Browse Topic: Bodies and Structures

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Design and Simulation Analysis of an Integrated Honeycomb-filled Front Bumper for a Special Vehicle2026-01-0475To be published on 04/07/2026
In frontal collisions of automobiles, the bumper beam at the front of the vehicle plays a crucial role in absorbing energy and protecting the vehicle body during a collision. To enhance the collision resistance of a specific type of special vehicle with a non-load-bearing body structure, this paper focuses on this type of vehicle and conducts a study on the design and collision performance of an integrated vehicle front bumper-impact beam structure based on aluminum alloy additive manufacturing technology. A novel bumper structure is proposed, which integrates the front bumper and the front impact beam of the vehicle and is integrally formed using aluminum alloy additive manufacturing technology. This integrated structure is directly connected to the vehicle frame. Firstly, based on the appearance of the special vehicle body and the form of the front impact beam of traditional passenger vehicles, an integrated design of the vehicle front bumper-impact beam structure is carried out and
王, Xufan, Yuan, Liu-Kai, Zhang, Tangyun, Wang, Tao, Zhang, Ming, Wang, Liangmo
Low Speed Bumper System Impact Variation Study2026-01-0474To be published on 04/07/2026
Variation studies are an important part of the product development (PD) process. They help to understand and estimate real-world deviation from design nominal parameters, optimize designs for robustness, reliability, and cost-efficiency. CAE and Virtual tools enable us to simulate a great number of different variation types and capture the full bandwidth of actual field performance - rather than the validation from a limited number of physical tests. In this study, the effects of various factors on vehicle performance during low-speed impacts, utilizing a Design of Experiments (DOE) approach have been investigated through virtual simulation. Low-speed impacts, typically defined as collisions occurring at speeds less than 2.5 mph, are critical for understanding vehicle insurability and compliance with regulatory standards. The factors examined include vehicle impactor position, impact speed, and angle of collision, part thickness variation, material card variation. The DOE methodology
Suravaram, Raghu Mohan Reddy, Islam, ABM Iftekharul, Larson, John, Tehrani, Babak, Koch, Lisa, Mathur, Mohit Sain
Sensor Fusion Method for In-Cabin Humidity Prediction2026-01-0131To be published on 04/07/2026
Maintaining optimal in-cabin humidity levels is part of occupant comfort, air quality, and the effective operation of climate control systems, particularly for functions like windshield defogging. This paper introduces a novel sensor fusion methodology for predicting in-cabin humidity distribution without dedicated humidity sensor. The proposed approach leverages readily available vehicle data, integrating information from ambient temperature sensors, in-cabin temperature sensors, occupant detection systems, window status, and climate control settings. By intelligently fusing these diverse data streams, a predictive model is developed to infer the dynamic humidity conditions within the vehicle cabin. We discuss the complex interactions between these parameters, such as the moisture contribution from occupants, the influence of external air ingress through open windows, and the dehumidifying or humidifying effects of the Heating, Ventilation, and Air Conditioning system. The paper
Ghannam, Mahmoud, Schroeter, Robert, Shaik, Faizan
Wind-tunnel investigation of snow/ice drag on a 30%-scale DrivAer model2026-01-0604To be published on 04/07/2026
Wind-tunnel tests were conducted using a 30%-scale DrivAer model, in estateback and notchback rear-geometry configurations, to investigate aerodynamic performance changes associated with snow and ice buildup on passenger vehicles. Around 20 snow/ice accumulation patterns were tested, at a Reynolds number of 2.8 million based on model wheelbase, for each of the notchback and estateback variants. 5 additional patterns were tested on the estateback with roof-rack support bars. Snow accumulation was modelled with foam, while ice accumulation was simulated with aluminum tape hand-formed to the desired shape. A simulated full-scale snow thickness of 58 mm on the hood, roof and trunk increased the wind-averaged drag coefficient by 16% for both model variants. With 90 mm of snow, the drag of the estateback variant increased by 19%. Drag changes increased with, but were not proportional to, snow thickness. Chamfered front and rear edges, representing windblown shapes, reduced the drag penalty
de Souza, Fenella, McAuliffe, Brian
Ultra-Low Latency Video Pipeline Optimization for Perception-Centric Autonomous Systems2026-01-0022To be published on 04/07/2026
Autonomous platforms such as self-driving vehicles, advanced driver-assistance systems (ADAS), and intelligent aerial drones demand real-time video perception systems capable of delivering actionable visual information at ultra-low latency. High-resolution vision pipelines are often hindered by delays introduced at multiple stages-sensor acquisition, video encoding, data transmission, decoding, and display-undermining the responsiveness required for safety-critical decision making. This study introduces a holistic system-level optimization framework that systematically reduces end-to-end video latency while maintaining image fidelity and perception accuracy. The proposed approach integrates hardware-accelerated encoding, zero-copy direct memory access (DMA), lightweight UDP-based RTP transport, and GPU-accelerated decoding into a unified pipeline. By minimizing redundant memory copies and software bottlenecks, the system achieves seamless data flow across hardware and software
Indrakanti, Rama Kiran Kumar
SUNRISE - A Harmonised Safety Assurance Framework for Connected, Automated MobIlity Systems2026-01-0060To be published on 04/07/2026
The SUNRISE project develops and demonstrates a harmonised Safety Assurance Framework (SAF) for Connected, Cooperative and Automated Mobility (CCAM) systems. The framework has been created in close alignment with the UNECE New Assessment/Test Method (NATM), and past and on-going international projects and initiatives. It also aligns with standardisation efforts in various standardisation bodies such as ISO, ASAM, SAE, and BSI. At the core of the SAF lies the Performance Assurance flow, which structures how safety evidence is generated and assessed. This flow is organised into three interconnected blocks: Scenario, Environment, and Safety Argument. The Scenario block encompasses the creation, formatting, and storage of scenarios that can be retrived to cover the system’s Operational Design Domain (ODD) and behaviour. The Environment block addresses the concretisation of test cases, their allocation across virtual, proving-ground, and real-world environments, and their execution. The
Zhang, Xizhe, Khastgir, Siddartha, de Vries, Stefan, Hillbrand, Bernhard, Op den Camp, Olaf, Bolovinou, Anastasia, Bourauel, Bryan, Ehrenhofer Gronvall, John Fredrik, Menzel, Thaddäus, Nieto, Marcos, Stettinger, Georg, Jennings, Paul
Investigation of a System for Headlight Glare Control Based on Photometric Zones2026-01-0515To be published on 04/07/2026
Headlight glare remains a constant problem among the driving public. Following several decades of mostly incremental progression in headlight design, the past twenty years have witnessed rapid evolutions in technology and design that have made substantial differences in the appearance and performance of automotive headlights. Most obviously, there has been a transition from yellowish-white sealed beam and halogen lamps, to high-intensity discharge and more conclusively, light-emitting diode sources with a distinct, cool-white color appearance. This transition has increased perceptions of brightness, both of the forward road scene (potentially benefiting the headlight user) and of the headlights themselves (increasing visual discomfort for opposing drivers). The mix of vehicles has also increased in size, resulting in higher-mounted headlights and the potential for higher light levels at other drivers’ eyes. Variability in headlight vertical aim has possibly decreased in very recent
Bullough, John D.
On-Engine Measurement of Automotive Turbocharger Turbine Blade Vibration2026-01-0201To be published on 04/07/2026
Automotive turbochargers are designed to avoid resonance of the turbine blades and backwall, which can result in High Cycle Fatigue failures. Blade Tip Timing is a method of turbomachinery testing which utilizes fiber optic probes to measure turbine blade displacements in real time on turbochargers spinning at upwards of 150,000 RPM. Historically, Blade Tip Timing measurements of automotive turbochargers have been made under steady-state conditions using a Hot Gas Stand. General Motors conducted testing of a turbocharger on a running engine to capture realistic exhaust pressure dynamics. A reference turbocharger was measured on an engine testbed running a production calibration; the same turbocharger was then tested on a Hot Gas Stand to observe how the blade behavior differed. Blade displacements were found to be lower on engine, because the dynamics of engine pulsation reduced the in-phase work available to drive the turbine blades, resulting in lower blade stresses and an
SCHWARZ, JORDAN, Goodheart, Rachel, Tappert, Peter, DePaoli, Dominic, Longacre, Christian
Elucidation of Flow Mechanisms Modulating Vehicle Wind Noise by using Large-Scale CFD Simulation2026-01-0614To be published on 04/07/2026
In vehicle development, noise reduction is critical for ensuring passenger comfort. As electric vehicles become prevalent and engine noise is minimized, wind noise becomes more noticeable. Modulated wind noise, which causes a sense of fluctuation due to atmospheric turbulence, wind gusts, and preceding vehicle wakes, causes significant discomfort. This noise is characterized as a high-frequency sound above 1 kHz, modulated at low frequencies owing to the wind velocity and direction fluctuating at several Hz. However, the mechanisms behind wind noise modulation are not fully understood, and no established countermeasures have been developed. This is because wind noise perceived through the side window is primarily caused by the A-pillar vortex and door mirror wake, which coexist as complex turbulent flows around the vehicle. Therefore, identifying the source of modulated wind noise around vehicles under fluctuating wind conditions is difficult. This study aims to identify the source of
Tajima, Atsushi, Hirata, Takumi, Ikeda, Jun, Kamiwaki, Takahiro, Wakamatsu, Junichi, Tsubokura, Makoto
Design, Fabrication, and Assessment of a User-Friendly Suspension System for a 2025 BAJA Vehicle2026-01-0588To be published on 04/07/2026
A suspension system was designed, fabricated, and tested following a systems design approach by the Desert Hare Off-road Team from South Dakota State University (SDSU). Compared to previous suspensions, the new suspension system is more reparable and contains a minimal number of custom parts, while still maintaining sufficient strength to withstand dynamic loads experienced when operating the vehicle. Modifications were also made to fit the newly designed vehicle body frame. As an integral part of the team’s 2025 Baja vehicle, the redesigned suspension system contributed to the vehicle’s improved performance during the 2025 SAE (Society of Automotive Engineers) Baja Competition. This paper presents a detailed account of the design, development, and fabrication process of the suspension system. The final design was tested and evaluated via both computer simulations and physical tests, whose efficiency and reliability were finally demonstrated by the team’s improved ranking in the 2025
Liu, Yucheng, Anderson, Matthew, Larson, Cody, Rodgers, Joshua, Seberger, Aaron, Letcher, Todd
ProGuard: A Real-time Preemptive Artificial Intelligence-Based Anti-Pinch System for Bus Entryways on Low-Power Edge Devices2026-01-0100To be published on 04/07/2026
This paper proposes ProGuard, a novel approach to preemptive pinch detection systems for buses. ProGuard utilizes state-of-the-art AI object detection algorithms to identify potential pinching events in bus entryways before pinching occurs. Modern conventional anti-pinch systems, such as pressure sensors or hall effect sensors, often rely on mechanical contact before triggering. While these systems are established safety mechanisms, they are reactive and therefore require some level of pinching before triggering. This reactive approach presents numerous safety concerns for passengers, especially when considering children on school buses. Existing preemptive detection methods, such as infrared or ultrasonic sensors, solve the problems presented by these reactive detection systems. However, these systems either lack the range or environmental resilience needed for reliable operation in buses. The critical nature of anti-pinch systems requires a robust and reliable solution that can adapt
Bradley, Hudson, Zadeh, Mehrdad, TAN, Teik-Khoon
HaloBus: Edge Computing‑Enabled Real‑Time Boarding and Exit Detection for Enhanced Transportation Safety Using Lightweight AI2026-01-0555To be published on 04/07/2026
This paper proposes HaloBus, an innovative, edge‑computing solution designed to mitigate this risk by detecting student boarding and exiting in real time using lightweight AI based methods. A persistent challenge in elementary school transportation is the issue of missing students after they exit their buses, which disproportionately impacts low-income households. Current safety systems are forced upon the individual households with their own methods. Common methods include applications on a personal device or a small tracker. However, not everyone can afford these options, and every parent deserves to feel like their child is safe. That is why HaloBus was invented. The system employs YOLOv5u—an Ultralytics‑enhanced, anchor‑free, split‑head architecture that offers a superior accuracy–speed tradeoff. By providing real-time, on-device alerts, HaloBus enables immediate intervention to prevent a student from being left behind, thereby shifting the focus from reactive post-incident
Getz, Grayson, Zadeh, Mehrdad, TAN, Teik-Khoon
A Study on the Relationship between Impact Conditions and Head Injury Criterion (HIC) in Powered-Two-Wheeler to Car Crashes2026-01-0571To be published on 04/07/2026
Road Traffic crash statistics highlight the importance of reducing fatalities among Powered-Two-Wheeler (PTW) riders, and suggest the necessity of a robust method to evaluate PTW crashworthiness performance. The objective of this study is to clarify the relationship between impact conditions and the Head Injury Criterion (HIC) to establish a fundamental basis for determining representative crash configurations for safety. A total of 1,272 PTW-front to car-side impact simulations were conducted by using production car and PTW models. HIC was used as a metric indicating likelihood of head injury. Velocities, impact angle, and impact locations were varied to create response surfaces. The surfaces were evaluated in terms of their accuracy in identifying the representative impact conditions. In addition, head trajectories were analyzed to clarify the kinematics until head impact. The Finite Element (FE) simulations produced the following findings. - The HIC distribution by Head Impact
Yanaoka, Toshiyuki, GUNJI, Yasuaki, Zulkipli, Zarir Hafiz, Matsushita, Tetsuya, Carroll, Jolyon, Puthan, Pradeep, Mohd Faudzi, Siti Atiqah, D-Wing, Kak, Miyazaki, Yusuke
Innovation Powered by High-Fidelity Multiphysics Modeling: A Holistic System Optimization of BorgWarner’s Next Generation Integrated Drive Modules2026-01-0497To be published on 04/07/2026
In the stringent market of BEV, the development of integrated Drive Modules (iDM) fitting to environmental and customer needs is mandatory. It is important to extract the best from the less. To achieve those goals, a deep insight of complex multiphysics phenomena occurring in an iDM has been achieved by accurate and validated models. This engineering methodology is applied through the development of BorgWarner products, comprising non-exhaustively iDM 180-HF, Externally Excited Synchronous Machine and Multi-Level Inverter. The paper will review the methodology development for deeper understanding involving in-house technical excellence and complemented by strategic partnerships with academic institutions and start-ups. It will present the approach of integrating advanced multiphysics models with high-quality experimental validations, specifically on loss evaluation on electrical machines and inverters. Complex models involving multiphysics such as thermal/fluid coupling or electric
Leblay PhD, Arnaud, Bossi, Adrien, Bourniche, Eric, DAVID, Pascal, Nanjundaswamy, Harsha
The Balance of Illumination and Glare Prevention of Upward Directed Lighting2026-01-0516To be published on 04/07/2026
This study investigates the ongoing challenge of balancing sufficient headlight illumination with the need to prevent glare for other drivers. It focuses on the upper portion of a headlight's beam pattern, which is particularly relevant for lighting overhead signs and the upper portions of vulnerable road users. This study investigates the influence of LED headlamp technology on upward directed lighting and compares illumination of systems with varying mounting heights. This is especially important when it comes to the performance of camera-based pedestrian detection and Automatic Emergency Braking (AEB) systems. Data was collected by testing multiple vehicles over time with pedestrians positioned at two distinct locations relative to the vehicle as well as some discrete points relative to the headlamp and independent of mounting height. The resulting analysis reveals trends, providing valuable insights for predicting optimal lighting strategies in future systems. These strategies may
Allen, Jodi Mary Jean
Comparison of Cyclic Aging and Coulombic Efficiency Measurements for Varied SOC Windows in Lithium-Ion Batteries.2026-01-0380To be published on 04/07/2026
State-of-charge (SOC) operating windows critically influence the long-term performance and reliability of lithium-ion batteries. While conventional cyclic aging studies across varying SOC ranges provide valuable insights into capacity fade and resistance growth, they often require extended testing periods to produce meaningful trends. Coulombic Efficiency (CE), defined as the ratio of discharge to charge capacity per cycle, has emerged as a promising early-life diagnostic tool for identifying parasitic side reactions and projecting long-term degradation. In this work, we present a comparative study of cyclic aging and CE behavior across multiple SOC windows (0–100%, 20–80%, 40–60%, and 80-100%) using eight 21700 NMC cells cycled at 25 °C on both a conventional cycler and an ultra-high precision cycler. Capacity retention, internal resistance evolution, and CE profiles were analyzed to establish correlations between SOC window and degradation rates. Results are expected to indicate that
Hussein, Huda, Panchal, Satyam, Gross, Oliver, Kollmeyer, Phillip, Emadi, Ali, Arora, Dipan
CAE Acceleration With Machine Learning For Results Prediction2026-01-0488To be published on 04/07/2026
Industries are following a tedious product development cycle for developing their product. In product development major steps includes design ideas, Drawings, CAD, CAE, Testing and design improvement cycle. This is a monotonous process and takes time which impacts on its time to deliver product and cost on development. Now a days industries are fast growing and targeting to reduce development cycle time and cost. AIML is impacting almost all areas in the industry and significantly reducing efforts time and cost. To make use of AIML in CAE, Altair Physics AI is an effective tool. To ensure the design of product traditional way is to develop a CAD of the product, develop, perform CAE and analyze performance. If we consider CAE procedure it is time consuming process which includes FEA model build, applying boundary conditions, running simulation and analyzing results which could take minutes to hours. By using ML with Physics AI we can make predictions on new design of the product in
Dangare, Anand Manohar, Kulkarni, Mandar
Development of a System for Regression Model Enhancement Utilizing Shape Generation AI2026-01-0499To be published on 04/07/2026
This study proposes a method to enhance regression models by shape generation AI. The approach focuses on automatically identifying regions within the design space where the model’s prediction accuracy is low. Once these regions are identified, new and diverse sample shapes are automatically generated by the shape generation AI and incorporated into the training dataset. The regression model is then retrained to improve its performance. By iteratively repeating this cycle of exploration, shape (FE mesh) generation, and model updating, the model’s reliability and accuracy across the entire design space are progressively enhanced. This method addresses data sparsity issues common in complex design tasks and enables better generalization to underrepresented regions. The effectiveness of the proposed system was demonstrated through a case study involving hood outer panels in automotive design. The results showed that adding AI-generated shapes improved prediction accuracy, particularly in
Taniguchi, Mashio
Machine Learning for Predicting Rotor and Brake Fluid Temperatures in Hill Descent Events2026-01-0159To be published on 04/07/2026
High thermal loads on brake systems during extended descents followed by vehicle soak pose significant safety and durability risks. Excessive rotor or fluid temperatures can cause loss of braking efficacy, fluid degradation or evaporation, thermal fade, and accelerated component wear. This study uses time history data of brake disc and fluid temperatures collected during controlled hill descent events and subsequent soak (park) periods, and simultaneously logs environmental conditions (ambient temperature, humidity, wind speed and direction) and brake specifications (rotor, caliper geometry, pad material, fluid type, and vehicle mass). Seventy six test runs from a dedicated validation program are used, each providing time history records that form the basis of our analysis. From these records we extract phase specific samples (descent and soak phase) and engineer compact descriptors, such as start and peak temperatures, environmental factors, rolling statistics and contextual metadata
poojari, Uday Kumar, Westphalen, Jan, Venugopal, Narayana
A study on Crack propagation characteristics of interlaced holes for key automotive components.2026-01-0186To be published on 04/07/2026
Aiming at the engineering problem that the stress interference of interlaced holes dominates crack propagation and directly affects driving safety in the hole group structure of key components such as chassis and body frame in the automotive field, in order to accurately reveal the quantitative influence of key parameters of interlaced hole placement (crack deflection Angle, longitudinal hole spacing) on the crack evolution of automotive hole group components, This study adopts the approach of numerical simulation combined with variable control to conduct systematic analysis. Taking an aluminum alloy thin plate with two relatively initial cracks (a commonly used structural material for automobiles) as the research object, multiple sets of typical interlocking hole structure variable models of automotive components covering different crack deflection angles and longitudinal hole spacings were constructed in the ABAQUS software. The J-integral was calculated by the circumscribed line
Chen, Yechao, Zhan, Zhenfei, Tang, Weiqin, Yang, Yutong, Gan, Yuan, Yan, Kaibo, HUANG, Shiyao
Inertial Pedal Displacement and Brake Switch Activation in Frontal Crash Events2026-01-0541To be published on 04/07/2026
This paper presents research into the inertial displacement of brake pedals and the subsequent activation of brake light switches during crash events. In certain scenarios—such as multiple-impact crashes or with pre-impact interactions such as curb strikes or sideswipes—inertial forces alone may generate sufficient brake pedal movement to trigger the brake switch, activating the brake lights. Such signals may be recorded by an Event Data Recorder (EDR) or observed by witnesses and mistakenly interpreted as an indication of intentional driver braking. To investigate this phenomenon, HYGE sled tests were performed using brake pedal assemblies and associated components from a Toyota Tacoma pickup truck and a Cadillac DeVille passenger sedan. The assemblies were subjected to acceleration pulses simulating a frontal impact, with high-speed video used to capture brake pedal displacement and brake light activation. The tests demonstrated that inertial loading from a pulse with a delta-V
Duran, Amanda, Walker, James, Barnes, Daniel, Osterhout, Aaron, Clayton, Aidan
Determining Video Frame Capture Rate through Reverse Engineering2026-01-0543To be published on 04/07/2026
The timing of video recordings, along with the spatial positioning of objects, is a fundamental parameter for calculating the speed time history. If the task involves determining an object’s average speed over several to a dozen frames, the average inter-frame interval can be used as the basic time unit. However, if the objective is to compute speed from individual frames, the reliability of the timing becomes crucial. Without access to DVR hardware documentation, proprietary algorithms, or software – and considering the frequent hardware modifications and software updates - the most effective way to solve the problem is through a reverse-engineering approach. This study discusses several aspects of timing analysis, including: (1) making a test recording of a calibrated LED lightboard; (2) analyzing the relationship between the lightboard time and the presentation time stamp (pts) extracted from the file metadata; (3) investigating frequency interference occurring when recordings are
Wach, Wojciech
OFEODM: An Onboard Fast and Efficient Object Detection and Distance Prediction Model2026-01-0017To be published on 04/07/2026
Object detection and distance prediction have advanced significantly in recent years. The YOLO series has released its 11th version, along with numerous variants that have been applied across various fields. Meanwhile, the Detection Transformer (DETR) has repeatedly set new state-of-the-art (SOTA) records in the field of object detection. Depth Anything also released its second version last year, further pushing the boundaries of distance detection. Although these models achieve impressive performance, they often require substantial computational resources. However, for algorithms intended for real-world applications and deployment on onboard devices, computational resources are limited and valuable. Inference time per frame is a critical factor in ensuring an algorithm's reliability and feasibility. Designing a model that operates in real time without sacrificing accuracy remains an extremely challenging problem, and extensive research is ongoing in this area. To address this
Li, Taozhe, Wang, Hanchen, Hajnorouzali, Yasaman, Xu, Bin
Operational Feasibility of Battery Swapping in U.S. Transit: A Case Study of King County Metro2026-01-0402To be published on 04/07/2026
Battery swapping technology has emerged as a promising alternative to conventional plug-in charging for electric bus fleets, offering rapid turnaround times and improved vehicle availability. This paper investigates whether battery swapping can be integrated into U.S. public transit bus operations without disrupting existing timetables. A Seattle based public transit agency- King County Metro is taken as a case study in this paper. Using General Transit Feed Specification data from King County Metro, a MATLAB model was built that reconstructs blocks and layovers, extracts dwell-time opportunities, and performs block distance and block time analyses to understand operational rhythms. A mathematical energy model was developed that maps route mileage, efficiency, and layover availability to swap decisions, using a look-ahead rule that defers exchanges whenever the next feasible layover can still be reached while respecting a minimum state-of-charge. The workflow estimates how many swaps
Vadlapatla, Taraka Rishi, Jankord, Gregory, D'Arpino, Matilde
Aerodynamic Development of Maruti Suzuki VICTORIS2026-01-0602To be published on 04/07/2026
MSIL (Maruti Suzuki India Limited), India's leader in automotive sector, has various SUVs (Sports Utility Vehicle) in its model lineup. Conventionally, SUVs are considered to have an aggressive stance with a bold on-road presence, and this bold design language often deteriorates aerodynamic drag performance. In the past decade, the demand for this segment has significantly grown, whereas the CAFE (Corporate Average Fuel Economy) norms have become more stringent. To cater to this growing market demand, MSIL planned for a new compact SUV - VICTORIS with targeted best-in-class aerodynamic performance. This paper illustrates the aerodynamic development process for the vehicle using CFD (Computational Fluid Dynamics) and full scale WTT (Wind Tunnel Test). During the initial stages, the bolder design of the VICTORIS deteriorated the aerodynamic drag of the vehicle. Styling exterior surface modifications and addition of new aero parts facilitated the recovery of aerodynamic drag performance
Dey, Sukanta, Singh, Shekhar, Kumar, Chandan, Alphonse, Felix Regin
Analysis of Failure Causes and Optimisation of Automotive Cycloidal Rotor Pumps2026-01-0184To be published on 04/07/2026
Cycloidal rotor pumps are widely employed in automotive and aerospace industries due to their compact structure, high volumetric efficiency, and minimal flow pulsation. With the advancement of new energy vehicles, rotor pumps are increasingly required to operate reliably under more demanding conditions, including higher rotational speeds, elevated pressures, and more severe operating environments. These requirements place greater emphasis on pump durability and structural integrity. This study investigates a fracture failure of the internal rotor observed during bench testing of a cycloidal rotor pump. Metallographic and physicochemical analyses were conducted on the failed rotor. The results indicated that the fracture was not attributable to material defects. Instead, the failure originated from improperly designed slot locations within the rotor, which created a structural weak point at the slot opening. Additionally, sharp corners introduced during machining of the slots resulted
Li, Meng, Xie, JIa, Qin, Gongyu, Yang, Hanming, Wang, Liangmo
Integrated Welding Simulation and Experimental Characterization of Weld-Metal and Heat-Affected-Zone Strength in AA6063-T62026-01-0230To be published on 04/07/2026
In the context of automotive lightweighting and efficient manufacturing, welding is a key joining method for aluminum body structures due to its maturity, versatility, and cost effectiveness. This study investigates MIG butt welding of AA6063-T6 sheets using a sequential thermo-mechanical finite element model with a double-ellipsoid heat source. Thermocouple histories and macroscopic metallography of the weld-pool morphology are used to validate the predicted temperature field, and post-weld deformation measured by a coordinate measuring machine is compared with the simulation to confirm overall model reliability. Hardness mapping across the joint partitions the material into weld metal (WM), heat-affected zone (HAZ), and base metal (BM). Miniature tensile specimens extracted along the weld provide local mechanical properties, from which linear strength–hardness relations are established. Building on these results, a five-material equivalent strength model covering WM, HAZ-I, HAZ-II
Shao, Jiyong, Meng, Dejian, Xiang, Yao, Gao, Yunkai
From Static Ground to Moving Ground Wind Tunnels: Feature Selection for Reliable Estimation of Drag Coefficient Discrepancies2026-01-0203To be published on 04/07/2026
Moving ground wind tunnels offer a more accurate test environment for ground vehicle drag coefficient measurement due to their highly realistic representation of the boundary layer phenomenon. However, historically most vehicles have been tested on static ground wind tunnels. As a result, the measured drag coefficient of these vehicles may not be sufficiently realistic for certification purposes. Therefore, it is valuable to build statistical models to estimate moving-ground wind tunnel drag coefficient by using information from a static-ground wind tunnel and other relevant vehicle characteristics such as presence of aerodynamic devices (spoilers, air dams, etc.). However, to build accurate statistical models, appropriate predictive features must be identified as a first step. In this paper, an aerodynamic feature selection study has been conducted to identify vehicle characteristics that contribute to drag coefficient estimation discrepancies between a static- and a moving-ground
Singh, Yuvraj, Jayakumar, Adithya, Rizzoni, Giorgio
Night Vision Goggles (NVG) Compatible Lighting for Civil AircraftAS5452C (Current)3/13/2026
This SAE Aerospace Standard (AS) will specify what type of NVGs are required and minimum requirements for compatible crew station lighting, aircraft exterior lighting such as anti-collision lights, and position/navigation lights that are “NVG compatible.” Also, this document is intended to set standards for NVG utilization for aircraft so that special use aircraft such as the Coast Guard, Border Patrol, Air Rescue, Police Department, Medivacs, etc., will be better equipped to chase drug smugglers and catch illegal immigrants, rescue people in distress, reduce high-speed chases through city streets by police, etc. Test programs and pilot operator programs are required. For those people designing or modifying civil aircraft to be NVG compatible, the documents listed in 2.1.3 are essential.
A-20A Crew Station Lighting
Aircraft Tire Chine DesignAIR8776 (Current)3/4/2026
The purpose of this SAE Aerospace Information Report (AIR) is to present a sample of the range of tire chine designs approved for application on aircraft requiring non-standard water spray deflection.
A-5C Aircraft Tires Committee
Failure Cause Analysis of Valve-Regulated Lead-Acid Battery on Fire in Communication Equipment Room2026-01-70222/27/2026
This paper carried out the fire failure analysis of valve-regulated lead-acid battery in communication equipment room. Through disassembly and observation of the battery and iron frame of battery cabinet in the area of fire origin, we obtained the key residual traces and used the physical and chemical analysis methods such as macroscopic/microscopic morphology, EDS, X-ray and metallographic, it was finally judged that the leakage of the battery electrolyte lead to the connection of the battery electrode plate and the iron frame and subsequently the electric heating fault caused the fire accident. Furthermore, we put forward some suggestions according to the existing problems, which may contribute to the prevention of similar failures.
Guo, Yuhang
Aerospace Standards Index - 2026ASIN20262/25/2026
This valuable resource lists all Aerospace Standards (AS), Aerospace Recommended Practices (ARP), Aerospace Information Reports (AIR), and Aerospace Resource Documents (ARD) published by SAE. Each listing includes title, subject, document number, key words, new and revised documents, and DODISS-adopted documents. AMS Index - Now Available!
Front Decorative LampJ3098_202602 (Current)2/24/2026
This SAE Recommended Practice applies to a decorative lamp(s) installed on the front of motor vehicles. This lamp(s) is intended only to be decorative and is not to impair the effectiveness of any required lighting device. This recommended practice establishes uniformity in use guidelines for the performance, installation, activation, and switching of a front decorative lamp(s).
Signaling and Marking Devices Stds Comm
Prediction of Dynamic Stiffness of Automotive Components Using Support Vector Methods2026-01-50162/23/2026
In the current scenario of EV revolution in the automotive industry, NVH performance of the vehicles is one of the major points of sale to the customers. Auxiliary components play one of the predominant roles in the contribution of noise to overall vehicle interior or exterior sound pressure levels, which impact customer vehicle comfort. CAE prediction of NVH performance of automotive components involves a lot of design iterative processes, large server space utilization, and time-consuming. To reduce cost and time, data-driven technologies like AI algorithms can help CAE engineers because of their high efficiency and high precision. In the current research, a wiper motor mount stiffness prediction algorithm was designed based on the historical data using CAE analysis and AI algorithms, and improved prediction accuracy by tuning the parameters of AI algorithms using grid search methodology. High prediction accuracy of wiper motor mount stiffness has been achieved with the method of
Paturi, Yuva Venkata Sekhar
Experimental Investigations on Appendages of a Racing Motorcycle2026-01-50112/20/2026
In this experimental work, a detailed analysis of the wind tunnel measurements on scaled motorbike models equipped with different front wings was performed considering four wing configurations operating at different Reynolds numbers and roll angles. Global forces acting on the models were measured by a high-resolution dynamometric balance, while velocity fields in the wake were measured by means of the Particle Image Velocimetry technique. Throughout the paper, overall models’ performances are investigated, demonstrating similar behavior for drag coefficients and various trends for lift coefficients. The without- and single-wing configurations were shown to have positive sign, and conversely, the double- and closed-wing cases—with negative sign—generated downforce due to the presence of significant upward velocities, which in turn modified the wake shape. Furthermore, the improvements in closed-wing configuration compared to without- and single-wing ones were noticeable, while slight
Moscato, Giorgio, Romano, Giovanni Paolo
Failure Modes for High-Lift Actuation Load PathsAIR7061 (Current)2/17/2026
This SAE Aerospace Information Report provides examples of single failure modes for components used in fixed-wing, high-lift actuation systems’ load paths, as well as the typical hazards posed by those failures at the aircraft level.
A-6B3 Electro-Mechanical Actuation Committee
Design and Development of Integrated Brake and Bull Cage System for Enhanced Tractor Performance and Sustainability2026-28-00052/12/2026
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 7.9%, significantly improving tractor stability and performance
Dumpa, Mahendra Reddy, Dhanale, Swapnil, Perumal, Solairaj, Gomes, Maxson, Redkar, Dinesh, Savant, Kedarnath, V, Saravanan
Design evolution of Novel Subframe for a Multilink Rear Suspension of an e-SUV2026-28-00072/12/2026
As there is a major shift in customer demand for energy efficient transportation, electric vehicle development has taken prominence worldwide as they provide pollution free and noise free mobility. The subframe being an important structural component of the chassis system, the designers always find it challenging to provide best-in-class rear subframe (RSF) optimized in terms of cost and weight within the available packaging space especially in an electric sport vehicular boundary. The main function of rear subframe is to transmit forces to BIW without deflections hence for this it should be very stiff. At the same time, it should be light in weight and simpler to industrialize. In the present work, the design evolution of a novel sub-frame assembly for a multilink rear suspension of a born electric sports utility vehicle (e-SUV) platform is detailed. With increased rear axle weight contributed by the battery weight and rear mounted motor, the design evolution of the rear subframe (RSF
Nidasosi, Basavraj Maruti, J, Ramkumar, Nayak, Bhargav, Mani, Arun, M, Sudhan
Accidental Dooring Warning and Assist System2026-28-00532/12/2026
Dooring accidents occur when a vehicle door is opened into the path of an approaching cyclist, motorcyclist, or other road user, often causing serious collisions and injuries. These incidents are a major road safety concern, particularly in densely populated urban areas where heavy traffic, narrow roads, and inattentive behavior increase the likelihood of such events. To address this challenge, this project presents an intelligent computer vision based warning system designed to detect approaching vehicles and alert occupants before they open a door. The system can operate using either the existing rear parking camera in a vehicle or a USB webcam in vehicles without such a feature. The captured live video stream is processed by a Raspberry Pi 4 microprocessor, chosen for its compact size, low power consumption, and ability to support machine learning frameworks. The video feed is analyzed in real time using MobileNetSSD, a lightweight deep learning object detection model optimized
C, Jegadheesan, T, Karthi, Gurusamy, Varun Sankar, Balraj, Tharun, Murugaiya, Tamilselvan
A Data-Driven Method for Typical Landing Gear Structure Optimization Based on Neural Networks01-19-01-00022/6/2026
The landing gear, as a crucial component of an aircraft, is pivotal for maintaining the safety and reliability of air travel. This study introduces a data-driven structural optimization method aimed at mitigating the peak strain on the landing gear’s rocker arm. The initial phase involves selecting nine design variables for parametric modeling to generate an initial dataset. Subsequently, the Maximum Information Coefficient (MIC) technique is used to conduct a parameter sensitivity analysis, enabling the identification and elimination of variables with minimal influence. A comparative analysis between the Genetic Algorithm–Backpropagation Neural Network (GA-BPNN) and BPNN reveals that GA-BPNN has a superior fitting capability on the enhanced dataset. By applying Particle Swarm Optimization (PSO), the optimal solution for GA-BPNN is identified. The implementation of this optimized method results in a 38.16% reduction in peak strain, validating its feasibility and reliability in
Chen, Hu, Shi, Shi, Wang, Meng, Fang, Xingbo, Wei, Xiaohui, Nie, Hong
SAE TOMORROW TODAY - Episode 318 - A New Era For Aerospace and Defense135542/5/2026
What if booking a trip into orbit were as easy as booking a flight on your phone? As the defense and aerospace industries evolve at unprecedented speed, what once felt like science fiction is fast becoming reality. For a deep dive into the latest innovations reshaping the skies, we welcomed back Todd Tuthill, Managing Partner, Rincon Aerospace, to discuss everything from the rise of reusable rockets to the democratization of access to low Earth orbit. Listen in as he shares an insider perspective on trends like blended wing aircraft, AI adoption in aerospace, and the coming wave of drone delivery and eVTOLs. It's an episode you don't want to miss! We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in mobility with the leaders, innovators and strategists making it all happen--and give us a review on your
Patterson, Lori
Certain Investigations to Improve the Aerodynamic Performance Parameters of a Surface-Modified Airfoil Structure2026-01-60012/3/2026
Flight vehicles operating in low-speed environments face significant aerodynamic challenges due to weak laminar boundary layers, which lead to early flow separation, reduced lift, and increased pressure drag. Airfoils often experience laminar separation bubbles and abrupt stall, making their performance unstable and difficult to predict. This paper aims to address the low-speed aerodynamic parameter analysis using passive flow control techniques on modified NACA 0021 airfoil profile. The novelty of this research method lies in the integration of dimple-based passive flow control structures on the upper surface of a NACA 0021 airfoil specifically designed to delay flow separation and enhance low-speed aerodynamic performance. Unlike most previous studies that focus on conventional vortex generators or active flow control methods, this work uniquely demonstrates that strategically dimple on the airfoil surface modifications significantly improves the lift characteristics. The methodology
Lakshmanan, D., Raman, Senthil Kumar Bella, Sivakumar, Aravinth, Pillai, Balaji Shanmuga
Establish Relation of Car Door Window Glass Opening on Door Assembly Dynamic and Vibrational Behavior2026-01-50062/2/2026
Window glass is a component of the side door assembly of cars. It provides a clear vision for passengers and outsiders. It functions as a temporary opening and ventilation system for the car. It is a part of a car’s aesthetics; it adds stiffness to the door and protects the occupants from different weather conditions. The objectives of this study were to understand the effect of fully and partially opened or closed window glass on the dynamic behaviors of door assemblies and to develop a process to assess these dynamic behaviors. An assessment methodology was developed to determine the effects of various window glass positions on the dynamic behavior of the door assembly. An authenticated finite element (FE) model was used to complete this investigation. The finite element model of the door assembly was validated by correlating the modal frequencies with their corresponding mode shapes. The correlated FE model with the window glass fully closed was called the baseline (W0), and eight
Jadhav, Pandurang Maruti, Waghulde, Kishor B., Bhortake, Rupesh V.
Materials for Use in Optical Parts Such as Lenses and Reflex Reflectors of Motor Vehicle Lighting DevicesJ576_202601 (Current)2/2/2026
This SAE Recommended Practice is intended as a guide toward standard practice and is subject to change to keep pace with experience and technical advances. This document establishes additional performance requirements and provides test methods and requirements to evaluate the suitability of materials intended for optical applications in motor vehicles. The tests are intended to determine physical and optical characteristics of the materials only. Performance expectations of finished assemblies, including plastic components, are to be based on tests for lighting devices, as specified in SAE Standards and Recommended Practices for motor vehicle lighting equipment. Glass and materials inclusive to the light source are not in scope for this method.
Lighting Materials Standards Committee
Accelerating down the road to AUTONOMY26TOFHP02_022/1/2026
Commercial success of the autonomous truck may be closer than we think. The last half decade has brought the best of times and worst of times for the commercial autonomous truck sector. While some perceived pillars of this technology have fallen, others have continued to carry the weight of bringing driverless trucks closer to commercialization. Consolidation was inevitable given the volume of speculative investment that brought a tidal wave of capital to various startups. Even so, some industry experts and Wall Street investors wondered if the autonomous truck sector might collapse entirely.
Wolfe, Matt
Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight26AERP02_032/1/2026
Between the 1920s and 1930s, aluminum started replacing wood as the primary material in aircraft construction and soon became the backbone of modern aviation. Its popularity stemmed from a combination of properties, high strength-to-weight ratio, corrosion resistance, and ease of forming that made it ideal for demanding aerospace applications. Throughout much of the 20th century, high-strength aluminum alloys dominated aircraft design, accounting for 70-80 percent of commercial airframes and more than half of many military aircraft. Even after the introduction of fiber-polymer composites in the early 2000s, aluminum has remained a critical material because it continues to offer the strength, lightness, and versatility needed for modern aviation. Industry forecasts predict that commercial air travel will double in the next 25 years, which means more pollution will be released into the atmosphere. One way to help reduce these emissions is by building airplane fuselages and wings with
Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace26AERP02_012/1/2026
Carbon fiber-reinforced polymers (CFRPs) have become essential in modern aerospace structures, from fuselage skins and wing components to nacelles, interior structures, and a growing range of primary load-bearing parts. Their high strength-to-weight ratio delivers major benefits in fuel efficiency, payload capacity, and fatigue performance. Yet achieving reliable adhesive bonds on CFRP surfaces remains a persistent engineering challenge. The low intrinsic surface energy of composites - particularly under thermal cycling, vibration, and moisture exposure - limits bond durability unless surfaces are properly prepared. Plasma surface treatment has emerged as a pivotal solution, offering a fast, controllable, and non-destructive way to increase surface energy, improve wettability, and enhance adhesion across complex geometries. This is especially important as the aerospace industry transitions from thermoset to thermoplastic composites (TPCs), which enable faster processing, lower
Overview of Aircraft Landing Gear Shimmy Analysis MethodsAIR6280 (Current)1/26/2026
This SAE Aerospace Information Report (AIR) provides an overview of the tire properties, strut properties, damper properties, and other landing gear mechanical properties that contribute to shimmy stability and are required for shimmy analysis. A variety of analysis techniques and assumptions are presented.
A-5 Aerospace Landing Gear Systems Committee
Electroluminescent Coating Systems for Heavy-Duty Trucks: Advancing Safety and Sustainability through Smart Surface Technology2026-26-02751/16/2026
As the transportation industry pivots towards safer and more sustainable mobility solutions, the role of advanced surface technologies is becoming increasingly critical. This paper presents a novel application of electroluminescent (EL) coating systems in heavy-duty trucks, exploring their potential to enhance vehicular safety and reduce environmental impact through lightweight, energy-efficient lighting integration. Electroluminescent coatings, capable of emitting light uniformly across painted surfaces when electrically activated, offer a transformative alternative to conventional external lighting and reflective materials. In the context of heavy-duty trucks, these systems can significantly improve visibility under low-light and adverse weather conditions, thereby reducing the risk of road accidents. Furthermore, the uniform illumination achieved without bulky fixtures contributes to aerodynamic efficiency, supporting fuel economy and reducing carbon emissions. use of this coating
Harel, Samarth Dattatraya, Borse, Manoj, L, Kavya
Development of Sustainable Textile Solutions Using Recycled and Bio-Based Materials for Automotive Soft Trims2026-26-02361/16/2026
The rising importance of sustainability in the automotive sector has led to increased interest in circular and environmentally responsible materials, particularly for plastic trims parts, both interior and exterior. This study focuses on developing textile solutions using recycled polyethylene terephthalate (r-PET) sourced from post-consumer plastic waste, along with bio-based fibres such as bamboo. These materials made into woven and knitted fabrics are studied to suit different vehicle interior applications. r-PET textiles show promising strength, aesthetic appeal, and durability performance. Bamboo fabrics are known for their natural antimicrobial properties and enhanced breathability. Extensive testing is performed to validate explored sustainable materials performance against key automotive requirements. With this study, we gain an understanding of the performance of variedly sourced sustainable raw materials for automotive specific textile applications by different manufacturing
Deshpande, Sanjana, Borgaonkar, Subodh
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