traditional testing techniques that use actual batteries and e-motors present several difficulties, such as significant safety hazards, inadequate infrastructure, expensive battery prices, and a shortage of prototype-grade parts. This paper presents a comprehensive approach for traction inverter validation using the AVL Inverter TS™ system incorporating an advanced Power Hardware-in-the-Loop (PHiL) test system based on e-motor emulation technology. It enables safe, efficient, and reliable testing eradicating the need for actual batteries or mechanical
Mehrotra, SoumyaChhabra, Rishabh
The rising demand for high-performance 4x4 electric vehicles (EVs) has necessitated development in Noise, vibration and harshness (NVH) optimization, especially in critical components such as compressor bracket. This study focuses on NVH optimization of a dual-stage compressor bracket, comparing its performance against conventional single stage isolation bracket. The dual-stage bracket is evaluated for isolation effectiveness, modal frequency alignment, and overall NVH performance, while ensuring compliance with stiffness targets. Additionally, dual-stage design meets stringent stiffness requirement, confirming structural integrity under dynamic loads. Modal analysis results reveal that the dual-stage configuration effectively shifts critical frequencies away from operational ranges, reducing resonance risks. The results highlight the dual-stage bracket's ability to address NVH challenges in high-performance 4x4 EVs, offering a robust solution for improving cabin comfort and vehicle
Hazra, SandipTangadpalliwar, Sonali
In pursuit of a distinct sporty interior sound character, the present study explores an innovative strategy for designing intake systems in passenger vehicles. While most existing literature primarily emphasizes exhaust system tuning for enhancing vehicle sound quality, the current work shifts the focus toward the intake system’s critical role in shaping the perceived acoustic signature within the vehicle cabin. In this research work, target cascading and settings were derived through a combination of benchmark and structured subjective evaluation study and aligning with literature review. Quantitative targets for intake orifice noise was defined to achieve the desired sporty character inside cabin. Intake orifice targets were engineered based on signature and sound quality parameter required at cabin. Systems were designed by using advanced NVH techniques, Specific identified acoustic orders were enhanced in the intake system to reinforce the required signature in acceleration as well
Sadekar, Umesh AudumbarTitave, UttamPatil, JitendraNaidu, Sudhakara
With introduction of Diesel Particulate Filter to achieve CEV/TREM V Emission Limits for off-highway segment, there is a requirement of DPF regeneration at defined intervals depending on time of operation and soot loading in DPF. This can be achieved by two methods. First is the frequent regeneration or Active regeneration, wherein fuel is injected before DOC (Diesel Oxidation Catalyst) at specific temperature to burn the soot in the DPF. The second method is the continuous or Passive regeneration, where soot is burnt based on NO2. DPF frequent regeneration (Active Regeneration) requires soot load estimation in DPF over entire engine operation range as well as vehicle operation in different climatic conditions. Frequent regeneration leads to oil dilution and penalty in the fuel consumption. More frequent regeneration promotes the chemical aging of DOC, leading to the poor performance of DOC which results in deteriorating performance of SCR(Selective Catalytic Reduction) situated
Sharma, RakshitGarg, VarunDhiman, NitishGrauenfels, Attila
During vehicle launches in 1st gear, a lateral shake (undulation) and a pronounced metallic hitting noise were observed in the underbody. The noise was identified as the propeller shaft's second universal joint (UJ) yoke striking the fuel tank mounting bracket. Sensitivity to these issues varied with acceleration inputs: light pedal input during a normal 1st gear launch on a flat road resulted in minimal undulation, whereas wide open throttle (WOT) conditions in 1st gear produced significant lateral shake and intensified hitting noise. Further investigation revealed that the problem persists across all gears and occurs consistently during normal driving conditions, with continuous impact between the propeller shaft yoke and the fuel tank mounting bracket. Extensive experimental measurements at the vehicle level indicated that these issues were primarily caused by the center-mounted propeller shaft joint deviating from its central position and rotating eccentrically under torque. This
Sanjay, LS, ManickarajaKumar, SarveshKanagaraj, PothirajSenthil Raja, TB, Prem PrabhakarM, Kiran
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
Air pollution from vehicle exhaust emissions is a growing issue in major cities around the world. Hydrogen is a clean and carbon-free fuel that presents a promising alternative to the fossil fuels. However, despite its environmental advantages, hydrogen internal combustion engines still produce some nitrogen oxides as a by-product due to high combustion temperatures. This study investigates the effectiveness of current exhaust after-treatment technologies designed to reduce NOx emissions in hydrogen-powered engines. A comparative analysis is conducted between the conventional urea-based selective catalytic reduction used in diesel engines and emerging hydrogen-based selective catalytic reduction technologies for hydrogen engines. The analysis is performed using CFD simulation in ANSYS Fluent, focusing on NOx reduction efficiency and other operational parameters. The results provide valuable insights into the feasibility and effectiveness of hydrogen SCR in achieving reduced NOx
Kashyap, KeshavKhandagale, AnupPetale, Mahendra
Affordable, efficient and durable catalytic converters for the two and three-wheeler industry in developing countries are required to reduce vehicle emissions and to maintain them at a low level; and therefore, to participate in a cleaner and healthier environment. Especially, metallic catalyst substrates developed by Emitec Technologies GmbH with structured foils like the Longitudinal Structure (LS), or LS-Design® are fully compatible to this effort with more than 70% share of produced 2/3 Wheelers metallic catalyst substrates for the Indian market in 2024. One decade after the market introduction of this LS structure, Emitec Technologies GmbH will introduce now a new generation of foil structure: the Crossversal Structure (CS) or CS-Design®, that improves further the affordability, the efficiency of metallic catalytic converters, keeping the durability at same level as previous substrate generation. The paper will briefly review the development of metallic substrates for 2/3 wheelers
Jayat, FrancoisSeifert, SvenBhalla, AshishGanapathy, Narayana Prakash
Environmental pollution is one of the growing concerns of our society. As vehicle emissions are a major contributor to air pollution, emission control is a primary goal of the Automotive industry. Vehicle emissions are higher due to improper combustion, which leads to toxic gases being generated from the exhaust system. Unburnt fuel is one of the leading causes of toxic pollutants such as Carbon Monoxide, Nitric Oxides (NOx) and Hydrocarbons. The catalytic converter converts these gases into less toxic substances such as Carbon Dioxide, Nitrogen, and water vapor. The catalytic converter performs efficiently after reaching its “Light Off” temperature, after which the catalyst becomes active. Hence, elevated temperature of the exhaust gases aids in efficient conversion. Presently, the gases from the exhaust system are approximately at a temperature of 300°C-600°C. This paper outlines the concept of a Peltier (Thermoelectric) Module - based system, which helps maintain the high
Venkateshwaran, AishwaryaSoodlu, ShashikiranM, Mathaiyan