Technical Papers - SAE Mobilus

SAE Technical Papers are written and peer-reviewed by experts in the automotive, aerospace, and commercial vehicle industries and provide the latest advances in technical research and applied technical engineering information.

Items (118,643)

Optimization of Wire Electrical Discharge Machining Parameters for Invar 36 Material Using Regression Modeling

2025-28-0122To be published on 02/07/2025

Wire Electrical Discharge Machining (WEDM) is a commonly employed technique for shaping conductive materials such as SAE 1010 steel, providing highly accurate machining capabilities. This low-carbon steel has excellent formability, weldability, and machinability, making it useful in many contexts including bolts, nuts, valves and cold headed fasteners. The objective of this study is to improve the efficiency and precision of the Wire Electrical Discharge Machining (WEDM) process for SAE 1010 material. This will be achieved by creating a predictive model using an Adaptive Neuro-Fuzzy Inference System (ANFIS). The study investigates the influence of WEDM parameters, specifically pulse-on time, pulse-off time, and discharge current, on important machining outcomes such as surface roughness (Ra), material removal rate (MRR). The experimentation has been planned and conduced as per Taguchi L9 orthogonal array design. The ANFIS predictive model is constructed by utilizing the obtained

Pasupuleti, Thejasree, Natarajan, Manikandan, Raju, Dhanasekar, Krishnamachary, PC, Silambarasan, R

Development of AI Prediction Tool for Fused Deposition Modeling of ABS Material for automobile applications

2025-28-0127To be published on 02/07/2025

Additive Manufacturing (AM), notably Fusion Deposition Modeling (FDM), has grown in popularity owing to its ability to create complicated forms from a variety of materials. This research aims to increase the efficiency and accuracy of the FDM process for Acrylonitrile Butadiene Styrene (ABS) material. ABS plastic material is an important material in automotive manufacturing due to its strength, durability, and versatility. It is used extensively for a wide range of components, including dashboard components, bumpers, fenders, exterior trim, and interior trim. The objective will be accomplished by the development of a prediction model using an Adaptive Neuro-Fuzzy Inference System (ANFIS). The research investigates the influence of FDM parameters, including layer height, nozzle temperature, and printing speed, on significant printing characteristics such as dimensional accuracy, surface quality, printing speed, and dimensional deviation. The essential data is derived from empirical

Natarajan, Manikandan, Pasupuleti, Thejasree, Kumar, V, Kiruthika, Jothi, Katta, Lakshmi Narasimhamu, Silambarasan, R

Material Augmentation for Coaxial Propellers of Titan’s Unmanned Airship: Implementation of Advanced Composites for the Propulsive System Under Unconventional Loading conditions with Incorporation of Structural Integrity Examinations

2025-28-0167To be published on 02/07/2025

Exploration vehicles on Titan are to be developed with considerations on the atmosphere present, especially the abundance of Nitrogen. This study focuses on identification of optimum materials for the propellers supporting an airship specifically created for Titan exploration. The base airship is designed to accommodate the coaxial propeller. The base of this airship is to be developed with four weather stations for collection of data samples. The stations are installed on inflatable platforms and have storage devices for recording and transmitting data collected by the aerobot. The airship will operate in Titan's atmosphere and atmospheric conditions, focusing on its design and computational analysis of structural effects and fluid dynamics. The Titan aerobot is built with a co-axial 4-blade propeller, horizontal and vertical fins, and a reaction wheel for yaw maneuvers. The co-axial propulsive system is capable of overcoming drag during steady level flight in the Titan atmosphere

Baskar, Sundhar, Vinayagam, Gopinath, Pisharam, Akhila Ajith, Gnanasekaran, Raj Kumar, Raji, Arul Prakash, Stanislaus Arputharaj, Beena, L, Natrayan, Ganesan, Balaji, Raja, Vijayanandh

Computational Evaluations of Structural Integrity in Unmanned Aquatic Vehicles Utilizing Various Conventional and Hybrid Composites using Hydro-Structural Analyses

2025-28-0056To be published on 02/07/2025

This study focuses on developing and deploying an Unmanned Aquatic Vehicle (UAV) capable of underwater travel. The primary objectives of this project are to detect the presence of dimethyl sulfide and toluene, as well as to identify any potential oil leakage in underwater pipelines. The UAV has a maximum operating depth of 300 m below the water surface. The design of this UAV is derived from the natural design of Rhinaancylostoma, an underwater kind of fish. The maximum operational setting for this mission is fixed at a depth of approximately 300 m beneath the surface of the sea, and the choice of this species is suitable for fulfilling the objectives of this undertaking. This technology will mitigate the risk associated with human interaction in inspection processes and has the potential to encompass various other resources in the future. The initial design data of the UAV is determined using analytical processes and verified formulas. The selection of the airfoil is done by comparing

Veeraperumal Senthil Nathan, Janani Priyadharshini, Rajendran, Mahendran, Arumugam, Manikandan, Raji, Arul Prakash, Sakthivel, Pradesh, Madasamy, Senthil Kumar, Stanislaus Arputharaj, Beena, L, Natrayan, Raja, Vijayanandh

Innovative Design and Multi-Parametric Computational Investigations on the Propulsive System of a Pentacopter Unmanned Aerial Vehicle

2025-28-0181To be published on 02/07/2025

This work focuses on the design and multi-parametric analysis of a designed propeller for a Pentacopter unmanned aerial vehicle (UAV). The basic and secondary design inputs, along with performance data like propeller diameter, pitch angle, chord length, and lift coefficient, are established using a standard analytical method. Approximately ten distinct airfoils, specifically NACA 2412, NACA 4109, NACA 4312, NACA 4409, NACA 4415, NACA 5317, NACA 6409, NACA 6412, NACA 23024, and NACA 25012, are evaluated over 13 Reynolds Numbers with the angle of attacks (AOA) of 20, varying from -5 to 15 degrees, for the purpose of detailed propeller design. The lift and drag coefficient values for ten distinct airfoils, utilizing a Reynolds number of 13 and 20 angles of attack, are obtained from the XFOIL software. Three sophisticated airfoils are selected from a pool of ten based on their high Lift-to-Drag (L/D) ratio performance. The selected airfoils with a high L/D ratio are NACA 6409, NACA 4109

Veeraperumal Senthil Nathan, Janani Priyadharshini, Arumugam, Manikandan, Rajendran, Mahendran, Solaiappan, Senthil Kumar, Kulandaiyappan, Naveen Kumar, Madasamy, Senthil Kumar, Stanislaus Arputharaj, Beena, L, Natrayan, Raja, Vijayanandh

Innovative Design and Comprehensive Computational Investigations on the Performance Enhancement of Advanced Horizontal Axis Turbines for Unmanned Marine Vehicles

2025-28-0188To be published on 02/07/2025

The integration of advanced horizontal axis turbines (HATs) into unmanned marine vehicles (UMVs) significantly enhances their operational efficiency by providing power sources. These vehicles, designed for diverse applications, require efficient power systems to operate autonomously over extended periods. The major disadvantages are limited battery life and energy storage capabilities that restrict the operational range and endurance of the UMVs. Utilizing HATs in UMVs provides a renewable energy source, reducing operational costs. This continuous power supply enhances mission capabilities and promotes energy independence, making them ideal for long-term missions. Thus, using Computational fluid dynamics (CFD) models, hydrodynamic and aerodynamic analyses were carried out. For the hydrodynamic scenario, a velocity of 10 m/s and for the aerodynamic case, 27.7778 m/s, were taken into consideration. It is concluded that the UMV with Stepped HAT modification can be effectively employed for

Gunasekaran, Durga Devi, Kannan, Haridharan, Sourirajan, Laxana, Vinayagam, Gopinath, Gnanasekaran, Raj Kumar, Kulandaiyappan, Naveen Kumar, Stanislaus Arputharaj, Beena, L, Natrayan, Raja, Vijayanandh

Ascertainment of Optimized Profile of Hybrid Vortex Bladeless Turbine for Unmanned Surface Vehicles using Progressive Computational Studies

2025-28-0185To be published on 02/07/2025

This work addresses an innovative method for improving energy harvesting in Bladeless wind turbines (BWT) by implementing profile modifications to the wind turbine for fixing it in Unmanned Surface Vehicles (USV). The streamlined flow undergoes a transformation and generates a vortex in the vicinity of the structure when the wind impacts the BWT. As the velocity increases, the wind strikes the structure with greater force, resulting in an imbalance that causes the structure to vibrate. To convert this vibrational energy of the wind turbine into electrical energy, the research investigates the use of a variety of profile modifications to capitalize on the aerodynamic effect generated by the structure. The entire cylindrical shape is altered to tapered shape, airfoil shapes with coordinates such as NACA 0012, 0015, 0018, 4412 and 4420. In addition to these shapes, hybrid models were also constructed by merging models made from two airfoil coordinates, including NACA 0018 & 4412, NACA

Veeraperumal Senthil Nathan, Janani Priyadharshini, Rajendran, Mahendran, Arumugam, Manikandan, Raji, Arul Prakash, Sakthivel, Pradesh, Stanislaus Arputharaj, Beena, L, Natrayan, Ganesan, Balaji, Raja, Vijayanandh

Innovative Design and Comprehensive Aerodynamic Performance Investigations on Propeller Positions of the Advanced Multirotor Hexacopter

2025-28-0182To be published on 02/07/2025

This work deals with computational investigations of the component performances of Advanced Hexacopters under various maneuverings of the focused mission profiles. The Advanced Hexacopter is a kind of multirotor vehicle that contains more propellers and flexible arms, which makes this multirotor very maneuverable and aerodynamically efficient. This Hexacopter was designed specifically to execute multi-perspective applications along with enhanced payload-carrying capability. This Advanced Hexacopter contains a frame composed of modified arms equipped with coaxial rotors, which servo motors control. By providing specific and simple inputs to the microcontroller, the Hexacopter can autonomously undergo forward and backward maneuverings. The primary objective of this study is to analyze and compare different propeller configurational clearance sets that improve the maneuvering capability of this unmanned aerial vehicle (UAV), specifically emphasizing forward/backward and side maneuvering

Raja, Vijayanandh, Narayanan, Sidharth, Elangovan, Logesh, Arumugam, Lokesh, Sourirajan, Laxana, Raji, Arul Prakash, Kulandaiyappan, Naveen Kumar, Gnanasekaran, Raj Kumar, Madasamy, Senthil Kumar

Integrated Driver Health Monitoring System With Real-time Alerts Using In-Cabin Sensors and Vehicle Telematics

2025-28-0195To be published on 02/07/2025

Automotive industries focus on driver safety leading to raising improvements and advancements in Advanced Driver Assistance Systems (ADAS) to avoid collisions and provide safety and comfort to the drivers. This paper proposes a novel approach toward Driver health and fatigue monitoring systems that uses cabin cameras and biometric sensors communicating continuously with vehicle telematics systems to enhance real-time monitoring and predictive intervention. The data from the camera and biometric sensors is sent to the machine learning algorithm (LSboost) which processes the data and if anything is wrong concerning the driver's behavior then immediately it communicates with vehicle telematics and sends information to the emergency services. This approach enhances driver safety and reduces accidents caused due to health-related driver impairment. This system comprises several sensors and fusion algorithms are applied between different sensors like cabin camera and biometric sensors, all

Bhargav, Matavalam

Operation of Advanced Flying Wing UAV: Examination of Structural Performance Under Aberrant Pressure and Thermal Loading Conditions with Integrated Computational Study

2025-28-0060To be published on 02/07/2025

The objective of this research is to present a novel variant of an Unmanned Aerial Vehicle (UAV) with an advanced flying wing configuration capable of detecting and rescuing individuals affected by avalanches. This leads to testing of the UAV, to identify if it can operate efficiently at the intended temperature and atmospheric conditions. Typically, UAVs can operate in a broad spectrum of temperatures. Regions prone to avalanches would experience near-cryogenic temperatures. The notion is investigated and tested in this specific scenario. The chosen location is Siachen, where temperatures can become as low as -25 degree Celsius (°C). It has been proven that a thermal camera aids the UAV to detect the distinct body heat signatures of individuals who are trapped under snow. The selection of wing, propeller, and vertical stabilizer airfoils is guided by standard analytical calculations, while the overall model is developed using 3D EXPERIENCE. The computational tests are conducted using

Veeraperumal Senthil Nathan, Janani Priyadharshini, Pisharam, Akhila Ajith, Sourirajan, Laxana, Baskar, Sundhar, Vinayagam, Gopinath, Stanislaus Arputharaj, Beena, L, Natrayan, Sakthivel, Pradesh, Raja, Vijayanandh

Multi-Objective Optimization for Contemporary Drilling of Nimonic Alloy Using Taguchi-Grey Relational Analysis

2025-28-0050To be published on 02/07/2025

The objective of this research is to develop an optimization strategy for the Electrochemical Drilling process on Inconel 800HT material, taking into account various performance factors. The optimization strategy relies on the integration of the Taguchi method with Grey Relational Analysis (GRA). Inconel 800HT is extensively utilized in aerospace, nuclear, and marine industries, specifically in situations that are prone to corrosion. The experimental trials are structured based on Taguchi's principle and encompass three machining variables: feed rate, electrolyte flow rate, and electrolyte concentration. This inquiry examines performance indicators like the rate of material removal, surface roughness, as well as geometric parameters such as overcut, shape, and orientation tolerance. Based on the investigation, it is determined that the feed rate is the primary factor that directly affects the intended performance criteria. In order to enhance the accuracy of predictions, multiple

Pasupuleti, Thejasree, Natarajan, Manikandan, D, Palanisamy, Silambarasan, R, Krishnamachary, PC

Smart Machining of Titanium Grade 7: ANFIS Application for Process Parameter Prediction

2025-28-0160To be published on 02/07/2025

Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in materials that conduct electricity, regardless of their level of hardness. Due to the growing demand for superior products and the necessity for quick design adjustments, decision-making in the manufacturing industry has grown increasingly intricate. This study specifically examines Titanium Grade 5 and suggests the creation of an Adaptive Neuro-Fuzzy Inference System (ANFIS) model for predictive modelling in ECM. The study employs a Taguchi-grey relational analysis (GRA) methodology to attain multi-objective optimization, with the goal of concurrently maximizing material removal rate, minimizing surface roughness, and achieving precise geometric tolerances. Analysis of variance (ANOVA) is used to assess the relevance of process characteristics that impact these performance measures. The ANFIS model presented for Titanium Grade 5 provides more flexibility, efficiency, and accuracy in

Natarajan, Manikandan, Pasupuleti, Thejasree, D, Palanisamy, Kiruthika, Jothi, Silambarasan, R

Preparation of Copper Antimony Sulfide Thin Film Solar Cells by Chemical Synthesis

2025-28-0117To be published on 02/07/2025

CuSbS2 is a promising ternary semiconductor for use as an absorber layer in third-generation thin film heterojunction solar cells. This newly developed optoelectronic material offers a viable alternative to CdTe and Cu(In,Ga)Se2 due to its composition of inexpensive, readily available, and non-toxic elements. These films were successfully produced at an optimal substrate temperature of 533 K using the conventional spray technique. X-ray diffraction and Raman studies confirm that the films exhibit a chalcostibite structure. Characterization studies reveal that the films possess lattice parameters of a = 0.60 nm, b = 0.38 nm, and c = 1.45 nm, with an absorption coefficient of 105 cm-1 and a band gap of 1.50 eV. Notably, the films exhibit p-type conductivity. All these studies confirm that CuSbS2 as an absorber layer is highly suitable for solar cell applications. An attempt was made in this study to improve the crystallinity of the CuSbS2 films by different experimental conditions. (i

Kumar, YB Kishore, Yb, Kiran, Tarigonda, Hariprasad, Reddy M, Surya Sekhar

Method Development for Virtual Validation of Tractor Three-Point Linkage for customer practices in Haulage application

2025-28-0069To be published on 02/07/2025

This paper discusses the design and analysis of the Three-point linkage of an agricultural tractor for uncommon abusive usage practices during haulage applications. Some operators use the Three-point linkage for additional traction to navigate gradient surfaces, which requires additional wheel torque to overcome road slope when the trailer is attached. These maneuvers induce higher loads on Three-point linkage components, such as the lower link, lift rod, and powertrain components, which may lead to structural failures. A virtual simulation and lab-level test methodology need to be established to simulate the usage pattern upfront and predict potential failures. Multi-body dynamics (MBD) simulation was deployed to simulate the physics and extract realistic loads for Computer Aided Engineering (CAE) analysis. Data acquisition was carried out to record the strain levels during the uncommon haulage usage practices, which will be used for further studies. CAE analysis has been carried out

Kumar, Yuvaraj, Perumal, Solairaj, V, Ashok Kumar, Savsani, Smitkumar, Subbaiyan, Prasanna Balaji, Bhandwalkar, Anand, V V H Krishna Prasad, Tadikamalla

Designing Next-Generation Piston Geometry for LPG Powered Spark Ignition Engines: An Integrated CFD and Experimental Approach

2025-28-0123To be published on 02/07/2025

The efficiency of combustion has a major impact on the performance and emission characteristics of a spark-ignited LPG (Liquified Petroleum Gas) engine. The shape of the combustion chamber determines the homogeneous charge intake velocity, which is crucial for the turbulent motion that encourages flame propagation and quickens combustion. It need the right amount of compression ratio, charge squish velocity and turbulent kinetic energy to sustain combustion and propel laminar flames. There are a number of names for the motion of the charge within the cylinder: swirl, squish, tumble and turbulence. All of these terms affect how air and fuel are mixed and burned. Piston shape affects in-cylinder motion, which in turn reduces fuel consumption and improves combustion characteristics. The shape of the piston quench zone has a substantial impact on the charge velocity inside the combustion chamber. The impact on charge motion was analyzed using computer modeling using STAR-CD on pentroof

Sagaya Raj, Gnana, R L, Krupakaran, Pasupuleti, Thejasree, Natarajan, Manikandan

Development of ANFIS Predictive Model for Additive Manufacturing (Fusion Deposition Modeling) of PETG Material for automotive components

2025-28-0124To be published on 02/07/2025

Additive Manufacturing (AM), specifically Fusion Deposition Modeling (FDM), has become widely popular due to its capacity to produce intricate shapes using different materials. The objective of this study is to improve the efficiency and accuracy of the FDM process for Polyethylene Terephthalate Glycol (PETG) material, which is used for producing automotive components that require impact resistance, dimensional stability, and good surface finish. This will be achieved by creating a predictive model using an Adaptive Neuro-Fuzzy Inference System (ANFIS). The study examines the impact of FDM parameters, such as layer height, nozzle temperature, and printing speed, on important printing attributes like dimensional accuracy, surface quality, printing speed and dimensional deviation. The necessary information is obtained from experimental trials of FDM printing, which were conducted using various combinations of parameters. The experimental trials have been planned by Taguchi’s approach

Pasupuleti, Thejasree, Natarajan, Manikandan, Kumar, V, Kiruthika, Jothi, Katta, Lakshmi Narasimhamu, Silambarasan, R

Data-Driven Optimization of Titanium Grade 7 Machining for Automotive Applications

2025-28-0143To be published on 02/07/2025

Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in materials that conduct electricity, irrespective of their level of hardness. With the rising demand for superior products and the necessity for quick design modifications, decision-making in the industrial sector becomes increasingly complex. This study specifically examines Titanium Grade 5 and suggests creating prediction models through regression analysis to estimate performance measurements in ECM. The experiments are formulated based on Taguchi's ideas, utilizing a multiple regression approach to deduce mathematical equations. The Taguchi method is utilized for single-objective optimization in order to determine the ideal combination of process parameters that will maximize the material removal rate. ANOVA is a statistical method used to determine the relevance of process factors that affect performance measures. The suggested prediction technique for Titanium Grade 5 exhibits

Natarajan, Manikandan, Pasupuleti, Thejasree, Kumar, V, Krishnamachary, PC, Somsole, Lakshmi Narayana, Silambarasan, R

Optimization of Fusion Deposition Modeling Parameters for PLA Material for Automobile Interior Using Taguchi based TOPSIS Approach

2025-28-0131To be published on 02/07/2025

Additive Manufacturing (AM) techniques, particularly Fusion Deposition Modeling (FDM), have revolutionized manufacturing by enabling the fabrication of complex geometries with various materials. PLA is mostly used for both under-the-hood components and aumobile interior items including carpets, upholstery and protective wrappings used in vehicle manufacture and transportation. This study focuses on enhancing the efficiency and quality of FDM for PolyLactic Acid (PLA) material through the application of Taguchi-Grey Relational Analysis (GRA) optimization. The research investigates the influence of FDM parameters, including layer height, nozzle temperature, and printing speed, on critical printing characteristics such as dimensional accuracy, surface finish, and mechanical strength. Experimental trials are conducted based on a Taguchi orthogonal array design to systematically explore the parameter space. Grey relational grades are calculated to quantify the relationships between input

Natarajan, Manikandan, Pasupuleti, Thejasree, D, Palanisamy, Katta, Lakshmi Narasimhamu, Silambarasan, R

A Machine learning Approach for the prediction of Surface Roughness Using The Tool Vibration Data In Turning Operation

2025-28-0152To be published on 02/07/2025

Surface roughness is a key factor in different machining processes and plays an important role in ergonomics, assembly, wear and fatigue life of components. Functionality, performance and durability of parts are also affected by surface roughness. Although maintaining an optimum surface roughness is a major challenge in many manufacturing industries. Surface roughness during machining depends upon machining parameters such as cutting speed, feed rate and depth of cut. Also, tool vibrations during machining have significant influence in surface roughness. In this work an attempt is made to predict the surface roughness of machined components during the turning process by using machine learning techniques with vibration signals. By varying different machining parameters and keeping other tooling and material properties same, a range of surface roughness values can be obtained. For each condition, corresponding tool vibration signals were recorded. Our experimental setup involves

S S, Safeer, Sadique, Anwar, D, Navaneeth

Optimization of Fused Deposition Modeling Using Taguchi-Based Grey Relational Analysis for TPU used in Auto parts

2025-28-0158To be published on 02/07/2025

Fused Deposition Modeling (FDM) is a highly adaptable additive manufacturing method that is extensively employed for creating intricate structures using a range of materials. Thermoplastic Polyurethane (TPU) is a highly versatile material known for its flexibility and durability, making it well-suited for use in industries such as footwear, automotive, and consumer goods. Hoses, gaskets, seals, external trim, and interior components are just a few of the many uses for thermoplastic polyurethanes (TPU) in the automobile industry. The objective of this study is to enhance the performance of Fused Deposition Modeling (FDM) by optimizing the parameters specifically for Thermoplastic Polyurethane (TPU) material. This will be achieved by employing a Taguchi-based Grey Relational Analysis (GRA) method. The researchers conducted experimental trials to examine the impact of key FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical responses

Pasupuleti, Thejasree, Natarajan, Manikandan, Ramesh Naik, Mude, Silambarasan, R, D, Palanisamy

Vibration-based cutting tool condition monitoring in face milling process using wavelet features and machine learning algorithms – A comparative study

2025-28-0151To be published on 02/07/2025

In automotive applications, most of the engineering components come across the material removal process in manufacturing. Face milling is one of the prominent material removal processes wherein a multi-point cutter is used to machine the flat workpiece to bring it to its required dimension. In the material removal process, the cost of the cutting tool occupies the major part of the total manufacturing cost of a product. Also, the continuous usage of the cutting tool results in tool wear. The usage of the cutting tool after the threshold value of the tool wear deteriorates the surface finish of the workpiece which leads to product rejection. Hence, optimal tool usage is inevitable. The continuous monitoring of the cutting tool condition will ensure optimal tool usage. In the present work, four real-time tool conditions are considered, namely, fresh tool (G), tool flank wear (FW), tool flaking on rake surface (FL) and tool with broken tip (B). Vibration signals are acquired while milling

D, Pradeep Kumar, Syed, Shaul, V, Muralidharan, S, Ravikumar

Powering Precision: Ensemble Learning for Superior Battery Health Estimation

2025-28-0204To be published on 02/07/2025

In recent years, there has been a notable shift from fossil fuels to renewable energy sources due to energy challenges and the scarcity of oil resources. This transition has significantly increased the adoption of battery-powered electric vehicles (EVs) and hybrid electric vehicles (HEVs), replacing traditional internal combustion engine (ICE) vehicles. A crucial element of EVs and HEVs is the Battery Management System (BMS), which is essential for ensuring the battery pack operates safely, reliably, and efficiently. As batteries experience numerous charge and discharge cycles, their performance inevitably degrades, which can lead to failure and potentially catastrophic outcomes if the battery unexpectedly reaches the end of its life. This paper presents an innovative machine learning-based method to estimate battery health and mitigate related risks on real time battery data. The study employs proprietary data collected from Nickel Cobalt Aluminum (NCA) chemistry cells under dynamic

Joshi, Umita, Mandhana, Abhishek

Software Architecture for Autonomous Vehicles Using Matlab Simulink

2025-28-0190To be published on 02/07/2025

Autonomous vehicles utilise sensors, control systems and machine learning to independently navigate and operate through their surroundings, offering improved road safety, traffic management and enhanced mobility. This paper details the development, software architecture and simulation of control algorithms for key functionalities in a model that approaches Level 2 autonomy, utilising MATLAB Simulink and IPG CarMaker. The focus is on four critical areas: Autonomous Emergency Braking (AEB), Adaptive Cruise Control (ACC), Lane Detection (LD) and Traffic Object Detection. Also, the integration of low-level PID controllers for precise steering, braking and throttle actuation, ensures smooth and responsive vehicle behaviour. The hardware architecture is built around the Nvidia Jetson Nano and multiple Arduino Nano microcontrollers, each responsible for controlling specific actuators within the drive-by-wire system, which includes the steering, brake and throttle actuators. Communication

Ann Josy, Tessa, Sadique, Anwar, Thomas, Merlin, Manaf T M, Ashik, Vr, Sreeraj

A Simulation Methodology for Rainwater Ingress into Vehicle HVAC Cowl Box With Design Improvement

2025-28-0163To be published on 02/07/2025

Cowl Box is the first element of HVAC air passage and responsible for keeping rainwater away from blower unit without much impacting the HVAC air flow rate. Rainwater ingress to HVAC system affects passenger comfort. The main design objectives to be achieved in the design of HVAC cowl box includes minimizing the pressure drop and eliminating the chances of water ingress in cowl box. There are CFD tools available to study the cowl box pressure drop. However, methods available to study rain water ingress in cowl box are expensive in both mesh preparation and computational time. Using SPH (Smooth Particle based Hydrodynamics) based Preonlab tool, an attempt has been made in this work to study the design improvements of HVAC cowl box to eliminate the chances of flooding during raining. ANSYS FLUENT tool used to study the pressure drop of each design. The objectives of the simulation are to examine the cowl box pressure drop and water ingress quantity into the HVAC module. Designs with

Baskar, Subramaniyan, A, Boopalshanmugam, Raju, Kumar

FPGA Implementation of HLS crypto accelerators for embedded security in autonomous vehicles

2025-28-0205To be published on 02/07/2025

The growing ubiquity of autonomous vehicles (AVs) has introduced a new attack surface for malicious actors: the embedded systems that govern a vehicle's critical operations. Security breaches in these systems could have catastrophic consequences, potentially leading to loss of control, manipulation of sensor data, or even physical harm. To mitigate these risks, robust cybersecurity measures are paramount. This research delves into a specific threat – side-channel attacks – where attackers exploit data leakage through unintentional physical emanations, like power consumption or electromagnetic waves, to steal cryptographic keys or sensitive information. While various software and hardware countermeasures have been proposed, this study focuses on the implementation of masking techniques within the realm of embedded security. Masking techniques aim to obfuscate sensitive data during cryptographic operations, making it significantly harder for attackers to exploit side-channel

Deepan Kumar, Sadhasivam, R, Vishnu Ramesh Kumar, M, Boopathi, Manojkumar, R, R, Gobinath, M, Vignesh

Design and Development of Range Extended-Hybrid Power Train for Two-Wheeler

2025-28-0194To be published on 02/07/2025

Environmental awareness is being fostered in every sector, with particular emphasis on the automotive industry. Conventional internal combustion engines responsible for greenhouse gas emissions and health issues. Researchers are looking for alternative technologies to reduce carbon footprint and for green environment. In this study, electric drive train is designed for 20% range extension and retrofitted in conventional two-wheeler. A control strategy has been developed, tested and successfully deployed on the vehicle. The hybrid drivetrain architecture is assessed for complexities such as the required space for the battery and the location for fitting the electric motor. During low-speed conditions, the electric motor reduced the emissions and minimized fuel consumption. Consequently, the overall utilization of internal combustion engines at low-speed condition has decreased, leading to a decrease in the vehicle's fuel consumption and tailpipe emissions

Banad, Chandrashekhar B, Devunuri, Suresh, Nair, Jayashri Narayanan, Hadagali, Balappa, Prasad, Gvl

Autonomous Drone Solution for Human-Wildlife Conflict Management

2025-28-0198To be published on 02/07/2025

Human-wildlife conflicts pose significant challenges to both conservation efforts and community well-being. As these conflicts escalate globally, innovative technologies become imperative for effective and humane management strategies. This paper presents an integrated autonomous drone solution designed to mitigate human-wildlife conflicts by leveraging technologies in drone surveillance and artificial intelligence. The proposed system consists of stationary IR cameras that are setup within the conflict prone areas, which utilizes machine learning to identify the presence of wild animals and to send the corresponding location to a drone docking station. An autonomous drone equipped with high resolution IR cameras and sensors is deployed from the docking station to the provided location. The drone camera utilizes object detection technology to scan the specified zone to detect the animal and emit animal repelling ultrasonic sound from a device integrated to the drone to achieve non

Sadanandan, Vaishnav, Sadique, Anwar, George, Angeo Pradeep, Vinod, Vishal, Raveendran, Darshan Unni

Exploring Trapezoidal Salt Gradient Solar Pond Performance A Combined Numerical and Experimental Analysis with and without Reflective Covered Surface

2025-28-0201To be published on 02/07/2025

This study investigates the thermal performance of trapezoidal salt gradient solar ponds through a combined approach of experimental analyses and MATLAB numerical simulations. Salt gradient solar ponds offer a promising solution for sustainable energy generation by harnessing solar radiation and storing it as thermal energy for various applications. However, optimizing their performance is essential to maximize energy efficiency and economic viability. Laboratory experiments were conducted to evaluate the thermal dynamics of trapezoidal salt gradient solar ponds under different conditions, including the presence or absence of a reflective covered surface. These experiments provided valuable empirical data on temperature distribution and heat storage capacity. Additionally, numerical simulations were performed using MATLAB to model the thermal behavior of the ponds and validate the experimental findings. The simulations allowed for a deeper understanding of the underlying mechanisms

J, Vinoth Kumar

Design and Test methodology development of Retainer plate in Forward and Reverse mechanism of Tractor Transmission

2025-28-0079To be published on 02/07/2025

ABSTRACT: In the Automobile tractor- transmission system plays major role to transfer power from Engine to final drive through gear box enabling Forward/reverse(F/R) movements during field operations and transportation conditions. The F/R retainer plate with idler gear, shaft is located between clutch housing and transmission gear box housing. If the retainer housing plate gets failure, then power will not be able to transfer from engine to transmission gear box main drive. In one of the tractor model Retainer plate failures was observed during field testing. To simulate the failure mode from field to lab condition, the resultant forces and angle were calculated based on the gear torque and gear ratio of the drive line assembly. The resultant loads were applied on Idle gear shaft assembly through servo actuator in cyclic mode at FTL lab. The failure was observed in the Retainer plate and location of failure was matching with Field failure. CAE Virtual simulation was carried out for

V, Saravanan, Mani, Suresh, Kumar, Sasi, More, Amit, Dumpa, Mahendra Reddy

Design and Finite Element Analysis of Pneumatically Actuated Soft Gripper under Combined Positive and Negative Pressure

2025-28-0044To be published on 02/07/2025

Soft-bending actuators have garnered significant interest in the field of robotics and biomedical engineering due to their ability to mimic the bending motions of natural organisms. In this study, we propose a novel soft bending actuator that utilizes combined positive and negative pressures to achieve enhanced performance and control. The actuator consists of a flexible elastomeric chamber divided into two compartments: a positive pressure chamber and a negative pressure chamber. By selectively applying positive and negative pressures to the respective chambers, controlled bending motion can be achieved. The combined positive and negative pressure approach allowed for faster response times and increased flexibility compared to traditional soft actuators. Additionally, the actuator exhibited a high level of controllability, enabling precise manipulation of the bending motion. Its flexibility, controllability, and enhanced performance make it suitable for a wide range of tasks requiring

Lalson, Abirami, Sadique, Anwar

Advanced Parameter Forecasting for Titanium Grade 19 Machining in Automotive Applications

2025-28-0045To be published on 02/07/2025

Electrochemical machining (ECM) is a remarkably effective technique for producing detailed designs in materials that can conduct electricity, regardless of their level of hardness. As the desire for high-quality products and the necessity for rapid design changes grow, decision-making in the industrial sector becomes increasingly intricate. This work focuses on Titanium Grade 9 and proposes the development of prediction models using regression analysis to estimate performance measurements in ECM. The experiments are designed using Taguchi's methodology, employing a multiple regression approach to produce mathematical equations. The Taguchi technique is utilized for the purpose of single-objective optimization in order to determine the optimal combination of process parameters that will optimize the rate at which material is removed. ANOVA is a statistical method used to assess the relevance of process factors that impact performance indicators. The suggested prediction technique for

Pasupuleti, Thejasree, Natarajan, Manikandan, Ramesh Naik, Mude, Silambarasan, R, D, Palanisamy

An Integrated Material Science Approach to Evaluate the Viability of Ethoxy Ethane and Rubber Seed (Heavea Brasiliensis) Biodiesel as Sustainable Fuel for Compression Ignition Engines

2025-28-0130To be published on 02/07/2025

The primary issues in using pure vegetable oils for internal combustion engines are their high soot output and reduced thermal efficiency. Therefore in the present investigation, a Heavea Brasiliensis biodiesel (HBB) is used as a carbon source of fuel and ethoxy ethane as a combustion accelerator on a compression ignition (CI) engine. In this investigation, an only one cylinder, four-stroke, air-cooled DI diesel engine with a rated output of 4.4 kW at 1500 rpm was utilized. Whereas heavea brasiliensis biodiesel was delivered straightly into the cylinder at almost close to the end of compression stroke and ethoxy ethane was sprayed instantly in the intake manifold in the event of intake stroke. At various loads, the parameter of ethoxy ethane volume rate were optimised. To minimise exhaust emissions, an air plasma spray technology was employed to cover the engine combustion chamber with a thermal barrier coating. Because of its adaptability for high-temperature applications, YSZ (Yttria

Sagaya Raj, Gnana, Natarajan, Manikandan, Pasupuleti, Thejasree

CogniGuardianRoadscape: Advancing Safety through AI-Driven Roadway Audits

2025-28-0019To be published on 02/07/2025

The escalation of road infrastructure anomalies, such as speed breakers and potholes, presents a formidable challenge to vehicular safety, efficient traffic management, and road maintenance strategies worldwide. In addressing these pervasive issues, this paper proposes an advanced, integrated approach for the detection and classification of speed breakers and potholes. Utilizing a sophisticated blend of deep learning methodologies and enhanced image processing techniques, our solution leverages Object Detection to analyze and interpret real-time visual data captured through advanced vehicle-mounted camera systems. This research meticulously details the comprehensive process involved in the development of this system, including the acquisition and preprocessing of a vast, varied dataset representative of numerous road types, conditions, and environmental factors. Through rigorous training, testing, and validation phases, the model demonstrates remarkable proficiency in recognizing and

Thangaraju, Shanmuganathan, Nagarajan, Meenakshi, Ganesan, Maragatham, Raja, Selvakumar, Sirotiya, Aviral, Jasrotia, Bhargav

Vibrational, Thermal and Mechanical Performance Analysis of Hybrid Composite Plates Composed of Kenaf and Ridge Gourd Fibers with Waste Plastic Materials

2025-28-0030To be published on 02/07/2025

This study investigates the performance and highlights the mechanical, thermal, and vibrational characteristics of hybrid fibre composite plate composed of Kenaf Fibre (KF), Ridge Gourd Fibre (RGF), Waste Plastic Materials (WPM), and matrix materials. The raw materials undergo an alkaline treatment involving 2 hours of agitation with 5% NaOH. Following treatment, KF, RGF, and WPM are combined with epoxy resin using compression moulding to form four different hybrid composite plates in the %wt of 10:20:5, 20:10:5, 10:10:5, and 20:20:5. Various tests are conducted to evaluate their properties, including the Tensile Test, Shear Test, and Flexural Test, adhering to ASTM standards D638, D7078, and D790, respectively. The results indicate that 20:20:5 plate showed higher tensile strength (21.70 MPa), flexural strength (77.23 MPa), and shear strength (18.13 MPa. Subsequently, Thermo gravimetric Analysis (TGA) was conducted on the 20:20:5 composite plate due to its superior mechanical

D R, Rajkumar, R, Baranitharan, Basha, Mohamed Humayun, S, Kamalesh

Crash performance study on high-speed electric two wheeler battery enclosure

2025-28-0203To be published on 02/07/2025

The growth rate of Electric Vehicles (EVs) industry and the annual production rate have increased significantly over the years. This is due to the development of rechargeable electrical energy storage system (battery pack), which is the main power source for EVs. Lithium-ion batteries (LIBs) pack is predominantly used across all major vehicle category such as 2 wheelers, 3 wheelers and light commercial vehicle. LIB is one of the high energy-dense sources of volume. However, LIBs have a challenge to poses a risk of short circuits and battery pack explosions, when expose to an external damage. Controlled crash analysis is performed for various velocities ranging from 40 kmph to 70 kmph against an obstruction directly and at an offset from the wheel, so as to mimic the real-world crash of high-speed two-wheelers. The behaviour of the battery enclosure is examined through evaluating the structural integrity of the battery enclosure used in a realistic two-wheeler after crash at various

Venkatesan Sr, Aiyappan, Nelson, N Rino, Hariharan Nair, Adarsh

Study the Effect of Fasteners Coating Materials to Resolve the Leakage Issue in Steering Gear Assembly

2025-28-0128To be published on 02/07/2025

Abstract: In commercial vehicle industry, Hydraulic Power Assisted Steering (HPAS) gear plays a vital role to utilize the hydraulic force by amplifying the mechanical input. HPAS gear consists of housing, sector shaft, side cover, worm shaft, valve housing and rack piston. Side cover assembly is connected with housing assembly through bolts which is in exposure to high pressure hydraulic fluid. During high pressure running condition, torque relaxation in the bolt is observed which leads to the loosening of bolts and tends to hydraulic fluid leakage through bolts. Since, some of the bolts are exposed to the fluid environment in the inner surface of the housing, the existing phosphate coated bolts are relaxed and loosened due to the bolts that exposed to the oil environment which have insufficient coefficient of friction in bolt head and thread. To overcome the bolt failure during high pressure hydraulic application various bolt coating analysis is experimented to withstand the

Ayyappan, Rakshna, Govindarasu, Anbarasu, P, Rajasekar, D, Senthil Kumar

OPTIMIZED DESIGN AND ANALYSIS OF A HIGH-PERFORMANCE, TRACK-FOCUSED QUAD BIKE FOR THE INDIAN MARKET

2025-28-0061To be published on 02/07/2025

A comprehensive approach to the optimized design and analysis of a track-focused quad bike specifically tailored for the Indian market. The design process integrates multiple critical factors, including driver ergonomics, aesthetics, and strategic component placement, to establish the optimal vehicle dimensions. The primary objective is to ensure comfort, functionality, and visual appeal while addressing the unique demands of the Indian terrain and user preferences. A meticulous selection process for tires and suspension geometry is conducted using the advanced Optimum Kinematics software. This optimization ensures that the vehicle can adeptly handle a variety of road conditions, providing superior performance and stability. The vehicle’s core structure features a space frame chassis, engineered to minimize tubing and facilitate ease of fabrication, contributing to both weight reduction and structural integrity. A robust 600cc 4-cylinder engine is selected, emphasizing an optimal power

Thanikonda, Praveen Kumar, Shaik, Amjad, Tappa, Raju, Ratlavath, Ramu, Navar, Adarsh, Challa, Ajith Kumar

A Comparative Study on fault diagnosis of Electrical vehicle motor testing machine Gear Components Using machine Learning algorithms

2025-28-0177To be published on 02/07/2025

Electric vehicles (EVs) are the way of the future for the automobile industry. The drive motor is a vital part of modern EVs. A motor testing machine is used to verify the critical parameters of the electrical motor, which is seen to be of the utmost importance. Electric motor characteristic curve points and their electromagnetic behaviour under different conditions are regularly found using the motor testing machine. But it has been noted that a flaw in the testing machine's helical gear arrangement causes frequent malfunctions and less-than-ideal performance, which impacts the assembly line's effectiveness in producing electric cars. The research project is to enhance the motor test bench apparatus by modifying crucial design parameters using machine learning and vibration signal analysis methods. Vibration signals are recorded at various gear settings before statistical features are extracted. Following that, these signals are classified using classifiers such Quadratic SVM and

S, Ravikumar, Syed, Shaul, V, Muralidharan, D, Pradeep Kumar

Structural Analysis of Two-Wheeler Handlebars under Varied Loads

2025-28-0053To be published on 02/07/2025

This study presents a comprehensive structural analysis of a two-wheeler handlebar subjected to various loading conditions, aiming to evaluate its strength, durability, and safety. During operation, two-wheelers encounter multiple forces, making the handlebar a critical component for rider control and safety. The analysis begins by investigating the different types of loads experienced during typical riding scenarios, including static loads when the bike is stationary, and dynamic loads arising from rider movements, braking, and handling. The primary objective is to understand how these loads impact the handlebar's structural integrity. To achieve this, critical load cases are identified and categorized. Braking loads, which apply force primarily in the forward direction due to deceleration, are examined. Manhandling loads are analyzed to understand the multidirectional forces acting on the handlebar during transportation and parking. Additionally, vertical loads are assessed

Prajapati, Akash, Rathore, Avijit Singh, Bhaskara Rao, Lokavarapu

Optimizing Titanium Alloy Grade 7 Machining with Grey Relational Analysis

2025-28-0049To be published on 02/07/2025

Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in materials that conduct electricity, irrespective of their level of hardness. Due to the growing need for superior products and the requirement for quick design adjustments, decision-making in production has become more complex. This study focuses on Titanium Grade 5 and suggests creating predictive models utilizing a Taguchi-grey technique to achieve multi-objective optimization in ECM. The trials are structured based on Taguchi's principles, utilizing Taguchi-grey relational analysis (GRA) to simultaneously maximize several performance indicators. This entails optimizing the pace at which material is removed, decreasing the roughness of the surface, and attaining precise geometric tolerances. ANOVA is used to assess the relevance of process variables that affect these measures. The suggested predictive technique for Titanium Grade 5 outperforms current models in terms of flexibility

Pasupuleti, Thejasree, Natarajan, Manikandan, Kumar, V, Sagaya Raj, Gnana, Krishnamachary, PC, Silambarasan, R

Gear misalignment optimization for Electric Drive Unit using Machine learning based Prescriptive Analytics

2025-28-0166To be published on 02/07/2025

Gear mesh misalignment in electric drive unit may result in shifts in the load distribution of a gear pair that can increase contact and bending stresses. It may move the peak bending and contact stresses to the edge of the face width, and also increase gear noise. Lower misalignment value is often required to reduce the peak bending and contact stresses and have a balanced load distribution along the gear flank. This paper delineates a method which is also called prescriptive analytics that combines virtual simulations, Machine learning (ML) and optimization techniques to minimize different gear misalignments for electric vehicle drive unit. The gear misalignments are dependent on stiffness of different components in the drive unit. So, a comprehensive approach that incorporates effect of individual components and their interactions is needed. Generally, an assembly level virtual simulation is performed to evaluate gear misalignments. In order to minimize the misalignments, manual

Penumatsa, Venkata Ramana Raju, Thomas, Benson, Black, Derrick, Jain, Sachin

Cutting-Edge Coating Materials for Dual Fuel Diesel Engines Using Acetylene Aspiration

2025-28-0134To be published on 02/07/2025

A diesel engine with a Yttria Stabilised Zirconium (YSZ) thermal barrier layer (TBL) on the piston crown was used in an experiment. The aim of the investigation was to evaluate the influence of the thermal barrier layer on the efficiency and pollution levels of a diesel engine. The selection of YSZ as the coating material was based on its desirable physical properties including a high coefficient of expansion when exposed to heat, low degree of thermal conductivity, and a high Poisson's number. These characteristics make it a suitable material for use in coatings applied to engine components. In addition to their current research, the scientists are also focusing on identifying sustainable substitutes for conventional petroleum fuels. This is because of the growing concern over environmental impacts and the limited availability of fossil fuel resources. The researchers are seeking new options that are both environmentally friendly and capable of meeting the world's energy demands. By

Sagaya Raj, Gnana, Natarajan, Manikandan, Pasupuleti, Thejasree

AI-Driven Optimization of Advanced Machining for Haste alloy by ANFIS Method

2025-28-0141To be published on 02/07/2025

Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in materials that conduct electricity, independent of their level of hardness. Due to the increasing demand for superior products and the necessity for quick design modifications, decision-making in the manufacturing sector has become progressively more difficult. This study primarily examines the use of Inconel 625 in vehicle applications and suggests creating regression models to predict performance parameters in ECM. The experiments are formulated based on Taguchi's ideas, and mathematical equations are derived using multiple regression models. The Taguchi approach is employed for single-objective optimization to ascertain the ideal combination of process parameters for optimizing the material removal rate. ANOVA is employed to evaluate the statistical significance of process parameters that impact performance indicators. The proposed regression models for Inconel 625 are more versatile

Natarajan, Manikandan, Pasupuleti, Thejasree, D, Palanisamy, Silambarasan, R, Krishnamachary, PC

Thermal Buckling Analysis of Axially Layered Aluminium Silicon Nitride Functionally Graded Thin Beam using Taguchi Method

2025-28-0172To be published on 02/07/2025

This study investigates the thermal buckling behavior of functionally graded material (FGM) thin beams, specifically targeting their application in engine hood panels. The FGM material utilizes Aluminum and Silicon Nitride, offering a combination of metal's strength and ceramic's heat resistance. The analysis focuses on optimizing the critical buckling temperature under various boundary conditions, mimicking the real-world scenario of an engine hood experiencing uneven heating. The FGM structure is designed with four axially arranged layers, where the ceramic and metal content gradually changes throughout the thickness. Finite element analysis software (ANSYS) is employed to evaluate the buckling behavior under different temperature loads. To optimize the thermal performance of the engine hood panel, the Taguchi L9 orthogonal array technique is implemented using Minitab 19 software. Layers 1-4 of the FGM beam are considered process parameters, and the critical buckling temperature

Pawale, Deepak, Bhaskara Rao, Lokavarapu

Investigating the Influence of Fiber Orientation on Frequency Response of Laminated Composite Plates using Taguchi Method

2025-28-0183To be published on 02/07/2025

This study investigates the frequency response characteristics of laminated composite rectangular plates, focusing on the influence of fiber orientation. The composite plates, composed of 12 layers of glass fiber reinforced polymer composites (GFRP), were chosen for their superior mechanical properties and broad applicability in engineering fields, including the automotive sector. In automotive engineering, these composites are valued for their lightweight properties and high strength, contributing to enhanced performance and fuel efficiency. The analysis employed a combination of finite element methods and Taguchi experimental design techniques to understand how fiber orientation affects the dynamic behavior of these plates. Finite element analysis (FEA) was conducted using ANSYS Parametric Design Language (APDL), a computational tool known for handling complex geometries and material behaviors accurately. This software enabled precise simulations of the dynamic responses of the

N, Suhas, C V, Prasshanth, U, Anish Kumar, Bhaskara Rao, Lokavarapu

Fabrication And Analysis of Pneumatically Actuated Soft Robotic Gripper With Negative Pressure

2025-28-0145To be published on 02/07/2025

Soft-bending actuators are gaining considerable attention in robotics for handling delicate objects and adapting to complex shapes, making them ideal for biomimetic robots. Soft pneumatic actuators (SPAs) are favoured in soft robotics due to their compliance and safety features. Using negative pressure for actuation, it enhances stability by reducing the risk of sudden or unintended movements, crucial for delicate handling and consistent performance. Negative pressure actuation is more energy-efficient, safe and are less prone to leakage, increasing reliability and durability. This paper involves development of a new soft pneumatic actuator design by comparing various designs and to determine its performance parameters. This paper depicts on designing, and fabricating flexible soft pneumatic actuators working under negative pressure for soft robotic applications. Uniaxial tensile tests were conducted to characterise the properties of materials used to fabricate the soft actuator, and

Warriar J S, Sreejith, Sadique, Anwar, George, Boby

Optimization of WEDM Parameters for Invar 36 Automotive Components Using Taguchi-Grey Relational Analysis

2025-28-0153To be published on 02/07/2025

Wire Electrical Discharge Machining (WEDM) is an essential procedure used to shape intricate geometries in conductive materials such as Invar 36, which is recognized for its minimal thermal expansion characteristics used for high temperature applications especially in automobile engine parts and exhaust valves. The objective of this study is to improve the effectiveness and precision of Wire Electrical Discharge Machining (WEDM) for Invar 36 material by utilizing Taguchi-based Grey Relational Analysis (GRA). The study examines the impact of WEDM parameters, specifically pulse-on time, pulse-off time, and discharge current, on important machining outcomes such as surface roughness (Ra), material removal rate (MRR). The experimentation have been planned and conduced as per Taguchi L9 orthogonal array design. Grey relational grades are computed to measure the correlation between input parameters and machining responses, enabling the determination of the most favourable parameter

Natarajan, Manikandan, Pasupuleti, Thejasree, Kumar, V, Sagaya Raj, Gnana, Krishnamachary, PC, Silambarasan, R

Optimization and Regression Modeling of Additive Manufacturing (Fused Deposition Modeling) of PETG Material for Automobile applications

2025-28-0146To be published on 02/07/2025

Additive Manufacturing (AM) techniques, specifically Fused Deposition Modeling (FDM), have transformed the manufacturing industry by allowing the creation of intricate shapes using different materials. Polyethylene Terephthalate Glycol (PETG) is a thermoplastic that is commonly used in additive manufacturing (AM) because of its advantageous mechanical properties, resistance to chemicals, and ease of processing. PETG is used especially for producing automotive components that require impact resistance, dimensional stability, and good surface finish. It can be used for interior trim parts, protective covers, and exterior components The primary objective of this study is to enhance the FDM process parameters for PETG material and construct regression models that can accurately forecast important performance metrics. An investigation was carried out through experimental trials to examine the impact of FDM process parameters, such as layer thickness, infill density, printing speed, and

Natarajan, Manikandan, Pasupuleti, Thejasree, Shanmugam, Loganayagan, Katta, Lakshmi Narasimhamu, Silambarasan, R, Kiruthika, Jothi

Optimization of machining parameters based on desirability function analysis for Stir Casted Aluminium Hybrid Metal Matrix Composites

2025-28-0119To be published on 02/07/2025

These days, aluminum and other material composites are indispensable for a wide range of engineering applications, including automotive-related ones. The machinability investigations of hybrid metal matrix composites (HMMC) made of Al 6061 are reported in this paper. Graphene nanoparticles (GNp) and boron carbide were used to reinforce Al6061 alloy for the experiment. Stir casting was used to create the hybrid composite under the right circumstances. Since HMMC is difficult to machine using traditional machining techniques, the advanced method of electrical discharge machining (EDM) was used. On stir-casted Al-B4C-GNP composites, EDM machinability investigations were conducted. Using input parameters such pulse on time, pulse off time, and peak current for the response of material removal rate (MRR) and surface roughness, Taguchi based Desirability function Analysis was used to optimize the EDM process parameters. The optimal machining parameters have been determined by the composite

Kala, Lakshmi K, Madhuri, K, Reddy, Damodara, Tarigonda, Hariprasad, R L, Krupakaran, Tharehallimata, Gurubasavaraju, Naidu, B Vishnu Vardhana

Enhancing Thermal Performance of Trapezoidal Porous Medium Solar Ponds: Experimental and Numerical Analysis

2025-28-0207To be published on 02/07/2025

This study investigates the thermal efficiency of trapezoidal porous medium solar ponds through a multifaceted approach encompassing laboratory experiments, outdoor contrasts, and numerical analysis. Laboratory experiments were conducted to evaluate the heat storage capabilities of various porous materials. Outdoor contrast experiments, involving two mini solar ponds with a surface area of 0.42m×0.42m and a bottom area of 0.09m×0.09m, examined the thermal performance enhancement offered by porous medium incorporation. Factors such as the presence of a cover and the type of porous medium were analyzed for their influence on temperature distribution. Results revealed a notable increase in the maximum temperature of the solar pond by approximately 10°C following the introduction of porous medium. Furthermore, numerical evaluation utilizing MATLAB provided deeper insights into the experimental data, enriching our understanding of the thermal dynamics specific to trapezoidal porous medium

J, Vinoth Kumar

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