Browse Topic: Analysis methodologies

Items (9,347)

Development and Validation of Rear Head Surround Foam Performance Specification for Stock Car Racing

2025-01-8353To be published on 04/01/2025

Over the last two decades many improvements have been made in stock car racing driver safety. The head surround of the NASCAR (National Association for Stock Car Auto Racing, LLC) seating environment serves as an effective restraint for head protection during lateral and rear impacts. However, previous rear head foam material specifications did not address low severity impacts that occur frequently during typical driving, such as race restart vehicle nose to tail contact. This study focused on developing a test methodology for comprehensive evaluation of rear head surround foam materials for repeated helmet-to-foam impacts of varying severity. Specifically, this study aimed to formulate a specification that maintains previous material performance at high speed, while decreasing head accelerations at low speed. Quasi-static and dynamic drop tower testing of sample materials was used to analyze the energy absorption capabilities of various foams and served to develop finite element

Gray, Alexandra N., Harper, Matthew G., Mukherjee, Sayak, Patalak, John P.

Analysis and Comparison of Metrics to Assess Submarining Behavior with the Hybrid III 5th Percentile Dummy in the Rear Seat

2025-01-8711To be published on 04/01/2025

Real-world data show that abdominal loading due to a poor pelvis-belt restraint interaction is one of the primary causes of injury in belted rear-seat occupants, highlighting the importance of being able to assess it in crash tests. This study analyzes the phenomenon of submarining using video, time histories, and statistical analysis of data from a Hybrid III 5th female dummy seated in the rear seat of passenger vehicles in moderate overlap frontal crash tests. This study also proposes different metrics that can be used for detecting submarining in full-scale crash tests. The results show that apart from the high-speed videos, when comparing time-series graphs of various metrics, using a combination of iliac and lap belt loads was the most reliable method for detecting submarining. Five metrics from the dynamic sensors (the maximum iliac moment, maximum iliac force drop in 1 ms, time for 80% drop from peak iliac force, maximum pelvis rotation, and lumbar shear force) were all

Jagtap, Sushant R, Jermakian, Jessica S, Edwards, Marcy A

Multi-source error analysis for loading disk of suspension kinematics & compliance test bench

2025-01-8291To be published on 04/01/2025

The suspension Kinematics & compliance (K&C) characteristics test bench can simulate the excitation of the road to the wheels under various typical working conditions in a quasi-static manner on the bench, enabling the measurement of the K&C characteristics of the suspension system without knowing the specific suspension structure form, parameters, etc., assisting in the entire design process of the vehicle. In this paper, aiming at various geometric source errors existing in the processing and assembly process of the K&C characteristic test bench, an evaluation method based on the homogeneous transformation matrix is proposed to establish the position error of the center of the end loading disk in the series motion chain. Firstly, the mapping relationship between the position error of the end loading disk in the series mechanism kinematic chain and the assembly error is established by using the homogeneous transformation matrix. Then, the change matrix of the coordinate system from

Sun, Haihua, Duan, Yupeng, Wu, Jinglai, Zhang, Yunqing

Design Validation of Automotive Inverter Components: the importance of Fatigue Simulations

2025-01-8639To be published on 04/01/2025

Vibration qualification tests are currently indispensable for vehicle manufacturers and their suppliers. Carmakers’ specifications are therefore conceived to challenge the mechanical endurance of car components in the face of numerous in-service detrimental phenomena: fatigue damage, shocks or accidents, and mechanical degradation. In the automotive industry, components are commonly qualified by means of a test without failure, the goal being to determine whether it will or not "pass" customer requirements. Validation of new or newly designed components is obtained via bench test and structural simulation. Simulation has gained traction in recent years because it represents the first step of the design validation process. In particular, Finite Element Analysis simulations are so powerful that they not only justify physical testing (shaker tests) on prototypes but enable engineers to optimize the design and predict the durability of the part. This paper illustrates how FEA simulations

Durai, Arumugapandian, LEON, Renan, Bonato, Marco, RAJA, Antony, KUMAR, Lalith, NIWA, Takehiro

Application of AI/ML based Image Analytics in Auto Component Fracture Analysis

2025-01-8228To be published on 04/01/2025

This paper introduces an innovative digital solution for the categorization and analysis of fractures in Auto components, leveraging Artificial Intelligence and Machine Learning (AI/ML) technologies. The proposed system automates the fracture analysis process, enhancing speed, reliability, and accessibility for users with varying levels of expertise. The platform enables users to upload images of fractured parts, which are then processed by an AI/ML engine. The engine employs an image classification model to identify the type of fracture and a segmentation model to detect and analyze the direction of the fracture. The segmentation model accurately predicts cracks in the images, providing detailed insights into the direction and progression of the fractures. Additionally, the solution offers an intuitive interface for stakeholders to review past analyses and upload new images for examination. The AI/ML engine further examines the origin of the fracture, its progression pattern, and the

Sahoo, Priyabrata, Rawat, Sudhanshu, Garg, Vipin, Naidu, Garima, Sharma, Amit, Narula, Rahul, Bindra, Ritesh, Khera, Pankaj, Goel, Pooja, MONDAL, ARUP

Study on the Impact of Vehicle Pitch During Braking on Pedestrian Leg Injuries

2025-01-8741To be published on 04/01/2025

With the increasing prevalence of Automatic Emergency Braking Systems (AEB) in vehicles, their performance in actual collision accidents has garnered increasing attention. In the context of Active Emergency Braking (AEB) systems, the pitch angle of a vehicle can significantly alter the nature of collisions with pedestrians. Typically, during such collisions, the pedestrian's legs are the first to come into contact with the vehicle's front structure, leading to a noticeable change in the point of impact. Thus, to investigate the differences in leg injuries to pedestrians under various pitch angles of vehicles when AEB is activated, this study employs the Total Human Model for Safety (THUMS) pedestrian finite element model, sensors were established at the leg location based on the Advanced Pedestrian Legform Impactor (aPLI), and a corresponding vehicle finite element model was used for simulation, analyzing the dynamic responses of the pedestrian finite element model at different pitch

Hong, Cheng, YE, BIN, Zhan, Zhenfei, Liu, Yu, Wan, Xinming, Hao, Haizhou

A framework for modeling mechanically induced thermal runaway in lithium-ion batteries

2025-01-8134To be published on 04/01/2025

Battery safety is a paramount concern in the development of electric vehicles (EVs), as failures can lead to catastrophic consequences, including fires and explosions. Ensuring the reliability and robustness of lithium-ion cells under various conditions is essential for the widespread adoption of EVs. With the rapid global adoption of EVs, understanding how battery cells perform under extreme conditions such as mechanical or thermal abuse is crucial for ensuring safety. This study investigates the dynamic behavior of lithium-ion pouch cells under mechanical abuse conditions, focusing on improving safety measures in EV battery systems. Our research systematically examines the response of these cells at different states of charge (SOC), through controlled dynamic tests. These tests, which involve varying strain rates and punch geometries, offer significant insights into the mechanical thresholds that lead to cell failure. By analyzing the data, we gain a deeper understanding of the

Patanwala, Huzefa, kong, Kevin, Challa, Vidyu, Darvish, Kurosh, Sahraei, Elham

Optimization design of bow shaped component structure for tire scraping machine

2025-01-8294To be published on 04/01/2025

Utilizing the precision capabilities of SolidWorks software, an initial 3D digital model of the tire changer was constructed and then imported into Ansys for static structural analysis. By applying different meshing forms to the bow-shaped component of the tire changer and executing an exhaustive array of load simulation solutions, the total deformation and distribution of maximum principal stress of the bow-shaped component were obtained, enabling an assessment of its stress distribution and structural response under operating conditions.According to the results of the solution calculations, the total deformation and maximum principal stress distribution obtained from the hexahedral-dominated meshing method were nearly identical to those from the surface meshing method. Based on the finite element analysis results, structural optimization design was carried out on the initial 3D model of the tire changer, primarily by introducing reinforcing ribs and rib plates to enhance the

Zhu, Hengjia, Gao, Yunyi, Yao, Yanan, chao, wang

Aggressive Autonomous Control on Snow and Ice

2025-01-8040To be published on 04/01/2025

In cold and snowy areas, low-friction and non-uniform road surfaces make vehicle control complex. Manually driving a car becomes a labor-intensive process with higher risks. To explore the upper limits of vehicle motion on snow and ice, we use an existing aggressive autonomous algorithm as a testing tool. We built our 1:5 scaled test platform and proposed an RGBA-based cost map generation method to generate cost maps from either recorded GPS waypoints or manually designed waypoints. From the test results, the AutoRally software can be used on our test platform, which has the same wheelbase but different weights and actuators. Due to the different platforms, the maximum speed that the vehicle can reach is reduced by 1.38% and 2.26% at 6.0 m/s and 8.5 m/s target speeds. When tested on snow and ice surfaces, compared to the max speed on dirt (7.51 m/s), the maximum speed decreased by 48% and 53.9%, respectively. In addition to the significant performance degradation on snow and ice, the

Yang, Yiming, Bos, Jeremy P.

Using CAN Electrical Signals for Cybersecurity and Harness Diagnostics

2025-01-8080To be published on 04/01/2025

This paper describes a novel invention which is an Intrusion Detection System based on fingerprints of the CAN bus analogue features. Clusters of CAN message analogue fingerprints can be associated with each ECU on the network. During a learning mode of operation, fingerprints can be learnt with the prior knowledge of which CAN identifier should be transmitted by each ECU. During normal operation, if the fingerprint of analogue features of a particular CAN identifier does not match the one that was learnt then there is a strong possibility that this particular CAN identifier’s message is symptomatic of a problem. It could be that the message has been sent by either an intruder ECU or an existing ECU has been hacked to send the message. In this case an intruder can be defined as a device that has been added to the CAN bus OR a device that has been hacked/manipulated to send CAN messages that it was not designed to (i.e. could be originally transmitted by another device). It could also

Quigley, Christopher, Charles, David

Controllability and Driving Automation

2025-01-8679To be published on 04/01/2025

A key challenge for manufacturers of automotive systems, hardware components and software products with no contribution to driving automation is the stringent requirements imposed on elements while being integrated into vehicles with driving automation. The result is increased development cost and low reusability. For such elements or components with no contribution to driving automation, their functions and failure modes remain unchanged when comparing vehicle integration with and without driving automation. The influence of driving automation is not accounted for in the current approach of classifying risk while conducting a Hazard Analysis and Risk Assessment (HARA). Functional safety standards for on-road vehicles rely on human intervention as a parameter to classify risk. Since current safety standards for on-road vehicles are not inclusive of driving automation concepts, classification of risk, based on existing definitions of parameters such as controllability, leads to

Shah, Mihir, Ibarra PhD, Ireri

Modeling and Evaluation of FSAE Vehicle Cockpit Ergonomics

2025-01-8610To be published on 04/01/2025

This paper seeks to define an analytical approach to ergonomic design, utilizing RAMSIS software to create a driver model that considers the discomfort, fatigue, and force availability to evaluate cockpit designs that are produced from defined constraint inputs. The multifunctional model is applicable to various settings of vehicle design and is tuned toward proving performance in operation tasks, as well as setting the groundwork for a multi-variable optimization to determine the preferred driver controls positions for effort and fatigue pareto surfaces. Initial research done in the RAMSIS ergonomic software develops a collection of fatigue and joint discomfort data related to individual joint angles. Anthropometric data is compiled to show the proportional limb lengths from an individual’s sex and height percentile. The optimization function works by selecting a range of driver percentiles and creating random vehicle control positions within the bounds established. From this, each

Mayor, J.Rhett, Bezaitis, Megan, Oromi, Negar, Winters, Emily, Repp, Alex

Sensitivity Analysis of the Vehicle Dynamic Simulation Software Package Within Virtual Crash 5 Using Design of Experiments (DOE

2025-01-8693To be published on 04/01/2025

Previous papers have utilized a design of experiments (DOE) to evaluate the sensitivity of vehicle dynamics simulation of the postimpact motion of a vehicle that included high initial rotational rates. The previous papers analyzed four vehicle dynamic simulation softwares; HVE (SIMON and EDSMAC4), PC-Crash and VCRware, and applied the DOE to determine the most sensitive factors present in each simulation software. This paper will include Virtual Crash 5 into this methodology to better understand the significant variables present within this simulation model. This paper will follow a similar DOE to that which was conducted in the previous paper. 32 trials were conducted which analyzed ten factors. Aerodynamics, a factor included in the previous DOE, was not included within this DOE due to Virtual Crash 5 not accounting for that factor. The same three response variables from the previous DOE were measured to determine the effect of the various factors. These response variables are the x

Roberts, Julius, Civitanova, Nicholas, Stegemann, Jacob, Buzdygon, David, Thobe, Keith

Deformation Behavior and Springback Analysis of Anti-Collision Beam on Bending Forming

2025-01-8247To be published on 04/01/2025

Since aluminum alloys (AA) are widely used as structural components across various industries, higher requirements for shape-design, load-bearing, and energy-absorption capacity have been put forward. In this paper, we present the development of a numerical model, integrated with a compensation method, that effectively predicts processing defects in the anti-collision beam of a vehicle, resulting in a marked improvement in its forming quality. Specifically, different constitutive models are investigated for their applicability to the beam, enabling a precise evaluation of its structural performance under large deformation. The Johnson-Cook failure model is introduced to better characterize the fracture behavior of the beam under severe structural damage. The three-point bending experiment served as a rigorous examination, demonstrating good consistency between the experimental and simulation results. Furthermore, a prediction model for assessing the forming quality during the bending

Zhang, Shizhen, Meng, Dejian, Gao, Yunkai

Research on Torque Management Safety Monitoring Control for Hybrid Vehicles

2025-01-8579To be published on 04/01/2025

Hybrid vehicles are driven by the vehicle controller, engine controller and motor controller through torque control, and there may be unexpected acceleration or deceleration of the vehicle beyond the driver's expectation due to systematic failure and random hardware failure. Based on the torque control strategy of hybrid vehicles, the safety monitoring model design of torque control is carried out according to the ISO 26262 safety analysis method. Through the establishment of safety goals and the analysis of safety concepts, this paper conducts designs including the driver allowable torque design for safety monitoring, the driver torque prediction design for safety monitoring, the rationality judgment design of driver torque for safety monitoring, the functional safety degradation design and the engine start-stop status monitoring, enabling the system to transition to a safe state when errors occur. Among them, the design of the driver's allowable torque includes the allowable

Jing, Junchao, Wang, Ruiguang, Liu, Yiqiang, Huang, Weishan, Dai, Zhengxing

A study on affections of Different Skull-brain Interface Modeling Approaches on Intracranial Responses in Finite Element Analysis

2025-01-8733To be published on 04/01/2025

The mechanical behaviors of brain-skull interface are rather complex and difficult to understand, and various simplified connecting or contacting methods are usually used to simulate the interactions between the brain and skull in the current head finite element (FE) models. Considering the modeling approach of the brain-skull interface determines how loads are transmitted from skull to brain and affects on the intracranial brain responses, therefore, it is essential to study the affections of different brain-skull interface modeling approaches on intracranial brain responses and obtain an accurate load transmission mechanism to study brain injuries. In this study, the head FE model which is a part of the Advanced Chinese Human Body Models (AC-HUMs) is used and some modifications were made on the modeling method of the brain-skull interface in this head FE model. First, head FE model with several different brain-skull interface modeling methods including tied contact, shared nodes

Gan, Qiuyu, Junpeng, Xu, Jiang, Binhui, Zhou, Runzhou, Zhang, Liying

A Control Strategy for Height Adjustment in Closed-Loop Air Spring Suspension System

2025-01-8798To be published on 04/01/2025

This study investigates the closed-loop air spring suspension system by developing comprehensive models for both the air spring and its associated pipeline. To address issues such as "overcharging," "over-discharging," and significant overshoot during vehicle height adjustment, a threshold control strategy was developed. This strategy manages the trigger conditions for height adjustment to mitigate overshoot and precision problems. Experiments demonstrated that while this control strategy reduced overshoot and improved accuracy, it introduced the risk of excessive control due to varying threshold settings across different modules. To resolve this issue, a fuzzy PID controller was designed, utilizing fuzzy rules to adapt PID parameters in real-time, thereby enhancing height adjustment control. Testing confirmed that the fuzzy PID controller effectively resolved the issues associated with threshold control and also improved the rate of height adjustment. Furthermore, to prevent excessive

Zheng, Guoqing, Yin, Zhihong, Chen, Shiwen, Shangguan, Wen-Bin

Design of A Differential Braking Controller Based on Road Reaction Force Estimation to respond to Steering System Failure in Autonomous Driving Situations

2025-01-8797To be published on 04/01/2025

As the electrification of chassis systems accelerates, the demand for fail-safety strategies is increasing. In the past, the steering system was mechanically connected, so the driver could respond directly to some extent. However, the Steer-By-Wire system is composed of the column and rack bar as electrical signals, so the importance of response strategies for steering system failure is gradually increasing. When a steering system failure occurs, a differential braking control using the difference in braking force between the left and right wheels was studied. Recently, some studies have been conducted to model the wheel reaction force generated during a differential braking. Those studies linearly modeled the reaction force generated at the kingpin axis. Since actual tires and road surfaces are nonlinear and cause large model errors, model-based control methods have limited performance. Also, in previous studies assumed that the driver normally operates the steering wheel in a failure

Kim, Sukwon, Kim, Young Gwang, Kim, SungDo, Moon, Sung Jin

CAATS - Automotive Wind Tunnel Calibrations

2025-01-8762To be published on 04/01/2025

Wind tunnel calibration is necessary for repeatable and reproducible data for all industries interested in their output. Quantities such as wind speed, pressure gradients, static operating conditions, ground effects, force and moment measurements, as well as flow uniformity and angularity are all integral in an automotive wind tunnel’s data quality and can be controlled through appropriate calibration, maintenance, and statistical process control programs. The purpose of this technical paper is to (1) provide a basis of commonality for automotive wind tunnel calibration, (2) help customers and operators to determine the calibration standards best suited for their unique automotive wind tunnel and, (3) complement the American Institute of Aeronautics and Astronautics recommended practice R-093-2003(2018) Calibration of Subsonic and Transonic Wind Tunnels as specifically applied to the automotive industry. This document compiles information from various automotive wind tunnel customers

Bringhurst, Katlynn, Best, Scott, Nasr Esfahani, Vahid, Senft, Victor, Stevenson, Stuart, Wittmeier, Felix

Modeling and Prediction of Truck Tire Temperature Using Advanced Computational Techniques

2025-01-8758To be published on 04/01/2025

This paper explores the development of a Finite Element tire-road interaction thermal model for a Mixed Service Drive (MSD) truck tire sized 315/80R22.5. Physical experiments were performed at a high-speed track in Hällered, Sweden for a truck combination traveling at a constant speed of 80 km/h. For this investigation, the Gross Combination Weight is approximately 42 tons. In the Finite Element Analysis environment, ESI PAMCRASH, the truck tire is designed with hyperelastic Ogden solid rubber definitions. The Ogden material definition is used in this application as it is more suitable to perform thermal and wear analysis. The Finite Element truck tire model is designed to build up temperature through tire-road friction contact. The truck tire model simulates the thermal build-up over time for select tires on a High-Capacity transport truck combination, such as a tractor-semitrailer, particularly a free-rolling semi-trailer and dolly tire. Tire models over real-time in the FEA

Ly, Alfonse, Collings, William, El-Sayegh, Zeinab, El-Gindy, Moustafa, Johansson, Inge, Oijer, Fredrik

Applications of Advanced High-Strength Steels for Automotive Structures – Haulage Load body for EV

2025-01-8219To be published on 04/01/2025

To develop a Light weight Load body structure for Electric haulage vehicle application without affecting strength & durability of the product. Conventional haulage Load body given for diesel vehicle application weight is approximately 20% of vehicle Kerb weight. Payload carried by customer does not get affected much. Electric vehicle Kerb weight is comparatively higher than diesel vehicle, due to battery packs & its mounting structures. So the payload carried by customer is getting affected. Hence Load body weight must be reduced to 10-15% of Kerb weight. By considering past field failure data, customer loading pattern, durability trials & CAE static structural analysis, light weight Load body is designed with optimized sections & HSS material. To delight the customers, Number of Floor cross members & sideboard pillars not reduced which is their first impression before buying any haulage vehicle. Multiple iterations & design failure mode effective analysis was done before finalizing

Lakshminarayanan, Karthik

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

2025-01-8735To be published on 04/01/2025

With the widespread application of the Automatic Emergency Braking System (AEB) in vehicles, its impact on pedestrian safety has received increasing attention. However, after the intervention of AEB, the kinematic characteristics of pedestrian leg collisions and their corresponding biological injury responses also change. At the same time, in order to accurately evaluate the pedestrian protection performance of vehicles, the current assessment regulations generally use advanced pedestrian protection leg impactors (aPLI) and rigid leg impactors (TRL) to simulate the movement and injury conditions of pedestrian legs. Based on this, in order to explore the collision boundary conditions and changes in injury between vehicles and APLI and TRL leg impactors under the action of AEB, this paper first analyzes the current passive and active assessment conditions. Secondly, the simulation software LS-DYNA is used to build a finite element model of APLI and TRL impactor-vehicle collisions to

YE, BIN, Hong, Cheng, Wan, Xinming, Liu, Yu, Cheng, James, LONG, YONGCHENG, Hao, Haizhou

On the critical importance of physical modelling for the analysis of coastdown data

2025-01-8774To be published on 04/01/2025

Novel experimental and analytical methods were developed, with the objective of improving the reliability and repeatability of aerodynamic and road-load results derived from coastdown tests. The new methods were applied in the context of a coastdown test campaign conducted using a SUV and a tractor-trailer. Both vehicles had been tested in the NRC 9m Wind Tunnel, providing aerodynamic comparison-points. The rationale behind the novel techniques was to minimize the number of unknowns in the equation of motion by measuring directly the following parameters: axle mechanical resistance, rolling resistance at low speed and wheel-axle moments of inertia. This was achieved, respectively, by means of an axle-deceleration apparatus, a low-speed hauling facility and a wheel-oscillator developed for this study. In addition, the speed-dependence of tire rolling resistance was measured at a private laboratory, via rotating-drum tests, and modeled using a previously-validated exponential formulation

de Souza, Fenella, Tanguay, Bernard

Numerical Investigation of Gas Diffusion Layer Properties in PEMFC

2025-01-8314To be published on 04/01/2025

This study presents a comprehensive numerical analysis of the characteristics of the gas diffusion layer (GDL) in proton exchange membrane fuel cells (PEMFCs). Fuel cells are devices that generate electricity by reacting hydrogen with oxygen. Hydrogen supplied from a high-pressure tank reacts with oxygen within the fuel cell stack, generating electricity that drives a motor. Given the diverse design requirements for fuel cells, including applications in commercial vehicles and stationary systems, efficient material design through numerical models and simulations is indispensable. The GDL, composed of carbon fibers and resin, functions as a cushion under cell compression and facilitates the transport of electrons, heat, gas, and water. Its microstructure significantly influences these properties, making precise design crucial. In this study, we automated the material exploration by varying parameters such as the diameter and quantity of carbon fibers, as well as the amount and

Ota, Yuki, Dobashi, Toshiyuki, Nomura, Kumiko, Hattori, Takuya, Maekawa, Ryosuke

Residual Stress Analysis in Arc Welded Lap Joints of High Strength Steel Sheets and Welding Wire Using Material Properties at Heating and Cooling

2025-01-8313To be published on 04/01/2025

A technical approach is presented for the precise analysis of residual stress in arc welded lap joints of high strength steel sheets. This approach involves the development of a method to measure material properties during both the heating and cooling processes. The measured material properties are then utilized in a thermal elastic-plastic finite element method (FEM) to analyze the welding residual stresses in the lap joints. The analysis accuracy is investigated by comparing the results using material properties measured during heating, cooling, or both. The maximum temperature distribution on the surface of the heat affected zone (HAZ) is measured and accurately predicted through welding thermal conduction analysis. When the material properties measured on heating only or cooling only or both were, respectively, used in thermal elastic-plastic FEM, the analyzed results showed that the stress history in arc welded joints of 780MPa high strength steel sheets are different. The

Ohnishi, Yoichiro, Sato, Kentaro, Ma, Ninshu, Narasaki, Kunio, Weihao, Li, Yasuda, Koichi

Study on the Influence Mechanism of Camber and Load on the Linear zone of Tire Side-slip Mechanical Properties

2025-01-8274To be published on 04/01/2025

The linear region of the side-slip mechanical properties of tires is often used in the simulation of linear monorail models of vehicles, especially in the design of active control systems. Side-slip stiffness is a key parameter of the tire side-slip, and is significantly affected by camber and load. In the context of obtaining the virtual data of tires by finite element (FE) simulation, this paper studies the mechanism of the influence of camber on the linear area of tire side-slip mechanical characteristics based on the tire FE model, and also analyzes the influence of the load according to the asymmetric distribution of the load in the contact patch caused by camber. Firstly, the FE model of the tire is established with the design parameters and the accuracy of the model is verified. Secondly, three indexes which are load proportion, load utilization rate and contribution rate of side-slip stiffness are proposed, and the influence of camber on side-slip stiffness is quantitatively

Yin, Hengfeng, Suo PhD, Yanru, Wu, Haidong, Min, Haitao, Liu, Dekuan

Research on path tracking control of electric Towbarless aircraft taxiing system in crosswind condition

2025-01-8283To be published on 04/01/2025

An aerodynamic finite element model of King 350 aircraft is established, and the crosswind load of the aircraft under different wind characteristics is analyzed. A lateral dynamic model of the electric towbarless towing vehicle (TLTV) – aircraft system with TLTV rear wheel differential steering and front universal follower wheel is derived to investigate the effects of the crosswind on the aircraft towing trajectory, under different towing velocities and crosswind direction/strength. A Model predictive control (MPC) strategy is presented for the distributed TLTV rear-wheel vehicle speed control to compensate the disturbance of the crosswind on the aircraft traction. The proposed aircraft towing tracking method is simulated in Simulink-Adams environment. The result shows that the proposed control method has a good speed and path control performance

Zhu, Hengjia, Bai, Zehao, Xu, Yitong, Zhang, Wei

Dynamic Performance Optimization of Double-isolation rubber mounts Based on Neural Network and Genetic Algorithm Collaboration

2025-01-8266To be published on 04/01/2025

As a crucial connecting component between the powertrain and the chassis, the performance of rubber mounts is directly related to the NVH (Noise, Vibration, and Harshness) characteristics of electric vehicles. This paper proposes a double-isolation rubber mount, which, compared to traditional rubber mounts, incorporates an intermediate skeleton and features inner and outer layers of "cross-ribs". The design parameters can be simplified to: skeleton diameter, skeleton thickness, main rib width, and main rib thickness. To comprehensively evaluate its performance, a finite element analysis (FEA) model of the proposed double-isolation rubber mount was first established in Abaqus, with static stiffness and dynamic performance analyzed separately. The results indicate that, compared to traditional rubber mounts with similar static stiffness, this design effectively controls dynamic stiffness in the high-frequency range. To expand the effective vibration isolation frequency range of the

xu, che, Kang, Yingzi, tu, xiaofeng, shen, dongming

Fatigue strength of grey cast iron – new insights regarding the size effects

2025-01-8238To be published on 04/01/2025

Grey cast iron (GJL) is one of the oldest cast iron materials and is still in use in many applications in the automotive industry due to the good characteristics in relation to lubrication, heat conductivity and damping. Especially engine parts benefit from these parameters. Nevertheless, the design of these components has always been challenging in terms of maximizing material utilization for lightweight designs for components under cyclic loading. In particular, with regard to the influence of the statistical (component size), geometrical (notches) and technological (microstructural) size effects, the existing guidelines and literature lack the necessary information to provide a comprehensive understanding. Within a comprehensive study, different GJL materials have been investigated at Fraunhofer LBF to provide a more detailed information about the influence of size effects on its fatigue strength. Accordingly, a variety of specimen sizes, geometries, and microstructures were

Bleicher, Christoph, Kansy, Axel

Load-Deflection Evaluation of Bump Stoppers Using a Machine Learning Approach

2025-01-8208To be published on 04/01/2025

The accurate prediction and evaluation of load-deflection behavior in bump stoppers are critical for optimizing driving performance and durability in the automotive industry. Traditional methods, such as extensive experimental testing and finite element analysis (FEA), are often time-consuming and costly. This paper introduces a machine learning-based approach to efficiently evaluate load-deflection curves for bump stoppers, thereby streamlining the design and testing process. By leveraging a comprehensive dataset that includes historical test results, material properties, and geometrical dimensions, various machine learning models, including Neural Networks, were trained to predict load-deflection behavior with high accuracy. This approach reduces the reliance on extensive physical testing and simulations, significantly enhancing the design optimization process, leading to faster development cycles and more precise performance predictions. A case study is presented to demonstrate the

Hazra, Sandip, Tangadpalliwar, Sonali

Numerical Modeling of a Sandwich Structure Integrated with Shear Thickening Fluid (STF) for Impact Energy Absorption

2025-01-8745To be published on 04/01/2025

Shear Thickening Fluid (STF) exhibits tunable stiffness under varying loading velocities, making it an ideal candidate for energy absorption in transportation systems subjected to complex loading conditions, such as crash scenarios. Recent research highlights that integrating STF with conventional structures can significantly enhance overall energy absorption performance. In this study, we developed a novel sandwich plate by combining a newly designed bio-inspired 3D periodic structure with STF, aiming to create an advanced energy absorber. A finite element model of this system was developed and validated against experimental data. Using this numerical model, we conducted comprehensive impact simulations to investigate the effects of impact velocity and STF viscosity on key structural responses, including peak and mean stress, as well as energy absorption. The contributions of both the fluid and solid components were analyzed. Our findings indicate that the integrated structure

Zhu, Feng, Deb, Anindya

The influence of impact location and angle on the dynamic response of a large omnidirectional child dummy head and neck complex

2025-01-8740To be published on 04/01/2025

Head injuries are a common cause of fatality and long-term impairment in child occupants in motor vehicle crashes. The National Highway Traffic Safety Administration (NHTSA) has developed the Large Omnidirectional Child (LODC) Anthropomorphic Test Device (ATD) where the head was designed to match pediatric biomechanical impact response targets from previous literature. The purpose of this study was to compare experimental and computational results for eight impact directions at 45-degree increments around the LODC head under two levels of impact severity: low and high, corresponding to nominal velocities of 3.08 m/s and 5.42 m/s, respectively. The experimental setup consists of the LODC head and neck assembly rigidly attached to a circular fixture plate and a hemispherical-shaped impactor 76.2 mm in diameter. The acceleration and angular velocity responses were measured and computed from the LODC finite element (FE) head CG and compared against the experimental data. Experimental peak

Challa, Abhishikt, Noll, Scott, Hutter, Erin

A Modified Johnson-Cook Model Considering Strain-Temperature Coupling for Welding Simulation of Aluminum Alloy Bumper

2025-01-8243To be published on 04/01/2025

The metal inert-gas (MIG) welding technique employed for aluminum alloy automotive bumpers involves a complex thermo-mechanical coupling process at elevated temperatures. Attaining a globally optimal set of model parameters continues to represent a pivotal objective in the pursuit of reliable constitutive models that can facilitate precise simulation of the welding process. In this study, a novel piecewise modified Johnson-Cook (MJ-C) constitutive model that incorporates the strain-temperature coupling has been proposed and developed. A quasi-static uniaxial tensile model of the specimen is constructed based on ABAQUS and its secondary development, with model parameters calibrated via the the second-generation non-dominated sorting genetic algorithm (NSGA-II) method. A finite element simulation model for T-joint welding is subsequently established, upon which numerical simulation analyses of both the welding temperature field and post-welding deformation can be conducted. The results

Yi, Xiaolong, Meng, Dejian, Gao, Yunkai

Analysis of Frequency at Minimum Dynamic Stiffness for a Hydraulic Engine Mount with Floating Decoupler under high frequency excitation

2025-01-8264To be published on 04/01/2025

The primary functions of mounts include providing structural support, sound insulation, and vibration damping. Dynamic stiffness and phase angle are critical metrics for evaluating their NVH (Noise, Vibration, and Harshness) performance. This paper examines a floating decoupler hydraulic mount featuring a long decoupling membrane channel. A nonlinear lumped parameter model is developed to calculate the dynamic stiffness and phase angle. The model incorporates fluid flow in the lower chamber and variations in the support reaction force of the decoupling membrane under switching conditions. Parameters of the nonlinear lumped parameter model, including rubber stiffness, equivalent piston area, and volumetric compliance of the fluid chamber, were analyzed and calculated using the finite element method. The influence of different decoupling membrane channel structures on the frequency corresponding to the minimum high-frequency dynamic stiffness was investigated based on the established

Li, Shenghao, Zhang, Shenglan, Yu, Chao, Tu, Xiaofeng, Shangguan, Wenbin

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

2025-01-8621To be published on 04/01/2025

The proliferation of the electric vehicle (EVs) in the US market led to an increase in the average vehicle weight due to the integration of the larger high-voltage (HV) batteries. To comply with this weight increase and meet stringent US regulations and Consumer Ratings requirements, Vehicle front-end rigidity has substantially increased. This increased stiffness in the larger vehicles (Large EV pickups/SUVs) may have a significant impact during collision with smaller vehicles. To address this issue, it is necessary we consider adopting a vehicle compatibility test like EuroNCAP MPDB in North American market as well. This study examines the influence of mass across vehicle classes and compares the structural variations for each impact class. The EuroNCAP MPDB (Moving Progressive Deformable Barrier) protocol was referenced for this analysis. Our evaluation approach comprises of two sections: the impact of the barrier mass on to the vehicle structure (V2B) and vehicle-to-vehicle impact

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

High frequency finite element approach for structural components in automotive industry

2025-01-8636To be published on 04/01/2025

Typical CAE support in automotive industry is focused on using finite elements analysis to support vibrations and acoustics. The virtual methods have multiple advantages compared to physical test in terms of time to produce results and the cost of multiple iterations been assessed is lower in the CAE models. Particularly in vibrations finite element models have proved to be reliable to correlate with testing in the case of low frequencies. High frequencies are challenging for CAE predictions and low frequency models show a limitation to perform vibration analysis, the results usually tend to deviate from the testing. This investigation covers the work done with finite element models specially prepared to analyze high frequency vibrations of structural components in a body in prime

Alonso, Liliana, Alvarez, Ezequiel

Multi-objective optimization of the electric bus body frame based on the PSO-BP-MOMVO approach

2025-01-8652To be published on 04/01/2025

This paper focuses on the design optimization of a commercial electric bus body frame with steel-aluminum heterogeneous material orienting the performances of strength, crashworthiness and body lightweight. First, the finite element (FE) model of the body frame is established for static and side impact analysis, and the body frame is partitioned into several overall regions according to the thickness distribution of the components. The thickness of each region is regarded as the variable for the sensitivity analysis by combining the relative sensitivity method and the Sobol index method, and nine variables to which the performance indexes are more sensitive are selected as the final design variables for design optimization. Then the surrogate models are developed, and in order to improve the accuracy of the surrogate models, a model-constructing method called the particle swarm optimization BP neural network (PSO-BP) data regression prediction is proposed and formulated. In this method

Yang, Xiujian, Tian, Dekuan, Cui, Yan, Lin, Qiang, Song, Yi

Dynamic Tailgate Water Management Simulation Using Smoothed Particle Hydrodynamics

2025-01-8625To be published on 04/01/2025

Tailgate opening can cause rain that has settled on its surfaces to run off onto the customer or into the rear load space, causing annoyance. Relatively small adjustments to tailgate seals and encapsulation can effectively mitigate these effects. However, these failure modes tend to be discovered relatively late in the design process as they, to date, need a representative physical system to test – including ensuring that materials used on the surface flow paths elicit the same liquid flow behaviours (i.e. contact angles and velocity) as the production vehicle surfaces. In this work we describe the development and validation of an early-stage simulation approach using a Smoothed Particle Hydrodynamics (SPH) Code (PreonLab). This includes its calibration against fundamental experiments to provide models for the flow of water over automotive surfaces and their subsequent application to a tailgate system simulation which includes fully-detailed surrounding vehicle geometry. This approach

Gaylard, Adrian Philip, Weatherhead, Duncan

Validation of Elastomeric SLA Control Arm Bushing Fatigue Life Under Multi-Channel Road Load Input

2025-01-8235To be published on 04/01/2025

The rapid virtualization of engineering workflows for elastomer parts calls for the pairing of robust simulation capabilities with correspondingly thorough validation. Continuing prior work, which established a simulation workflow for simulating fatigue performance of elastomeric bushings operating under a full schedule of 6 channel (3 forces + 3 moments) road load histories, the present report presents the results of an experimental program comparing predicted and measured fatigue performances for an SLA control arm bushing. The experimental fatigue testing program was conducted on a servo-hydraulic 3 axis test rig. The rig was designed to provide radial (cross-car), axial (for-aft), and torsional inputs into the bushing. The test schedule was comprised of 11 virtual test track events. The individual events were run using remote parameter control playback of virtual road load data acquisition signals. Four bushings were operated under the subject loading schedule. Bushings were tested

Mars, WILL, Barbash, Kevin, Wieczorek, Matthew, Pham, Liem, Braddock, Scott, Steiner, Ethan, Strumpfer, Scott

Brittle or Ductile – or Both? The Role of Print Orientation on the Mechanical Properties of PLA Samples Built by Material Extrusion Additive Manufacturing

2025-01-8335To be published on 04/01/2025

The automotive industry leverages Material Extrusion (MEX)-based Additive Manufacturing (AM) to reduce lead time and costs for prototypes, rapid tooling, and low-volume customized designs. For effective design, the mechanical and physical properties of a material need to be known. This paper examines the impact of print orientation on the tensile properties of Polylactic Acid (PLA), selected for its ease of use and accessibility. Double-angle builds were included. Dog bone samples were designed to the ASTM D638 tensile testing standard and printed solid with a 0.2mm layer height, two outer walls, and a 45° raster-fill angle, with layers alternating by 90°. A nomenclature was developed to represent rotations around the X, Y, and Z axes. Testing was conducted on the MTS Criterion Model 43, 50 kN system. From the experimental stress-strain curves, the Young’s modulus, and yield, ultimate, and fracture stresses, in relation to build orientation, were extracted. Notable differences can be

Strelkova, Dora, Urbanic, Ruth Jill

A Review of Off-Road Datasets, Sensor Technologies and Terrain Traversability Analysis

2025-01-8339To be published on 04/01/2025

Autonomous ground navigation research and application has seen development and improvement in urban and structured environments with an increase in publicly available published datasets. However, autonomous ground navigating on off-road and unstructured conditions is still challenging due to the limited datasets, difficulties caused by environmental conditions, diverse terrain types and sensor limitations which affect vehicle perception. The recently available published public offroad datasets are presented here, integrated with the sensor technologies used and terrain traversability analysis and techniques. This study identifies the gaps in the existing datasets and examines the limitations of sensing technologies used and the challenges of terrain traversability analysis. In doing so, we suggest recommendations for creating more comprehensive off-road datasets incorporating advanced sensor technologies and refined terrain traversability analysis methods. The review provides

Musau, Hannah, Ruganuza, Denis, Indah, Debbie, Mukwaya, Arthur, Gyimah, Nana, Bhosale, Mayuresh, Patil, Ashish, Gupta, Prakhar, Mwakalonge, Judith, Jia, Yunyi, Grabowsky, David, Mikulski, Dariusz, Siuhi, Saidi, Hong, Jae

Light weight Haulage Load body for Sustainable Mobility applications

2025-01-8216To be published on 04/01/2025

To develop a Light weight load body structure for Electric haulage vehicle application without affecting strength & durability of the product. Conventional haulage load body given for diesel vehicle application weight is approximately 20% of vehicle Kerb weight. Payload carried by customer does not get affected much. Electric vehicle Kerb weight is comparatively higher than diesel vehicle, due to battery packs & its mounting structures. So the payload carried by customer is getting affected. Hence load body weight must be reduced to 10-15% of Kerb weight. By considering past field failure data, customer loading pattern, durability trials & CAE static structural analysis, light weight load body is designed with optimized sections & HSS material. To delight the customers, Number of Floor cross members & sideboard pillars not reduced which is their first impression before buying any haulage vehicle. Multiple iterations & design failure mode effective analysis was done before finalizing

Lakshminarayanan, Karthik

Mechanical property analysis of triply periodic minimal surface structure with a novel hybrid structure

2025-01-8215To be published on 04/01/2025

Triply periodic minimal surface（TPMS）structure, demonstrates significant advantages in vehicle design due to its excellent lightweight characteristics and mechanical properties. To enhance the mechanical properties of TPMS structures, this study proposes a novel hybrid TPMS structure by combining Primitive and Gyroid structures using level set equations. Following this, samples were fabricated using selective laser sintering (SLS). Finite element models for compression simulation were constructed by employing different meshing strategies to compare the accuracy and simulation efficiency. Subsequently, the mechanical properties of different configurations were comprehensively investigated through uniaxial compression testing and finite element analysis (FEA). The findings indicate a good agreement between the experimental and simulation results, demonstrating the validity and accuracy of the simulation model. For TPMS structures with a relative density of 30%, meshing with S3R elements

TANG, Haiyuan, XU, Dexing, SUN, Xiaowang, Wang, Xianhui, Wang, Liangmo, Wang, Tao

Electric Vehicle Drive Unit Power Losses and Efficiency Estimation: A Coupled 1D Analytical and 3D CFD Approach for High Fidelity Prediction

2025-01-8522To be published on 04/01/2025

This study presents a sophisticated approach to accurately estimating the power losses in the electric vehicle drive unit (e-DU) through a combination of 1D analytical models and 3D computational fluid dynamics (CFD). Understanding and accurately estimating these power losses is crucial for enhancing efficiency and range of electric vehicle (EV). The primary focus is on the types of power losses attributable to mechanical contact friction and oil drag within components such as gear meshes, bearings, and seals. The research specifically examines different analytical models for quantifying power losses due to gear mesh contact and bearing friction. These models were validated against experimental test data, allowing for a comprehensive understanding of their accuracy across a range of operational parameters. Additionally, the impact of oil properties and oil jet flow rates on power losses related to gear and bearing drag was analyzed using analytical methods and correlated with CFD

Motin, Abdul, Ganamet, Alain

Integrated design for body in white fabricated by additive manufacturing and its mechanical performance analysis

2025-01-8613To be published on 04/01/2025

With the development of additive manufacturing technology, the concept of integrated design has been introduced and deeply involved in the research of body design. In this paper, by analyzing the structural characteristics of the electric vehicle body, we designed a body in white with the additive manufacturing process, and analyzed its mechanical properties through finite element method. According to the structural characteristics of the body, the integrated structure was modeled in three dimensions using CATIA. For the mechanical properties of the body, the strength and stiffness of the body structure were simulated and analyzed based on ANSYS Workbench. The results show that for the strength of the body, the maximum stress of the simulation results was compared with the permissible stress, and the maximum stress was calculated to be less than the permissible stress under each working condition. For the body stiffness, the displacement of the body deformation was used to measure, and

Xu, Cheng, Zhang, Tang-yun, Wang, Tao, Wang, Liangmo, Cao, Can

Study on Ergonomic Design Optimization and NVH Characteristics of Baja Racing Car

2025-01-8612To be published on 04/01/2025

As a kind of off-road racing car, the driving condition of Baja is extremely bad. In order to allow the driver to control the vehicle well in complex working conditions, it is particularly important to provide a comfortable and convenient driving space and handling space for the driver. In this paper, firstly, RAMSIS is used to carry out the ergonomics verification of the racing car from the comfort analysis, reachable area analysis and visual field analysis, and optimize the design of the cockpit layout of the Baja racing car. Then the NVH characteristics of the Baja racing car frame are studied, and the 12-order modal results are obtained by finite element analysis and simulation. Then the natural frequency of the frame is measured by experiments, and the experimental results are verified to match the theoretical values. The research shows that the above steps can design a comfortable driving posture and operating space for the racer, and provide experience for the future layout of

Liu, Silang

Innovative Methods for Predicting Material Stress-Strain Curves Based on Transfer Learning and Artificial Intelligence

2025-01-8317To be published on 04/01/2025

The mechanical properties of materials play a crucial role in predicting performance across various applications. However, traditional methods for measuring these properties often involve complex, resource-intensive, and time-consuming tests, which may be impractical in certain situations. The Small Punch Test (SPT) is a small-sample detection technique for evaluating material mechanical properties, characterized by its "non-destructive" nature: applying localized loads to small specimen samples and measuring the resulting deformation. While SPT can obtain load-displacement curves for specimens, it cannot directly reflect material mechanical properties and relies on empirical formulas for estimation. To address this challenge, we designed a specialized SPT experiment and fixture, and established a Finite Element Method (FEM) model. We developed a multi-fidelity model capable of predicting the mechanical properties of steel and aluminum alloys, representing a novel machine learning

Zou, Jie, Li, Shanshan, Huayang, Xiang, Chen, Yechao

A data-driven synthetic population approach to estimate multi-noise lifetime durability loads for the sustainable design of electric vehicles

2025-01-8295To be published on 04/01/2025

Designing for the durability of motor vehicles requires accounting for various stress factors, including tractive loads, thermal loads, and structural loads. For electric vehicle propulsion systems, it's crucial to consider not just the magnitude of these loads but also their temporal sequence throughout the vehicle’s lifespan. The order and timing of these loads influence factors such as charge and discharge cycles, and active motor heating, which ultimately impact the damage to components like the cell and the inverter. Traditionally, lifetime loads for durability assessments are derived from a single user load profile that represents a cumulative damage equivalent to the desired warranty threshold. This profile is typically based on historical usage data, user scenarios, and industry experience but may not capture the diverse failure modes of different propulsion components. This approach also adds material mass, size, and capacity increasing lifecycle emissions, reducing

Ramakrishnan, Sankaran, khapane, Prashant

Image-based Machine Learning Methods in Materials Microstructure and Failure Analysis

2025-01-8324To be published on 04/01/2025

Image-based machine learning (ML) methods are increasingly transforming the field of materials science, offering powerful tools for automatic analysis of microstructures and failure mechanisms. This paper provides an overview of the latest advancements in ML techniques applied to materials microstructure and failure analysis, with a particular focus on the automatic detection of porosity and oxide defects and microstructure features such as dendritic arms and eutectic phase in aluminum casting. By leveraging image-based data, such as metallographic and fractographic images, ML models can identify patterns that are difficult to detect through conventional methods. The integration of convolutional neural networks (CNNs) and advanced image processing algorithms not only accelerates the analysis process but also improves accuracy by reducing subjectivity in interpretation. Key studies and applications are further reviewed to highlight the benefits, challenges, and future directions of

Akbari, Meysam, WANG, Andy, Wang, Qigui, Yan, Cuifen

Design and Optimization of a Novel Aluminum-Intensive Spaceframe-Based Electric Mailvan Prototype Driven by CAE

2025-01-8323To be published on 04/01/2025

Despite the known advantages of aluminum in terms of its lower density and comparable strength-to-weight as well as stiffness-to-weight ratios as those of steel, superior recyclability and high residual value, etc., there are only a handful of vehicles in global markets, mostly outside the reach of the common man, made primarily of aluminum. As cost of material and joining of parts is a deterrent in large scale adoption of aluminum as a material of choice for vehicle body design, a novel architecture is necessary for minimizing weight, maximizing performance and lowering cost of tooling. Additionally, a lightweight vehicle cannot be behind in terms of crash safety compared to its predominantly steel body-based counterparts. With these objectives in mind, a novel aluminum-intensive electric mailvan based on a spaceframe body architecture comprised mainly of low-cost extrusions has been designed and prototyped primarily driven by CAE. The design methodology consists of selective testing

Deb, Anindya, Karthika, M R

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