Browse Topic: Design Engineering and Styling

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Enabling Flexibility Services through Interoperable V2X Infrastructures: Advanced Modeling and Operational Validation in the FLEXV2X Project2026-37-0024To be published on 06/09/2026
The integration of Electric Vehicles (EVs) as active grid resources represents a pivotal shift towards decarbonisation. However, the implementation of effective Vehicle-to-Everything (V2X) services faces technical challenges regarding interoperability, predictive management, and battery health preservation. This work presents a comprehensive system design and research methodology developed within the framework of the FLEXV2X project, aimed at addressing interdependencies within a unified bidirectional charging ecosystem. The proposed scientific framework addresses two complementary timescales. At the device level, the study details the modelling and optimisation of bidirectional converters, focusing on control algorithms designed to ensure robust dynamic response and efficiency. Building upon this hardware foundation, the paper describes a system-level optimisation strategy. By employing open-source cyber-physical modelling, the architecture simulates complex EV-grid interactions. This
Lutzemberger, Giovanni, Barater, Davide, Ceraolo, Massimo, Fera, Cesare, Leaver, Ian, Pasini, Gianluca
Design-Driven Sustainability of Automotive Components: A Comparative LCA from Conventional to Metal and Composite Additive Manufacturing2026-37-0037To be published on 06/09/2026
The increasing pressure to decarbonize manufacturing systems is pushing industry beyond conventional lightweighting strategies toward material and process paradigms, capable of delivering functional performance with radically lower environmental impact. In this context, polymer-based composite Additive Manufacturing (AM) offers an underexplored yet highly promising pathway for sustainable production of load-bearing components. This study presents a preliminary comparative cradle-to-gate Life Cycle Assessment (LCA) of a Formula SAE brake pedal, assessing the environmental transition from conventional CNC machining of Aluminum 7075-T6 to additive manufacturing solutions, with specific focus on Carbon-Fiber-Reinforced Polymer (CFRP) composites. Two topology-optimized designs, respectively for Powder Bed Fusion (PBF) in AlSi10Mg and Material Extrusion (MEX) in PETG-CF are compared to machined aluminum benchmark. The analysis is integrated in the product and process design following ISO
Dalpadulo, Enrico, Russo, Mario, Apté MD, Raphaëlle, Leali, Francesco
A Holistic CFD Methodology for Full- and Multi-Cycle Simulation of Hydrogen Direct-Injection Internal Combustion Engines2026-37-0016To be published on 06/09/2026
Hydrogen is emerging as a viable energy carrier for the decarbonization of internal combustion engines (ICEs), representing a necessary step toward the long-term sustainability of this technology. In particular, hydrogen direct injection (DI) operation is receiving increased attention due to its inherent advantages over port fuel injection (PFI), such as reduced risks of abnormal combustion, higher specific power, and improved thermal efficiency. However, the mixture preparation process in DI operation generally leads to a stratified charge, especially under intermediate-to-late injection strategies, which in turn strongly affects ignition, combustion performance, and engine-out emissions. Therefore, investigating mixture formation, its key influencing parameters, and the resulting effects on the combustion process is essential for the proper design and optimization of hydrogen-fuelled DI ICEs. In this context, computational fluid dynamics (CFD) emerges as a powerful tool to address
Capecci, Marcolucio, Lucchini, Tommaso, Sforza, Lorenzo, Pezza, Vincenzo, Tosi, Sergio
Integration of energy consumption simulation in optimal charging planning for battery electric long-haul trucks2026-37-0019To be published on 06/09/2026
Vehicle fleet decarbonization is a key objective for the coming years, with electrification representing the primary pathway to achieving the targets set by the European Union. The share of battery electric trucks in new registrations has been gradually increasing especially in light and medium size trucks. The replacement rate of diesel long-haul trucks with zero emission trucks is still low due to challenges posed by added complexity and limitations of battery charging. Depot overnight charging is not sufficient to cover the energy needs of a truck covering large distances and careful planning of the route using public charging infrastructure is crucial for an optimized route minimizing extra costs and range anxiety. The current work aims to develop a methodology to propose the optimal charging locations for a given route of a battery electric truck based on nearby stations along the route. Our study uses an open-source optimization algorithm for the fixed route vehicle charging
Perdikopoulos, Michail, Doulgeris, Stylianos, Livitsanos, Georgios, Kazakis, Thomas, Mellios, Giorgos, Ntziachristos, Leonidas
Development and validation of a one-dimensional model for an opposed-piston free-piston engine generator with parametric analysis2026-37-0021To be published on 06/09/2026
Opposed-piston free-piston engine generators (OFPEGs) have emerged as a promising technology for next-generation hybridized and electrified transportation systems, offering the potential for high efficiency, reduced mechanical complexity, and favorable noise, vibration, and harshness (NVH) characteristics. By eliminating the conventional crankshaft mechanism and directly coupling a free-piston engine with linear generators, OFPEGs enable the direct conversion of combustion energy into electrical power. This architecture is particularly attractive for hybrid and range-extender applications, where operational flexibility and high system efficiency are critical to achieving significant reductions in fuel consumption and CO₂ emissions. Despite these advantages, the performance of OFPEG systems is governed by a strong coupling between piston dynamics, in-cylinder combustion processes, and electrical loading conditions. This coupling presents substantial challenges for system design, control
Wang, Jiayu, Morandi, Nicola, Lucchini, Tommaso, FENG, HUIHUA, Jia, Boru, Ren, Peirong
CFD Modelling of an Asymmetric Hydrogen Injector Cap for Direct Injection Applications: Design Impact on Jets Structure and Momentum Flux2026-37-0011To be published on 06/09/2026
The adoption of hydrogen as a carbon-neutral sustainable fuel for internal combustion is regarded as a promising solution to reduce greenhouse gases and pollutant emissions. In this framework, the injection system plays a crucial role, being responsible for delivering a large amount of fuel to the combustion chamber. Currently, low-pressure direct injection is considered one of the best solutions to ensure the appropriate fuel delivery. The use of caps has proven particularly effective, as they enable a potentially unlimited range of geometries while minimizing modifications to the injector hardware. Experimental campaigns and computational fluid dynamics (CFD) simulations can be used together as complementary tools to speed up the development process and explore multiple combinations of parameters, thereby optimizing the overall design of both the engine and the caps. In the present paper, a single-hole GDI-derived hydrogen prototype injector equipped with a two-hole asymmetric cap
Pavan, Nicolo, Breda, Sebastiano, Duni, Andrea, Martino, Manuel, Fontanesi, Stefano, Postrioti, Lucio
Comparison of Detailed Chemistry and Flamelet-Based Models for Hydrogen Combustion in a Heavy-Duty PFI Engine2026-37-0014To be published on 06/09/2026
Addressing climate change requires substantial reductions in emissions from the transportation sector, where alternative fuels for internal combustion engines play a crucial role. Among these options, hydrogen stands out as a compelling energy carrier capable of enabling low-carbon combustion while leveraging existing engine technologies. Its adoption can support a transition toward fuel-flexible powertrains and deliver rapid decreases in exhaust carbon emissions. This approach is particularly relevant for hard-to-abate segments such as heavy-duty transportation, where full electrification remains challenging. Building on this perspective, this numerical study investigates the modelling behaviour of a heavy-duty port fuel injection (PFI) internal combustion engine fuelled with hydrogen. Initially, the mixture was assumed to be fully premixed to avoid uncertainties related to injection and mixing processes and to significantly reduce computational cost; this assumption was subsequently
Scopelliti, Alex, Misul, Daniela Anna, Baratta, Mirko, Gallo, Alessandro, Rapetto, Nicola, Vargiu, Luca
Analysis of a sorption energy storage system for cabin air heating and dehumidification in electric vehicles2026-37-0034To be published on 06/09/2026
This work investigates the integration of a Sorption Thermal Energy Storage (TES) into the Air Conditioning (AC) system of electric vehicles. The proposed device reduces the energy demand for cabin heating under winter conditions, leading to a driving range increase. The TES dehumidifies the cabin air through a desiccant bed (zeolite 4A), preventing window fogging, enabling higher air recirculation rates, and consequently reducing the required heating power. An experimentally validated numerical model was used to analyze the adsorption and regeneration processes and to identify suitable operating conditions. Regeneration was found to be effective at moderate temperatures (around 120°C), with a counter-current airflow configuration providing faster and more efficient desorption compared to parallel-flow operation. A simplified model integrating TES, AC unit and cabin was developed and used to compare different configurations. Heating energy consumption with and without TES under
Verlingieri, Rebecca, Calabrese, Luigi, Freni, Angelo, Marocco, Luca, Scudeler, Gabriele, De Antonellis, Stefano
An Along-the-Channel Pseudo-2D Approach for Spatially Resolved PEM Fuel Cell Dynamics2026-37-0010To be published on 06/09/2026
The longevity of proton-exchange membrane fuel cells is influenced by degradation processes whose rates depend on local operating conditions such as temperature, humidity, liquid-water saturation, and reactant availability. Along-the-channel gradients imposed by the flow field can therefore be relevant when interpreting operating behaviour and when formulating models intended to support control and system studies. The AlphaPEM framework provides a dynamic through-plane description, but, in its baseline form, does not explicitly resolve axial non-uniformities in the MEA. This paper presents a pseudo-2D extension of AlphaPEM that couples an along-the-channel gas-channel model to a segment-wise MEA submodel. The original model already implements a plug-flow model discretized into multiple axial control volumes to capture the evolution of species and water vapour along the flow direction. This contribution adds a MEA model derived from the original through-plane formulation with local
Ringeisen, Björn, Günthner, Michael, Kargl, Pascal
Improvement of rCF behaviour through the introduction of NF2026-37-0039To be published on 06/09/2026
The use of recycled carbon fibres (rCF) allows for reduction of emissions impacting energy and resource requirements. A major drawback of using rCF composites is the discontinuous nature of the fibres as this limits the performance and applications. The present investigation aimed to overcome some of these limitations by manufacturing hybrid composites by combining rCF and natural fibres (NF). One of the key observations was a significant change in the failure mode of hybrid samples under various loading scenarios, where the composite did not shatter but rather failed in a controlled manner. Initial results also showed an overall improvement impact properties in comparison to plain rCF. Similar performance was observed in other tests. Research was focused on determining the most effective ply sequencing under different types of loading and understanding the effect of the ply sequence on the failure mechanisms. It was determined that depending on the application, the layups does effect
Hnatyk, Dawid, Chrysanthou, Andreas, De Vuyst, Tom, Ismail, Sikiru
Rapid Fuel Distribution Prediction in RCCI Marine Engines Using CFD-Informed, Active Learning Framework2026-37-0017To be published on 06/09/2026
Accurate prediction of in-cylinder fuel distribution (FD) is fundamental to reduced-order combustion modeling and emissions prediction, yet remains computationally prohibitive with high-fidelity CFD alone. This work develops a CFD-informed machine-learning surrogate for spatial FD in a large-bore diesel engine, based on a Wärtsilä W20 injector and representative engine conditions. A fully coupled injector–spray–engine CFD framework under engine-like RCCI inert conditions determines the needle-lift profile and resolves the combined effects of injector geometry, needle dynamics, and operating conditions on in-cylinder flow, capturing physical phenomena not reproducible by isolated free-spray simulations. A high-fidelity database is generated using Latin Hypercube Sampling, from which FD is extracted at 15 CAD before top dead center within an annular multi-zone (MZ) representation consistent with reduced-order combustion models. A multi-output Random Forest (RF) surrogate, augmented with
Moradi, Jamshid, Salahi, Mahdi, Heidarabadi, Shadab, Andwari, Amin, Konno, Juho, Wik, Christer, Mikulski, Maciej
Numerical simulation of spark-ignited flame kernels towards prospective application to hydrogen SI engines2026-37-0015To be published on 06/09/2026
The ongoing energy transition demands the decarbonization of the transport sector, for which the use of premixed hydrogen in spark-ignition (SI) engines appears very promising. However, modeling the combustion of the lean hydrogen/air mixtures required for safe, efficient, and low-NOx engine operation involves multiple open issues. Correct prediction of flame kernel initiation and growth is a difficulty that hydrogen shares with hydrocarbon fuels, while properly accounting for the instabilities that characterize lean hydrogen flames is an additional demanding task. In this work, a 1D kernel expansion model of general validity recently proposed by the authors is implemented into OpenFOAM, an open-source 3D CFD software package, to enable numerical simulation of expanding spark-ignited flame kernels. Firstly, the OpenFOAM framework is presented focusing on XiFluid, its thermophysical combustion model based on a regress variable whose evolution depends on the laminar flame speed. Then
Dotteschini, Enrico, Pretto, Marco, Giannattasio, Pietro, Gadalla, Mahmoud
Effect of Ar mass ratio and mixture equivalence ratio on the integrated hydrogen argon power cycle2026-37-0012To be published on 06/09/2026
This paper investigates hydrogen combustion in an argon–oxygen (Ar–O₂) environment for compression ignition engine applications using computational fluid dynamics (CFD). The numerical framework is validated through two independent datasets: experimental results from Sandia National Laboratories and hydrogen jet ignition experiments conducted in an Ar–O₂ atmosphere, establishing confidence in the predictive capability of the model. A parametric analysis is performed to evaluate the effects of excess air ratio (λ) and argon mass fraction on ignition characteristics, combustion efficiency, and engine performance. The results indicate that operating under lean conditions improves combustion efficiency but leads to a substantial reduction in engine load. Increasing the argon mass ratio enhances engine thermal efficiency, primarily due to the higher specific heat ratio of argon, which improves the thermodynamic efficiency of the cycle. However, elevated argon concentrations significantly
Chitsaz, Iman, Ahammed, Sajid, Kakoee PhD, Alireza, Salahi, Mohammad Mahdi, Andwari, Amin, Ahmad, Zeeshan, Hyvonen, Jari, Mikulski, Maciej
Automated Design Sustainability Evaluation Framework: a CAD-Integrated Tool for Real-Time Costing and LCA in Automotive Engineering2026-37-0044To be published on 06/09/2026
As the automotive industry faces increasingly rigorous environmental regulations and an approaching obligation for Digital Product Passports (DPPs), incorporating sustainability metrics into the early design phase has become a necessity. Traditionally, Life Cycle Assessment (LCA) and manufacturing cost estimation are performed during or after the design phase using specific methods and tools, resulting in costly iterations and delayed decision-making. This paper introduces a preliminary computational tool that combines 3D CAD and spreadsheet software via VBA integration. The framework automates the generation of an “Extended Bill of Materials” by extracting geometric and manufacturing data directly from CAD models. This tool’s classification logic is a key innovation that intelligently processes CAD features to identify component categories, such as sheet metal, machined parts, or plastic injections. This automated recognition allows the framework to implement specific algorithmic
Guadagno, Maurizio, Cecconi, Leonardo, Berzi, Lorenzo, Delogu, Massimo
Augmented Reality and Multimodal Interfaces for Astronaut Training and In-Orbit Operations2026-26-0796To be published on 06/01/2026
Augmented Reality (AR) and multimodal human–machine interfaces (HMI)—combining visual overlays, voice, gesture, eye-tracking, and biometric sensing—are now maturing into flight-relevant technologies capable of transforming astronaut training and in-orbit operations. These interfaces reduce task time, lower error rates, and mitigate cognitive load, thereby strengthening both crew autonomy and mission safety. For India, the timing is critical: Gaganyaan human spaceflight program is approaching decisive crewed missions in the late 2020s, and the Bharatiya Antariksh Station (BAS) is targeted for the 2030s. AR/MMI can be positioned not as an accessory but as a core enabling system for training throughput, real-time crew support, and resilient station operations. This paper provides (i) an overview of India’s current scenario, including Gaganyaan astronaut training ecosystems, IIT Madras collaborations on AR/VR, and Vyommitra humanoid readiness; (ii) synthesis of global case studies—NASA
Yadav, Anoop Singh
Data-Driven Air Traffic Management: Forecasting Demand, Modeling Delay Propagation, and Demand Capacity Balancing2026-26-0772To be published on 06/01/2026
Air traffic management (ATM) systems must accurately estimate flight demand, analyze network delays, and optimize capacity. This research uses a global airline dataset with passenger information, airport characteristics (including geographic markers and continental classifications), flight scheduling data (timing and destination details), crew information, operational status records, and OpenSky Network real-time states data to create an intelligent ATM decision-support framework. Advanced machine learning (ML) methods like gradient boosting and sequential modeling are used to build network models of flight routes between origins and destinations, develop temporal demand patterns for individual airports, analyze delay factors, and predict congestion periods. The research uses mixed-effects statistical models using crew data to measure operational variability and demographic and nationality-based analysis to identify demand trends for improving staffing and security processing during
Senthilkumar, N., S, Gopalakrishnan, Gopinath, S
Evaluating Volume and Hardness change in Fluorocarbon and Ethylene Propylene Rubber Elastomers: Effects of Fluid Aging2026-26-0758To be published on 06/01/2026
Abstract: This research paper investigates the performance of FKM (Fluorocarbon) seal material when exposed to a 50:50 ethylene glycol-water mixture. The study aims to determine the volume change percentage and Hardness change of FKM elastomers under standardized testing conditions. The experimental approach follows ASTM D471 and ASTM 2240 guidelines, focusing on weight and hardness measurements of the test samples to establish a success criterion. The results provide critical insights into the chemical compatibility and durability of FKM elastomers in Aerospace and industrial applications where ethylene glycol-water mixtures are commonly used. The findings contribute to enhanced material selection and design considerations for sealing applications subjected to glycol-based fluids. Samples of FKM material were immersed in the fluid at controlled temperatures and durations, simulating real-world operational conditions. The primary metric of interest, volume change percentage and
Yarolkar, Makrand, Patil, Sandip, Singh, Tanul
Vibration based methods for Non-destructive prediction of Buckling loads2026-26-0737To be published on 06/01/2026
Using vibration data for prediction of buckling loads have been proven effective for various geometries including rods, plates and shells. The Arbelo approach of the vibration correlation method is derived to improve the reliability of the prediction for cylindrical and spherical shell structures. In this work, a more simplified form of the Arbelo approach is proposed which has higher prediction accuracies of the buckling with lesser pre-load levels. A parameter called Stiffness Decay Index (SDI) is introduced as a measure of the stiffness degradation by normalizing the loaded natural frequency with respect to the unloaded state, offering an effective means of buckling prediction with improved accuracy and without causing any damage or permanent deformation to the structure. Numerical and experimental evaluations of the Stiffness Decay Index are carried out for various geometries. The advantages of using SDI in place of the Arbelo approach of the vibration correlation technique are
Rangarajan, Gopikrishna, V, Vishwajith, Raju, Gangadharan, Dinavahi, Ramkrishna
Finite Element Approach for Fatigue Life Prediction of Threaded Bolts with Experimental Validation2026-26-0745To be published on 06/01/2026
Predicting the fatigue life of threaded bolts is crucial in aerospace and mechanical assemblies where cyclic loading can cause early joint failure. Previous research conducted experiments to develop S-N curves for high-strength bolts under different pretension and temperature conditions (Zhang et al. 2024). However, there are a very few numerical methods that can replicate these results, especially for bolts with screw threads. In this work a finite element analysis (FEA) methodology is developed to predict the fatigue performance of threaded bolts under axial loading and validated using the experimentally derived Series-1 S-N data for M20 high-strength bolts. The approach includes detailed FEA modelling (3D solid) with explicit thread geometry to capture local stress distributions under cyclic tensile loading. Peak stress amplitudes are employed to estimate fatigue life by applying the Basquin relation and the Series-1 S-N curve. The results are compared with the calculated fatigue
K R, Lesanth, S, Suhail Ahmed, C, Arunvetrivel, P, Krishnakumar, P S, Premkumar, Vasantharaj, C
Hybrid Physics-Informed Neural Network and PID Control for Fault-Tolerant Autonomous Multi-copters2026-26-0770To be published on 06/01/2026
This paper addresses the critical challenge of fault-tolerant control in autonomous multi-copters, particularly under conditions of one or two rotor failures a scenario that often leads to severe instability and a complete loss of directional control due to unbalanced torque and resultant autorotation. Existing advanced control strategies, including optimal approaches such as LQR, typically require precise system modeling and state estimation, which are difficult to achieve in real-world, dynamic failure scenarios. Alternative methods like fuzzy logic, sliding mode control, and gain-scheduling either lack robust generalization or are impractical for enumerating all possible failure cases. In this work, a hybrid control framework integrating Physics Informed Neural Networks (PINN) with a standard PID controller is proposed for fault-tolerant operation of autonomous multi-copters subject to multiple actuator failures. PINNs incorporate governing physical laws as regularization in their
Charapalle, Samruddhi, Venugopalan, Nandagopalan, Nerkundram Muralidharan, Arun, Sundararaj, Laveen
Sensitivity Analysis of Geometric Imperfections in Aerospace structures2026-26-0738To be published on 06/01/2026
Launch vehicle structures are designed to withstand flight loads ensuring design adequacy after thorough structural assessment. In general, Preliminary FE model assumes perfect geometry of structures for analysis without considering profile imperfections arising during course of fabrication. These deviations, occurring during manufacturing, can significantly reduce the structure's load capacity. Traditional analysis often relies on simplified or theoretical imperfection models, which are different from "fabricated" hardware, leading to either underestimation or over estimation of margin for structural design loads. This paper presents a robust methodology for a cylindrical structure by directly incorporating measured manufacturing deviations into the finite element (FE) model. Thin-walled cylindrical structures, particularly those with complex stiffening patterns like isogrid panels, are sensitive to geometric imperfections. The subject hardware exhibited significant non-conformances
Sharma, Amit, Singh, Nishant, Xavier, Shijo, R, Suresh
Investigation of Acoustic Fill Effect of a Launch Vehicle Payload Fairing2026-26-0759To be published on 06/01/2026
The payload fairing of a launch vehicle is subjected to extremely high acoustic loads, with peak levels occurring during lift-off and transonic aerodynamic regimes. The external acoustic field penetrates the fairing, producing intense internal sound pressure levels that can challenge the integrity of spacecraft components. Accurate characterization of the vibroacoustic behaviour of the payload fairing and its enclosed cavity is therefore essential to ensure spacecraft survivability. The internal acoustic field is governed by the coupled dynamics of the fairing structure and the spacecraft configuration, making it critical to quantify the acoustic environment for different payload arrangements. This study presents a detailed vibroacoustic analysis of a payload fairing with multiple spacecraft configurations to evaluate the resulting internal sound pressure distribution. Vibroacoustic finite element analysis (FEA) is employed in the low frequency range, while statistical energy analysis
S R, Arun Raj, Jayan, Mahind, George, P
Leveraging True Altitude Data to Improve Static Pressure Calibration from Dynamic Manoeuvres2026-26-0729To be published on 06/01/2026
Accurate calibration of aircraft air data systems is essential for reliable measurement of flow angles, altitude, and airspeed, particularly during dynamic flight manoeuvres where errors can become significant. Externally mounted vanes and probes are used to measure flow angles, local pressures and temperature, respectively. However, because these sensors are positioned close to the aircraft fuselage, they operate within disturbed local flow fields that differ notably from the free-stream conditions. As a result, their outputs require Position Error Corrections (PEC) to accurately estimate free-stream parameters such as pressure, temperature, and flow angles. The pre-flight PEC data or calibration tables for these sensors are generated based on the CFD predictions/wind tunnel experiments. All the flight-measured local variables from air data sensors need to pass through the air data computers, which contain these lookup tables, to obtain the free stream information. Despite the pre
TK, Khadeeja Nusrath, Patel, Dr. Ambalal V, J, Prabhavathi Bhai
Automated Flight Maneuver Recognition for Intelligent Flight Simulator2026-26-0713To be published on 06/01/2026
The rapid growth in the number of aircrafts and pilots emphasizes the need for an AI-enabled training framework that can offer precise, automated examination of flight maneuvers, thereby optimizing the pilot’s training efficiency and minimizing iterations of the conduct of flight maneuvers thereby reducing the training time of the pilot for a flight. This paper introduces a novel hybrid methodology to intelligently detect manoeuvres performed during a flight using signal processing and machine learning techniques. A general framework is developed that can be used for all kinds of flight phases and aircraft types. The framework is implemented in a two-step approach. Firstly, Continuous Wavelet Transform (CWT) of the signals of interest for different manoeuvres are generated, to find the time at which a manoeuvre happens during a sortie. CWT looks at the energy levels in the transformed signal and uses smart thresholding technique to pick out only the parts with high energy, to extract
Sahu, Akash, C, Poornima, C, Aravindh, Kaliyari, Dushyant, TK, Khadeeja Nusrath
Influence of Boundary Conditions on Dynamic Characterization of Launch Vehicle Structures with Closely Spaced Modes2026-26-0730To be published on 06/01/2026
Dynamic characterization tests play a critical role in launch vehicle applications, as they provide the frequencies and mode shapes required for refining Finite Element Models (FEM) and ensuring structural integrity. While such tests are often routine when mode shapes in orthogonal planes are well separated, practical challenges arise when modes are closely spaced. In these cases, careful test planning and execution become essential to obtain reliable results. A key factor influencing test outcomes is the boundary condition of the test article. Although free-free suspension, achieved through very low-frequency support, is theoretically ideal, it is often impractical. As a result, most dynamic characterization tests are performed with a base-fixed condition, where the properties of the supporting structure can influence the measured response. For structures with asymmetry limited to a single axis, mode shapes are typically expected to align along that axis; however, deviations may occur
Panda, Ajay Kumar, Avirah, Nohin K, Shaikh, Altafhusen
THERMO-STRUCTURAL ANALYSIS OF GRID FINS FOR RE-ENTRY MODULES2026-26-0749To be published on 06/01/2026
Grid fins are lattice structures employed as aerodynamic control surfaces to achieve the required static stability of re-entry modules during atmospheric descent. Grid fins help to stabilize the re-entry modules by counteracting aerodynamic instabilities, especially when the module is moving through the atmosphere at high speeds. Each panel within the grid fin functions as an individual fin, generating lift and drag forces that enhances the overall stability of the re-entry module. In contrast to conventional fins, grid fins incorporate a distinctive waffle-like pattern or grid pattern configuration, offering superior aerodynamic performance in supersonic regimes and enabling compact storage through folding during launch followed by deployment at the time of exigency. The separation of re-entry modules from their launch vehicles is typically executed using high-thrust, fast-acting solid rocket motors (SRMs) which provide the impulsive force needed for clean detachment. The primary
Mali, Somanath Nandu, Sundar Raj, R, Sundaresan, MK, R, Suresh
Surface Protection Strategies for Dome-Shaped Structures Against Cavitational Erosion2026-26-0744To be published on 06/01/2026
Cavitation is a critical phenomenon encountered in fluid-structure interactions, especially when submerged or partially submerged bodies rapidly emerge from liquid environments. In aerospace and marine applications, dome-shaped structures that transition through water at high velocities experience intense cavitational forces due to rapid pressure fluctuations and vapour bubble collapse near the surface. These effects can lead to severe surface erosion, noise generation, and structural fatigue, compromising performance and longevity. This study investigates the occurrence of cavitation on dome-shaped geometries emerging from water with varying velocities and explores the effectiveness of a thin elastomeric (rubber-based) coating in mitigating these detrimental effects. Experimental simulations and computational fluid dynamic (CFD) analyses were conducted to evaluate pressure distribution, vapour bubble dynamics, and material response under static flow conditions. The results demonstrate
Velayudhan, Gautham, P S, Premkumar, S, Suhail Ahmed, P, Krishnakumar, Vasantharaj, C
Numerical Methodology For Aircraft Light Explosion Proofness Study2026-26-0790To be published on 06/01/2026
The increasing demand for safety and reliability in aerospace applications necessitates rigorous testing of aircraft components, including light units, for explosion proofness. Traditional explosion proofness tests are destructive, expensive, and time-consuming, requiring significant resources for test setups and prototypes. To address these challenges, this research presents a numerical methodology using Computational Fluid Dynamics (CFD) simulations to investigate the explosion proofness for aircraft light units. The primary motivation of this study is to develop a cost-effective and efficient alternative to physical testing that provides comprehensive insights into explosion dynamics and facilitates design optimization. This work contributes to advancing engineering practices in the aerospace industry by demonstrating the efficacy of CFD simulations in evaluating and enhancing the explosion proofness of light units. The proposed CFD model, implemented in ANSYS Fluent, adheres to the
Selvaraj, Sugumaran, Nataraja, Prabhu
Integrating Human Factors and Predictive Modeling for Enhanced Aviation Safety: A Data-Driven Approach to Risk Mitigation and System Design2026-26-0795To be published on 06/01/2026
The evolution of the aviation industry from manual control to highly automated and autonomous systems has brought human factors to the forefront of safety, design, and operational efficiency. This paper presents an integrated analysis combining machine learning techniques with statistical modeling to assess the impact of human-system interaction on aviation incident outcomes. The first phase of this research involved a longitudinal dataset covering aircraft design evolution, training programs, and incident records. Using classification algorithms, including XGBoost, the study achieved an accuracy of 81.82% in predicting incident likelihood. Performance metrics such as F1-scores (0.85 for “Incident” and 0.78 for “No Incident”) highlighted the model’s robustness in identifying risk patterns associated with human factors and system complexity. In the second phase, 50 plus detailed aviation incident reports were analyzed using logistic regression, t-tests, and Cook’s Distance to identify
Valiyaparambil, Praveen
Predictive Obsolescence Management2026-26-0780To be published on 06/01/2026
This abstract is towards Aerospace Sustainability - End-of-Life Management for Aerospace Assets. In the field of Aerospace, which has a long Life-Cycle process [20-30Years], Component Obsolescence has become a major problem as it prevents Maintenance & sustenance of a product with committed life-cycle period. Obsolescence Management plays a vital role by deriving strategic plans on proactive obsolescence where the system needs to be supported for several decades. This abstract analyzes the obsolescence challenges in the Aviation industry especially in Avionics System impacted by component obsolescence and present the possible proactive obsolescence management in terms of Engineering, Technology, and business/cost elements. The Obsolescence problem cannot be avoided but the impact of obsolescence and mitigate the risk can be minimized by planning and managing response. The obsolescence risk assessment for the Bill Of Materials (BOM) is a paramount activity to manage obsolescence
Dharmananyala, Rohith, Munirathnam, Krishna, Marokeyfrancis, Joisyjose, Sadashivaiah, Nagesh, Kondamari, Harshitha
Wear Resilience Characteristics of 2% Silicon Nitride Strengthened AZ31 Magnesium Composite2026-26-0740To be published on 06/01/2026
To develop magnesium matrix composites, ceramic silicon nitride (Si3N4) particles are used to strengthen the magnesium (AZ31) matrix by adding 2 wt.%. The composite is developed by disintegrated melt deposition vacuum stir casting method. Microstructural studies reveal the presence of Si3N4 particles and their uniform distribution. A L9 orthogonal array planned using Taguchi’s experimental design is chosen for three wear parameters axial load (AL), rotational speed (RS), and time duration (TD) for trials as per G99 standard in pin-on-disc apparatus. Experimental outcomes show a rise in axial stress; wear loss increases dramatically. Because the area of contact shrinks as sliding speed increases, wear loss diminishes dramatically. When the AL is low, CoF increases, and when the AL is large, CoF drops. When the sliding speed is increased, CoF decreases. To optimize multiple responses effectively, the TOPSIS method (Technique for Order of Preference by Similarity to Ideal Solution) was
Senthilkumar, N., Dhinakar Raj, C K
Effect of strap-on geometry on the aerodynamics of multibody launch vehicle2026-26-0727To be published on 06/01/2026
Strap-on boosters play a crucial role in heavy launch vehicles by providing additional liftoff thrust without major changes to the baseline design, enabling launch with existing propulsion systems. However, strap-on boosters introduce additional pressure drag and alters the overall aerodynamics of the vehicle. While efforts have been previously made to derive empirical relationships to predict the aerodynamics of different strap-on configurations, most are case-specific and primarily limited to estimating drag coefficients (CD) [1]. Strap-on geometry has a vital role in flow field interference effects. The present study focuses on primary non-dimensional geometric parameters such as (1) strap-on core diameter ratio (Ds/Dc), (2) strap-on core length ratio (Ls/Lc), and (3) strap-on-core radial gap (Xg/Dc). The results are used to derive an empirical relationship which can be applied during preliminary design stage of a launch vehicle to predict axial force coefficient (CA), normal force
Muraleedharan, Archana P., G, Ramana Bharathi, S, Gnanasekar
Integrating Formal Methods into Model Based Systems Engineering(MBSE) to Mitigate Requirement Escapes2026-26-0712To be published on 06/01/2026
The industry is undergoing a significant digital transformation in the way system requirements are defined, communicated, and managed. Major original equipment manufacturers (OEMs) are moving toward fully model-based development processes, with plans to deliver requirements exclusively in the form of system models. It is no longer sufficient to manage requirements using traditional document-based approaches; instead, organizations must adopt tools and processes that enable the consumption, interpretation, and implementation of model-based requirements. Preparing to meet this industry direction is critical to maintaining competitiveness and alignment with our customers’ expectations. Model-Based Systems Engineering (MBSE) plays a central role in this transition. MBSE enables engineers to define, analyze, and manage system requirements, architectures, behaviors, and verification strategies within a cohesive model-based framework. It supports traceability, promotes consistency across
Gupta, Chandan, Nakkeeran, Rupashree
CFD based Performance Prediction of Centrifugal Compressor2026-26-0726To be published on 06/01/2026
In modern engineering, compressors play a vital role across numerous industries by enabling the delivery of fluids at elevated pressures for a variety of applications, including HVAC systems, aircraft engines, and process industries. The performance of centrifugal compressors, in particular, is characterized by parameters such as flowrate, efficiency, and pressure rise, all of which are critical to the reliability and efficiency of associated equipment. Traditional methods of evaluating compressor performance, such as physical testing, are often time-consuming and costly, making them less practical for iterative design or optimization. Advancements in Computational Fluid Dynamics (CFD) have provided a faster and more cost-effective means of assessing compressor behavior. This study presents a comprehensive CFD-based analysis of a two-stage centrifugal compressor utilized in HVAC applications, with a focus on predicting surge points and mapping the surge line at various operating speeds
Turaga, Vijay Kumar, Aadi Gopalakrishna, Pradeep, Gugulothu, Sampath
Zero Waste Manufacturing in Aerospace Circular Design Approaches from Concept to End-of-Life2026-26-0775To be published on 06/01/2026
Achieving zero waste in aerospace manufacturing demands a fundamental shift from traditional end-of-pipe solutions to circular design principles embedded from the earliest stages of product development. This paper presents a practical framework for integrating circularity into aerospace systems, emphasizing design strategies that minimize material waste, facilitate disassembly, and enable component recovery throughout the product lifecycle. The approach is structured around five key pillars: 1. Design for Modularity and Disassembly 2. Material Substitution to Enhance Recyclability 3. Waste Segregation and Characterization in Manufacturing Processes 4. Component-Level Circularity Readiness Scoring 5. Collaborative Supplier Engagement to Establish End-of-Life Pathways To support implementation, a Circularity Readiness Assessment Tool has been developed, enabling engineers to evaluate designs against circularity criteria such as disassembly ease, material recyclability, and supplier
S, Chaitra
Novel material architecture for enhanced high cycle fatigue life in turbofan engine fan blades2026-26-0748To be published on 06/01/2026
High Cycle Fatigue (HCF) is a critical failure mode in turbofan blades, primarily driven by resonance phenomena when the blade’s natural frequency aligns with engine-induced excitations. Traditional approaches to mitigate HCF often involve geometric modifications or damping treatments, which can adversely affect aerodynamic performance or increase component weight. This study explores alternative methodologies to strategically alter the natural frequency of turbofan blades while maintaining aerodynamic efficiency and structural integrity. A novel material architecture is proposed, consisting of a dual-metallic configuration with a high-stiffness core and a lightweight, fatigue-resistant outer shell. This design enables precise tuning of the blade’s dynamic response by leveraging the contrasting mechanical properties of the core and outer materials. The dual-metallic structure shifts the natural frequency away from critical excitation zones, thereby reducing the risk of resonance
S, Ravivarman, Inamdar, Prachi, De, Rohit
Assessment of Injection Gate Location effects on Mechanical Performance of Short Fiber Reinforced Plastic Components using Digimat2026-26-0746To be published on 06/01/2026
The mechanical performance of short fiber-reinforced plastic (SFRP) components is highly sensitive to fiber orientation, which is significantly influenced by the injection gate location during the molding process. Traditionally, gate placement decisions are driven by warpage minimization strategies, often overlooking mechanical performance under diverse load cases. This research introduces an automated workflow within Digimat-MS that integrates injection gate optimization into the early design phase, leveraging Integrated Computational Materials Engineering (ICME) principles. The proposed methodology enables engineers to upload either of Marc, Abaqus or Ansys input decks, select a component of interest, assign material cards, and define gate scenarios. A Design of Experiments (DOE) is then executed locally or remotely, allowing Digimat to simulate and evaluate multiple gate configurations. The system aggregates results and identifies optimal gate locations based on the initiation of
Kauthale, Tanmay, Madhavan, Vinay, Soni, Ganesh
Reducing Test Campaigns through Advanced Yield Surface Modeling for New Aircraft Metal Grades2026-26-0755To be published on 06/01/2026
Qualification of new aerospace alloys requires extensive mechanical testing to capture anisotropy and ensure reliable performance under complex loading conditions. This process is costly and time-consuming, particularly with emerging manufacturing routes such as additive manufacturing. Advanced yield surface prediction offers a route to reduce test campaigns by linking microstructural features to macroscopic constitutive models. In this work, Digimat is employed as a multi-scale material modeling platform to generate yield surfaces of polycrystalline metals using computational homogenization. Representative volume elements (RVEs) are constructed from experimental texture and grain morphology data, and their response under multiaxial loading is simulated using a crystal plasticity framework. The computed yield loci are then fitted with phenomenological functions (e.g. Barlat2000), enabling calibration of anisotropic yield models from virtual testing. As a case study, an AA6016-T4 sheet
Padhan, Manas, Uppaluri, Rohith, Lemoine, Guerric, Soni, Ganesh
Accelerating aircraft verification and certification through an integrated virtual and physical testing approach2026-26-0710To be published on 06/01/2026
Aircraft verification and certification entails a variety of testing tasks and requires coordination among numerous stakeholders across different disciplines to ensure alignment on requirements. Historically, certification strategies have relied on both physical testing and high-fidelity simulation. The integration of these complementary approaches is essential to address their respective blind spots and to support credible certification evidence. A key challenge lies in the rigorous correlation of simulation models with physical test data. Flutter verification, for instance, is a critical component in defining the aircraft’s flight envelope and plays a foundational role in certifying safe operational boundaries. In this work, the process of freedom from flutter verification starting from the pre-test analysis is demonstrated. This work introduces a novel approach to combining simulation and test data with the aim to accelerate and streamline the verification process leading to more
Hallez, Raphael, Yadabettu, Dayanand Kumar, de Boer, Jens, Aspasiou, Vicky
A Robust Framework For Dynamic Soaring Trajectory Generation Accounting For Variation Of Aerodynamic Derivatives With Flight Conditions2026-26-0771To be published on 06/01/2026
Dynamic soaring is a biologically inspired flight technique that harnesses wind shear for energy-efficient, sustained flight, as demonstrated by seabirds such as albatrosses. This capability holds significant promise for unmanned aerial vehicles (UAVs) tasked with long-endurance missions in challenging environments. Existing approaches to trajectory generation have largely relied on direct optimal control formulations or differential-flatness-based methods, often under the simplifying assumption of constant aerodynamic derivatives. Such assumptions, however, limit accuracy and robustness when UAVs encounter variations in flight conditions. This paper presents a robust six-degree-of-freedom (6-DOF) trajectory generation framework that enhances the flatness-based formulation by incorporating sideslip and the complete set of stability and control derivatives. The study begins with a comparative analysis between the original and improved formulations using Floquet stability theory and
Swaminathan, Bharath
Risk-Driven Program Management Framework - Abstract2026-26-0716To be published on 06/01/2026
Avionics programs face increasing complexity due to evolving safety, certification, and cybersecurity requirements. Conventional program management approaches, focused mainly on cost and schedule, often overlook the dynamic and interdependent risks inherent in developing safety-critical systems. This gap results in late surprises, inefficient resource use, and challenges in achieving certification milestones. This paper introduces a risk-driven program management framework tailored for avionics, where risk identification, assessment, and mitigation are embedded within the governance model rather than treated as a parallel activity. The framework integrates industry standards such as DO-178C, DO-254, DO-326A, and ARP4754A, ensuring alignment with regulatory expectations while promoting a holistic view of program health. A key feature of the approach is the use of digital dashboards and predictive analytics to transform static risk registers into actionable tools. These dashboards
Rahul, Saurabh, Benikireddy, Raghunatha
Weight Estimation of Novel Aircraft Configurations in Early Design Phase2026-26-0773To be published on 06/01/2026
Initial Weight estimation based on the Top Level Aircraft Requirements, hereon referred to as TLAR, is one of the key points to begin with the design of any aircraft. A quick and accurate estimation at the initial stages allows to achieve optimal design solution in fewer steps. This has more relevance in a setup like DOE, i.e., Design of Experiments, where the idea is to explore the complete design space and choose the best solution. At present, there are techniques available to estimate the weight from TLAR for conventional tube and wing configurations with JetA1 fuel. These techniques are primarily based on trends and empirical equations that have been derived from historical data of aircrafts previously built. A lot of new aircraft concepts have been (eg: VTOL) and are being (eg - BWB, H2 as fuel, OpenFan Propulsion etc.) considered for the commercial future. Currently, there are no standard methods established to estimate their weights due to the scarcity of historical data. The
Goyal, Tushar
Effect of Fluid Flow/Time Duration on Static Voltage Generation for Aerospace Hose Assembly2026-26-0757To be published on 06/01/2026
Static electricity is an electrical imbalance on the surface of a material that can interact with other components made of the same or different materials. Fluid (hydrocarbons) flow within the hose assembly generates static voltage due to the friction caused by fluid flow in pipes, which needs to be appropriately quantified and dissipated. Accumulation of such static charge may lead to sudden discharge, resulting in spark generation. Spark generation around fuel flow might lead to system failure and failure in aircraft engines. Experiments were conducted to analyze the static voltage generated in the hose assembly with a fixed hose assembly length due to fuel flow, with the objective of achieving acceptable voltage levels to avoid ESD (electrostatic discharge) failure. The procedure includes fuel flow rate monitoring and voltage measurement. The testing revealed that the curvature of the hose affects the readings, highlighting the importance of consistent meter alignment. Using a
Waghmare, Shashank
Estimation of dynamic responses at internal points of a nested sub-structure with two-level Craig-Bampton reduction2026-26-0747To be published on 06/01/2026
Dynamic analyses of large and complex structural assemblies usually employ sub-structure coupling or Component Mode Synthesis (CMS) methods. The most widely used CMS method for dynamic analyses is the Craig-Bampton (CB) method. The displacement transformation of the CB method employs fixed-interface normal modes and interface constraint modes as the component modes. Dynamic analyses utilizing Craig-Bampton-reduced sub-structure matrices will provide information about dynamic responses at interface degrees-of-freedom (DOFs) and at generalized DOFs corresponding to fixed interface normal modes. However, physical responses at internal DOFs cannot be obtained directly from these analyses. In order to extract dynamic responses at selected internal DOFs, Output Transformation Matrices, which define a relation between responses at component modes and at internal DOFs, are used. In this paper, an approach to estimate and validate the internal point dynamic responses in a nested sub-structure
Ramachandran, Nirmal
Porosity Matters: Multiscale Simulation of Composite Panel Performance in Aerospace Structures2026-26-0731To be published on 06/01/2026
Porosity in carbon fibre reinforced polymers (CFRP) remains a critical concern for aerospace engineers, as even minor voids introduced during manufacturing can undermine the reliability of structural components. This work explores the influence of interply porosity on composite panel behaviour, employing a multiscale simulation approach that bridges material characterisation and full-scale structural analysis. The study begins with virtual coupon testing using Digimat-VA and Digimat-MF, enabling the prediction of material allowables and the assessment of defect variability. Homogenised material properties derived from these simulations are then applied to detailed panel models constructed in MSC Apex, ensuring accurate representation of layup and orthotropic behaviour. The workflow can support a range of structural load cases, allowing for the evaluation of stiffness, buckling, or other relevant scenarios as dictated by aerospace certification requirements. Nonlinear finite element
Savane, Vishal, Kumar, Rajat
Design and Multi-Faceted Validation of UAV Arm Clamps, Landing Gear and Motor Mounts via Generative Design in Autodesk Fusion 3602026-26-0734To be published on 06/01/2026
The reliability of the entire airframe is essential for Unmanned Aerial Vehicles (UAVs) deployed in critical surveillance and disaster management missions. Performance cannot be compromised, as even minor structural weaknesses can impact flight stability and mission success. This work introduces a thorough "design–simulate–build–test" process that combines advanced simulation, additive manufacturing, AI-driven generative design, and experimental validation to construct an assembly of high-performance UAV structural components. Motor mounts, arm clamps and landing gear were among the important structural components of a custom UAV that were redesigned using the suggested technique. With the use of Autodesk Fusion 360's generative design tools, every component was tailored for Fused Filament Fabrication (FFF) additive manufacturing. Their mechanical performance was first predicted through a detailed Finite Element Analysis (FEA) framework. To experimentally validate these simulations
Krishna Bansal, Vaibhav
An Integrated Digital Engineering Framework for Parametric Design and Finite Element Analysis of Aerospace Systems2026-26-0735To be published on 06/01/2026
Digital engineering initiatives in aerospace demand more than conventional finite element analyses; they require integrated, traceable, and systematic workflows that shorten iteration cycles, enable rapid trade-off studies, and ensure verification across the design process. FEAST (Finite Element Analysis of Structures)—an indigenous finite element software developed by VSSC, ISRO—provides structural analysis capabilities, but its native command structure is not directly compatible with automated, iterative design exploration. This limitation creates a gap between solver functionality and the needs of modern model-based engineering, where efficiency, reproducibility, and scalability are critical. To address this gap, a unified workflow is proposed that links parametric geometry modeling, load-case management, solver execution, and results visualization in a seamless manner. The framework automates repetitive pre- and post-processing tasks, enables systematic evaluation of alternative
Gupta, Shivangi, T J, Raj Thilak, P, Deepak
Hybrid Digital Twin for Aero-Engine Bearing Prognostics: A Physics-Informed Machine Learning Approach to RUL Prediction2026-26-0718To be published on 06/01/2026
Unscheduled maintenance due to the failure of critical components, such as aero-engine rolling element bearings, is a leading cause of costly Aircraft-on-Ground (AOG) events; consequently, current time-based maintenance practices are inefficient and prone to risk. This paper develops a resource-efficient Hybrid Digital Twin (HDT) model for an engine bearing, focusing on the dynamic prediction of spall growth due to Rolling Contact Fatigue (RCF), thereby enabling a condition-based maintenance paradigm. The HDT architecture integrates two core models: (1) a physics-informed model that uses established life and fatigue theory to define initial degradation thresholds and constrain the failure envelope, and (2) a data-driven Recurrent Neural Network (RNN) (specifically, an LSTM) for dynamic degradation rate modeling. The methodology utilizes a Monte Carlo simulation coupled with RCF progression equations to generate a large, synthetic run-to-failure dataset under varying operational loads
Mohamed, Abbas
SAE TOMORROW TODAY - SAE Standards: Building Consensus for Moving Mobility Forward135634/16/2026
Standards aren't flashy ... but they make modern mobility possible by enabling emerging technologies to scale safely. Listen in as we sit down with SAE International experts Christian Thiele, Senior Director of Global Vehicle Ground Standards, and David Franks, Standards Specialist Engineer for Aerospace, for a wide‑ranging conversation on how SAE standards quietly enable trust, interoperability, and scale across automotive and aerospace. This discussion spans EV charging, wireless roads, automated driving, advanced air mobility, hydrogen propulsion, and the growing role of artificial intelligence. Go behind the scenes to learn how these standards are developed, the importance of industry consensus, and why they often exceed regulatory safety requirements. Are you interested in shaping the standards behind next-gen mobility technology? Get involved at sae.org/standards/development. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to
Patterson, Lori
Engine Cooling Fan Structural AnalysisJ1390_202604 (Current)4/13/2026
Three levels of fan structural analysis are included in this practice: a Initial structural integrity. b In-vehicle testing. c Durability (laboratory) test methods. The initial structural integrity section describes analytical and test methods used to predict potential resonance and, therefore, possible fatigue accumulation. The in-vehicle (or machine) section enumerates the general procedure used to conduct a fan strain gage test. Various considerations that may affect the outcome of strain gage data have been described for the user of this procedure to adapt/discard depending on the particular application. The durability test methods section describes the detailed test procedures for a laboratory environment that may be used depending on type of fan, equipment availability, and end objective. The second and third levels build upon information derived from the previous level. Engineering judgment is required as to the applicability of each level to a different vehicle environment or a
Cooling Systems Standards Committee
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