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Performance Evaluation of a Novel Coolant Channel Configuration for Liquid-Based Battery Thermal Management in Electric Vehicles2026-28-0042To be published on 02/12/2026
The performance and longevity of lithium-ion (Li-ion) batteries in electric vehicles (EVs) are critically dependent on effective thermal management. As internal heat generation during charge and discharge cycles can lead to uneven temperature distribution, exceeding optimal operating limits (25 - 40°C) can significantly degrade battery performance and lifespan. This study presents a performance evaluation of a novel liquid-based Battery Thermal Management System (BTMS) featuring a dual-directional coolant channel configuration designed to enhance thermal uniformity and heat dissipation. The proposed configuration combines horizontal and vertical coolant passages in an indirect cooling layout to address the limitations of conventional serpentine-type channels. A comprehensive thermal analysis was carried out under realistic loading conditions using three coolant types: water, ethylene glycol-based G48, and graphene-enhanced water nanofluids. These were evaluated for thermal conductivity
Selvan, Arul Mozhi, Periyasamy, Muthukumar, R, Thiruppathi
Effect of Minimum Quantity Lubrication during Machining of Incoloy 800H Using Vegetable Oil Enriched With Nano Particles2026-28-0038To be published on 02/12/2026
In this experimental work an effort has made to investigate the machining of difficult to machine Incoloy 800H super alloy. Cryogenically treated textured cutting inserts and vegetable oil enriched with nano particles were used for this study. The turning experiments were performed with different parameters such as Cutting speed, feed rate and depth of cut. Surface Roughness, Cutting Force, Tool-Tip Temperature and Power were the output responses considered. Grey Relational Analysis (GRA) and Analysis of Variance (ANOVA) analysis were used to optimize the machining parameters and to find the most influencing machining parameter on the output responses. The results showed that the optimal machining conditions considered were cutting speed at 35 m/min, feed rate at 0.06 mm/rev and depth of cut at 0.5 mm for the multiple-characteristic performances and it was improved by 3.86 % with this approached method. Also, Tool-tip temperature and Power were reduced during machining with cryo
Natarajan, Manikandan
Selection and Optimization of Process Parameters in Wire Arc Additive Manufacturing for Automotive Structural Applications2026-28-0039To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) has emerged as a promising technology for fabricating large, complex metal structures with reduced material wastage and improved design flexibility. In the automotive sector, WAAM offers significant potential for producing lightweight and high-strength components, particularly for structural applications. However, the quality and performance of WAAM-fabricated parts are highly dependent on the careful selection and optimization of process parameters such as wire feed rate, travel speed, arc voltage, current, and inter-pass temperature. This review focuses on the systematic evaluation of key process parameters influencing the mechanical properties, surface integrity, dimensional accuracy, and microstructural characteristics of WAAM-produced structures intended for automotive applications. The study also explores various optimization techniques—such as Taguchi, response surface methodology (RSM), and artificial intelligence (AI)-based approaches
V, Aravind
Surface Integrity and Process Efficiency studies on Wire EDM Parameters for Machining Hastelloy Components for automobile parts2026-28-0037To be published on 02/12/2026
Hastelloy, a high-performance nickel-based alloy, is widely used in aerospace, chemical, and marine industries due to its exceptional corrosion resistance and mechanical strength. However, its superior properties also make it difficult to machine using conventional processes. Wire Electrical Discharge Machining (WEDM) offers a non-conventional approach to accurately machine Hastelloy components with minimal thermal damage. This study focuses on optimizing key WEDM process parameters pulse-on time, pulse-off time, peak current, servo voltage, and wire feed to enhance surface quality and material removal rate. A Taguchi L9 orthogonal array was used to design experiments, and analysis of variance (ANOVA) was applied to identify the most significant factors affecting performance. The results revealed that optimized settings led to a notable reduction in surface roughness and improved cutting efficiency. The study provides a strategic framework for the effective machining of Hastelloy
Bangaru, Haritha
Machinability Evaluation of WAAM-Fabricated Alloys Using Wire EDM and Parameter Optimization Techniques2026-28-0036To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is increasingly utilized for fabricating near-net shape metal components due to its high deposition rates and cost-effectiveness. However, post-processing of WAAM-fabricated parts, especially to achieve precise dimensions and surface finish, is essential. Wire Electrical Discharge Machining (WEDM) presents an effective solution for such requirements due to its ability to machine hard-to-cut materials with high precision. This study investigates the machinability of WAAM-fabricated alloy specimens using WEDM by analyzing key output responses such as material removal rate (MRR), surface roughness (Ra), and kerf width. Taguchi and other optimization techniques were employed to identify the optimal combination of WEDM parameters including pulse-on time, pulse-off time, peak current, and wire feed. Experimental results demonstrated that specific parameter settings significantly enhance machinability while maintaining structural integrity. The findings
Bangaru, Haritha
PERFORMANCE AND EMISSION CHARACTERISTICS OF LEMON PEEL OIL BIODIESEL WITH DIETHYL ETHER AND ETHANOL IN A CI ENGINE: AN EXPERIMENTAL INVESTIGATIONS2026-28-0052To be published on 02/12/2026
The rising global energy demand and the adverse environmental impacts of fossil fuel consumption have intensified the search for sustainable alternative fuels. Among the various biodiesel sources, lemon peel oil (LPO) offers promising potential due to its biodegradability, availability from waste resources, and favorable combustion characteristics. This study investigates the performance and emission characteristics of LPO biodiesel blended with diethyl ether (DEE) and ethanol in a compression ignition (CI) engine. Three blends B5, B10, and B15 were prepared by varying the proportions of LPO, DEE, and ethanol with conventional diesel. The physicochemical properties of the blends were evaluated as per ASTM standards and found to be compatible with CI engine requirements. Experiments were conducted on a variable compression ratio (VCR) CI engine under different load conditions. Results showed that the B10 blend exhibited superior brake thermal efficiency (BTE), achieving an improvement
M, Boopathi, G, Manikandan, Deepan Kumar, Sadhasivam, A, Tamilselvan, K, Nithyanandhan, S, Karthik, j, Deepan Chakrawarthi, X, Leslie Peter
Dynamic Stiffness Prediction in Cracked Cantilever Beams Using Enhanced ANN Techniques2026-28-0050To be published on 02/12/2026
This research paper presents an in-depth investigation into the application of Artificial Neural Networks (ANN) for predicting the dynamic stiffness characteristics of cantilever beams affected by cracks of varying depths and positions. Structural failure due to vibration remains a critical concern, and this study focuses on how crack-induced changes in modal stiffness compromise structural reliability. A significant research gap identified in previous studies is the limited consideration of crack location; this work addresses that gap by analyzing how both crack depth and position influence the natural frequency of the beam. Using modal analysis on cantilever beams with identical dimensions but different crack configurations, it was observed that deeper cracks and cracks near the fixed support led to a marked reduction in natural frequency, making the structure more vulnerable to resonance. Cracks located at the free end, however, showed negligible impact. To model and predict these
SB, Harshini, Rajkumar, Manjari, R, Krithika, K, Anusha, K, Divya, Bhaskara Rao, Lokavarapu
Numerical Investigation of Aerodynamics Performance of Spoiler on Racing Car2026-28-0049To be published on 02/12/2026
Technology has paved the way for motorsports to advance exponentially. The main area of focus in modern automobiles and race cars is Aerodynamics. It plays a crucial role in vehicle dynamics due to the need for stability at high speeds under varying environments. The Research and development of aerodynamics have come a long way, with the use of basic, inverted air-foils to generate downforce, thus pushing the car to the ground for better contact patch, to unending development of diffusers to improve ground effect, reducing drag with minimal sacrifice of downforce. Previous papers have conducted studies of various air-foil designs for inverted rear wings, and various diffuser designs as well. With various methodologies conducted and parameters obtained, our paper is all about the modification of design of an inverted double-element rear wing and integration with a diffuser with vertical skirts, underneath. The main intent is to enhance downforce with such design and apply in high
Damodaran, Darshan, Ganesan, Balaji, Raja, Vijayanandh, GANESAN, Santhosh Kumar, G, Boopathy
Modelling and Analysis of Complex Shaped Cracks2026-28-0048To be published on 02/12/2026
This study offers a thorough analysis using finite element methods (FEA) to examine how fatigue cracks grow in three different materials: Structural steel , Titanium alloy (Ti Grade 2), and epoxy/aramid-based printed circuit board (PCB) laminates. Using ANSYS Workbench, we ran simulations under both static and repeated loading to understand how these materials fracture. The approach was based on Linear Elastic Fracture Mechanics (LEFM), employing the Maximum Circumferential Stress Criterion to predict where cracks might start and how they could spread. Also, the Equivalent Domain Integral (EDI) method helped us calculate the Stress Intensity Factors (SIFs) when cracks are under mixed loading modes. We modeled the growth of fatigue cracks using the Paris Law, relying on material-specific constants (C and m) drawn from previous studies and experimental tests. For example, titanium Grade 2 showed Paris Law constants with C values between 1.8 × 10⁻¹⁰ and 7.9 × 10⁻¹² m/cycle, and m values
T, LOKESH, Bhaskara Rao, Lokavarapu
ACCIDENTAL DOORING WARNING AND ASSIST SYSTEM2026-28-0053To be published on 02/12/2026
The term dooring refers to the accidents where a vehicle door is suddenly opened into the path of an oncoming cyclist or motorcyclist. These issues are serious road safety hazards, especially in congested urban areas where people may be careless. This project proposes an intelligent, computer vision based warning system designed to detect the approaching vehicles and alert the occupants in the vehicle before opening the door. The system uses the rear parking camera in vehicles with rear parking system or a USB webcam in vehicles without rear parking system to capture live video feed, which is processed by a Raspberry Pi 4 microprocessor. The system will run a lightweight deep learning model, MobileNetSSD, through TensorFlow Lite. Detected objects are classified in real time, and the relative distance of other vehicles is estimated using bounding box dimensions. If a vehicle is identified within a preset safety distance threshold, a clear visual warning is displayed to prevent door
C, Jegadheesan, T, Karthi, Gurusamy, Varun Sankar, Balraj, Tharun, Murugaiya, Tamilselvan
Historical Memory-Based Database Management System for Effective ADAS Configuration in Autonomous and Connected Vehicles2026-28-0057To be published on 02/12/2026
The ability to store data is crucial for an autonomous vehicle system. Memorizing traffic signs, including their locations, can be easier than trying to read and understand them on the fly. Using the vehicle's location and other vehicle data, decisions can be made faster when using existing memory data. This study outlines a technique that utilizes an environmental structure database as a tool for decision-making in diverse vehicle scenarios. By collectively learning and storing vehicle location, historical data, and past actions, this paper results in a way to predict the environmental structure in advance and use the necessary control signals to optimize vehicle operation. In a connected vehicle system, there can be many reasons and factors to be considered in various events such as vehicle speed, parking location, speed changes, speed bumps, braking, etc. These are stored in a separate database, and the accuracy of the results is increased by comparing the actual data at that time
Santhiyagu, Arulanantha Samy
Effect of EGR and Ethanol additive on Performance and Emission Characteristics of Diesel Engine Fuelled with Rubber Seed Biodiesel Blends2026-28-0055To be published on 02/12/2026
Alcohol is being considered as an alternative to traditional fuels for compression ignition engines due to their oxygen content and biomass origin. Although alcohol generally has lower cetane numbers, which makes them more favorable for premixed combustion, they also offer potential for lowering emissions in internal combustion engines, particularly when combined with strategies such as exhaust gas recirculation (EGR). This research focuses on enhancing the performance of a single-cylinder, four-stroke diesel engine by introducing ethanol into the intake port during the intake phase. Diesel and rubber seed biodiesel were used as primary fuels and were directly injected into the combustion chamber. The findings indicated that adding ethanol to rubber seed biodiesel, along with 10% EGR, led to improved brake thermal efficiency and a reduction in NOX emissions. The ethanol injection timing and duration were optimized for effective dual-fuel operation. At full engine load, the highest
Saminathan, Sathiskumar, G, Manikandan
Intelligent Driver Behavior Analytics for Enhanced Road Safety2026-28-0054To be published on 02/12/2026
The present work on Intelligent Driver Behavior Analytics System that monitors and analyzes road users to ensure road safety and regulatory compliance, the system developed by using machine learning algorithms with the help of Raspberry Pi micro controller. It is said that most road accidents are caused by driver incompetency, yet, dangerous driving behavior is hard to detect on the road; this system monitors dangerous driving and other related behaviors that cause road accidents as well as contribute to noise pollution. It also alerts vehicle pauses on high-risk areas like road edges and also compares the routes planned to routes traveled on the GPS to alert any route slippage. Drivers, fleet managers and fleet operators get real-time feedback, and they are encouraged to take corrective action immediately. The system is expandable and is applicable to transportation agencies, public safety organizations and individuals who own vehicles and need to hone road safety and performance
Prasad, Gvl
Forced Vibration Analysis of Solid and Hollow Functionally Graded Shafts2026-28-0051To be published on 02/12/2026
This paper presents a comparative study on the forced vibration behavior of functionally graded material (FGM) shafts in solid and hollow configurations. FGMs exhibit a continuous variation in material composition from ceramic-rich surfaces to metal-rich cores, enhancing mechanical performance under dynamic loading. A finite element-based analysis is conducted using ANSYS Workbench under simply supported boundary conditions to evaluate the natural frequencies and mode shapes. The study investigates the influence of shaft geometry, material gradient, and structural configuration on vibrational characteristics. Results indicate that solid shafts generally exhibit higher natural frequencies due to increased stiffness, while hollow shafts offer reduced weight with moderate frequency shifts. Additionally, smoother material gradients improve dynamic stability. These findings offer valuable insights for optimizing FGM shaft design in automotive and aerospace applications where weight-to
R, Tharrun, Addanki, Karishma, D, Manish, Bhaskara Rao, Lokavarapu
Sustainable Machining of Aluminium Alloys: Experimental Insights into WEDM Process Optimization2026-28-0034To be published on 02/12/2026
The most advanced mathematics transforms aluminum alloys into one of the most highly intricate materials into practically any engineering application based on the mechanical properties of ductility and low fatigue sensitivity. The use of aluminum alloys permeates critical industries like aerospace and automotive, besides being strong contenders in other high-performance applications. Their inherent corrosion resistance certainly gives an edge to aluminum alloys for applications in rigorous service environments. Conventional manufacturing processes would not successfully create components with some geometrical complexity; hence, advanced machining processes are being developed. Among them is Wire Electrical Discharge Machining (WEDM), which is increasingly being adopted within the EDM family, as it efficiently machines hard and complex shapes at high accuracy. The present investigation deals with WEDM of aluminum alloy using Taguchi's design of experiments approach, while focusing on
Natarajan, Manikandan
Effect of Shot Peening on the Fatigue Life of Polylactic Acid Parts in Automobiles2026-28-0032To be published on 02/12/2026
Polylactic Acid (PLA), is a biodegradable thermoplastic and most widely used materials in automobiles also inherent fatigue performance limitations and its deployment in demanding load-bearing automobile applications. Shot peening, a well-established surface treatment known to significantly enhance the fatigue life of metallic materials, presents a potential post-processing strategy to improve the durability of polymers. The proposed work investigation into the effects of controlled shot peening pressure on the various behavior of injection molded PLA specimens. The outlined methodology encompasses the fabrication of PLA samples conforming to ASTM standards, the application of shot peening using precisely defined parameters, comprehensive characterization of the resulting surface modifications (including roughness, hardness, morphology, and systematic uniaxial fatigue testing according to ASTM D7791. Fatigue tests will generate fatigue behavior and fatigue life (by varying number of
Ranganathan, Soundararajan
Design and Fabrication with Validation of a Smart Adaptive Anti-Roll Bar System for Enhanced Stability in Electric Vehicles2026-28-0029To be published on 02/12/2026
This project presents the design and characterisation of high-performance automobile anti-roll bars from the metal matrix composite of AA6082 aluminium alloy reinforced by 5 wt% Boron carbide (B4C), 10 wt% Fly ash, and 10 wt% Silicon carbide (SiC), prepared by stir casting for optimum particle dispersion. Mechanical characterisation revealed 22% greater ultimate tensile strength to 415 MPa, 31% greater hardness to 132 HB, and 27% greater fatigue life than the unreinforced AA6082, with only moderate lower density from fly ash addition. Finite Element Analysis in SolidWorks also confirmed the reinforced anti-roll bar to demonstrate 11% lower maximum Von Mises stress and 14% lower equivalent strain in simulated cornering loads, indicating greater durability and deformation resistance. Optical microscopy also confirmed homogeneous reinforcement particle dispersion and optimum grain refinement for greater grain refinement and wear resistance. These results demonstrate the technical promise
Deepan Kumar, Sadhasivam, S, Manikandan
Galvanic Corrosion Susceptibility Analysis and Mitigation strategies in Automotive Battery Packs2026-28-0018To be published on 02/12/2026
As electric vehicles continue to revolutionize transportation, ensuring the reliability of their powertrain systems and battery packs has become a critical focus. One key challenge is galvanic corrosion, which occurs when dissimilar metals in contact are exposed to an electrolyte, such as seashore moisture or road salt used in snow or ice zones. This corrosion can weaken structural components, compromise electrical conductivity, and reduce the lifespan of critical systems. Common areas at risk include metallic joints within battery enclosures, busbars, cooling systems, and electrical connectors. Environmental factors such as high humidity and temperature fluctuations further amplify the issue, making it a pressing concern for manufacturers. This paper aims to systematically identify critical galvanic joints within electric powertrain systems and battery packs and provide effective strategies to mitigate corrosion risks. Preventative measures include choosing compatible materials with
NARAIN, ADITYA, Venugopal, Sivakumar, Gopalan, Vijaysankar, Varatharajan, Senthilkumaran
Design and Development of Circular Crash Boxes: Evaluating Single and Dual Screw-Groove Configurations for Enhanced Crashworthiness2026-28-0013To be published on 02/12/2026
This study investigates the design and development of circular crash boxes aimed at enhancing crashworthiness through the analysis of screw-groove configurations. Two specific designs were evaluated: one featuring a single screw in two grooves and another incorporating two screws in four grooves. Finite Element Method (FEM) simulations were conducted using LS-DYNA, wherein a 700 kg impactor struck the crash boxes at varying velocities. The materials tested included Al5052 aluminium alloy and mild steel. In this study, we assessed and compared key crashworthiness performance metrics to evaluate the effectiveness of energy-absorbing structures. Results indicated that higher impact velocities led to increased energy absorption and peak forces but resulted in decreased crush force efficiency. Notably, the configuration with two screws in four grooves exhibited superior energy absorption and more favourable load distribution compared to the single screw design. These findings underscore the
R, Teddy Samuel, Mayakrishnan, Jaikumar
ALTERNATE CATALYST FOR DOC IN A CATALYTIC CONVERTER2026-28-0016To be published on 02/12/2026
Emission norms have become much more stringent to reduce emissions from vehicles. Diesel engines in particular are the predominant contributors to higher emissions. Diesel Oxidation Catalyst (DOC) in diesel engine catalytic converter systems is the crucial component in reducing harmful emissions such as Carbon Monoxide (CO) and unburnt Hydrocarbons (HC). DOCs often rely on expensive noble metals like platinum or palladium and rhodium as catalyst materials,significantly inflating the cost of emission control units. The proposed idea is to explore MnOxCeO₂ (Manganese Oxide-Cerium Oxide) as an alternative catalyst to traditional DOC materials, with the goal of delivering effective oxidation performance while reducing overall system cost. MnOx-CeO₂ catalysts are promising due to their good low-temperature activity, oxygen storage capacity, and redox behaviour, which are beneficial for diesel engines operating under varied conditions. These properties help improve the oxidation of CO and HC
C, Jegadheesan, T, Karthi, Rajendran, Pawan, Muruganantham, Kowshiik, S, Vaitheeshwaran
Design and Development of a Hybrid Rocket Propulsion System for Micro-Scale SAM Interceptor Missiles2026-28-0012To be published on 02/12/2026
The increasing prevalence of agile and low-signature aerial threats, such as Unmanned Aerial Vehicles (UAVs), necessitates the development of advanced and flexible air defense systems. Conventional Surface-to-Air Missiles (SAMs) at the micro-scale are often limited by short engagement times and an inability to counter saturating threats. This paper presents the conceptual design and analysis of a novel loitering interceptor missile designed to overcome these limitations. The core innovation is the synergistic integration of a throttleable hybrid rocket propulsion system with a mission-adaptive airframe featuring morphing fins. The methodology involves the theoretical design of a HTPB-based hybrid motor capable of operating in both high-thrust boost and low-thrust loiter modes. Computational Fluid Dynamics (CFD) analysis is employed to evaluate the aerodynamic performance of the missile with its fins in both stowed (high-speed) and deployed (loiter) configurations. Preliminary results
E, Rahul
Influence of varying shoulder profiles in pin-less tool on friction stir welding of thin plates2026-28-0028To be published on 02/12/2026
This study explores the thermal and mechanical characteristics of Friction Stir Welding (FSW) using pin-less tools with varied shoulder geometries to weld 2 mm dissimilar plates. FSW is a solid-state joining technique known for minimizing weld defects and enhancing joint integrity, particularly in the applications requiring high precision and low thermal distortion. Using simulation-based analysis via ANSYS, three custom-designed tool profiles are considered (i.e) spiral, concentric, and diamond tip, were evaluated. The rotational speeds considered are 500, 1000, and 3000 rpm at a constant traverse speed of 90 mm/min. The 3D models of the FSW tool with required shoulder profiles and thin plates are developed using Solid works. The tool and plates are characterized using tungsten carbide and aluminium-magnesium for workpieces. The simulations focused on key field variables including, temperature distribution, residual stress, and deformation on the welded plates. Results indicated that
Nelson, N Rino
AI-Driven Process Optimization in Wire Arc Additive Manufacturing of Nickel Alloys Using ANFIS2026-28-0025To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is gaining significance in recent years as a process for additive manufacturing that produces large and complex components with high deposition rates at economically feasible rates. Nickel-based alloys, praised for their unique features, like mechanical strength, corrosion resistance, and thermal stability, find widespread application in the aerospace, marine, and energy sectors. However, achieving the desired surface finish, dimensional precision, and mechanical performance of WAAM nickel alloy structures is a continuing challenge because of the complex interactions occurring between the process parameters. The study presents an experimental analysis conducted to establish the effect of important process parameters of WAAM-wire feed rate, travel speed, welding current, interpass temperature-on the quality indicators such as surface roughness, dimensional accuracy, and hardness. For the purpose of prediction and process control, the Adaptive Neuro
Natarajan, Manikandan
Synthesis, characterization and electro active properties of poly (Meta Toudine-co-Fluro aniline) Ag dispersed nanocomposites: Shielding Composite as surface Coat or Enclose the ECU Housing for preventing signal distortion and ensuring reliable engine performance2026-28-0022To be published on 02/12/2026
A series of electroactive nanocomposites of silver dispersed poly (metatoludine-co-o-fluroaniline) copolymer has been prepared by in-situ polymerization method. The chemical molecular structures are identified by using UV–visible spectra, FTIR, X-ray diffraction instruments, SEM analysis. We propose that these composite materials possess a Electromagnetic Shielding interference coat or enclose the engine control unit (ECU) housing in the form of surface coating or moulded shell in order to prevent signal distortion and ensuring reliable engine performance in automobiles. This composite material possesses lightweight, corrosion-resistant EMI shielding solution for ECU housings. Implementation of these products significantly reduced signal interference from nearby high-power electronics, ensuring stable engine operation. The proposed system offers a cost-effective, lightweight alternative to metallic shielding in vehicular electronics in automobile industries.
Pachanoor, Vijayanand, Kumar, V
Parameter Optimization for Improved Surface Finish in WAAM-Fabricated Steel Structures2026-28-0023To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is a cost-effective and scalable metal additive manufacturing technique widely used for fabricating large metallic components. However, surface finish remains a critical challenge, especially for structural applications where post-processing needs to be minimized. This study focuses on optimizing key process parameters to improve the surface finish of ER70S-6 steel structures fabricated using the WAAM process. Experiments were designed using a statistical approach to systematically vary parameters such as wire feed rate, travel speed, voltage, and inter-pass cooling time. Surface roughness was measured using standard metrology tools, and the results were analyzed to identify the most influential parameters. An optimized parameter set was proposed based on the experimental outcomes, leading to a significant reduction in surface roughness without compromising the structural integrity of the deposited material. The findings contribute to enhancing
PN, Vani
TOPSIS-Based Multi-Criteria Optimization of WAAM Parameters for Automotive Component Fabrication2026-28-0026To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) can make huge, complicated metal parts quickly and cheaply, making it popular in the automobile sector. This study uses TOPSIS, a multi-criteria decision-making method, to improve WAAM process parameters such wire feed rate, travel speed, and current. Automotive applications need surface roughness, deposition rate, and dimensional precision, which WAAM-fabricated components must meet. TOPSIS normalizes and ranks experimental findings to find parameter combinations that perform best across many quality metrics. The results show that integrated optimization improves component quality and consistency, making WAAM a feasible and economical sustainable vehicle manufacturing option.
Pasupuleti, Thejasree
Experimental Investigation of Process Parameter Effects in WAAM of Nickel-Based Alloys2026-28-0027To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is an evolving discipline in metal additive manufacturing characterized by rapid deposition, cost-effectiveness, and centrality to the near-net-shape fabrication of large-scale components. This study will concentrate on WAAM application to deposit nickel alloys, which find extensive use in aerospace, power generation, and marine industries, due to their good mechanical strength, corrosion resistance, and thermal stability. However, some drawbacks in WAAM processing of nickel alloys include thermal distortion, porosity, and residual stress. The research looks at how key WAAM process parameters, including wire feed rate, travel speed, current, and interpass temperature affect geometric accuracy, surface integrity, and mechanical performance of the fabricated components. Microstructural characterization was done using optical microscopy, and hardness distribution was measured as an indication of mechanical uniformity throughout the builds. It is
Natarajan, Manikandan
Effect of Gasoline as manifold fuel for Prosopis juliflora biodiesel fuelled CRDI stationary diesel Engine in Dual-Fuel Mode2026-28-0014To be published on 02/12/2026
Utilisation of non-edible biodiesel in the diesel engine has tremendously increased nowadays. This is due to its renewable nature and produces less pollution than conventional diesel, except for NOx emissions. To overcome the drawbacks, some additional fuel is added to take part in the combustion along with the biodiesel in a dual-fuel mode (DFM). In the present work, an investigation was carried out to assess the effect of gasoline as a manifold injection fuel (MIF) under 0, 10, and 20% energy share (ES) on Prosopis juliflora biodiesel (PJBD) fueled diesel engine in the DFM, and compared with single fuel mode (SFM). The diesel B0 (100% Diesel), and PJBD blends B10 (10% PJBD and 90% diesel), and B20 are used as direct injection fuel (DIF) in three fuel combinations. The experiment was carried out in a common rail direct injection, 3.7 kW stationary single-cylinder diesel engine under a constant speed of 1500 rpm. Compared to diesel SFM, the PJBD SFM shows a slightly lower brake thermal
Tamilvanan, A.
Optimized Design, Analysis, and Validation of a Tractor Muffler for Enhanced Back-Pressure Control and Cost Efficiency2026-28-0004To be published on 02/12/2026
Internal combustion engines generate intense acoustic pulses during combustion, necessitating the use of exhaust mufflers to suppress noise emissions. With evolving regulations on permissible noise levels and the automotive industry's drive toward lightweight, high-performance vehicles, muffler designs must balance effective sound attenuation, minimal back pressure, and reduced mass. This study presents a comparative analysis of three muffler configurations serpentine, rectangular, and zigzag designed using SolidWorks for a light commercial vehicle (LCV) diesel engine. The models were evaluated using computational fluid dynamics (CFD) simulations to assess their acoustic and flow performance. Each design incorporated internal baffle arrangements to enhance sound absorption while aiming to minimize back pressure. The serpentine model featured a perforated baffle layout that promoted multiple reflections and dissipated acoustic energy more efficiently. Simulation results indicated that
Deepan Kumar, Sadhasivam, R, Krishnamoorthy, D, Ashokkumar
Development of Multiple level Auto Mode for Climate control in electric vehicles2026-28-0008To be published on 02/12/2026
Electric vehicles, or EVs, are significantly transforming the automotive industry as a cleaner and more environmentally friendly which finds an alternative solution for the vehicles propelled using internal combustion engines. As EV utilize the energy directly from the battery which causes customer or a user to be in panic state as charging infra is not developed well in most of the countries, thus improving vehicle efficiency and driving range requires optimizing energy consumption from battery of EVs. Apart from traction motor load for driving, major supplemental loads in electric car are climate control system, sometimes referred to as HVAC (Heating, Ventilation, and Air Conditioning). HVAC systems can consume a lot of battery power, especially during severe temperatures, which can drastically reduce the vehicle's range. Range anxiety continues to be an important barrier to the general adoption of EVs, the intelligent climate management systems which helps to reduce HVAC power usage
Mulamalla, Sarveshwar Reddy, SV, Master Eniyan, M, Nisshok, Anugu, Anil, E A, Muhammed, Guturu, Sravankumar
Design evolution of novel rear sub frame structure for multilink suspension and electric vehicle platform2026-28-0007To be published on 02/12/2026
As there is a major shift in customer demand for energy efficient transportation electric vehicle development has taken immediate significance worldwide as they provide pollution free, noise free mobility environment. In the current work, the authors evaluate novel Rear sub-frame assembly structure with multilink suspension and further for a born electric vehicle platform with increased rear axle weight contribution due to rear motor and battery weight. The Sub Frame is the important structural component of the chassis system. Hence designers face the challenge of providing a best-in-class optimized Rear sub-Frame in terms of cost and weight within the available vehicular boundary. Rear sub-Frame assembly is designed with unique cross member structure and novel motor mounting arrangement on the side member with the given complex hard points or attachments of the suspension linkages, to meet the electric vehicle packaging requirement. Sub frame is designed with light weight to withstand
Nidasosi, Basavraj Maruti, J, Ramkumar, NAYAK, Bhargav, MANI, ARUN, M, Sudhan
A Data-Driven Evaluation of Actuated Signal Control for Improved Traffic Flow in Sathyamangalam City2026-28-0059To be published on 02/12/2026
A Vehicle Actuated (VA) traffic signal control system utilizes advanced control logic to dynamically respond to real-time traffic demands, minimizing overall delays and optimizing signal timings at intersections, particularly those with multiple phases. The primary objective is to design an automated system that adjusts traffic control based on traffic density. To achieve this, a comprehensive traffic volume survey is conducted to analyze traffic flow characteristics. By converting traffic volume from all directions into equivalent passenger-car units (PCUs), engineers calculate the optimal cycle and green times to reduce delays. The system's primary goal is to selectively implement control strategies that yield the greatest benefits, maximizing overall efficiency and effectiveness. To evaluate the effectiveness of actuated signal control in managing traffic flow at key intersections in Sathyamangalam city, based on a comprehensive study of traffic volume counts, signal design
Shanmugam, Loganayagan, Kumar, V
Experimental Investigation of Bio-Butanol Addition into Diesel, Biodiesel, and Diesel-Biodiesel blends on the Thermal Release of the Power Pack2026-28-0056To be published on 02/12/2026
Biodiesel and Bio-Butanol are among the renewable fuels that are manufactured from the waste cooking oil and the cut waste vegetables and fruits. This research work includes the investigation of volume of bio-butanol that can be blended with diesel, biodiesel and diesel-biodiesel blends such that the properties of the final blend along with the test of solubility under 25 deg Celsius for sixty days in a controlled environment, possesses competent properties with respect to base values of diesel. Following this an investigation of performance, combustion and emission characteristics of diesel power pack has been performed. The results indicate that biobutanol can be blended with diesel up to 20%, up to 50% with diesel-biodiesel (20%), and 35% with biodiesel. The test in the power pack depicts that the thermal efficiency, smoke , carbon monoxide and hydrocarbons from the fueled power pack are found to be higher when comparing the reference values of diesel. However, the values of fuel
B, Prabakaran, Yasin PhD, Mohd, Mamat, Rizalman
Aerodynamics Performance Analysis of Effect of Interference on Drone Arms Unsig Computational Fluid Dynamcis Simulations2026-28-0046To be published on 02/12/2026
In this research, the aerodynamic behavior of drone arms by comparing two different shapes – a traditional cylindrical arm and an airfoil-shaped arm. The main focus is to analyze and compare the interference drag created by both shapes using computational fluid dynamics (CFD). In general, cylindrical arms are commonly used in commercial and custom drones, but they create more drag during flight, which reduces the drone’s overall efficiency. On the other hand, airfoil-shaped arms have the potential to reduce drag and improve flight performance. To understand the drag characteristics, both geometries will be designed using Catia V5 software and simulated in ANSYS Fluent under uniform airflow conditions and k-ω turbulence model. The simulation was carried out at different inlet conditions such as freestream velocity of 50 m/s and 100 m/s and maneuvering at different angles of attack varies from 0 to 30 m/s with steps of 5 deg. This research work helps to reveal different aerodynamics
Ganesan, Balaji, A, Rohithvarman, M, Shyam Sundar, T, Aathish, S, Sasikumar, Raja, Vijayanandh, G, Boopathy, GANESAN, SANTHOSH
Design and Development of Integrated Brake and Bull Cage System for Enhanced Tractor Performance and Sustainability2026-28-0005To be published on 02/12/2026
Conventional tractor transmission systems feature separate Brake and Bull Cage housings, with brakes often being proprietary components and Bull Cage designed by the Original Equipment manufacturer (OE). To optimize design and performance, an innovative integrated system was developed, combining an in-house braking system with a unitized Bull Cage assembly. This robust design reduces part count, eliminates proprietary dependency (except for friction liners), and enhances performance. Virtual simulations performed under RWUP conditions demonstrated enhanced strength and stiffness in the integrated design. In this Integrated Brake & Bull Cage assembly (IBCA) , the braking layout was reconfigured from a 4+1 friction design to a 3+2 configuration which improved balancing, enhancing customer braking experience and increasing contact area by 11%. This adjustment extends friction liner life and boosts mechanical advantage by 7.5%, significantly improving tractor stability and performance
Dumpa, Mahendra Reddy, Dhanale, Swapnil, Perumal, Solairaj, Gomes, Maxson, Redkar, Dinesh, Savant, Kedarnath, V, SARAVANAN
Experimental and Predictive Study on WEDM of Aluminium Alloys Using Taguchi and ANFIS2026-28-0040To be published on 02/12/2026
The attributes of aluminium alloys are acknowledged in the varied usage of these alloys because they have excellent mechanical properties and good ductility while being less vulnerable to fatigue. These alloys are widely applied in engineering disciplines. The aerospace and automotive industries are important industries using these alloys, and many other progressive engineering applications continue to embrace the use of these alloys. Their resistance to corrosion makes them even better suited for usage in some harsh environments. Unfortunately, producing parts with very complicated geometries through conventional machining techniques is still a challenge. To try to solve this limitation, there have been several advanced machining processes. Among them is Wire Electrical Discharge Machining (WEDM) - a specific form of Electrical Discharge Machining (EDM) for an effective solution for complex and hard-to-machine components. In this study, efforts have been made to study the WEDM process
Natarajan, Manikandan
Multi-Objective Optimization of WAAM for Sustainable Production of Automotive-Grade Components2026-28-0030To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) has emerged as a promising technology for fabricating large-scale metal components with reduced material waste and lead time, aligning with the goals of sustainable manufacturing. This study presents a multi-objective optimization approach for WAAM to enhance both the manufacturing efficiency and sustainability of automotive-grade components. Key process parameters such as travel speed, wire feed rate, and current were systematically varied to evaluate their impact on dimensional accuracy, mechanical performance, and energy consumption. A statistical design of experiments framework was employed, and multiple performance objectives were optimized simultaneously using suitable decision-making techniques. The results demonstrate that optimized WAAM settings not only meet structural and functional requirements for automotive applications but also contribute to material and energy savings. This approach supports the integration of sustainability into
Pasupuleti, Thejasree
Enhancing combustion, performance and emission profiles using kapok methyl ester blends with hydrogen2026-28-0058To be published on 02/12/2026
This study investigates the potential of using a dual green alternative fuel combination, the one is hydrogen fuel and another one is biodiesel for enhancing the Combustion, performance and emission characteristics of a compression ignition engine. The kapok oil methyl ester was blended with diesel in proportions of 20% (K20) and 40% (K40) by volume. The hydrogen gas was supplied at a constant flow of 4 liter per minute (LPM). The experimental fuels are neat diesel D100, K20 (80% Diesel and 20 % kapok methylester), K40 (60% Diesel + 40 % Kapok methyleter), K20 + H4L (K20 with 4 LPM hydrogen) and K40+H4L (K40 with 4 LPM hydrogen). These blends were tested in a single cylinder direct injection diesel engine under different load conditions at a constant speed of 1500 rpm, combustion, performance and emissions characteristic were evaluated and compared with base fuel. The results indicated that te use of B20 and B40 blends without hydrogen led to reduced brake thermal efficiency due to
Anbarasan, ANBARASAN, M, KUMARESAN
CFD Simulation of Combustion and Emission Characteristics of Pure Spirulina Microalgae Biodiesel in a Single-Cylinder DI Diesel Engine2026-28-0043To be published on 02/12/2026
This study examines the combustion and emission characteristics of pure Spirulina microalgae biodiesel (B100) in a single-cylinder direct-injection (DI) diesel engine using computational fluid dynamics (CFD) in ANSYS Fluent. A 2D axisymmetric sector model of the engine was developed and simulated with a moving mesh to capture dynamic piston motion throughout the engine cycle. The Discrete Phase Model (DPM) was applied to simulate spray atomization and droplet evaporation, while a non-premixed combustion model and RNG k-ε turbulence model were used to resolve in-cylinder combustion dynamics. The thermophysical properties of Spirulina biodiesel were defined from literature data to accurately model fuel injection, vaporisation, and ignition phenomena. The study focused on analysing in-cylinder pressure, temperature, and emission characteristics such as NOx, CO, and soot, and compared the results with those of conventional diesel fuel. Simulation results indicated that Spirulina biodiesel
Kumar, B Varun
Experimental Optimization of WEDM for Post Processing of Wire Arc Additive Manufactured Alloys2026-28-0041To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is widely adopted for producing large-scale metal components due to its high deposition rates and material efficiency. However, WAAM-fabricated parts often exhibit poor surface finish and dimensional inaccuracies, necessitating precision post-processing. Wire Electrical Discharge Machining (WEDM) offers a suitable solution for finishing such components, especially those made from hard-to-machine alloys. This study presents an experimental investigation into the optimization of WEDM process parameters such as pulse-on time, pulse-off time, peak current, and wire feed for post-processing WAAM-fabricated alloys. Using a Taguchi design of experiments and statistical analysis, the influence of each parameter on surface roughness, material removal rate (MRR), and dimensional accuracy was evaluated. The optimized parameters yielded improved surface integrity and machining efficiency, making WEDM a reliable post-processing technique for enhancing the
Pasupuleti, Thejasree
Statistical Optimization of Wire Arc Additive Manufacturing Parameters Using Taguchi Methodology2026-28-0035To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is an emerging metal additive manufacturing process known for its high deposition rates and cost-effectiveness in fabricating large-scale components. However, the quality of the final build is highly sensitive to process parameters such as wire feed rate, travel speed, voltage, and current. In this study, the Taguchi method is employed to statistically optimize key WAAM process parameters with the aim of improving surface finish and mechanical integrity of the deposited parts. An L9 orthogonal array was used to design experiments, and signal-to-noise (S/N) ratios were analyzed to identify optimal parameter settings. Analysis of variance (ANOVA) was performed to determine the significance of each factor on the selected output responses. The results demonstrated that specific combinations of process parameters can significantly reduce surface roughness and enhance bead geometry. The optimized settings obtained through the Taguchi approach provide a
PN, Vani
Computational study on dynamic handling performance of a retro-fitted Electric Two wheeler using 125cc powered ICE reference2026-28-0047To be published on 02/12/2026
With the development in motor technology and battery manufacturing technologies, the scope for a budget working EV has been increasing in India. There remains an after-mark potential for conversion of an ICE powered two-wheeler to an EV power train. Such a move reduces the carbon footprint from the vehicle drastically and is still being explored. This study investigates the effect of replacing the ICE with an electric motor in a 125cc motorcycle, with a particular focus on vehicle handling performance using Slalom test. The two wheelers were modelled using calculated mass properties and estimated / calculated moments of inertia using CAD for both ICE and electric powertrains. The electric propulsion system took into consideration the role of a battery pack in the mass and MI calculation. The framework with degrees of freedom is well established in BIKESIMTM simulation environment. A slalom test with automatic gear shift and throttle to maintain speed of the vehicle was set-up to
Sankarasubramanian, Hariharan
An Integrated Model Approach for Predicting Vehicle Dynamics Performance during HiL Validation2026-28-0044To be published on 02/12/2026
In the automotive industry, increasing noise regulations are influencing product sales and passenger comfort, creating a need for more effective noise testing methods. Hardware-in-Loop (HiL) based virtual acoustic testing serves as a critical step before Driver-in-Loop testing, allowing for the assessment of noise levels inside and outside the vehicle under various conditions before real-world testing is performed. This study addresses the conversion of a physical vehicle model in the AMESim environment into FMU-RT (Linux) format, and the translation of a powertrain control system from Simulink to C++ code. Key challenges in the FMU-RT conversion include the integration of appropriate submodels for each component and enabling the interfaces necessary for SCANeR and virtual acoustic testing. In the C++ code conversion, challenges involved configuring the correct parameters, ensuring the model runs at a fixed time step and sampling time of 1 ms, and resolving issues related to the
visuvamithran, Rishikesan, CHOUGULE, Sourabh, Srinivasan, Rangarajan, LAURENT, Nicolas
Experimental Analysis on the Performance and Emission Characteristics of Direct Injection Diesel Engine Fuelled with Chlorophyta Algae Oil Biodiesel Blends2026-28-0045To be published on 02/12/2026
Chlorophyta algae, also known as green algae, are rich in oils suitable for biodiesel production. They grow quickly using minimal resources and can be cultivated on non-arable land. The extracted oils can be converted into biofuels that improve engine performance and reduce emissions. This makes Chlorophyta algae a sustainable and eco-friendly alternative to fossil fuels. This study presents an experimental investigation into the performance and emission characteristics of Chlorophyta algae oil biodiesel blends (A20 and A30) compared to conventional diesel (D100) in a direct injection (DI) diesel engine. The analysis reveals a notable enhancement in brake thermal efficiency (BTE), with A20 showing a 2.5% improvement and A30 demonstrating a 1.2% increase, attributed to enhanced combustion kinetics. Furthermore, brake specific fuel consumption (SFC) decreases by 4.1% and 6.8% for A20 and A30, respectively. Emission analysis indicates significant reductions in carbon monoxide (CO
M, Selvam, R, Ganapathy Srinivasan, Ka, Harish, Selvamani, Muthukumar, B, Sanjai
Topology Optimization of Steering Knuckle using Aluminium-Carbon Fiber Hybrid Material2026-28-0010To be published on 02/12/2026
The steering knuckle is the most vital element of a car; it is associated with the suspension system, front wheel, wheel hub, as well as chassis through the steering and braking systems. It travels along the driver's chosen paths with the help of the steering system. Under different conditions, it encounters a variety of loads. By implementing the steering knuckle's topology optimisation and moving from the present production material to a hybrid material, the major focus of this project is to lower the weight of a steering knuckle. In the automotive manufacturing and industrial sectors, the future car must be lightweight and fuel-efficient. This is due to a lighter steering knuckle generates higher power and less vibration because there is less inertia when driving. 5% carbon fibre and 95% aluminium (5XXX series) make up the hybrid material's makeup. Using the IGS format, the steering knuckle model's design was imported from SOLIDWORKS 2020 to ANSYS Workbench 18.1 for static analysis
M, Venkatesan, P, Nithyanand
Optimization of Exhaust System Design to meet Backpressure, Durability, Thermal Safety, and Accessibility for EU6 Heavy Duty Trucks.2026-28-0006To be published on 02/12/2026
Any Automotive exhaust system is evaluated based on the following criteria, namely pass-by noise (PBN), exhaust backpressure, durability & reliability (D&R), Thermal Safety, and cost. Exhaust Aftertreatment System/Devices (EATS) has become integral to BS-IV or EU-IV onwards vehicles, which require additional emissions testing. This paper covers an innovative exhaust solution for a 17L, 780 hp engine Eu6 vehicle, having a higher exhaust gas flow rate and severe application (duty cycle), and the same packing space of exhaust upstream pipe. In addition, it was the requirement to take account of field failure issues observed in earlier products (running in the field) and to resolve problems faced during the Beta Proto Build. Authors have optimized the Design using CFD (for backpressure) , Durability analysis (Structural life), IPS simulation (for Accessibility) and Thermal simulation (hot spot analysis). The designed exhaust upstream pipe is an innovative twin-bellow configuration with
Rokade, Aditya, P, Balu Mukesh, Kolavennu, Prajwal, Biswas, Sanjoy
Parameter Selection Strategies for High-Performance WAAM Structures in Automotive Engineering2026-28-0033To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) has gained traction as an advanced fabrication technique for producing large, structurally demanding components in the automotive industry. Achieving high-performance WAAM structures requires precise control and selection of key process parameters, which directly influence mechanical strength, dimensional accuracy, and surface quality. This study investigates the effect of critical process variables—including wire feed rate, travel speed, current, voltage, and inter-layer cooling time—on the structural integrity of WAAM-fabricated components designed for automotive use. A systematic experimental approach, supported by statistical modeling and optimization tools, was employed to identify parameter combinations that yield optimal results. The outcomes demonstrate improved microstructural uniformity, reduced residual stresses, and enhanced tensile properties in the fabricated parts. The findings serve as a foundation for developing robust parameter
V, Aravind
Statistical Modeling of Wire Arc Additive Manufacturing Parameters Using Regression Analysis2026-28-0024To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is gaining prominence for fabricating large metal components due to its high deposition rate and cost-effectiveness. However, the quality and performance of WAAM-fabricated parts are strongly influenced by process parameters such as wire feed rate, travel speed, arc voltage, and current. This study presents a statistical modeling approach using regression analysis to predict the effects of these key parameters on critical output responses, including bead geometry, surface roughness, and material deposition rate. Experiments were designed using a structured methodology, and the collected data were analyzed to develop linear and multiple regression models. The accuracy and reliability of the models were evaluated using statistical metrics such as R² and p-values. The results demonstrate that regression-based models can effectively predict WAAM outcomes, enabling process optimization and quality control. This approach provides a valuable tool for
Pasupuleti, Thejasree
Investigation of Wear and Friction Characteristics of 3D printed PLA and PLA–Carbon Fiber Composites against a Tribometer Counter Part Surface2026-28-0031To be published on 02/12/2026
PLA (poly Lactic Acid) carbon fiber composites is most widely used in industrial applications especially in automotive, consumer electronics sector due to low cost prototyping and durability. In this proposed work, investigation on PLA and PLA+CF 3D printed samples are taken for wear and friction testing with same material counterpart. This experiment helps to analyze wear and friction resistance by applying material interaction between part on pin, counterpart on disc with varying applied load of 5,10,15 to 20N and sliding velocity of 1m/s and 3m/s. At first designing the required prototype (Part sample, counterpart disc) with material as PLA, PLA+CF. The unique of the research, tested samples are 3D printed pin and counterpart disc, both are same material. Each sample subject to 4 different load and 2 different sliding velocity. In this work we use two materials namely PLA, PLA+CF composite material. In this work PLA and PLA Carbon Fiber materials are comparatively analysed where PLA
Ranganathan, Soundararajan, Karthickkumar, S, Alwin Jones, J
EXPERIMENTAL ANALYSIS AND SIMULATION STUDY OF AN AUTOMOBILE RADIATOR WITH NANOFLUIDS2026-28-0020To be published on 02/12/2026
A nanofluid is the suspension of nanoparticles in a base fluid. Nanofluids are promising fluids for heat transfer enhancement due to their anomalously high thermal conductivity. The thermal conductivity enhancement mechanisms of nanofluids have not been fully understood yet. In the first part of this study, a detailed literature review about the thermal conductivity of nanofluids is performed. Experimental studies are discussed in terms of the effects of some parameters such as particle volume fraction, particle size, and temperature on the thermal conductivity of nanofluids. Enhancement mechanisms proposed to explain nanofluid thermal conductivity are also summarized. Research about the forced convection of nanofluids is important for the practical application of nanofluids in heat transfer devices. Recent experiments showed that heat transfer enhancement of nanofluids exceeds the thermal conductivity enhancement of nanofluids. This extra enhancement might be explained by thermal
R, GOWTHAM
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