Wind noise is an important indicator for evaluating cabin comfort, and it is essential to accurately predict the wind noise inside the vehicle. In the early stage of automotive design, since the geometry and properties of the sealing strip are often unknown, the contribution of the sealing strip to the wind noise is often directly ignored, which makes the wind noise obtained through simulation in the pre-design stage to be lower than the real value. To investigate the effect of each seal on wind noise, an SUV model was used to simulate the cases of not adding body seals, adding window seals, and further adding door seals, respectively. The contribution of each seal to wind noise was obtained and verified by comparing it with the test results. The influence of the cavity formed at the door seal was also addressed. In the simulations, a CFD solver based on the lattice Boltzmann method (LBM) was used to solve the external flow field, and the noise transmitted into the interior of the

Zhang, Yingchao, He, Tengsheng, Wang, Yuqi, Niu, Jiqiang, Zhang, Zhe, Shen, Chun, Zhang, Chengchun

Traffic Flow Prediction Based on the Optuna–CNN–BiLSTM–GBRT Model

12-09-01-0001

04/24/2025

Abstract Traffic flow prediction is very important in traffic-related fields, and increasing prediction accuracy is the primary goal of traffic prediction research. This study proposes a new traffic flow prediction method, which uses the CNN–BiLSTM model to extract features from traffic data, further models these features through GBRT, and uses Optuna to tune important hyperparameters of the overall model. The main contribution of this study is to propose a new combination model with better performance. The model integrates two deep learning models that are widely used in this field and creatively uses GBRT to process the output features of the front-end model. On this basis, the optimal hyperparameters and the robustness of the model are deeply explored, providing an effective and feasible solution to the difficult problems in traffic flow prediction. This model is experimentally studied using three different data transformation methods (original data, wavelet transform, Fourier

Ma, Changxi, Jin, Renzhe

Analysis of the Effect of Combination Frame Flexibility on Weave Modes

2024-32-0049

04/18/2025

The weave mode of a motorcycle is known to be affected by the flexibility of the vehicle frame. The weave mode has been shown to be more unstable in the 10-DOF model than in the 4-DOF model. However, it is not clear why the weave mode would be unstable, given the six different frame flexibilities. In this study, the authors analyzed the stability of the weave mode in a 4-DOF model when the same was integrated with two types of frame flexibilities. In the vehicle specifications used in the analysis, the combination of the bending flexibility of the front forks and the torsional flexibility of the main frame destabilizes the weave mode. The analysis results show that the phase delay of the front tire lateral force is caused by the phase delay of the steering angle. The combined bending flexibility of the front forks and the torsional flexibility of the main frame results in a large phase lag in the steering angle.

Haraoka, Reiya, Katayama, Tsuyoshi, Yoshino, Takahiko

Fatigue Analysis of Motorcycle Rear Swing Arm on Different Road Surfaces

2024-32-0046

04/18/2025

The rear swing arm, a crucial motorcycle component, connects the frame and wheel, absorbing the vehicle’s load and various road impacts. Over time, these forces can damage the swing arm, highlighting the need for robust design to ensure safety. Identifying potential vulnerabilities through simulation reduces the risk of failure during the design phase. This study performs a detailed fatigue analysis of the swing arm across different road conditions. Data for this research were collected from real-vehicle experiments and simulation analyses, ensuring accuracy by comparing against actual performance. Following CNS 15819-5 standards, road surfaces such as poorly maintained, bumpy, and uneven roads were tested. Using Motion View, a comprehensive multi-body dynamic model was created for thorough fatigue analysis. The results identified the most stress-prone areas on the swing arm, with maximum stress recorded at 109.6N on poorly maintained roads, 218.3N on bumpy surfaces, and 104.8N on

Chiou, Yi-Hau, Hwang, Hsiu-Ying, Huang, Liang-Yu

Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions

2024-32-0038

04/18/2025

The arc welding process is essential for motorcycle frames, which are difficult to form in one piece because of their complex shapes, because a single frame has dozens of joints. Many of the damaged parts of the frames under development are from welds. Predicting the strength of welds with high reliability is important to ensure that development proceeds without any rework. In developing frames, CAE is utilized to build up strength before prototyping. Detailed weld shapes are not applicable to FE models of frames because weld shapes vary widely depending on welding conditions. Even if CAE is performed on such an FE model and the evaluation criteria are satisfied, the model may fail in the actual vehicle, possibly due to the difference between CAE and actual weld bead geometry. Therefore, we decided to study the extent to which the stresses in the joint vary with the variation of the weld bead geometry. Morphing, a FE modeling method and design of experiment method, was utilized to

Hada, Yusuke, Sugita, Hisayuki

Necessity of Body Torsional Rigidity of Personal Mobility Vehicles (PMVs) with an Inward Tilting Mechanism

2024-32-0013

04/18/2025

In traditional four-wheeled automobiles, the imbalance between the roll moment, which is the product of the centrifugal force during a turn acting on the center of gravity and the height of the center of gravity, and roll stiffness, which is the product of the left-right difference in tire vertical load and the tread width and commonly used among automotive suspension engineers, of the front and rear sections necessitates body torsional rigidity. However, there is a lack of specific cases and guidelines for constructing the body structure of three-wheeled PMVs (Personal Mobility Vehicles) with a tilting mechanism from the perspective of vehicle dynamics characteristics. In this paper, the basic considerations related to the dynamics of such three-wheeled PMVs are investigated. We use the term “torsional rigidity” to refer to the stiffness as the torsional deformation of the body itself, and the term “roll stiffness” to refer to the moment that counteracts the roll moment during a turn

Haraguchi, Tetsunori, Kaneko, Tetsuya

A Low-Entry Bus Body Structure Performance under the Conditions of the New Car Assessment Program Frontal Crash Tests

09-13-02-0007

04/09/2025

The New Car Assessment Program (e.g., US NCAP and EuroNCAP) frontal crash tests are an essential part of vehicle safety evaluations, which are mandatory for the certification of civil means of transport prior to normal road exploitation. The presented research is focused on the behavior of a tubular low-entry bus frame during a frontal impact test at speeds of 32 and 56 km/h, perpendicular to a rigid wall surface. The deformation zones in the bus front and roof parts were estimated using Ansys LS-DYNA and considered such factors as the additional mass (1630 kg) of electric batteries following the replacement of a diesel engine with an electric one. This caused stabilization of the electric bus body along the transverse axis, with deviations decreased by 19.9%. Speed drop from 56 to 32 km/h showed a reduction of the front window sill deformations from 172 to 132 mm, and provided a twofold margin (159.4 m/s2) according to the 30g ThAC criterion of R80. This leads to the conclusion about

Holenko, Kostyantyn, Dykha, Aleksandr, Koda, Eugeniusz, Kernytskyy, Ivan, Royko, Yuriy, Horbay, Orest, Berezovetska, Oksana, Rys, Vasyl, Humeniuk, Ruslan, Berezovetskyi, Serhii, Chalecki, Marek

Compatibility between Stability and Curving Ability of Railway Vehicles Using Conventional and Unconventional Bogie Frame Models

02-18-03-0014

04/09/2025

This article analyses the fundamental curving mechanics in the context of conditions of perfect steering off-flanging and on-flanging. Then conventional, radial, and asymmetric suspension bogie frame models are presented, and expressions of overall bending stiffness kb and overall shear stiffness ks of each model are derived to formulate the uniform equations of motion on a tangent and circular track. A 4 degree of freedom steady-state curving model is formulated, and performance indices such as stability, curving, and several parameters including angle of attack, tread wear index, and off-flanging performance are investigated for different bogie frame configurations. The compatibility between stability and curving is analyzed concerning those configurations and compared. The critical parameters influencing hunting stability and curving ability are evaluated, and a trade-off between them is analyzed. For the verification, the damped natural frequencies and mean square acceleration

Sharma, Rakesh Chandmal, Sharma, Sunil Kumar, Palli, Srihari, Rallabandi, Sivasankara Raju, Sharma, Neeraj

Virtual Analysis of Sound Propagation for Automotive Industry

2025-01-8631

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. [7] 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

Effect of Catalyst Coating Strategy on NOx Reduction and Passive Soot Oxidation for Selective Catalytic Oxidation-Selective Catalytic Reduction Catalyst on Diesel Particulate Filter

2025-01-8490

04/01/2025

Selective catalytic oxidation/reduction catalysts coated on diesel particulate filters (SDPF) are an important technology route to meet next-stage emission regulations. The previous research of the research group showed that compared with SDPF coated with Cu-SSZ-13, the SDPF coated with novel selective catalytic oxidation-selective catalytic reduction (SCO-SCR) catalyst, which combined MnO2-CeO2/Al2O3 and Cu-SSZ-13, can simultaneously improve NOx reduction and soot oxidation performance. Catalyst coating strategy is an important parameter affecting the performance of SDPF. In this study, the effects of different coating strategies of SCO-SCR catalysts (C25, C50, C75, and C100) on the performance of NOx reduction and soot oxidation in SDPF were investigated. The results show that, as the inlet gas temperature increases, NO emissions first decrease and then increase, NOx conversion efficiency first increases and then decreases, and the rich-NO2 area, NH3 oxidation rate, N2O, CO, CO2

Chen, Ying-jie, Tan, Piqiang, Yao, Chaojie, Lou, Diming, Hu, Zhiyuan, Yang, Wenming

Research and Structural Optimization of Lattice Core based on Monocoque of Formula Student Racing Car

2025-01-8003

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 Ansys simulation and Matlab collaborative optimization, which will be verified by three-point bending experiments. Different from the previous lightweight work based a lot on experience, this

Cheng, Zhu H., Liu, JJ

Investigation of Skin Friction Topology on the AeroSUV Using GLOF Meter

2025-01-8782

04/01/2025

In this study, the aerodynamics and surface flow field of a 1/5 scale SUV vehicle model called “AeroSUV” were experimentally investigated. The aerodynamics and surface flow field investigations were carried out in the wind tunnel at Hiroshima University with a Reynolds number ReL = 1.2×106, 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 surface 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 surface 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

Hijikuro, Masato, Shimizu, Keigo, Nakashima, Takuji, Hiraoka, Takenori

Rough Road Vehicle Dynamics Analysis for Vehicle Vibration Assessment

2025-01-8306

04/01/2025

This study is to demonstrate a vehicle dynamics simulation process to assess vehicle vibration performance. A vehicle dynamics model including non-linear tuning elements and flexible vehicle body is simulated on ride roads. The goal of the simulation is acceleration responses at the passenger locations in frequency domain. Body interface loads are recovered from the vehicle dynamic simulations. Frequency response function (FRF) of the body structure is ready in a fashion that input forces are applied to all body interface locations to the suspension and powertrains. This will give acceleration response sensitivity of the body structure to each body interface. The sum of body interface loads multiplied by FRF at each interface produces acceleration responses in frequency domain. A mid-size sedan model was used to demonstrate the process. A full vehicle dynamics model using Ansys Motion was simulated on a virtual ride road at a constant speed. The body loads were recovered in time domain

Hong, Hyung-Joo, Maddula, Pavan Kumar, Jun, Hyochan

Research on the Boundary of Pedestrian Leg Impactor Test in Low-Speed Passive and Active Conditions

2025-01-8735

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

Lattice Based Localized Energy Absorber for Improved Vulnerable Road User Performance for a Vehicle

2025-01-8723

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, such as hood stiffness and packaging space constraints, can lead to higher Head Injury Criteria (HIC15) 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 have limited energy absorbing capacity and tuning capability. This paper focuses on usage of a novel 3D printed energy absorbers, based on various kinds of lattice structures. These absorbers are either sandwiched between the inner and the outer

Kinila, Vivekananda, Agarwal, Varun, V S, Rajamanickam, Tripathy, Biswajit, Gupta, Vishal

Validation of SynthEyes for Use in Collision Reconstruction

2025-01-8688

04/01/2025

Accurate reconstruction of vehicle collisions is essential 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 and reduces the ability to determine moments of acceleration or deceleration. A more detailed speed profile can be calculated by solving for the vehicle’s position in each video frame; however, this method is time-consuming and can introduce spatial and temporal error 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 reconstructionists for determining vehicle speed from video. This study examines the

Perera, Nishan, Griffiths, Harrison, Prentice, Greg

Effects of Aging on PVC-Based Instrument Panel Skin for Passenger Airbag Deployment Analysis

2025-01-8321

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 on 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

G, Karthigan, Savic, Vesna, Ravichandran, Gowrishankar

Hierarchical Feature-Based Localization Using Scene Graphs in Off-Road Navigation

2025-01-8046

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

Integrated Design for Body in White Fabricated by Additive Manufacturing and its Mechanical Performance Analysis

2025-01-8613

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

Adapting the Technology Readiness Level (TRL) Framework to Automated Vehicle Development

2025-01-8671

04/01/2025

Abstract The technological advancements in the automotive industry have seen a significant leap with the introduction of automated driving system (ADS)-equipped Vehicles (AVs), with potential for enhanced safety, efficiency, and mobility. 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 stage 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. The claim that the AV is ready to transition from one

Swaminathan, Sunder, Wishart, Jeffrey, Zhao, Junfeng, Russo, Brendan, Rahimi, Shujauddin

A Time-Aware Shaper-Based Method for Addressing Traffic Bursts and out-of-Order Induced by IEEE 802.1CB in in-Vehicle Networks

2025-01-8079

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

Regression Model based Method for Stiffness Design of Laminated Glasses

2025-01-8320

04/01/2025

This paper presents a new regression model-based method for accurate predictions of stiffness of different glass laminate constructions with a point-load bending test setup. Numerical FEA models have been developed and validated with experimental data, then used to provide training data required for the statistical model. The multi-variable regression method considered six input variables of total glass thickness, thickness ratio of glass plies as well as high-order terms. Highly asymmetrical, hybrid laminates combining a relatively thick soda-lime glass (SLG) ply joined with a relatively thin Corning® Gorilla® Glass (GG) ply were analyzed and compared to standard symmetrical SLG-SLG constructions or a monolithic SLG with the same total glass thickness. Both stiffness of the asymmetrical laminates and the improvement percentage over the standard symmetrical design can be predicted through the model with high precision.

Yu, Chao, Cleary, Thomas, Joubaud, Laurent, kister, Evan, Fisher, W Keith

Predicting Forming Limit of Hot Stamping Boron Steel Using a Modified Zener-Hollomon Parameter based Ductile Failure Criterion

2025-01-8225

04/01/2025

Combined with a modified Zener-Hollmon parameter, a recently proposed ductile failure criterion is further improved to predict the forming limit of boron steel at hot stamping temperatures. The ductile failure criterion takes into account the critical damage at localized necking or at fracture as a function of strain path and initial sheet thickness. The modified Zener-Hollomon parameter accounts for both effect of varying strain rate and temperature for Boron steel. Working FEM simulation, the capability of the ductile failure criterion is further demonstrated by predicting forming limit of a boron steel in an isothermal Nakajima dome test. Comparison shows the prediction matches quite well with the measurement.

Sheng, ZiQiang, Mallick, Pankaj

Integrated Body Structure to Accommodate Manual and Power Door Sunshade Variants in a Vehicle

2025-01-8616

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

Study on Relative Displacement in Assembly Structure Sections for Pre-Validation of Door Trim Noise

2025-01-8618

04/01/2025

The pre-validation process for door trim noise has gained increasing importance as noise standards have become more stringent with the transition to electric vehicles. Currently, the validation process employs squeak and rattle director simulations to evaluate noise based on relative displacement values. However, this approach is time-intensive. To address this limitation, we have improved process efficiency by developing a database of relative displacement values derived from the cross-sectional and structural characteristics of matching parts. This advancement enables noise pre-validation using only cross-sectional and structural information.

Cho, Wonhyung, Na, Hyunghyun, Kim, Donghyeon, Kim, JongSoo, Shin, Dongwan

Simulating the DrivAer Notchback Car Model using Wall-Function LES

2025-01-8777

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

Structural Seam Weld Optimization with Efficient Approach of DFSS

2025-01-8248

04/01/2025

In automotive engineering, seam welds are frequently used to join or connect various parts of structures, frames, cradles, chassis, suspension components, and body. These welds usually form the weaker 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 will present the case testimony to show the approach throughout

Qin, Wenxin (Daniel), Li, Fan, Pohl, Kevin J.

Barrier Weight Prediction for Vehicle Compatibility in North America Market Using Finite Element Analysis

2025-01-8621

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 assembly of the larger high-voltage (HV) batteries. To comply with this weight increase and to meet stringent US regulations and Consumer Ratings requirements, Vehicle front-end rigidity (stiffness) has increased substantially. 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 to consider adopting a vehicle compatibility test like Euro NCAP MPDB (European New Car Assessment Program Moving Progressive Deformable Barrier) for the 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 Euro NCAP MPDB (European New Car Assessment Program Moving Progressive Deformable Barrier) protocol referenced for this analysis. Our evaluation

Kusnoorkar, Harsha, Koraddi, Basavaraj, Guerrero, Michael, Sripada, Venu Vinod, Tangirala, Ravi

Drop Test Correlation in Front & Rear Landing Scenario for Two-Wheeler (Motorcycle) using Multibody Simulation

2025-01-8638

04/01/2025

Two wheelers motorcycles are used for many purposes e.g. commuting from one place to another, long highway rides, racing and off-roading. Motorcycles which are used in off-road conditions require higher suspension strokes to absorb large oscillations due to terrain conditions. These motorcycles undergo jumps of varying heights and different vehicle orientations. In some of the dynamic situations front wheel may land on the ground before the rear and in other cases it may be vice versa. To make sure that the vehicle is durable enough to withstand loads in such operating conditions, vehicle drop test was developed in test lab where vehicle is dropped from predefined heights in both front & rear wheel landing conditions. Same test 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. Accelerations at

Jain, Arvind Kumar, Nirala, Deepak

Establishment of Failure Simulation Models for Bonding of Carbon Fiber Laminated Skins and Cores in Monocoque Structures Based on Formula Student Racing Cars

2025-01-8006

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. In recent years, 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, significant stress at the adhesive layer between the skin and the core material at both ends of the laminate, often lead 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 Spreadsheet. Therefore, it is necessary to consider the influence of the bonding factor of toughened epoxy prepreg film on the mechanical properties of the laminated plate. This

Ning, Zicheng

Simulation and Parameter Optimization of Commercial Vehicle Cab Suspension System

2025-01-8268

04/01/2025

Taking a commercial vehicle cab suspension system as the research focus, a rigid-flexible coupled dynamics model was established based on the nonlinear characteristics of the integrated damper air spring and bushings. 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

Hao, Qi, Zhu, Yuntao, Sun, Wen, Sun, Kai, Sun, Zhiyong, Huang, Yu, Zhen, Ran, Shangguan, Wen-Bin

A Methodology for Minimizing Liftgate-Induced Low-Frequency Boom Noise in Vehicles

2025-01-8617

04/01/2025

The significance of the liftgate's role in vehicle low-frequency boom noise is highlighted by its modal coupling with the vehicle's acoustic cavity modes. The liftgate's acoustic sensitivity and susceptibility to vehicle vibration excitation are major contributors to this phenomenon. This paper presents a CAE (Computer-Aided Engineering) methodology for designing vehicle liftgates to reduce boom risk. Empirical test data commonly show a correlation between high levels of liftgate vibration response to vehicle excitations and elevated boom risk in the vehicle cabin. However, exceptions to this trend exist; some vehicles exhibit low boom risk despite high vibration responses, while others show high boom risk despite low vibration responses. These discrepancies indicate that liftgate vibratory response alone is not a definitive measure of boom risk. Nonetheless, evidence shows that establishing a vibration level control guideline during the design stage results in lower boom risk. The

Abbas, Ahmad, Haider, Syed

The Aerodynamic Development of the Range Rover

2025-01-8781

04/01/2025

The current 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 under-floor 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 outgoing 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

Chaligné, Sébastien, Gaylard, Adrian Philip, Simmonds, Nicholas, Turner, Ross

Efficient Simulation of Multi-Body Dynamics with Roller Guide Joints Using Julia

2025-01-8285

04/01/2025

Nonlinearities in mechanical systems pose significant challenges for efficiently solving multi-body dynamics (MBD) problems. Although simulations of traditional mechanisms with perfect joints can be performed efficiently, joints in practical applications are often characterized by clearances, leading to reduced simulation efficiency and accuracy. Improving solver effectiveness is essential for simulating systems with nonlinearities. This paper explores the use of Julia, a high-performance open-source programming language, to solve MBD problems formulated as index-1 differential-algebraic equations (DAEs). Euler parameters (quaternions) are employed to represent the orientation of rigid bodies. To illustrate the method's adaptability in addressing non-standard joint types, both perfect and imperfect (with clearance or friction) planar roller guide joints are modeled alongside common perfect joints. A case study of a vehicle sliding door system is presented. The numerical results are

Tong, Jiachi, Meng, Dejian, Lian, Yubo, Gao, Yunkai, Yang, James

Validation of the Use of Quasistatic Force Deformation Measurements for Determining Collision Force in Low-Speed Override/Underride Collisions

2025-01-5018

03/21/2025

The purpose of this study was to investigate the use of quasistatic force deformation (QSFD) data to represent the collision forces in low-speed collinear collisions when there is damage to vehicle body structures as well as the bumpers. In this study five full-scale underride/override crash tests were performed and simulated with QSFD data. In each crash test a bumper or a trailer underride guard on a bullet vehicle overrode the rear or front bumper of a target vehicle and damaged structures above the bumper of the target vehicle. A QSFD measurement was performed substantially similar to the vehicle interactions in the crash using a complete exemplar target vehicle that was rigidly attached to the earth. The output of a QSFD measurement is force deflection data for the vehicle pair. Each crash test was simulated using the QSFD data, the weights of the test vehicles, the closing speed of the test vehicles, and the restitution measured in the crash test. The output of a simulation was

Gall, Jessica, Scott, William R., Bonugli, Enrique, Watson, Richard A., Fischer, Patrick

Classification of Pavement Distress Images Using Fusion Convolutional Neural Network of Dual Branch

2025-01-7131

02/21/2025

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

Analysis and Refinement of Road Boom Noise in Electric Vehicle

2025-28-0057

02/07/2025

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

Forced Vibration Analysis of Cracked Functionally Graded Beams

2025-28-0169

02/07/2025

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

Optimized Design and Analysis of a High-Performance, Track-Focused Quad Bike for the Indian Market

2025-28-0061

02/07/2025

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

Structural Analysis of Two-Wheeler Handlebars under Varied Loads

2025-28-0053

02/07/2025

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

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

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

2025-28-0172

02/07/2025

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

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