Browse Topic: Body structures

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Validation of SynthEyes for use in Collision Reconstruction2025-01-8688To be published on 04/01/2025
Accurate reconstruction of vehicle collisions is critical for understanding incident dynamics and informing safety improvements. Traditionally, vehicle speed from dashcam footage has been approximated by estimating the time duration and distance traveled as the vehicle passes between reference objects. This method limits the resolution of the speed profile to an average speed over given intervals, minimizing vehicle accelerations. A more detailed speed profile can be calculated by tracking the vehicle’s position in each video frame; however, this method is time-consuming, can introduce positional error and variable frame rate noise, and is often constrained by the availability of external trackable features in the surrounding environment. Motion tracking software, widely used in the visual effects industry to track camera positions, has been adopted by some collision reconstructionist for determining vehicle speed from video. This study examines the accuracy and reliability of using
Perera, Nishan, Griffiths, Harrison, Prentice, Greg
Technical Paper
Accuracy of Time Stamps in Digital and Network Video Recorders2025-01-8690To be published on 04/01/2025
Video analysis plays a major role in many forensic fields. Many articles, publications, and presentations have covered the importance and difficulty in properly establishing frame timing. In many cases, the analyst is given video files that do not contain native metadata. In other cases, the files contain video recordings of the surveillance playback monitor which eliminates all original metadata from the video recording. These “video of video” recordings prevent an analyst from determining frame timing using metadata from the original file. However, within many of these video files, timestamp information is visually imprinted onto each frame. Analyses that rely on timing of events captured in video may benefit from these imprinted timestamps, but for forensic purposes, it is important to establish the accuracy and reliability of these timestamps. The purpose of this research is to examine the accuracy of these timestamps and to establish if they can be used to determine the timing
Molnar, Benjamin, Terpstra, Toby, Voitel, Tilo
Technical Paper
The Accuracy of Vehicle Speeds, Decelerations, and Brake Onset Times Calculated from Onboard Dash Cameras2025-01-8691To be published on 04/01/2025
The goal of this study was to evaluate the influence of camera and video parameters on the accuracy of speeds and decelerations calculated from onboard dashboard cameras (“dashcams”). We equipped a single test vehicle with 5 commercially available dashcams. We also equipped the test vehicle with a 5th-wheel, a brake pedal switch, and a synchronization light visible to the dashcams. We conducted 9 emergency braking tests from about 60 km/h and calculated the reference speed and deceleration from the 5th-wheel data. The brake pedal switch indicated the moment of brake application. The light synchronized the dashcam videos to the 5th-wheel and brake pedal data. The 5 dashcams had horizontal fields of view (FOV) ranging from 120 to 170 degrees, frame rates of 30 or 60 frames per second (FPS), and resolutions of 1080p, 2K, or 4K. For each camera and brake test, we extracted the video from the dashcam and calculated its linear and rotational motion using SynthEyes, a 3D motion tracking and
Flynn, Thomas, Ahrens, Matthew, Young, Cole, Siegmund, Gunter P.
Technical Paper
Hierarchical Feature-based Localization using Scene Graphs in Off-road Navigation2025-01-8046To be published on 04/01/2025
While numerous advancements have been made in autonomous navigation for structured indoor and outdoor environments, these solutions often do not generalize well to off-road settings. There are unique challenges in such settings such as unreliable GPS, limited computational and memory resources, and sparse environmental features, making navigation particularly difficult. In our work, we propose a novel data structure called Hierarchical Dynamic Scene Graphs (HDSG) to address these challenges. HDSG captures environmental information at different resolutions, integrating both geometric and semantic features. It enables various navigation tasks such as localization, loop closure, and human interaction through the visualization of environmental features for remote operators. We evaluated the performance of localizing a robot's position within the world frame by comparing compact spatial descriptors extracted from semi-consecutive scene graphs, derived from 3D LiDAR point clouds. Compared to
Alam, Fardifa Fathmiul, Luricich, Federico, Li, Nianyi, Jia, Yunyi, Li, Bing
Technical Paper
INTEGRATED BODY STRUCTURE TO ACCOMMODATE MANUAL AND POWER DOOR SUNSHADE VARIANTS IN A VEHICLE2025-01-8616To be published on 04/01/2025
Door Sunshade in a vehicle has proven to be very comfortable and luxurious feature to the customers. Luxury vehicles provide Power Sunshade which is electrically operated with the activation of a switch, whereas cost conscious vehicles provide manual sunshade which requires manual coiling and uncoiling. This study is to develop a Door Panel structure that can accommodate both the Manual Sunshade and Power Sunshade, thereby serving both cost conscious as well as luxury seeking customers. Manual Sunshade consists only of cassette, Pull Bar, Spindle Mechanism and Hooks whereas the power sunshade consists of Cassette, Pull Bar, Spindle Mechanism, Flap mechanism, Bowden Cable Mechanism, Actuator and Motor. Due to this difference in Package, it becomes difficult to accommodate both Variants of Sunshade into the same body system. However, this study helps in developing a common body structure by ways of effective Packaging, Modifying the cable and Actuator Mechanism and critical packaging of
S M, Rahul, d, Anantha, Kakani, Phani Kumar
Technical Paper
Evaluation of Several Tesla Dashcam Angles for Model 3 and Y Via Reverse Project Photogrammetry2025-01-8700To be published on 04/01/2025
Tesla Model 3 and Model Y vehicles come equipped with a standard dash-camera feature with the ability to record video in four directions called TeslaCam. Additional views have been known to be recorded under specific circumstances, often triggered in impacts, and available to some owners through data requests to Tesla. Prior research into TeslaCam either did not fully explore all known camera views across multiple vehicles or the metadata associated with genuine copies of TeslaCam video. Testing and analysis of real-world crashes revealed a reliable methodology to conducting photogrammetry analysis utilizing the front, rear, and side cameras found on Tesla Model 3 and Model Y vehicles, how to verify the likelihood of any copy of TeslaCam being a genuine original video discovered during the course of an investigation, and how to examine ever changing video properties as new software becomes available for the vehicles. Moving and stationary Tesla vehicles captured frames of GPS
Jorgensen, Michael, Swinford, Scott, Imada, Kevin, Farhat, Ali
Technical Paper
Simulation and Parameter Optimization of Commercial Vehicle Cab Suspension System2025-01-8268To be published on 04/01/2025
Taking a commercial vehicle cab suspension system as the research focus, a rigid-flexible coupled dynamics model was established. Time-domain vibration acceleration signals were acquired at the connection points between the frame, cab, and suspension. The vibration signals at the frame and suspension connection points were input into the simulation model, where the vibration responses at the cab and suspension connection points were calculated and analyzed using the established cab suspension system model. The accuracy of the model was verified by comparing the simulation results with experimental data. The established cab suspension system model was further used to evaluate human vibration comfort within the cab, following national standards for subjective human perception. A piecewise polynomial function was employed to fit the stiffness-damping characteristics of the integrated damper air spring, resulting in the determination of the coefficients for each segment and the coordinates
Hao, Qi, Zhu, Yuntao, Sun, Wen, Sun, Kai, Sun, Zhiyong, Huang, Yu, Zhen, Ran, Shangguan, Wen-Bin
Technical Paper
Integrated design for body in white fabricated by additive manufacturing and its mechanical performance analysis2025-01-8613To be published on 04/01/2025
With the development of additive manufacturing technology, the concept of integrated design has been introduced and deeply involved in the research of body design. In this paper, by analyzing the structural characteristics of the electric vehicle body, we designed a body in white with the additive manufacturing process, and analyzed its mechanical properties through finite element method. According to the structural characteristics of the body, the integrated structure was modeled in three dimensions using CATIA. For the mechanical properties of the body, the strength and stiffness of the body structure were simulated and analyzed based on ANSYS Workbench. The results show that for the strength of the body, the maximum stress of the simulation results was compared with the permissible stress, and the maximum stress was calculated to be less than the permissible stress under each working condition. For the body stiffness, the displacement of the body deformation was used to measure, and
Xu, Cheng, Zhang, Ming, Wang, Tao, Zhang, Tang-yun, Cao, Can, Wang, Liangmo
Technical Paper
Research and structural optimization of lattice core based on monocoque of Formula Student racing car2025-01-8003To be published on 04/01/2025
Monocoque is a kind of integrated shell structure technology, which has gradually become the primary choice for various racing teams to make car bodies because of its advantages of small specific gravity and high specific strength. The unit of the monocoque is a carbon fiber composite sandwich structure, which is composed of two layers of carbon fiber skin inside and outside and core material between them. The inner and outer layers of the carbon fiber skin are stacked with carbon fiber composite materials of different directions and types. In this project, we plan to optimize the shape of the monocoque shell using the surface design software Alias, select core materials of different materials and structures, more advanced layups, and obtain feasible layup sequences and core material types through Hypermesh simulation and Matlab collaborative optimization, which will be verified by three-point bending experiments and circumferential shear experiments. Different from the previous
Cheng, Zhu H., Liu, JJ
Technical Paper
Barrier Weight Prediction for Vehicle Compatibility in North America Market using Finite Element Analysis2025-01-8621To be published on 04/01/2025
The proliferation of the electric vehicle (EVs) in the US market led to an increase in the average vehicle weight due to the integration of the larger high-voltage (HV) batteries. To comply with this weight increase and meet stringent US regulations and Consumer Ratings requirements, Vehicle front-end rigidity has substantially increased. This increased stiffness in the larger vehicles (Large EV pickups/SUVs) may have a significant impact during collision with smaller vehicles. To address this issue, it is necessary we consider adopting a vehicle compatibility test like EuroNCAP MPDB in North American market as well. This study examines the influence of mass across vehicle classes and compares the structural variations for each impact class. The EuroNCAP MPDB (Moving Progressive Deformable Barrier) protocol was referenced for this analysis. Our evaluation approach comprises of two sections: the impact of the barrier mass on to the vehicle structure (V2B) and vehicle-to-vehicle impact
Kusnoorkar, Harsha, Koraddi, Basavaraj, Guerrero, Michael, Sripada, Venu Vinod, Tangirala, Ravi
Technical Paper
Lattice based Localized Energy Absorber for Improved Vulnerable Road User Performance for a Vehicle2025-01-8723To be published on 04/01/2025
A passenger vehicle hood is designed to meet Vulnerable Road User (VRU) regulatory requirements and Consumer metric targets. Generally, hood inner design and its reinforcements, along with deformable space available under the hood are the main enablers to meet the Head Impact performance targets. However, cross functional balancing requirements like hood stiffness and packaging space constraints can lead to higher Head Injury Criteria (HIC) scores, particularly when secondary impacts are present. In such cases, a localized energy absorber is utilized to absorb the impact energy to reduce HIC within the target value. The current localized energy absorber solutions include the usage of flexible metal brackets, plastic absorbers etc. which has limited energy absorbing capacity and tuning capability. This paper focuses on usage of a novel 3D printed energy absorbers, based on various kind of lattice structures. These absorbers are either sandwiched between hood inner and the outer or are
Kinila, Vivekananda, Agarwal, Varun, V S, Rajamanickam, Tripathy, Biswajit, Gupta, Vishal
Technical Paper
Research on the Boundary of Pedestrian Leg Impactor Test in Low-Speed Passive and Active Conditions2025-01-8735To be published on 04/01/2025
With the widespread application of the Automatic Emergency Braking System (AEB) in vehicles, its impact on pedestrian safety has received increasing attention. However, after the intervention of AEB, the kinematic characteristics of pedestrian leg collisions and their corresponding biological injury responses also change. At the same time, in order to accurately evaluate the pedestrian protection performance of vehicles, the current assessment regulations generally use advanced pedestrian protection leg impactors (aPLI) and rigid leg impactors (TRL) to simulate the movement and injury conditions of pedestrian legs. Based on this, in order to explore the collision boundary conditions and changes in injury between vehicles and APLI and TRL leg impactors under the action of AEB, this paper first analyzes the current passive and active assessment conditions. Secondly, the simulation software LS-DYNA is used to build a finite element model of APLI and TRL impactor-vehicle collisions to
Ye, Bin, Hong, Cheng, Wan, Xinming, Liu, Yu, Cheng, James, Long, Yongchen, Hao, Haizhou
Technical Paper
Regression Model based Method for Stiffness Design of Laminated Glasses2025-01-8320To be published on 04/01/2025
There has been a growing interest in laminated sidelites (or door glasses) in automotive for the benefits of both security and comfort. Current standard products are a 2.1/0.76/2.1 mm construction with soda-lime glass symmetrically distributed on each side of a PVB layer. Due to low shear stiffness of PVB, the standard laminate has a significantly reduced flexural rigidity in comparison to a monolith with the same total thickness. A novel lightweight laminate concept with ultrathin chemically strengthened glass was developed by Corning [1]. This concept considered asymmetrical designs with thinner (0.5 – 1.1 mm) chemically strengthened Corning® Gorilla® Glass laminated to relatively thick outer ply of conventional soda-lime glass and was found to provide enhanced stiffness over standard symmetrical laminate designs of same total thickness. It is known that flexural rigidity of laminated glass depends on multiple variables, such as shape, load distribution and boundary constraining
Yu, Chao, Cleary, Thomas, Joubaud, Laurent, kister, Evan, Fisher, W Keith
Technical Paper
Structural Weld Optimization with Efficient Approach of DFSS2025-01-8248To be published on 04/01/2025
Structural Weld Optimization with Efficient Approach of DFSS Abstract In automotive engineering, welds are frequently used to join or connect various parts of structures, frames, cradles, chassis, suspension components, and body. These welds usually form the weakest material link for durability and impact loads, which are measured by lab-controlled durability and crash tests, as well as real-world vehicle longevity. Consequently, designing robust welded components while optimizing for material performance is often prioritized as engineering challenge. The position, dimensions, material, manufacturing variation, and defects all affect the weld quality, stiffness, durability, impact, and crash performance. In this paper, the authors present best practices based on studies over many years, a rapid approach for optimizing welds, especially seam welds, by adopting Design For Six Sigma (DFSS) IDDOV (Identify, Define, Develop, Optimization, and Verification) discrete optimization approach. We
Qin, Wenxin (Daniel)
Technical Paper
Rough Road Vehicle dynamics analysis for vehicle vibration assessment2025-01-8306To be published on 04/01/2025
Multibody dynamics analysis in vehicle development provides a few useful vehicle design guidelines in a few disciplines. The first discipline is vehicle handling simulation, where the major recommendation is suspension geometry and tuning of bushings, shocks and springs. The vehicle dynamics simulations on rough roads give insights about vehicle durability performance: vehicle components, subsystems, and the vehicle body systems. Almost all inputs to the vehicle systems come from tire to ground interactions, tire modeling is the most critical aspect in vehicle durability simulation, e.g. load prediction. The third discipline is the vehicle vibration performance assessment using vehicle dynamic simulations. This study is to demonstrate a vehicle dynamics simulation process to assess vehicle vibration performance. A vehicle dynamics model is simulated on ride roads, first. Hardware measurement can be done in a similar fashion to get the vehicle target performance or bench marking data
Hong, Hyung-Joo, Maddula, Pavan Kumar, Jun, Hyochan
Technical Paper
Effects of Aging on PVC-based Instrument Panel Skin for Passenger Airbag Deployment Analysis2025-01-8321To be published on 04/01/2025
Plasticized polyvinyl chloride (PVC) has many applications in automotive industry including electrical harnesses, door handles, seat and head rest covers, and instrument panel (IP) and other interior trim. In IP applications, the PVC skin plays a critical role in passenger airbag deployment (PAB) by tearing along the scored edge of the PAB door and allowing the door to open and the airbag to inflate to protect the occupant. As part of the IP, the PVC skin may be exposed to elevated temperatures and ultraviolet (UV) radiation during the years of the vehicle life cycle which can affect the PVC material properties over time and potentially influence the kinematics of the airbag deployment. Chemical and thermal aging of plasticized PVC materials have been studied in the past, yet no information is found how the aging affects mechanical properties at high rates of loading typical for airbag deployment events. This paper compares mechanical properties of the virgin PVC-based IP skin material
G, Karthigan, Savic, Vesna, Ravichandran, Gowrishankar
Technical Paper
A Time-Aware Shaper-Based Method for Addressing Traffic Bursts and Out-of-Order Induced by IEEE 802.1CB in In-Vehicle Networks2025-01-8079To be published on 04/01/2025
The trends of intelligence and connectivity are continuously driving innovation in automotive technology. With the deployment of more safety-critical applications, the demand for communication reliability in in-vehicle networks (IVNs) has increased significantly. As a result, Time-Sensitive Networking (TSN) standards have been adopted in the automotive domain to ensure highly reliable and real-time data transmission. IEEE 802.1CB is one of the TSN standards that proposes a Frame Replication and Elimination for Reliability (FRER) mechanism. With FRER, streams requiring reliable transmission are duplicated and sent over disjoint paths in the network. FRER enhances reliability without sacrificing real-time data transmission through redundancy in both temporal and spatial dimensions, in contrast to the acknowledgment and retransmission mechanisms used in traditional Ethernet. However, previous studies have demonstrated that, under specific conditions, FRER can lead to traffic bursts and
Luo, Feng, Ren, Yi, Zhu, Yian, Wang, Zitong, Guo, Yi, Yang, Zhenyu
Technical Paper
Investigation of Skin Friction Topology on the AeroSUV Using GLOF Meter2025-01-8782To be published on 04/01/2025
In this study, the aerodynamics and skin flow field of a 1/5 scale SUV vehicle model called “AeroSUV” were experimentally investigated. The aerodynamics and skin flow field investigations were carried out in the wind tunnel at Hiroshima University with a Reynolds number ReL = 1.2×10^6, baseline yaw angle β = 0° and crosswind conditions β = 5°, 10° and 15° for two rear ends, Estateback and Fastback. The results provide aerodynamic information and detailed skin flow field information for a standard middle-class SUV vehicle with different rear ends, which is important for automotive design. By applying GLOF measurements to automotive aerodynamics, the skin friction topology was revealed in detail as skin flow field information that is useful for understanding the physics of the flow. The skin friction topology clearly shows the separation lines, reattachment lines, and focus points associated with the separation flow, longitudinal vortices and recirculation vortices of this vehicle model
Hijikuro, Masato, Shimizu, Keigo, Nakashima, Takuji, Hiraoka, Takenori
Technical Paper
Simulating the DrivAer Notchback Car Model using Wall-Function LES2025-01-8777To be published on 04/01/2025
This paper summarizes work on the application of a new and fully parallelized native GPU-based finite-volume solver on the DrivAER Notchback configuration using a wall-function LES approach. A series of meshes generated using a Rapid-Octree strategy have been investigated, and results for drag, surface pressure coefficient and velocity profile are compared with available experimental data.
Menter, Florian, Dalvi, Ashwini, Flad, David, Sharkey, Patrick
Technical Paper
Establishment of Failure Simulation Models for Bonding of Carbon Fiber Laminated Skins and Cores in Monocoque Structures Based on Formula Student Racing Cars2025-01-8006To be published on 04/01/2025
In Formula SAE , the primary function of the frame is to provide structural support for the different components and withstand the applied load. Traditional truss steel tube body have drawbacks such as low strength and high weight, which has led most Formula Student teams worldwide to adopt monocoque made of carbon fiber composites, which are lighter and stronger. Enhancing the mechanical performance of carbon fiber laminates has been a key focus of research for these teams. In three point bending tests of carbon fiber laminates, the outer skin is primarily subjected to tensile forces. This results in significant stress at the adhesive layer between the skin and the core material at both ends of the laminate, leading to potential adhesive failure. Consequently, experimental boards often exhibit delamination between the outer skin and the core material, and premature core crushing, which compromises the mechanical performance of the laminate and fails to pass the Structural Equivalency
Ning, Zicheng
Technical Paper
The aerodynamics development of the Range Rover2025-01-8781To be published on 04/01/2025
The New Range Rover is the fifth generation of this luxury SUV. With a drag coefficient of 0.30 at launch, it was the most aerodynamically efficient luxury SUV in the world. This aerodynamic efficiency was achieved by applying the latest science. Rear wake control was realised with a large roof spoiler, rear pillar and bodyside shaping, along with an underfloor designed to reduce losses over a wide range of vehicle configurations. This enabled manipulation of the wake structure to reduce drag spread, optimising emissions measured under the WLTP regulations. Along with its low drag coefficient, in an industry first, it was developed explicitly to achieve reduced rear surface contamination with reductions achieved of 70% on the rear screen and 60% over the tailgate when compared against the out-going product. This supports both perceptions of luxury along with sensor system performance, demonstrating that vehicles can be developed concurrently for low drag and reduced rear soiling. This
Chaligné, Sébastien, Gaylard, Adrian Philip, Simmonds, Nicholas, Turner, Ross
Technical Paper
Adapting the Technology Readiness Level (TRL) Framework to AV Development2025-01-8671To be published on 04/01/2025
The technological advancements in the automotive industry have seen a significant leap with the introduction of ADS-Equipped Vehicles (AVs), with potential for enhanced safety, efficiency, and convenience. As the development of an AV transitions from the stages of conceptual design to deployment, assessing the maturity of the technology through a structured framework is crucial. This paper proposes the adaptation of the Technology Readiness Level (TRL) framework originally developed by NASA (and adopted widely in a variety of industries) to the AV industry to provide a consistent, understandable, and transparent method to describe an AV product’s state of development. The TRL framework is mated to the existing Safety Case Framework (SCF) developed in the Automated Vehicle – Test and Evaluation Process (AV-TEP) Mission, a collaboration between Science Foundation Arizona and Arizona State University. Advancing from one TRL to the next is argued through the satisfaction of requirements
Swaminathan, Sunder, Wishart, Jeffrey, Zhao, Junfeng, Russo, Brendan, Rahimi, Shujauddin
Technical Paper
Efficient Simulation of Multi-Body Dynamics with Roller Guide Joints Using Julia2025-01-8285To be published on 04/01/2025
Due to the existence of nonlinearities in mechanical systems, considerable concern has arisen regarding the effectiveness of solving multi-body dynamics (MBD) problems. Although simulations of traditional mechanisms with perfect joints could be solved with high efficiency, joints in practical applications are often characterized by clearances, leading to a significant reduction in simulation efficiency for such cases. Enhancing the effectiveness of solvers is essential for simulating systems with nonlinearities. This paper presents an exploration of using Julia, a high-performance, open-source programming language, to solve MBD problems based on index-1 differential-algebraic equations (DAE). Quaternions were utilized to represent the orientation of the rigid bodies. Alongside the modelling of common perfect joints, both planar perfect and imperfect roller guide joints were included to illustrate the method's adaptability in addressing non-standard joint types. Two case studies were
Tong, Jiachi, Meng, Dejian, Lian, Yubo, Gao, Yunkai, Yang, James
Technical Paper
Headliner design considerations to meet safety and regulations2025-01-8245To be published on 04/01/2025
Headliners are one of the largest components inside an automobile, stretching from the front windshield to the rear windshield. Besides its aesthetic purpose, it contributes to multiple other purposes like housing different components, helps in NVH, defines the interior roominess, and plays a crucial role in defining the deployment of curtain airbag. The headliner also plays a role in meeting regulatory requirements like upward visibility and headroom requirements of the occupants. During the deployment of curtain airbag, it is important that the headliner-pillar interface aids in the easy opening of airbag, with the least hindrance. This is defined by multiple factors like the location of headliner-pillar interface in “z” direction, and its distance from the airbag ramp bracket, the position of the inflator, the mountings of the headliner and pillar trims, to name a few. Also, during the deployment of the airbag, it is important that parts such as grabhandle, speaker grilles, etc
Sabesan, Arvind Kochi, D., Anantha, Kakani, Phani Kumar
Technical Paper
Correlation of Vehicle drop test in front & rear wheel landing condition using multibody dynamics simulations2025-01-8638To be published on 04/01/2025
Two wheelers motorcycles are used for many purposes e.g. commuting from place to another, long highway rides, racing and off-roading. Motorcycles which are used in off-road conditions require large suspension strokes to absorb large oscillations due to road conditions. These motorcycles undergo jumps of different heights and different vehicle orientations. In some of the dynamic situations front wheel may land first than the rear and in some of the situations rear may land first as compared to front. To make sure that the vehicle is durable enough to withstand loads in such operating conditions, vehicle drop test was developed at component test lab where vehicle is dropped from predefined heights in both front & rear wheel landing conditions. Same load case is simulated in multibody dynamics to capture loads at important connections of the frame. This paper presents the correlation exercise carried out to validate MBD model and simulation process with test data captured during lab test
Jain, Arvind Kumar, Nirala, Deepak
Technical Paper
Computer aided engineering for sound propagation in exterior environments2025-01-8631To be published on 04/01/2025
Physical testing is required to assess multiple vehicles in different conditions, specially to validate those related to regulations. The acoustic evaluations have difficulties and limitations in physical test; cost and time represent important considerations every time. Additionally, the physical validation happens once a prototype has been built, this takes place in a later phase of the development. Sound pressure is measured to validate different requirements in a vehicle, horn sound is one of these and it is related to a regulation of united nations (ECE28). Currently the validation happens in physical test only and the results vary depending on the location of the horn inside the front end of every vehicle. In this article, the work for approaching a virtual validation method through CAE is presented with the intention to get efficiency earlier in product development process.
Alonso, Liliana, Cruz, Raciel, Alvarez, Ezequiel
Technical Paper
Material selection of a Parcel shelf for structural performance and Perceived quality improvement through an assessment of wide range composite and sustainable materials.2025-01-8249To be published on 04/01/2025
In passenger vehicles, a parcel shelf is used to conceal luggage in the trunk compartment. Conventionally, materials used in new product development are heavy, making products less competitive in the market. As the automotive industry increasingly prioritizes lightweight products for EV, it is essential to find new alternative materials and technologies that meet performance standards and add value to the product. This research paper focuses on weight optimization, sustainable material section and cost reduction of the parcel shelf without compromising durability, stiffness, and load-bearing capabilities. The proposed material consists of ultra-lightweight composite materials available in various GSM and thicknesses, offering a high strength-to-weight ratio that contributes to: 1. Improved load vs. deflection ratio. 2. Enhanced aesthetics and perceived quality. The proposed material combination and strategy for the parcel shelf will result in a product that is half the weight of
Kinthala, Nareen Kumar, Patnaik, Manga, Khandelwal, Mohit, Kakani, Phani Kumar, Palaniappan, Elavarasan
Technical Paper
Predicting Forming Limit of Hot Stamping Boron Steel using a Modified Zener-Hollomon Parameter based Ductile Failure Criterion2025-01-8225To be published on 04/01/2025
This study combines a recently proposed ductile failure criterion with a modified Zener-Hollomon parameter to predict the forming limit of a boron steel at hot stamping temperatures. The Zener-Hollomon parameter is modified to include a parameter that accounts for the non-linear variation of strain rate during hot stamping. The combined ductile failure criterion takes into account the critical damage at localized necking or at fracture as a function of strain path, initial sheet thickness and strain rate variation. The process of determining various parameters in the failure criterion is explained. The capability of the ductile failure criterion is demonstrated by predicting forming limit of a boron steel in an isothermal Nakajima dome test. The criterion is further demonstrated by predicting fracture in hot stamping a B-Pillar part (NUMISHEET Benchmark #3 2008).
Sheng, ZiQiang, Mallick, Pankaj
Technical Paper
Classification of Pavement Distress Images Using Fusion Convolutional Neural Network of Dual Branch2025-01-713102/21/2025
In recent years, the issue of highway maintenance has become increasingly prominent. How to precisely detect and classify fine cracks and various types of pavement defects on highways through technical means is an essential foundation for achieving intelligent road maintenance. This paper first constructs the DenseNet201-PDC and MobileNetV2-PDC sub-classification networks that incorporate the three-channel attention judgment mechanism MCA. Secondly, based on the principle of parallel connection, a brand-new dual-branch fusion convolutional neural network DBF-PDC capable of classifying pavement defects in highway scenarios is proposed. Finally, this paper builds the Pavement Distress Datasets of Southeast University and conducts relevant ablation experiments. The experimental results demonstrate that both the attention mechanism module and the feature fusion strategy can significantly enhance the network's ability to classify pavement defects in highway scenarios. The average
Zhang, Ziyi, Zhao, Chihang, Shao, Yongjun, Wang, Junjun
Technical Paper
Thermal Buckling Analysis of Axially Layered Aluminium Zirconia Functionally Graded Beam2025-28-012002/07/2025
This study investigates the thermal buckling behavior of axially layered functionally graded material (FGM) thin beams with potential applications in automotive structures. The FGM beam is constructed from four axially stratified sections, with the proportional amount of metal and ceramic fluctuating through the thickness. The buckling analysis is carried out for three different support configurations: clamped-clamped, simply supported-simply supported, and clamped-simply supported. The primary objective is to identify the optimal thermal buckling temperature of the FGM thin beam using the Taguchi optimization method. Beam arrangements are established using a Taguchi L9 orthogonal array and analyzed using finite element software (ANSYS). Layers 1-4 of the axially layered beam are considered process parameters, while the thermal buckling temperature is the response parameter. Minitab software performs an Analysis of Variance (ANOVA) with a 95% confidence level to identify the most
Pawale, Deepak, Bhaskara Rao, Lokavarapu
Technical Paper
Analysis and Refinement of Road Boom Noise in Electric Vehicle2025-28-005702/07/2025
Customers are expecting higher level of refinement in electric vehicle. Since the background noise is less in electric vehicle in comparison with ICE, it is challenging for NVH engineers to address even minor noise concerns without cost and mass addition. Higher boom noise is perceived in the test vehicle when driven on the coarse road at a speed of 50 kmph. The test vehicle is rear wheel driven vehicle powered by electric motor. Multi reference Transfer Path Analysis (TPA) is conducted on the vehicle to identify the path through which maximum forces are entering the body. Based on the findings from TPA, solutions like reduction in the dynamic stiffness of the suspension bushes are optimized which resulted in reduction of noise. To reduce the noise further, Operational Deflection Shape (ODS) analysis is conducted on the entire vehicle to identify the deflection shapes of all the suspension components and all the body panels like floor, roof, tailgate, dash panel, quarter panel and
S, Nataraja Moorthy, Rao, Manchi Venkateswara, Raghavendran, Prasath, Selvam, Ebinezer
Technical Paper
Structural Analysis of Two-Wheeler Handlebars under Varied Loads2025-28-005302/07/2025
This study presents a comprehensive structural analysis of a two-wheeler handlebar subjected to various loading conditions, aiming to evaluate its strength, durability, and safety. During operation, two-wheelers encounter multiple forces, making the handlebar a critical component for rider control and safety. The analysis begins by investigating the different types of loads experienced during typical riding scenarios, including static loads when the bike is stationary, and dynamic loads arising from rider movements, braking, and handling. The primary objective is to understand how these loads impact the handlebar's structural integrity. To achieve this, critical load cases are identified and categorized. Braking loads, which apply force primarily in the forward direction due to deceleration, are examined. Manhandling loads are analyzed to understand the multidirectional forces acting on the handlebar during transportation and parking. Additionally, vertical loads are assessed
Prajapati, Akash, Rathore, Avijit Singh, Bhaskara Rao, Lokavarapu
Technical Paper
Optimized Design and Analysis of a High-Performance, Track-Focused Quad Bike for the Indian Market2025-28-006102/07/2025
This paper presents a complete approach to the optimized design and analysis of a trach-focused quad bike suitable for the Indian market. The process of design integrates several analytical factors, including driver ergonomics, aesthetics, and strategic component placement, to establish optimum vehicle dimensions. The primary objective is to address the unique demands of the Indian terrain and user preferences through ensure comfort, functionality, and visual appeal. The selection process for tires and suspension geometry is precisely conducted with the advanced OptimumKinematics software. This optimization provides greater performance and stability that the vehicle can accurately manage a variety of road conditions. The space frame chassis of a vehicle’s core structure features, engineered to minimalize tubing and facilitate ease of fabrication, contributing to both structural integrity and weight reduction. A robust 600cc four-cylinder engine is selected that emphasizing an optimal
Thanikonda, Praveen Kumar, Shaik, Amjad, Tappa, Raju, Ratlavath, Ramu, Navar, Adarsh, Challa, Ajith Kumar
Technical Paper
Thermal Buckling Analysis of Axially Layered Aluminium Silicon Nitride Functionally Graded Thin Beam using Taguchi Method2025-28-017202/07/2025
This research examines the thermal instability of slender beams composed of functionally graded materials (FGMs), with a specific focus on their suitability for engine hood components. The FGM combines the durability of aluminum with the heat tolerance of silicon nitride. The study aims to determine the maximum temperature the beam can withstand without buckling under various support conditions, simulating the uneven heat distribution experienced by engine hoods in actual use. The FGM structure comprises four longitudinally arranged layers, where the ceramic and metallic components gradually shift across the thickness. Finite element modeling software (ANSYS) is utilized to examine the buckling response under diverse temperature conditions. To enhance the thermal performance of the engine hood panel, the Taguchi L9 orthogonal array methodology is employed utilizing Minitab 19 software. The first four layers of the FGM beam are defined as process variables, while the critical buckling
Pawale, Deepak, Bhaskara Rao, Lokavarapu
Technical Paper
Forced Vibration Analysis of Cracked Functionally Graded Beams2025-28-016902/07/2025
This study investigates the forced vibration characteristics of a functionally graded material (FGM) beam possessing a square cross-section and featuring a V-shaped crack. The FGM beam exhibits a gradual transition in mechanical composition from a ceramic to a metallic surface. Employing finite element analysis software, a comprehensive numerical analysis is conducted to evaluate the frequencies and mode shapes of the cracked FGM beam under simply supported boundary conditions. The study meticulously explores the effects of various crack parameters, including crack opening width, depth, and location. The findings highlight the significant influence of the crack opening width on the frequencies, indicating that wider cracks result in decreased frequencies across all mode shapes. Conversely, the impact of crack depth and location on the dynamic behavior of the cracked FGM beam within the studied ranges appears relatively minor. These insights offer valuable perspectives into the
D, Manish, C V, Prasshanth, N, Suhas, Bhaskara Rao, Lokavarapu
Technical Paper
Numerical Study of Aerodynamic Flow and the Effects of Spoiler Wings on a Formula Student Race Car2024-01-524701/28/2025
Current work details the preliminary CFD analysis performed on custom-built race car by Team Sakthi Racing team as part of Formula SAE competition using OpenFOAM. The body of the race car is designed in compliance with FSAE regulations, OpenFOAM utilities and solvers are used to generate volumetric mesh and perform CFD analysis. Formula student tracks are typically designed with numerous sharp turns and a few long straights to maintain low speeds for safety. In order to enhance the cars’ performance in sharp turns, the race car should be equipped with aerodynamic devices like nose cone and wings on both the rear and front ends within the confines of the formula student racing rules. Thus, efficient aerodynamic design is highly critical to maximizing tire grip by ensuring consistent contact with the track, reducing the risk of skidding, and maintaining control, especially during high-speed maneuvers. In this work, the performance and behavior of the race car, both with and without the
Rangarajan, Kishore, Pushpananthan, Blesscin, Anumolu, Lakshman, Selvakumar, Kumaresh, Jayakumar, Shyam Sundar
Technical Paper
Methodology to Obtain the Operation Reaction Loads in Automotive Fuel Filler Door2024-36-010712/20/2024
During the development phase of any product, it is crucial to ensure functionality and durability throughout their whole lifecycle. Physical tests have been traditionally used as the main tool to evaluate the durability of a product, especially in the automotive industry. And the evolution of computational methods combined with the Engineering Fundamentals allowed Computer Aided Engineering (CAE) simulations to predict failures in considering different conditions without building a prototype to perform a test. The use of virtual product validation using CAE simulations leads to product design flexibility on early development phase and both development costs and time reduction. This paper presents a methodology for computing the operation reaction loads in an automotive fuel filler door, which is an input needed to virtually validate the subsystem in terms of durability. The methodology is based on rigid body motion assumptions and the result shows good accuracy when comparing the
Pereira, Rômulo Franco, Espinosa-Aguilar, Jonathan, Silva, Lucas, Sarmento, Alisson, Chou, Chun Heng
Technical Paper
Influence of the COVID-19 Pandemic on the Transition Process to Electronic Ticketing in Public Transport: A Case Study in a Brazilian City2024-36-002012/20/2024
The COVID-19 pandemic has reshaped public transportation dynamics globally, prompting shifts in passenger behavior and payment methods. Concurrently, the rise of fintech and Industry 4.0 has accelerated the adoption of digital payment solutions, aligning with the trend towards cashless societies. This study investigates the impact of the pandemic on the transition from cash to card payments for public transport fares in Belo Horizonte, Brazil. Leveraging data from the city's transparency portal, analyses were conducted on passenger numbers, payment methods, and card usage from November 2019 to November 2021. Findings reveal a steady usage of card payments compared to cash, with a notable increase in individual ticket card transactions post-vaccination. Conversely, employer-provided transportation voucher card usage experienced a decline. These trends suggest a preference among users for card-based payments, potentially driven by concerns over direct cash handling and adherence to
Rodrigues, Cádmo, Santos Júnior, Wagner
Technical Paper
Loss Function Curve to Quantify Customer (Dis)Satisfaction for Rear Opening Width Lower for Notch Back Vehicle2024-36-005112/20/2024
During the early phase of vehicle development, one of the key design attributes to consider is the trunk. Trunk is the pillar that is responsible for user’s accommodate their baggage and make into customer needs in engineer metrics. Therefore, it is one of the key requirements to be considered during the vehicle design. Certain internal vehicle trunk characteristics such as the trunk height and length are engineer metrics that influence the occupants’ perception for trunk. One specific characteristic influencing satisfaction is the rear opening width lower for notch back segment, which is the subject of this paper. The objective of this project is to analyze the relationship between the rear opening width lower with the occupant’s satisfaction under real world driving conditions, based on research, statistical data analysis and dynamic clinics.
Santos, Alex Cardoso, Silva, Gustavo, Genaro, Piero, Terra, Rafael, Pádua, Antônio, Benevente, Rodrigo, Lourenço, Sergio
Technical Paper
Dynamic SLAM with Real-Time Semantic Segmentation and Inter-Frame and Multi-Frame Motion Feature Detection2024-01-704212/13/2024
Traditional Simultaneous Localization and Mapping (SLAM) methods often assume static environments. This limitation can lead to inaccurate localization or even the loss of tracking in dynamic scenes. To address this issue, we propose a novel SLAM approach specifically designed for dynamic environments. Our method integrates the real-time image semantic segmentation network BisenetV2 with inter-frame and continuous multi-frame motion feature detection. Firstly, semantic segmentation is applied to render the semantic mask, which is then used by the inter-frame motion detection module to identify potential motion features. Subsequently, these suspected motion features are evaluated by a likelihood probability model across consecutive frames. Finally, points with a high probability of motion are monitored in real-time by the Luenberger observer, which filters out motion features and re-adds static ones. Our experiments demonstrate that semantic segmentation can meet real-time requirements
Qin, Xiaohui, Gao, Chengyu, Huang, Shengjie, Zeng, Conglei, Zhou, Yunshui
Technical Paper
Study of Functional Behaviour of Cast Magnesium Alloy with Zirconium Addition2024-01-520612/10/2024
Magnesium is the lightest material than aluminium and has a better specific strength, which is utilized for weight management applications. This research developed the magnesium (Mg) matrix with 0.1, 0.2, 0.3, and 0.5 percentages in weight (wt%) of zirconium (Zr) particles (grain refinement agent) via the squeeze cast technique. The argon inert gas is limit oxidation during the melting of Mg. The influence of Zr on the functional properties of Mg is studied and related to monolithic Mg without the Zr phase. The microstructural analysis provides the Zr particles are dispersed uniformly in the Mg matrix and exposed to superior mechanical properties. The Mg processed with 0.5 wt% of Zr offered maximum hardness, ultimate tensile strength, and elongation percentage, which are 53, 48.8, and 43.5 % better than the values of monolithic Mg. Besides, the optimum Mg refining with 0.5 wt% Zr microstructure is detailed with EDS and conforms to the contribution of Zr. This is used for automotive
Venkatesh, R., Manivannan, S., Das, A. Daniel, Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad
Technical Paper
Characteristics of Magnesium Composite Reinforced with Silicon Carbide and Boron Nitride via Liquid Stir Processing2024-01-523712/10/2024
The present aim of the investigation is to prepare and evaluate the excellence of boron nitride (BN) and silicon carbide nanoparticles on characteristics of magnesium alloy (AZ91D) hybrid nanocomposite. This constitution of AZ91D alloy hybrid nanocomposite is made through the liquid state processing route, which helps to improve the spread of particles in the AZ91D matrix. The impact of BN and SiC on microstructural and mechanical properties like tensile strength, hardness, and impact strength of AZ91D alloy composites are studied, and its investigational results are compared. Besides, microstructural studies have revealed that the structure of composite is found to have better BN and SiC particle dispersion and uniformity. The 5 percentage in weight (wt%) of BN and 5 wt% of SiC facilitated better tensile strength (183 MPa), hardness (85HV), and impact strength (21.4J/mm2) behaviour, which are 26, 30, and 35% better than the monolithic AZ91D alloy. This AZ91D/5wt% BN and 5wt% SiC
Venkatesh, R., Kaliyaperumal, Gopal, Manivannan, S., Karthikeyan, S., Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad, Karthikeyan, N.
Technical Paper
Effect of Combined Addition of Aluminium Titanium Carbide and Sodium on Aluminium Alloy2024-01-523912/10/2024
The grain refinement of aluminium alloy has the potential for various engineering utilization like automotive, marine, and aviation. Besides, the choice of grain refinement influences better performance and compatibility action. Aluminium alloy processed with zirconium grain refinement, high cost and risk of grain coarsening reasons, this research focused on Ti-C grain refinement with sodium modifier for T6 processing by aluminium alloy (AA6013) made by stir cast route. Impacts of Ti-C grain refinement with sodium modifier T6 processing on microstructural behaviour, hardness, and tensile performance are investigated, and the hardness and tensile are followed by ASTM E384 and ASTM E8 standards. The AA6013-T6 (1:1 Ti/C) with 0.15Na is found to have better grain refinement and found the TiC particle during the casting process, which leads to better enhancement of overall mechanical behaviour. The hardness, ultimate tensile, elongation percentage, and Young's modulus of AA6013-T6 (1:1 Ti/C
Venkatesh, R., Manivannan, S., Daniel Das, A., Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad
Technical Paper
Impact on FEAD Dynamic Performance of Mild Hybrid Engine with Increase in Engine Torque2024-28-020412/05/2024
Front End Accessory Drive (FEAD) systems are used in automobiles to transfer power from the engine-to-engine accessory components such as the alternator, water pump, etc. using a Belt and Tensioner. The emergence of Mild hybrid technologies has led to the replacement of alternator with Belt-driven Integrated Starter-generator (B-ISG). In conventional configuration of FEAD, the power transfer is in single direction but in mild hybrid engine power transfer is bidirectional: tight and slack side of the Belt changes as per Torque assist or Regeneration mode. The presence of an integrated starter-generator (ISG) in a belt transmission places excessive strain on the FEAD System and necessitates checking the dynamic performance of FEAD System thoroughly. Study of Increase in Engine Torque in existing Vehicle was done to understand its effect on various system. This vehicle is Mild Hybrid and consists of Belt-driven Integrated Starter generator system. Increase in Engine torque lead to
Kumar, Aditya, Gupta, Avinash, Bharti, Anil Kant
Technical Paper
Comprehend Dynamic Behaviour of Vehicle Body for Refined NVH Performance2024-28-026512/05/2024
Modal performance of a vehicle body often influences tactile vibrations felt by passengers as well as their acoustic comfort inside the cabin at low frequencies. This paper focuses on a premium hatchback’s development program where a design-intent initial batch of proto-cars were found to meet their targeted NVH performance. However, tactile vibrations in pre-production pilot batch vehicles were found to be of higher intensity. As a resolution, a method of cascading full vehicle level performance to its Body-In-White (BIW) component level was used to understand dynamic behavior of the vehicle and subsequently, to improve structural weakness of the body to achieve the targeted NVH performance. The cascaded modal performance indicated that global bending stiffness of the pre-production bodies was on the lower side w.r.t. that of the design intent body. To identify the root cause, design sensitivity of number and footprint of weld spots, roof bows’ and headers’ attachment stiffness to BIW
Titave, Uttam Vasant, Zalaki, Nitin, Naidu, Sudhakara
Technical Paper
A Study on Powertrain Modes for Optimizing the NVH Performance2024-28-018712/05/2024
The stiffness and positioning of engine mounts are crucial in determining the powertrain rigid body modes and kinetic energy distribution. Therefore, optimizing these mounts is essential in the automotive industry to separate the torque roll axis (TRA) and minimize vibration. This study aims to enhance mount locations by isolating the engine rigid body modes and predicting the inter-component force (ICF) and transfer function of the vehicle. The individual ICFs for engine mountings are calculated by applying a unit force at the bearing location. Critical frequencies are identified where the amplification exceeds the unit force at the mounting interface between the engine and the frame. The transfer function approach is utilized to assess the vibration at the handlebar. Both ICF and transfer functions analyze the source and path characteristics linked to critical response frequencies. This understanding aids in enhancing mounting positions to minimize vibration levels, thereby enhancing
Jha, Niraj Kumar, Yeezaku, Antony Neomin, Victor, Priyanka Esther, Krishnamurthy, Govindasamy
Technical Paper
Comparative Analysis of BIW Subassembly Simulation Techniques AutoForm vs LS-DYNA2024-28-016912/05/2024
Assembly simulation plays a pivotal role in predicting and optimizing the distortion of an assembly, particularly in the automotive industry where precision and efficiency are paramount. In BIW parts assembly, factors such as clamping, mechanical & thermal joining, and loading direction are important. These factors affect the quality of the final assembly. Predicting and optimizing these parameters in the early design stage can help reduce development time, cost and improve the quality of the final product. Currently, LS-DYNA is used for closures like doors, hoods, and fenders. However, the pre-processing, computation and post-processing time is significantly high in LS-DYNA making it challenging to use for the Entire BIW. Employing a comprehensive approach, authors assess the distortion results, preprocessing, calculation, and post-processing time of both simulation techniques. Notably, the study reveals that AutoForm offers over 50%-time savings across all stages compared to LS-DYNA
Talawar, Vaishnavchandan, Nalam, Swaroop Raju, Dhanajkar, Narendra, Kumar, Ajay, Pasupathy, Vivekanand, Chava, Seshadri
Technical Paper
Influence of Discrete Load Cases on Optimization of Chain Guide Design of Crawler Dozers under Various Ground Conditions2024-28-027012/05/2024
The undercarriage is a critical component in machines such as crawlers, excavators, and compact track loaders. It includes vital elements such as the track frame, chain guides, rollers, track chains, idlers, carrier rollers, final drive, and sprockets. Among all these machines, crawler dozers encounter harsh environments with various ground conditions. During operations, the chains are subjected to traverse and side loads, which cause the chains to tend to slip out of the bottom rollers. The chain guide plays a crucial role in assisting and maintaining the chain in the correct position. The forces acting on chain guides are influenced by factors such as track chain tension, roller wear, chain link wear, and counter-rotation (where one track moves forward while the other moves in reverse). Among all the load cases, there are two critical load cases which are vital to be studied in order to determine the required number of chain guides along with other attributes like profile or section
Masane, Nishant, Bhosale, Dhanaji, Sarma, Neelam K
Technical Paper
3D-Printed Reactor Core Makes Solar Fuel Production More EfficientTBMG-5219312/01/2024
In recent years, engineers at ETH Zurich have developed the technology to produce liquid fuels from sunlight and air. In 2019, they demonstrated the entire thermochemical process chain under real conditions for the first time, in the middle of Zurich, on the roof of ETH Machine Laboratory. These synthetic solar fuels are carbon neutral because they release only as much CO2 during their combustion as was drawn from the air for their production. Two ETH spin-offs, Climeworks and Synhelion, are further developing and commercializing the technologies.
Magazine Article
Computational Modeling of Aerodynamic Design Trends for a Production SUV Subjected to Incremental Design Changes: Roof Spoiler and Underbody Geometry15-18-01-000611/21/2024
In this work, we evaluated computational fluid dynamics (CFD) methods for predicting the design trends in flow around a mass-production luxury sport utility vehicle (SUV) subjected to incremental design changes via spoiler and underbody combinations. We compared Reynolds-averaged Navier–Stokes (RANS) using several turbulence models and a delayed detached eddy simulation (DDES) to experimental measurements from a 40% scale wind tunnel test model at matched full-scale Reynolds number. Regardless of turbulence model, RANS was unable to consistently reproduce the design trends in drag from wind tunnel data. This inability of RANS to reproduce the drag trends stemmed from inaccurate base pressure predictions for each vehicle configuration brought on by highly separated flow within the vehicle wake. When taking A-B design trends, many of these errors compounded together to form design trends that did not reflect those measured in experiments. On the other hand, DDES proved to be more
Aultman, Matthew, Disotell, Kevin, Duan, Lian, Metka, Matthew
Journal Article
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