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Niobium Alloyed Brake Disc for reduced NVH and emission control

2026-26-0285To be published on 01/16/2026

Recent regulations limiting brake dust emissions have presented many challenges to the brake engineering community. The objective of this paper is to provide a low cost, mass production solution utilizing well known existing technology to meet brake emissions requirements. The proposed process is to alloy the Gray Cast Iron with Niobium. The Niobium addition will reduce wear debris and improve NVH (Noise Vibration Harshness). The test methodology included: Manufacture of disc samples alloyed with Niobium, and Evaluation of airborne wear debris utilizing a pin-on-disc tribometer equipped with emission collection capability. The airborne emission and wear surfaces were further analyzed by Scanning Electron Microscopy, Energy Dispersive techniques (SEM-EDS), X-Ray Diffraction and Optical Microscopy. The cast iron test matrix included four groups; Unalloyed eutectic 4.3% Carbon Equivalent (CE), Unalloyed hypereutectic >4.3% CE, Niobium alloyed Eutectic and Niobium alloyed hypereutectic

Barile, Bernardo, Holly, Mike

Effect of the Flow Forming Process on the Mechanical properties and Microstructure of GDC & LPDC cast aluminum alloy wheels.

2026-26-0298To be published on 01/16/2026

Aluminum alloy wheels have become the preferred choice over steel wheels due to their lightweight nature, enhanced aesthetics, and contribution to improved fuel efficiency. Traditionally, these wheels are manufactured using methods such as Gravity Die Casting (GDC) [1] or Low Pressure Die Casting (LPDC) [2]. As vehicle dynamics engineers continue to increase tire sizes to optimize handling performance, the corresponding increase in wheel rim size and weight poses a challenge for maintaining low unsprung mass, which is critical for ride quality. To address this, weight reduction has become a priority. Flow forming [3,4], an advanced wheel production technique, offers a solution for reducing rim weight. This process employs high-pressure rollers to shape a metal disc into a wheel, specifically deforming the rim section while leaving the spoke and hub regions unaffected. By decreasing rim thickness, flow forming not only reduces overall wheel weight but also enhances strength and

Singh, Ram Krishnan, Medaboyina, HarshaVardhan, G K, Balaji, Gopalan, Vijaysankar, SUNDARAM, RAGHUPATHI, Paua, Ketan

Combustion noise quality improvement in a common rail Diesel Engine at Low idle for Agriculture Tractor

2026-26-0329To be published on 01/16/2026

Vehicle level NVH performance plays major role in customer comfort criteria. Tractor low idle rpm Sound Quality can be one of the parameter which influences customer purchasing decision based on comfort criteria. Modern diesel engines with stringent emission norms together with fuel economy requirements pose challenges to noise control. Common rail engine technology has advantage of precise fuel delivery and combustion control which needs optimization to achieve the conflicting requirements of noise, emission and fuel efficiency. Engine noise at low idle condition is dominated by combustion noise which depends on rate of pressure rise inside the cylinder during combustion. The important parameters which influence cylinder pressure rise are fuel injection timing, pilot injection quantity and its separation, rail pressure and EGR valve position. The study is carried out to understand which combustion parameter is most influencing to achieve better sound quality of engine. Taguchi design

p, Priyadarshan, Chavan, Amit, A, Kannanswamy, Patil, Sandeep, Chaudhari, Vishal V

Assessing the impact of hole piercing edge quality on fatigue samples for S550MC steel sheet.

2026-26-0306To be published on 01/16/2026

The exceptional strength, formability, and weldability of S550MC steel sheets make them a cornerstone material in the automotive industry. These properties translate into the creation of high-performance automotive components like chassis parts, structural reinforcements, and safety cages, ultimately contributing to enhanced vehicle safety and overall performance. Furthermore, S550MC steel boasts excellent fatigue resistance, a critical factor for ensuring long-term reliability in demanding automotive applications that experience repeated stress cycles. However, beyond its inherent properties, optimizing the performance of S550MC components hinges on a nuanced understanding of the critical relationship between hole edge quality and fatigue failure. This meticulous study delves into the impact of hole-piercing clearance on the quality of the hole edges in modified fatigue samples manufactured from S550MC steel, and its effect on the fatigue life. The surface morphology was assessed

Nahalde, Sujay, Hingalje, Abhijeet, Ughade, Vikas, Singh, Udita, More, Hemant

Tractor Clutch wear simulation by Inhouse development

2026-26-0572To be published on 01/16/2026

To develop an accelerated Clutch test simulation method at inhouse laboratory as System level of validation to replicate field phenomena in short time with controlled repeatability and increased test accuracy. Wet clutch is one of the M&M technology project for higher hp(75) tractors. Currently Mahindra having dry clutch system in higher hp tractors & presently Wet clutch development in progress for higher HP tractors for increasing clutch life & to reduce clutch pedal operation as per customer requirement, hence new test rig to be developed for validating new tractor wet clutch system as per RWUP. Previously tractor clutch system is completely evaluated through field testing on tractor level. Thus, there are several drawbacks in field testing like more waiting time to avail seasons, more testing time, evaluation of limited number of samples, non-availability of complete tractor on time, less accuracy, less repeatability of test results, unsafe conditions of rider, higher human fatigue

D, Yashwanth, Raja, R, Udayakumar, S, M, Jeevaharan, Vijayakumar, Narayanan

Streamlined Methodology for E-Motor Performance Evaluation using a configurable Universal Inverter

2026-26-0510To be published on 01/16/2026

Electric motor benchmarking is often constrained by limited availability of motor-specific data, particularly when dealing with commercially available or third-party electric motors. This paper presents a streamlined and scalable methodology for characterizing unknown eMotors using a configurable universal inverter platform. The proposed approach is specifically designed for OEMs and Tier 1 suppliers seeking to evaluate performance metrics such as torque accuracy, peak and continuous capability, efficiency, and control behaviour—without prior access to key motor parameters or simulation data. A central challenge in this context is the stepwise electromagnetic characterization required to determine the phase current needed for accurate speed and torque control, especially under a Maximum Torque per Ampere (MTPA) or Maximum Torque per Watt (MTPW) strategy. As this requirement is highly dependent on the motor’s topology and electromagnetic properties, most conventional approaches rely on

Kanya, Benjamin, Duchi, Francesco, Ravi, Abhishek

A Novel Approach to Deep Drawing Using Hybrid System and Pneumatic-Assisted Forming

2026-26-0301To be published on 01/16/2026

ABSTRACT: This paper presents a novel Plunger-Integrated Hybrid System aimed at enhancing the efficiency and performance of deep drawing operations in metal forming processes. The proposed hybrid system strategically combines the mechanical strength of metals with the elastic flexibility of polymers, specifically polyurethane rubber, to improve formability and reduce spring-back, two critical challenges in conventional sheet metal forming. A novel two-stage forming technique is employed, an initial drawing operation using a larger radius with polyurethane rubber, followed by final radius formation using the same rubber in conjunction with a pneumatic cylinder. This integrated approach ensures uniform force distribution via the embedded plunger, significantly minimizing forming defects and enhancing the dimensional accuracy of the final components. The solution has been validated using Finite Element (FE) simulation methods, confirming its capability to produce high-quality parts

Chava, Seshadri Reddy, Singh, Prakhar, DHANAJKAR, NARENDRA, Roy, Amlan, Raju, Gokul

Drive Cycle Type Identification Using Data Driven Methodologies

2026-26-0649To be published on 01/16/2026

Identifying the type of drive cycle is crucial for analyzing customer usage and optimizing vehicle performance and emission control. Methods that rely on geographical location are limited by varying driving conditions at the same location (e.g., heavy traffic during peak hours vs. free-flowing traffic at night). This paper proposes a methodology to identify the type of drive cycle (city, interurban, highway or others) using drive characteristics derived from vehicle data rather than geographical location. Real-world vehicle data from testing trucks is taken, whose drive profiles are already known. Initially, multiple characteristic features of the drive cycle are identified from literature surveys and domain experiences. These features, which can be extracted from basic signal data, include gear shifts, time spent in different driving modes (acceleration, cruise, standstill), velocity distributions, and an 'aggressiveness factor' representing overall driving style. Using ML based

REDDY, MALLANGI PRASHANTH, Gorain, Raju, Ganguly, Gourav

Data-Driven Prediction of Global Automotive Trends: Forecasting Fuel Economy and CO₂ Emissions Using Machine Learning

2026-26-0643To be published on 01/16/2026

In the pursuit of cleaner transportation and environmental sustainability, the global automotive industry is undergoing rapid transformation. This study leverages historical multi-decade vehicle data to develop predictive models for fuel economy and CO₂ emissions across a wide range of vehicle technologies. By utilizing advanced machine learning algorithms in Python and integrating insights through Power BI visualizations, the project identifies key correlations between vehicle attributes—such as weight, powertrain, and footprint—and their environmental performance. Results highlight the increasing impact of electric vehicle adoption, hybridization, and light weighting on overall emissions reduction. These insights help forecast the direction of fuel economy standards, emission patterns, and technology shifts across manufacturers and vehicle types. Beyond technical predictions, the study offers a decision-support framework for global policymakers, automotive designers, and

Hazra, Sandip, Tangadpalliwar, Sonali, Hazra, Sanjana

Advancing Sustainable Mobility: Transitioning to Zero-Emission Electric Vehicles with BEVs and FCVs

2026-26-0164To be published on 01/16/2026

The transportation and mobility sector is undergoing a profound transformation, with a growing emphasis on sustainability and minimizing the environmental impact of transportation. Among the most significant trends is the transition to electric vehicles (EVs) in the form of Battery and Fuel cell, which produce zero emissions without any harmful gases release in nature. This review highlights several infrastructure-related issues and critical factors that could drive India's transportation sector toward adopting electric vehicles. It also delves into the fundamental understanding of e-mobility, shedding light on the daily challenges and barriers it faces. Furthermore, the study explores research aspects, including the strategies, methods, and tools used for electric vehicles to complete the research on Battery electric vehicles (BEV) and also comparative analysis with Fuel cell vehicles (FCVs). The shift BEVs has been driven by decreasing battery costs and advancements in charging

Kumar, Dr. Vijay Bhooshan

Performance Evaluation and Optimization of Engine Brake System using Chassis Dynamometer

2026-26-0511To be published on 01/16/2026

Engine braking is a deceleration technique that leverages the internal friction and pumping losses within the engine. By closing the throttle and potentially selecting a lower gear, the engine creates a retarding force that slows the vehicle. This practice contributes to better fuel economy, decreased brake system load, and improved vehicle handling in specific driving scenarios, such as steep declines or slippery road surfaces. To alleviate stress on their primary braking systems and prevent overheating, heavy vehicles frequently incorporate engine-based braking. While older trucks relied on simple exhaust brakes with a butterfly valve to restrict exhaust flow, these had limited impact. Hence contemporary heavy vehicles almost exclusively use more advanced engine braking technologies. Traditionally, our heavy-duty vehicles use Exhaust brake system to elevate the braking performance on hilly terrains. Hence an improved sample of Engine brake was developed for enhanced braking

M, Vipin Prakash, Rajappan, Dinesh Kumar, R, Suresh, N, Gopi Kannan

Analysis and Optimization of Stick-Slip Behaviour in Metal-Plastic Interfaces for Connected Tail Lamp Assemblies in Electric Vehicles

2026-26-0332To be published on 01/16/2026

The seamless and sleek design of connected tail lamps adds a visually striking element to the car's exterior. It aligns with contemporary automotive trends and gives the vehicle a premium and futuristic appearance. Automakers use these lamps as a design signature to establish brand identity. Connected tail lamps improve visibility for drivers behind the vehicle. The assembly of connected tail lamps can pose several challenges, especially due to their complex design and integration requirements. Metal-plastic creak is a common concern in electric vehicles (EVs), often noticeable when driving on uneven roads. This primarily results from stick-slip behaviour at the interface of metal and plastic components, intensified by improper alignment. When the designed geometric dimensioning and tolerancing (GD&T) is not met in real manufacturing conditions, misalignment introduces unintended contact forces, leading to intermittent micro-sliding and frictional energy release, which manifests as an

MICHAEL STEPHAN, NAVIN ESTAC RAJA, C M, MITHUN, Mohammed, Riyazuddin

Enhanced Methodologies for predicting Automotive Wheel Bearing life and damage using RLDA

2026-26-0482To be published on 01/16/2026

The durability of wheel bearings is assessed in terms of raceway life and flange life. Raceway life focuses on the performance and damage tolerance of rolling elements, while flange life evaluates the structural integrity of wheel flanges under operational stresses. Traditionally, durability predictions relied on conventional design methods and analytic formulas for raceway spalling, as well as static load assumptions for flange fatigue analysis. Recently, integrating design of experiments (DOE) with traditional approaches has enhanced these methods, enabling systematic evaluation of design variables and loading conditions. This paper introduces a methodology for analysing raceway life and damage in automotive wheel bearings using RLDA (Road Load Data Acquisition) data. The process involves acquiring raw deterministic load data, filtering it to preserve high-peaked signals, and transforming the filtered data into block cycles derived from load time histories. Each block cycle contains

Narendra, Vishwanath, Mane, Yogiraj, Paua, Ketan, Singh, Ram Krishnan, Vellandi, Vikraman

Development of a Fuel Injector Driver for Accelerated Testing

2026-26-0564To be published on 01/16/2026

This paper presents the design and development of a cost-effective fuel injector driver for accelerated testing of injectors. The driver accurately simulates injection patterns across various vehicle operating conditions. It can be programmed with injection maps for different engines, test cycles as per part drawings, predefined engine running cycles, and manual control where the frequency and duty cycle of PWM pulses are user-defined. The device can also be operated remotely via a Wi-Fi access point. This setup played a pivotal role for rapid comparative analyses among different suppliers, aiding in the final product selection. Accelerated testing was performed under various operating cycles, with performance evaluations done periodically. Conducting such tests at the vehicle level or on engine test benches would involve significant time and cost. However, the rapid development of the microcontroller-based test setup enabled quick initiation and completion of testing in a short span

Bhatt, Pancham, Agrawal, Adheesh, Kuchhal, Abhinav

Machine learning model to predict Chest Injury during Thorax Impact on Human Body Models

2026-26-0665To be published on 01/16/2026

In recent years, virtual models have been handy in predicting potential injury risk to occupants in vehicle crashes. Virtual models offer detailing of occupant anthropometry and closest possible bio-fidelity over existing test devices. This study focuses on the assessment of chest deflections in frontal thorax impacts using virtual human body models of a few anthropometries and transforming the assessment of injuries of broader range of anthropometries (population). The study utilizes machine learning models to enable injury assessment across a broader range of body types. The study has taken a standard test scenario (Kroell load case) having frontal blunt thoracic impact. The load case is replicated in LS-DYNA and finite element human body models (HBMC) of 05th Female and 50th Male are used. The simulation setup replicates the boundary conditions as per literature, the responses necessary to measure chest deflection were validated & recorded. The outputs from the simulations and data

Sridhar, Raam, Arya, Bibhu, Divakar, Prajwal, R, Udhaya Kumar, Bhutki, Prasad, Kumar PhD, Devendra, Kurkuri, Mahendra, Mohan PhD, Pradeep

Lightweight AI Deployment for Legacy Automotive ECUs: A Practical Optimization Approach

2026-26-0663To be published on 01/16/2026

Automotive systems are increasing adopting data-driven and intelligent functionality in the areas of predictive maintenance, virtual sensors and diagnostics. This has led to a need for the AI models to be directly run on vehicle ECUs. However, most of these ECUs – especially those in cost-sensitive or legacy platforms lack the computational capacity and parallel processing support required for standard AI implementations. Given the stringent real-time and reliability requirements in automotive environments, deploying such models presents a unique challenge. This paper proposes a practical methodology to optimize both the training and deployment phases of AI models for low-computation ECUs that operate without parallelism. Designing lightweight model architectures, using pruning and quantization techniques to minimize resource utilization, and putting in place a strategy appropriate for single-threaded execution are the three main objectives of the developed approach. The goal is to

Sharma, Sahil, Mathew, Melvin

NN FMU: Deep Learning Models for Next-Gen xiL Vehicle Simulation

2026-26-0452To be published on 01/16/2026

Functional Mock-up Units (FMUs) have become a standard for enabling co-simulation and model exchange in vehicle system development. However, traditional FMUs derived from physics-based models can be computationally intensive, especially in scenarios requiring real-time performance. This paper presents a Python-based approach for developing a Neural Network (NN) based FMU using deep learning techniques, aimed at accelerating vehicle simulation while ensuring high fidelity. The neural network was trained on vehicle simulation data and developed using Python frameworks such as TensorFlow. The trained model was then exported into FMU, enabling seamless integration with FMI-compliant platforms. The NN FMU replicates thermal behavior of vehicle with high accuracy while offering a significant reduction in computational load. Benchmark comparisons with Physical Thermal Model demonstrate that the proposed solution provides both efficiency and reliability across various driving conditions

Srinivasan, Rangarajan, ASHOK BHARDE, Pooja, MHETRAS, Mayur, CHEHIRE, Marc

Fatigue Life Prediction Methodology for Vehicle Suspension System and correlation with Physical Test

2026-26-0459To be published on 01/16/2026

Fatigue Analysis is a safety critical area in design engineering for load bearing members. The design of a durable suspension system forms the foundation of vehicle architecture. The challenge lies in accurately predicting fatigue in critical areas to reduce field failures, primarily due to the absence of a validated methodology for fatigue calculation. This study provides an overview of fatigue assessment for Knuckle assembly/Rear Twist Beam based on digital Road Load/test Data for Finite Element Analysis (FEA) process for design development. This study makes use of Computer Aided Engineering (CAE) solvers such as Optistruct for model setup and fatigue tool such as nCode/FEMFAT for Fatigue Analysis. The methodology used for Fatigue estimation of rear suspension components such as Rear Twist Beam and Knuckle assembly is based on Digital Road Load Data/duty cycle loads applied to the suspension components at the hard point location at assembly level. The fatigue process used for

Kokare, Sanjay, Nagapurkar, Tejas, Iqbal, Shoaib

Virtual Powertrain Development and Calibration methodology: The Role of Model-in-the-Loop in Calibration and Testing of EV power Train integrated with real road simulation tools.

2026-26-0472To be published on 01/16/2026

The automotive industry has witnessed significant advancements in powertrain development over recent years, with further evolution expected in the near future. Modern vehicle propulsion systems now encompass a broad spectrum, including fully electric vehicles, plug-in hybrid models, mild 48V hybrid powertrains, and traditional internal combustion engine vehicles. This growing variety demands extensive engineering efforts for development and testing across different powertrain configurations. To facilitate the simultaneous advancement of multiple powertrain technologies while keeping costs manageable, optimizing calibration and testing processes is crucial. A combination of cutting-edge simulation techniques and state-of-the-art testing equipment offers an effective solution, introducing innovative testing methodologies that streamline the development of sophisticated propulsion architectures. This paper explores the implementation of Model-in-the-Loop (MIL) testing as a key methodology

Elumalai, Elakkia, P, SahayaSurendiraBabu, S, Sivashankar, J, Frederick Royston, S, Gowtham

The Road to SDV: A Maturity Model for Software-Defined Transformation

2026-26-0679To be published on 01/16/2026

Software Defined Vehicles (SDV), Software Defined Networks, Software Defined (electricity) Grids are just a few examples of how the Software Defined Transformation is unfolding across many industries today. This paper defines a maturity model for Software Defined Transformation and evaluates different industries including Automotive. This cross-industry view of Software Defined X (SDx) helps in analyzing where SDV's could be headed. Koster et all [2023] by BCG mentions 'The industries' SDV transformation is overshadowed by complexity', with players pursuing several directions in this transformation. While companies like Tesla are already making software centric cars, traditional OEMs like Stellantis, Toyota, Ford etc. are making huge investments and redefining their own business models, tech stacks and operations to leverage the power of software. There is an opportunity to introduce an overarching framework to bring clarity on this front by comparing SDx across industries. We propose

Mathur, Akshay Raj, Misra, Amit, Makam, Sandeep

Self-supervised diagnostics & prognostics framework for predictive maintenance in electric vehicles

2026-26-0673To be published on 01/16/2026

Predictive maintenance is essential for enhancing the reliability, safety, and operational efficiency of connected vehicles. However, traditional supervised learning approaches for fault prediction depend heavily on large, labeled datasets of failure events, which are often scarce and expensive to obtain in real-world automotive environments. This paper proposes an original self-supervised anomaly detection framework that predicts emerging failures using only healthy operational data, eliminating the need for explicit failure labels. The approach employs self-supervised pretext tasks, such as masked signal reconstruction and future telemetry prediction, to learn robust representations of normal multi-sensor behavior (e.g., temperature, pressure, current, vibration). An unsupervised anomaly detection model then identifies deviations from these learned patterns. This integrated with data-informed predictive models enable early detection of faults across critical subsystems such as

Kumar, Pankaj, Deole, Kaushik, Hivarkar, Umesh

Mitigating Air Flow Sensor Signal Variability to Optimize Engine Operation in Passenger Cars

2026-26-0512To be published on 01/16/2026

The need for advanced engine control systems has grown significantly in response to stricter emission regulations and increasing consumer demand for fuel-efficient passenger vehicles. Accurate estimation of intake air flow, coupled with precise fuel control, is essential to overcoming the challenges associated with modern gasoline engine performance. Hot-wire type mass air flow (MAF) sensors are commonly used for measuring intake air flow and are typically mounted on the clean side of the air intake system to protect them from contamination and extend their operational life. Reliable air flow measurement depends on maintaining a consistent and uniform flow across various engine speeds and load conditions. However, the optimal placement of the MAF sensor is often limited by engine packaging constraints, making sensor positioning a critical factor. Incorrect installation can result in inaccurate air flow readings, which negatively impact engine performance and emissions. During the

SONONE, SAGAR DINESH, Kale, Vishal, Kolhe, Vivek M

Methodology for optimizing the bench testing of Steering I shaft using vehicle level data to reduce overall product development time and cost.

2026-26-0560To be published on 01/16/2026

Steering I-shaft with rubber coupling (or hardy disc) is an important part of complete steering system mainly in body on frame vehicles. Hardy discs are used to dampen the vibrations that transmit to steering wheel through frame, steering gear and I-shaft. They also support to accommodate the variation between frame and BIW of body on frame vehicles. They are made up of rubber or other polymer composites, which have less torsional stiffness as compared to metals. The overall torsional stiffness of steering system reduces since the hardy disc is used in series in steering system, that impacts on the overall performance of steering system. So, during development I shafts with different design, stiffness of hardy discs are used to optimize the steering and NVH performance of vehicle. Considering the development time and cost, each design of I-shaft cannot be validated at vehicle level. The torsional and axial force or displacement of hardy disc is measured at vehicle level on different

Kabdal, Amit

Development of Component Level Testing Method for Passenger Car Wheels

2026-26-0504To be published on 01/16/2026

In the design of automotive wheels, safety is a crucial factor. Wheels contribute to a vehicle handling, braking and overall driving performance. Wheel are designed to withstand the weight of the vehicle and force generated during driving. It is the medium which isolates the obstacles coming from roads. Impact tests are usually performed after the wheel has been already designed and first prototypes have been produced. The test involves 90-degree free fall dynamic impact to determine the wheel resistance to deformation, cracking and overall structural failure. Its best method to captured the exact results during and post impact. These results are contributes the major role in development of automotive wheel rims. Most of the OEM’s are validating the wheels in virtual environment as FEA analysis software and LS Dyna. In this paper detailed procedure of testing of wheels at component level is presented. This work determines the development of test procedure for passenger car wheels in

Tormal, Uday Bapurao

Video 2 Scenario: A Novel Method to Generate Edge Case Traffic Scenarios from Dashcam Videos

2026-26-0666To be published on 01/16/2026

This paper presents Video 2 Scenario, a systematic and cost-effective method to generate edge case scenarios derived from road events captured in dash camera videos. Current methods for obtaining real-world scenarios rely on supplementary sensor data like LiDAR, GPS and radar, which require expensive sensor setups for data collection. Other scenario generation methods rely on manual effort by human experts, which can be laborious and time-consuming. Our proposed methodology utilizes state-of-the-art deep learning models to extract vehicle trajectories, road layouts and other scenario-specific elements and reconstructs a scenario in the format of simulation scripts. The scripts are then refined by replaying the scenario multiple times in a simulation with attached virtual sensors to minimize the discrepancy between the subsequently obtained simulated video data and the original dash camera video data. The refined simulation scripts ensure that critical edge case scenarios are replicated

Ramalingam, Surya Prasath, Priyadarshi, Marut, Khan, Parvej, Kumar, Vaibhav, Pandey, Gaurav, Lohani, Bharat

Measurement of Acoustic Sensitivity of Automotive Drum Brake to Multiple Faults

2026-26-0555To be published on 01/16/2026

Multiple faults can occur over time in drum brakes, which are commonly used on the rear of heavy vehicles and two-wheelers, compromising passenger safety and ergonomics. Given the recent success of artificial intelligence in fault diagnosis, it can be applied effectively to automotive brakes during operation when combined with advanced measurement techniques. However, monitoring the brake health during operation is challenging due to the rotational motion of components and space constraints for sensors. Consequently, this study investigates the use of measured radiated noise from drum brakes (instead of vibrations) to detect faults. A test bench mimicking typical on-road braking dynamics has been developed to operate in a controlled environment with pre-determined fault levels. This setup measures acoustic signals during transient brake events. Acoustic responses from several experiments that imitate three common brake fault conditions are measured. The acoustic sensitivity to each

Shripad, Kumar Milind Rewanand, Yella, Akash, Sundar, Sriram

Conceptual Framework for Real-Time Battery Health Estimation in Automotive Digital Twins Using Reinforcement Learning

2026-26-0658To be published on 01/16/2026

The explosive growth of electric vehicles (EVs) calls forth the need for smart battery management systems that can perform health monitoring and predictive diagnostics in real-time. The conventional battery modeling methods mostly do not cover the complicated, dynamic behaviors coming from different usage patterns. The study outlines a structure that would use Reinforcement Learning (RL)-based AI agent as a part of the Battery Electrical Analogy (BEA) simulation platform. With the help of the AI agent, different health parameters such as State of Health (SOH), State of Charge (SOC), and the signs of early thermal runaway can be predicted in real-time. The suggested design takes advantage of the simulation-based approach to have the agent learn and utilizes a decentralized cloud architecture suitable for scaling and reducing the response time. The RL agent performs an essential role in the process by tagging along with the continuous learning and the adjustment of the battery conditions

Pardeshi, Rutuja Rahul, KONDHARE, MANISH, Sasi Kiran, Talabhaktula

G-Test Adaptability in Embedded C Framework

2026-26-0562To be published on 01/16/2026

Software quality is a vital aspect of software engineering, where unit testing plays a significant role in ensuring code reliability and validating individual components against their design specifications. In this paper, we explore the implementation of Google Test, an open-source C++ testing framework, to facilitate automated unit testing for embedded C projects. The adoption of Google Test in C projects introduces multiple challenges, especially for embedded systems and Windows environments, due to configuration complexity, limited direct support for C files, and dependency handling. This work provides a practical and structured solution to overcome these hurdles by integrating Google Test using a customized Makefile and CMakeLists. The Makefile automates the complete testing pipeline: compiling source files, linking with the G-Test framework, executing test cases, and generating reports. This significantly reduces manual effort and the risk of human error in the build and test

Chavan, Sapna Sahebrao, Upadhyay, Saurabh, Athavale, Sarang, Anilkumar, Sandhya

Evaluation of critical ignition coil parameters for an application On naturally aspirated gasoline engines

2026-26-0589To be published on 01/16/2026

Today’s internal combustion engines require highly efficient combustion systems to meet stricter emission and fuel economy regulations. To fulfil to these requirements the ignition system of a gasoline engine plays a critical role. Along with ensuring that it meets the ignition characteristics across all engine operating conditions, it is also possess challenges like to comply with certain On-Board Diagnostics (OBD) norms .To meet these demands modern gasoline engines use inductive type ignition coils which are directly installed at the cylinder head above the spark plug. These ignition coils generate high voltage to produce a certain amount of spark energy and primary coil current which are necessary to meet the targets. However, it has been observed that in a traditional inductive type ignition coil system the ignition coil operating temperature can be a major limiting factor as it cannot exceed a maximum upper limit. The work described in this paper details the various systematic

Ghadge, Ganesh Narayan, Hosur, Viswanatha

Vehicle-to-Vehicle negotiation via Manoeuvre Coordination Messages for Cooperative Cut-In scenarios

2026-26-0274To be published on 01/16/2026

The automotive industry is rapidly extending the capabilities of automated systems by incorporating connectivity and cooperation features that enable real-time information exchange between vehicles and road infrastructure. Within the Connected, Cooperative, and Automated Mobility (CCAM) framework, Vehicle-to-Vehicle (V2V) communication is expected to play a key role in improving road safety, traffic efficiency, and driving comfort. This work addresses a practical implementation of the standardized Manoeuvre Coordination Messages (MCMs), as defined in the ongoing ETSI standard (ETSI TS 103 561). The proposed approach is demonstrated through a cooperative cut-in use case in which two vehicles negotiate a lane change manoeuvre. In the considered scenario, the ego vehicle, driven by a Highway Pilot (HWP) system, receives the intention to cut-in from a neighbouring cooperative vehicle through an MCM. In response, the ego vehicle adapts its behaviour by decelerating to generate a safe

Leiva Ricart, Gisela, Domingo Mateu, Bernat

Manufacturing process advancement in CNG Exhaust Valve to prevent seat wear issue

2026-26-0278To be published on 01/16/2026

Exhaust Valve CNG market share increased in India in recent years demanding for more durable and reliable CNG Engine. While in current scenario durability is one of the major concerns for CNG engine. Major issue faced in CNG powertrain is high wear at Exhaust valve CNG face due to excessive wear. In Current practice T400 Sintered material layer is deposited at Valve face which is very critical to achieve less wear at valve face. Due to manufacturing variability high level of variation is found mechanical properties of T400 deposit which is very critical for Exhaust Valve CNG performance. In this paper all important process parameters are discussed for achieving consistent Exhaust Valve CNG T400 deposit quality. Each process parameter detail impact on T400 material is studied and explained to achieve consistent quality of T400 deposit leading to robust design of Exhaust Valve CNG.

Poonia, Sanjay, KUMAR, CHANDAN

Structural design and simulation of Composite Metal Hybrid based battery enclosure for an electric vehicle

2026-26-0300To be published on 01/16/2026

Addressing the critical need for lightweight and safe energy storage solutions in electric vehicles, this paper presents the design and optimization of a novel Composite Metal Hybrid (CMH) battery pack structure. A computer aided simulation using Abaqus software was done to optimize the weight of battery pack. The structural integrity and crash worthiness of the optimized lightweight design were rigorously evaluated under various load cases like side impact (crush), shock loading and underfloor impact. Manufacturing aspects were discussed to ensure feasibility and integration. Modal analysis and load tests addressed demonstrate the CMH battery pack as a viable and promising lightweight solution for electric vehicle applications.

Shah, Bijay Kumar, Singh, Pundan Kumar, G., Manikandan

Contradictions of Automotive NVH with other Vehicle Performance and TRIZ tools for Innovative problem solving

2026-26-0347To be published on 01/16/2026

For safety towards Automotive engineering often faces design contradictions, particularly in Noise, Vibration, and Harshness (NVH) optimization. Traditional approaches rely on trade-offs, but TRIZ (Theory of Inventive Problem Solving) offers a structured methodology to resolve contradictions innovatively. This paper explores in depth the TRIZ-based solutions for 2 key NVH challenges: (1) exhaust systems requiring noise reduction while maintaining low engine back-pressure, (2) engine mounts requiring both softness for vibration isolation and hardness for durability& vehicle stability. By applying principles such as segmentation, dynamization, parameter change, cheap short living objects or mechanics substitution, the novel solutions are proposed to achieve superior performance without traditional compromises. Tuneable valves in the path of the exhaust gas flow and the power-train mounting focused on its Torque Roll Axis were shown to exemplify the TRIZ problem solving effectiveness

A, Milind Ambardekar

Balancing Ride Comfort: Optimizing Semi-Active Suspension Systems Through Multi-Objective Parameter Tuning

2026-26-0594To be published on 01/16/2026

Optimizing semi-active suspension systems for ride comfort presents significant challenges due to the inherently conflicting requirements of different ride conditions. Enhancing primary ride associated with low-frequency body motions—may compromise the system’s ability to handle secondary ride, which involves mid-frequency road irregularities. Conversely, tuning for impact loadcases like potholes or road discontinuities often introduces trade-offs that can worsen comfort or suspension performance under regular driving conditions. These conflicts necessitate a systematic approach to identify balanced suspension behavior across diverse frequency bands. This study focuses on the parameter tuning of a smart damper within a semi-active suspension system to optimize overall ride performance. The investigation is carried out using a high-fidelity vehicle model in ADAMS Car, while mode-FRONTIER is employed to perform multi-objective optimization. This approach targets specific tunable blocks

Mishra, Satyakam, Verma, Rahul Ranjan, PRASAD, TEJ PRATAP

Rear Wiper Motor with Nozzle Integration for Improved wiping performance and Perceived Quality

2026-26-0600To be published on 01/16/2026

In the current modern days of driving, rear wiping performance plays a crucial role in safe driving. This study focuses on improving the rear wiping with add on benefits like improved BSR performance, cost saving and perceived quality. This new concept has the rear wiper motor assembly which accommodates the nozzle also thereby making it a single unified assembly with reduced system complexity. This concept eliminates the complex hose routing of washer system for rear wiping which is usually packaged at spoiler or HMSL. It also helps in improved spray coverage and reduced dry wiping which in turn enhances system reliability with clean & quiet operation. This integrated nozzle concept is much more compact than the available products in the market with minimum number of end items. Also, this design comes with non-return valve which ensures there is no delay in the spray execution. And it improves the cleaning efficiency by maintaining consistent fluid pressure. This concept comes with

Dhage, Prashant, K, NAGARAJAN, G, Sabari Rajan

Study of real time impact on automotive cabin Air Quality due to the ambient air pollution in the severely polluted city

2026-26-0531To be published on 01/16/2026

This study investigates the concentrations of PM2.5 and PM10 inside an automobile under real-world driving conditions in Delhi, one of the most polluted cities globally. India faces severe air pollution challenges in many cities, including Delhi, which are consistently ranking among the most polluted cities in the world. Major contributors to this pollution include vehicular emissions, industrial activities, construction dust, and biomass burning. Exposure to PM2.5 and PM10 has been linked to numerous adverse health effects, including respiratory and cardiovascular diseases, aggravated asthma, decreased lung function, and premature mortality. PM2.5 particles, being smaller, can penetrate deeper into the lungs and even enter the bloodstream, causing more severe health issues. In big cities like Delhi, long driving times exacerbate exposure to these pollutants, as commuters spend extended periods in traffic. Measurements were taken both inside and outside the vehicle to assess the real

Gupta, Rajat, Pimpalkar, Ankit, Patel, Abhishek, Rajaur, Deepak, Kumar, Shubham, Joshi, Rishi, Kumar, Mukesh

Challenges in Compliance Testing of off-Board Electric Vehicle Chargers: Analysis of Typical Failures and Remedial Measures

2026-26-0582To be published on 01/16/2026

As India accelerates the adoption of electric vehicles (EVs) the development of a scalable, reliable, and efficient charging infrastructure becomes critical to ensuring the success of EV adoption. During type testing, the off board AC/DC EV chargers undergo a comprehensive assessment to ensure they meet safety and performance standards required by regulations. The tests examine crucial factors like electrical safety, EMC (electromagnetic compatibility), interoperability, environmental endurance, and mechanical strength. This paper provides information of the mandatory compliance requirements and highlights typical failure modes observed during the validation process of off-board chargers. Emphasis is placed on challenges associated with electrical safety, EMC performance, and interoperability. The objective is to support charger manufacturers to identify potential issues during design and development.

Murumkar, Aditya, Mulay, Abhijit B

Adaptability Survey and analysis of Camera Monitoring Systems (CMS) on Various Driving Population for Passenger Vehicles in Indian Driving Scenario

2026-26-0601To be published on 01/16/2026

This paper presents a comprehensive survey and data collection study on the adaptability of Camera Monitoring Systems (CMS) for passenger vehicles. With the growing demand for enhanced safety, automation, and driver assistance technologies, Camera Monitoring Systems (CMS) has emerged as a key component in modern automotive design. This study aims to explore the current state of camera-based monitoring in passenger vehicles, focusing on their adaptability through survey data collection of various driving population and analysis. This paper evaluates the acceptance of CMS configurations in replacement to conventional rear view mirrors through Position of Monitor, Clarity, CMS Adaptiveness to eyes, Comfort while turning, Merging into moving traffic, Monitoring Rear Traffic, while Getting Out of Car, while Overtaking, Coverage Area and Overall Acceptance. The findings offer valuable insights for manufacturers, engineers, and researchers working toward the evolution of intelligent vehicle

Sinha, Ankit, Tambolkar, Sonali Ameya, Belavadi Venkataramaiah, Shamsundara, Kauffmann, Maximilian

A systematic debugging methodology for identifying electric vehicle level EMC issues

2026-26-0525To be published on 01/16/2026

Electric two and three-wheelers present unique challenges in electromagnetic compatibility testing due to compact packaging, high-frequency switching, and low shielding practices. This paper presents a systematic debugging methodology for identifying and mitigating radiated emission and radiated immunity issues in these EV platforms. A comprehensive approach is outlined, covering radiated emission measurement, Bulk Current Injection based immunity simulation, and near-field probing techniques. For RI evaluation, BCI testing in the 20 MHz to 400 MHz range is used to simulate radiated threats on the vehicle's power and signal harnesses. For RE diagnosis, conducted emission measurements on vehicle harnesses are performed using current probes to capture high-frequency currents. Additionally, near-field electric probes are used at the component to identify dominant noise sources such as DC-DC converters, Motor control unit, and improperly grounded shielding. Case studies on 2W and 3W EVs

M, Gokul, Patel, Jinay, Mulay, Abhijit B

Performance Analysis of Hydrogen Fuel Cell Electric Vehicle for Intercity and Intracity Applications

2026-26-0266To be published on 01/16/2026

Hydrogen Fuel Cell Electric Vehicles (FCEVs) are emerging as a sustainable solution to reduce greenhouse gas emissions in the transportation sector, in line with the Paris Agreement and global net-zero emission goals. This paper presents a comprehensive performance analysis of the FCEV powertrain under intercity and intracity driving conditions. The study focuses on key parameters such as fuel cell system efficiency, energy consumption, hydrogen usage, and overall drivetrain response. Using simulation models validated with real-world driving data, the performance of the powertrain is evaluated across varying speed profiles, vehicle loads, and driving cycles. The analysis also considers the impact of auxiliary load including HVAC systems and consumption of other electric components on the powertrain efficiency and energy balance. Results highlight that the FCEV powertrain performs efficiently during intercity driving due to stable speed conditions and low stop-start frequency, while

Patil, Nikhil Nivrutti, Gawhade, Ravikant, Gadve, Dhananjay, Saurabh, Saurabh, Bhardwaj, Rohit, Ahmed, Yasir, Amancharla, Naga Chaithanya

Corrosion behavioral study of Sintered materials with Ethanol-Blended Fuels - E20 and E85

2026-26-0277To be published on 01/16/2026

The increasing adoption of ethanol-blended fuels, such as E20 (20% ethanol and 80% gasoline) and E85 (85% ethanol and 15% gasoline), necessitates a comprehensive understanding of their compatibility with automotive engine components to ensure durability and operational reliability. Fuel compatibility is particularly critical for components in direct contact with ethanol-rich fuels, as improper material selection or insufficient testing can lead to corrosion, material degradation, and compromised engine performance. This study focuses on evaluating the behaviour of sintered materials extracted from potential fuel-contact parts of automotive engines when exposed to E20 and E85 fuels. Testing was conducted in accordance with the SAE J1747 standard, which provides a systematic approach for assessing corrosion resistance and material degradation in fuel environments. Following the exposure tests, post-test evaluations included visual inspection to identify surface changes and Scanning

Karthikeyan, C., Venugopal, Sivakumar, Gopalan, Vijaysankar

Non-metallic inclusions in carburizing steels as a contributory factor for the formation of carbide net

2026-26-0290To be published on 01/16/2026

The article deals with the issue of identifying structural defects that contribute to the formation of a carbide net during thermochemical treatment of steel parts, which negatively affects the mechanical properties complex of finished products. Based on the available data, a theory has been put forward regarding the influence of the present non-metallic inclusions in the carburizing steels structure on carbide formation process in the hardened layer. As an experimentally the samples have been produced from the varying chemical composition alloy structure carburized steel (0.17-0.23 % C, 0.17-0.37 % Si, 0.80-1.10 % Mn, 1.00-1.30 % Cr, 0.03-0.09 % Ti). During microstructure analysis of the samples it has been establish that non-metallic inclusions, in particular sulfides, contribute to the formation of carbides and carbide net in steel due to their high chemical activity with carbon. Thus, contamination of the metal of carburizing steels with non-metallic inclusions is not only a defect

Runova, Iuliia, Chatkina, Mariia, Musienko, Aleksandr

Experimental Study on the Role of Hole Expansion Ratio in Enhancing Crashworthiness of Advanced High Strength Steel

2026-26-0295To be published on 01/16/2026

To meet light weighting and safety target, the automotive industry is increasingly using advanced high strength steel (AHSS) materials and advanced manufacturing techniques for complex body parts. To improve energy absorption of automotive body parts, various steel grades are developed by steel manufactures with variety of properties ( YS, UTS, EL %, HER). Also, the formability of AHSS grades (TS > 980 MPa) is challenging due to its limited edge ductility. This study focuses on role of hole expansion ratio in energy absorption of AHSS material. In the study, different AHSS material with variety of microstructure and properties are experimented, with the aim to identify the optimum properties, that can help to enhance crash worthiness of formed part. From experimentation, it is evident that hole expansion ratio plays important role in determining edge ductility, as well as energy absorption. This study may not only help to improve crash performance but also help for light-weighting of

Jain, Vikas, Bandru, Shreenu, Nadarge, Harshad, Misal, Swapnali, Deshmukh, Mansi, Paliwal, Lokesh

Nexifi11D: A Comprehensive Multidimensional Framework for Futuristic Manufacturing Ecosystems

2026-26-0282To be published on 01/16/2026

The manufacturing sector is undergoing a paradigm shift driven by hyper-connectivity, sustainability imperatives, and accelerated digital transformation. Conventional systems, however, remain constrained by their focus on isolated optimizations—such as predictive analytics, IoT-enabled sensing, or workforce scheduling—without providing an integrated operational perspective. To address this fragmentation, Nexifi11D is introduced as a comprehensive, multidimensional framework that consolidates 11 critical dimensions of manufacturing into a unified ecosystem. Nexifi11D advances beyond traditional Industry 4.0 architectures by seamlessly integrating intelligent algorithms, immersive simulation technologies, IoT infrastructure, and predictive systems within a scalable, interoperable mesh. The framework breaks down silos across key manufacturing domains—such as sustainability, cost, operations, and workforce—enabling holistic, data-driven, and proactive decision-making. Each integrated

Kumar, Rahul, Singh, Randhir

Reverse Engineering of CAN (Controller Area network) of an Electric vehicle

2026-26-0150To be published on 01/16/2026

The communication between different vehicle electronic controller units (ECU) for various applications (I.e. To propel the vehicle or for In-vehicle Infotainment) CAN (Controller Area Network) is most frequently used for In-Vehicle communication. Given the proprietary nature and lack of standardization in CAN (Controller Area Network) configurations, which are often not disclosed by manufacturers, the process of CAN reverse engineering becomes highly complex and cumbersome. Additionally, the scarcity of publicly accessible data on electric vehicles, coupled with the rapid technological advancements in this domain, has resulted in the absence of a standardized and automated methodology for reverse engineering the Controller Area Network (CAN). This process is further complicated by the diverse CAN configurations implemented by various Original Equipment Manufacturers (OEMs), which are often not disclosed to the public. In this paper the manual approach is taken for reverse engineering

KUMAR, ROHIT, Sahu, Hemant, Penta, Amar, Bhatt, Purvish

Optimizing Diesel Emission Controls through Advanced Software techniques to improve Diesel Oxidation Catalysts efficiency

2026-26-0061To be published on 01/16/2026

After the implementation of BS VI emission standards, effective exhaust after-treatment has become critical in minimizing harmful emissions from diesel engines. One significant challenge is the accumulation of hydrocarbons (HC) in the Diesel Oxidation Catalyst (DOC). Certain hydrocarbons may adsorb onto the catalyst surface yet remain unreactive, leading to potential operational inefficiencies. This phenomenon necessitates the desorption of unreactive hydrocarbons to allow space for more reactive species, thereby enhancing oxidation efficiency and overall catalyst performance. The process of desorption (DeSorb) is vital to maintaining the balance of reactive hydrocarbons within the DOC. When a vehicle is idling or low temperature duty cycles, unburnt fuel produces hydrocarbons that accumulate in the DOC. Upon acceleration, these hydrocarbons can lead to an uncontrolled rise in temperature, resulting in DOC push-out, catalyst damage, and downstream impacts on the Diesel Particulate

K, Sabareeswaran, K K, Uthira Ramya Bala, k, Janarthanan, A, Ravikumar, YS, Ananthkumar

Controls Solutions for Commercial Hydrogen Engines

2026-26-0112To be published on 01/16/2026

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, AVL has carried out multiple performance and emission development

Arnberger, Anton, Danninger, Alois, Mannsberger, Stefan, Breitegger, Bernhard

Achieving ride comfort in bus suspension by varying air spring performance

2026-26-0081To be published on 01/16/2026

Air springs are widely used in commercial buses to obtain better quality of ride and comfort. Selecting the right air spring is a critical aspect of suspension design. However, this selection process is often constrained by the limited availability of off-the-shelf components as the development of a custom air spring involves long lead time and high tooling cost. This can be justifiable only at high production volumes. Air springs are tunable as compared to conventional mechanical metal springs. Their performance can be adjusted by varying the internal air pressure and volume, enabling them to accommodate a wide range of vehicle load conditions. In actual design practice, component packaging constraints and fixed mounting dimensions often restrict the choice of air spring. Additionally, Front and rear suspension requires air springs with different characteristics. To overcome these limitations, an auxiliary air tank is also called a ping tank that can be used along with an existing

Patre, Kamlesh, Salunkhe, Swapnil, Paranjape, Shekhar

A comprehensive strategy for Diesel Particulate Filter calibration to address the diverse applications of Stage V Construction Equipment Vehicles.

2026-26-0143To be published on 01/16/2026

The legislation of CEV Stage V emission norms has necessitated advanced Diesel Particulate Filter calibration strategies to ensure optimal performance across diverse construction equipment applications in the Indian market. Considering the various duty cycles of cranes, backhoe loaders, forklifts, compactors, graders, and other equipment, different load conditions and operational environments require a comprehensive strategy to enhance DPF efficiency, minimize regeneration frequency, and maintain compliance with emission standards. The DPF, as an after-treatment system in the exhaust layout, is essential for meeting emission standards, as it effectively traps particulate matter. Regeneration occurs periodically to burn the soot particles trapped inside the DPF through ECU management. Therefore, understanding soot loading and in-brick DPF temperature behavior across various applications is the key. This paper explores the challenges in DPF calibration for CEV Stage V and provides a

Mohanty, Subham, Patil, Lalit, Chaudhari, Kuldeepak Arun, Mahajan, Atish, Madhukar, Prahlad

Multispeed EV Transmission – Gear Shift Simulation and Validation

2026-26-0157To be published on 01/16/2026

The advancement of electric vehicle (EV) transmission systems is currently a prominent trend aimed at decreasing carbon emissions and providing eco-friendly transportation alternatives. Most of the EV transmissions are single speed, but research conducted on multi speed EV transmissions show higher efficiency, good performance, high speed and torque demand when compared with single speed counterparts. Most of the multi speed EV transmissions that are developed are of non-synchromesh type, which have direct effect on NVH, driving dynamics and durability of drivetrain components. Due to aforementioned factors, gearshift analysis becomes critical for development. Simulation model is developed at early development phase for initial feedback. Using the feedback, drivetrain can be optimized furthermore and test on physical parts can be conducted for final verification. This paper provides a simulation based approach for modelling non-synchromesh two speed EV transmission using Simulation X

Patel, Hiral, Thambala, Prashanth, Sutar, Suresh, Todtermuschke, Karsten

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