Browse Topic: Analysis methodologies

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Structural Redesign and Functional Integration of an Electrohydraulic Brake Valve for Enhanced Performance and Manufacturability2026-28-0002To be published on 02/12/2026
The Electrohydraulic Brake Valve (EBV) is a critical component in full-power brake systems, particularly in heavy-duty and off-highway vehicles, where precise braking control and system reliability are paramount. This paper presents a comprehensive cost and weight optimization initiative focused on the EBV housing, which currently accounts for approximately 75% of the total assembly weight due to its bar-machined construction. The project involved a complete redesign of the EBV housing with the dual objective of reducing mass and enhancing functionality. Key improvements include the integration of sensor ports for real-time pressure monitoring, a dedicated provision for nameplate mounting to support customer traceability, and a transition to a cast-based design optimized through advanced core modeling. Material substitution and structural simplification were explored to further improve manufacturability and cost-efficiency. Finite Element Analysis (FEA) was employed to validate the
R, Thangarajan
Parameter Optimization for Improved Surface Finish in WAAM-Fabricated Steel Structures2026-28-0023To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is a cost-effective and scalable metal additive manufacturing technique widely used for fabricating large metallic components. However, surface finish remains a critical challenge, especially for structural applications where post-processing needs to be minimized. This study focuses on optimizing key process parameters to improve the surface finish of ER70S-6 steel structures fabricated using the WAAM process. Experiments were designed using a statistical approach to systematically vary parameters such as wire feed rate, travel speed, voltage, and inter-pass cooling time. Surface roughness was measured using standard metrology tools, and the results were analyzed to identify the most influential parameters. An optimized parameter set was proposed based on the experimental outcomes, leading to a significant reduction in surface roughness without compromising the structural integrity of the deposited material. The findings contribute to enhancing
PN, Vani
Statistical Modeling of Wire Arc Additive Manufacturing Parameters Using Regression Analysis2026-28-0024To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is gaining prominence for fabricating large metal components due to its high deposition rate and cost-effectiveness. However, the quality and performance of WAAM-fabricated parts are strongly influenced by process parameters such as wire feed rate, travel speed, arc voltage, and current. This study presents a statistical modeling approach using regression analysis to predict the effects of these key parameters on critical output responses, including bead geometry, surface roughness, and material deposition rate. Experiments were designed using a structured methodology, and the collected data were analyzed to develop linear and multiple regression models. The accuracy and reliability of the models were evaluated using statistical metrics such as R² and p-values. The results demonstrate that regression-based models can effectively predict WAAM outcomes, enabling process optimization and quality control. This approach provides a valuable tool for
Pasupuleti, Thejasree
Statistical Optimization of Wire Arc Additive Manufacturing Parameters Using Taguchi Methodology2026-28-0035To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is an emerging metal additive manufacturing process known for its high deposition rates and cost-effectiveness in fabricating large-scale components. However, the quality of the final build is highly sensitive to process parameters such as wire feed rate, travel speed, voltage, and current. In this study, the Taguchi method is employed to statistically optimize key WAAM process parameters with the aim of improving surface finish and mechanical integrity of the deposited parts. An L9 orthogonal array was used to design experiments, and signal-to-noise (S/N) ratios were analyzed to identify optimal parameter settings. Analysis of variance (ANOVA) was performed to determine the significance of each factor on the selected output responses. The results demonstrated that specific combinations of process parameters can significantly reduce surface roughness and enhance bead geometry. The optimized settings obtained through the Taguchi approach provide a
PN, Vani
Modelling and Analysis of Complex Shaped Cracks2026-28-0048To be published on 02/12/2026
This study offers a thorough analysis using finite element methods (FEA) to examine how fatigue cracks grow in three different materials: Structural steel , Titanium alloy (Ti Grade 2), and epoxy/aramid-based printed circuit board (PCB) laminates. Using ANSYS Workbench, we ran simulations under both static and repeated loading to understand how these materials fracture. The approach was based on Linear Elastic Fracture Mechanics (LEFM), employing the Maximum Circumferential Stress Criterion to predict where cracks might start and how they could spread. Also, the Equivalent Domain Integral (EDI) method helped us calculate the Stress Intensity Factors (SIFs) when cracks are under mixed loading modes. We modeled the growth of fatigue cracks using the Paris Law, relying on material-specific constants (C and m) drawn from previous studies and experimental tests. For example, titanium Grade 2 showed Paris Law constants with C values between 1.8 × 10⁻¹⁰ and 7.9 × 10⁻¹² m/cycle, and m values
T, LOKESH, Bhaskara Rao, Lokavarapu
Evolution of a Novel Hybrid Stab-Link for a Born Electric Sports Utility Vehicle2026-28-0001To be published on 02/12/2026
The present study details the design evolution and failure analysis of a novel hybrid stabilizer bar link (stab link) developed for the front suspension of a born electric sports utility vehicle (SUV) platform characterized by higher gross vehicle weight (GVW), increased wheel travel, and constrained packaging space. To address these challenges, a unique hybrid stab link was designed featuring dual plastic housings at both the metal ball joint ends, connected by a steel tube, and achieving a 30% weight reduction while offering enhanced articulation angles for extremely lower turning circle diameter (TCD) of the vehicle, compared to the conventional stab link. The unique hybrid stab failed under complex loading conditions during accelerated durability testing (ADT), prompting a comprehensive investigation. The failure analysis included road load data acquisition across various stab bar diameter configurations evolved during suspension tuning, different stabilizer link designs evolved
SELVENDIRAN, P, J, Ramkumar, NAYAK, Bhargav, M, Sudhan, Patnala, Avinash
Multi-Objective Optimization of WAAM for Sustainable Production of Automotive-Grade Components2026-28-0030To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) has emerged as a promising technology for fabricating large-scale metal components with reduced material waste and lead time, aligning with the goals of sustainable manufacturing. This study presents a multi-objective optimization approach for WAAM to enhance both the manufacturing efficiency and sustainability of automotive-grade components. Key process parameters such as travel speed, wire feed rate, and current were systematically varied to evaluate their impact on dimensional accuracy, mechanical performance, and energy consumption. A statistical design of experiments framework was employed, and multiple performance objectives were optimized simultaneously using suitable decision-making techniques. The results demonstrate that optimized WAAM settings not only meet structural and functional requirements for automotive applications but also contribute to material and energy savings. This approach supports the integration of sustainability into
Pasupuleti, Thejasree
Vibration Analysis of Rectangular and Circular Plates with Fixed Edges: Analytical and Computational Validation2026-28-0108To be published on 02/01/2026
This research is intended to comprehend the vibration response of two types of flat plates, rectangular and circular, when all their boundaries are constrained and they are in free vibration. These structures are common in aerospace components, mechanical enclosures, and civil structures where vibration parameters like natural frequency and mode shape decide their performance and reliability. We used three methods to research this: classical analytical models in terms of plate theory and Bessel functions, numerical analysis in ANSYS APDL, and Python customized code to model the theoretical calculations and show the vibrational response. The Python code computed the first 10 natural frequencies and plotted mode shape plots, which correlated well with analytical values at low modes and were useful in assessing where analytical models start deviating. For rectangular plates, analytical and simulation convergence was strong for the first mode with less than 1% deviation, but the deviation
N, Suhas, R, Sanjay, Bhaskara Rao, Lokavarapu
Design and Analysis of Fixtures for HMC – HSX 8602026-28-0096To be published on 02/01/2026
Fixtures are used for holding the work piece to avoid misalignment and to achieve maximum accuracy in manufacturing. Complex work pieces of the pump such as liquid head, hydraulic manifold, gearbox require fixture. These components are manufactured in VMC (Vertical Machining Center) as well as in HMC (Horizontal Machining Center) and so to avoid loading and unloading time fixtures are designed as per the requirements. To design optimum fixture finite element analysis is to be done considering the machining procedure of the components. Cutting forces and clamping forces are taken into consideration during analysis. Analysis is carried out at different tool positions to calculate the maximum deformation occurred. Keywords: Fixture, clamp, cutting force, clamping force, Machining Center
Kshirsagar, Swapna, Bhaskara Rao, Lokavarapu
Methodology for Shower Water Management in Electric Car Applications2026-28-0068To be published on 02/01/2026
All automotive vehicles with enclosed compartments must pass the Shower test standard - IS 11865 (2006). One of the most severe and critical areas of water leakage is “Water entry into HVAC opening”. Excess water flow in high-pressure conditions and seepage during long-time low-pressure conditions could potentially have a significant impact on water entry inside the HVAC suction cutout and subsequently into the cabin. The study clearly indicates that for making leak proof HVAC opening (suction interface), it is crucial for the structure of BIW Plenum, Trim Applique and its sealing components to be robust enough to effectively collect and divert the water during shower test condition. This robustness is necessary to ensure leakage prevention thru HVAC cutout in varying rain scenarios during customer usage of the vehicle. A systematic approach is followed for assessing leak tightness of the HVAC area. 1. CFD simulation performed to verify the flow path of water during shower test. It is
Gunasekaran, Mohanraj, NAMANI, Prasad, Ramaraj, Rajasekar, Junankar, Ashish, Raju, Kumar
Efficient Multi-Parameter Optimization of a Twist Beam Rear Axle for Electric Vehicles using TOPSIS method for Durability2026-28-0067To be published on 02/01/2026
This study investigates the parameter optimization of a Rear Twist Beam (RTB) for an electric vehicle (EV) during the early stages of product development. Adapting the RTB design from a current Internal Combustion Engine (ICE) vehicle platform presents a complex challenge: accommodating increased rear vehicle load while minimizing cost and maintaining existing rear hard points. To address this, a Computer-Aided Engineering (CAE)-driven optimization using the Taguchi method was employed, avoiding costly physical durability tests. The key design parameters considered were the thickness and material grade of the RTB's child parts: the cross beam, trailing arms, and reinforcements, while preserving their original shapes. An L8 orthogonal array was utilized to efficiently evaluate the influence of these parameters on durability performance, and the optimal combinations for maximizing durability were identified. Furthermore, an Analysis of Variance (ANOVA) was conducted to quantify the
Madaswamy, Arunachalam, Dhanraj, Sudharsun, Govindaraju, Karthik, Lokaiah, Srinivasan
Common Mode Voltage Reduction in Quasi-Z Source Inverter for Electric Vehicle Applications Using MBPWM Technique2026-28-0102To be published on 02/01/2026
Unlike traditional voltage source or current source inverters, ZSI/qZSI can boost and invert DC power in a single stage, making them attractive for applications like EVs where battery voltage may vary. Common mode Voltage (CMV) is the voltage between the neutral point of the motor and ground. High CMV in motor drive systems can cause: Higher leakage currents, Electromagnetic interference (EMI), Insulation stress, bearing currents, leading to premature motor failure. Reducing CMV is essential for reliable and safe EV operation. Pulse-width modulation (PWM) is used to control the QZSI output voltage. The QZSI offers several advantages over traditional inverters, including improved efficiency, reduced cost, and increased reliability. The proposed system is designed to reduce the CMV through a combination of passive LC filtering and shoot-through (ST) modulation techniques. The LC filter is designed to attenuate high-frequency components of the CMV while the ST modulation is used to
N, Kalaiarasi, R, Rajarajeswari, D, Anitha
Surrogate modeling for faster assessment of thermal performance and reliability of discrete packaging in power electronics2026-28-0100To be published on 02/01/2026
The thermal performance and reliability of discrete packaging in power electronics are critical due to miniaturization and high-density packaging. Optimizing solder joint design is essential to mitigate thermo-mechanical fatigue, a primary failure mechanism caused by repeated thermal cycling in power switching applications like MOSFET packages. This cycling leads to uneven expansion and contraction among materials, potentially resulting in cracks that impair heat dissipation or cause delamination. While physics-based finite element modeling (FEM) is effective for predicting solder joint lifetimes, it can be resource-intensive and slow during the conceptual design phase, where rapid decision-making is crucial. This paper introduces a surrogate modeling approach to deliver faster, data-driven solutions in early design stages. By employing a finite element-based virtual design of experiments (VDoE), the study analyzes multiple design parameters, such as thermal interface material (TIM
Naga Satyakrishna, Vinjamuri, Baikadi, Pawan Rao, Gromala, Przemyslaw
Genetic algorithm based optimization of Chaboche kinematic hardening parameters along with the validation of FE model through characterized crack initiation2026-28-0086To be published on 02/01/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a low voltage (LV) connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for thermo-plastic composite material Ultramid A3U44G6, we have adopted a novel approach of determining non-linear Chaboche Kinematic Hardening (CKH) model parameters from monotonic uniaxial temperature dependent tensile test data of Ultramid A3U44G6. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for Ultramid A3U44G6, here von Mises yield
Basu, Parichay
Tractor Cabin Structure Borne Noise Reduction in the Virtual Environment2026-26-0101To be published on 01/16/2026
In recent days, cabin variants in the tractor are preferred by the farmers for the Coziness and longer field hour operation with less fatigue. Noise perceived by customer is the most important factor taken into account during the design stage, as it’s directly linked with operator’s comfort. Observed noise levels has to be within the defined limits as per national/international standards Overall cabin noise levels is contributed by the structure borne noise below 630 Hz. Structure borne noise is the noise typically radiated by the door, roof, windshield, floor, fender and structure assembly due to the engine excitation through the transmission housings and backstories. This paper depicts the process of tractor cabin structure borne noise prediction in the virtual environment. Firstly, Engine bearing loads and axle bearings has been extracted in the virtual stage from the vehicle level driveline model using commercially available MBD software. The finite element (FE) model of the cabin
Qunasekaran, Pandiyanayagam, K, Somasundaram, Chavan, Amit
Optimizing rattle behaviour in metal-plastic interfaces for EV tail lamp assemblies2026-26-0332To be published on 01/16/2026
The seamless and sleek design of connected tail lamps adds a visually striking element to the car's exterior. It aligns with contemporary automotive trends and gives the vehicle a premium and futuristic appearance. Automakers use these lamps as a design signature to establish brand identity. Connected tail lamps improve visibility for drivers behind the vehicle. The assembly of connected tail lamps can pose several challenges, especially due to their complex design and integration requirements. Metal-plastic creak is a common concern in electric vehicles (EVs), often noticeable when driving on uneven roads. This primarily results from stick-slip behaviour at the interface of metal and plastic components, intensified by improper alignment. When the designed geometric dimensioning and tolerancing (GD&T) is not met in real manufacturing conditions, misalignment introduces unintended contact forces, leading to intermittent micro-sliding and frictional energy release, which manifests as an
Michael Stephan, Navin Estac Raja, C M, MITHUN, Mohammed, Riyazuddin, R, Prasath
Multiphysics Simulation Approach for Evaluating Thermo-structural Performance of Electric Motors Using Spatial Electromagnetic Loss Mapping2026-26-0387To be published on 01/16/2026
High power and torque density electric motor is finding increasing demands in modern-day electric and hybrid vehicles because of compact and light-weight designs. These high-performance requirements are achieved by increasing the current flow, strengthening the magnetic field as well as downsizing the motor dimensions and hence can lead to multiple failure modes if not designed properly. Higher current flow results in increased magnitude of losses within the motor components such as ohmic loss, iron loss, hysteresis loss and mechanical losses. All these localized losses contribute to higher operating temperature and temperature gradient that can act as a catalyst to several modes of failure. Hence, accurate prediction of temperature distribution across the motor components is very crucial to come up with a robust and durable motor design. A common approach of predicting component temperature is by assuming bulk losses for lamination stack, hairpin and magnets. This approach might be
Munshi, Irshad Ahmed, Elango, Gokul, Karmakar, Nilankan, Prasad, Praveen
Implementation of new educational technologies for training personnel for the transport industry2026-26-0241To be published on 01/16/2026
Today's challenges affect the system of training highly qualified personnel for the transport industry, which is actively transforming through the introduction of innovative educational technologies. Key areas have become digitalization of the educational process, integration of virtual simulators, augmented reality technologies (AR/VR) and platform solutions for managing educational programs. Today, transport education in Russia is focused on advanced training of specialists capable of working with autonomous transport and neural network solutions. Development prospects are associated with further integration of adaptive educational trajectories and global network platforms to ensure the competitiveness of graduates in the digital economy. Taking into account the specifics of the modern Russian transport industry, using an analytical method, the article examines solutions to some priority problems, namely: • Methods of modernizing educational programs through designing «professions of
Shishanov, Sergei, Kurmaev, Rinat, Revenok, Svetlana
A Novel Approach to Deep Drawing Using Hybrid System and Pneumatic-Assisted Forming2026-26-0301To be published on 01/16/2026
ABSTRACT: This paper presents a novel Plunger-Integrated Hybrid System aimed at enhancing the efficiency and performance of deep drawing operations in metal forming processes. The proposed hybrid system strategically combines the mechanical strength of metals with the elastic flexibility of polymers, specifically polyurethane rubber, to improve formability and reduce spring-back, two critical challenges in conventional sheet metal forming. A novel two-stage forming technique is employed, an initial drawing operation using a larger radius with polyurethane rubber, followed by final radius formation using the same rubber in conjunction with a pneumatic cylinder. This integrated approach ensures uniform force distribution via the embedded plunger, significantly minimizing forming defects and enhancing the dimensional accuracy of the final components. The solution has been validated using Finite Element (FE) simulation methods, confirming its capability to produce high-quality parts
Chava, Seshadri Reddy, Singh, Prakhar, Dhanajkar, Narendra, Roy, Amlan, Raju, Gokul
Integrated Evaluation of Pre-Crash Braking and Crash Injury Outcomes Using Human Body Models and ATDs2026-26-0019To be published on 01/16/2026
Traditionally, vehicle occupant safety research has focused on passive safety aspects like crashworthiness and occupant restraint systems. However, with the advent of Active Safety technologies such as Forward Collision Warning (FCW) and Autonomous Emergency Braking (AEB), research has expanded to include occupant kinematics during the pre-crash phase. AEB, by inducing occupant movement, often leads to out-of-position (OOP) behavior, compromising available space during the crash phase. Current Anthropometric Test Devices (ATDs) are limited in simulating occupant kinematics during the pre-crash phase, especially in the neck and torso regions. These devices are rigid and unable to replicate human body dynamics during low-acceleration events like AEB. To address this gap, Human Body Models (HBMs) such as THUMS, GHBMC, and SAFER are used to provide more biofidelic simulations. This study begins with physical vehicle trials conducted with human volunteers at various speeds to measure
Pendurthi, Chaitanya Sagar, THANIGAIVEL RAJA, T, Kondala, Hareesh, Sudarshan, B.Sudarshan, Nehe, Vaibhav, Rao, Guruprakash
Rear Wiper Motor with Nozzle Integration for Improved wiping performance and Perceived Quality2026-26-0600To be published on 01/16/2026
In the current modern days of driving, rear wiping performance plays a crucial role in safe driving. This study focuses on improving the rear wiping with add on benefits like improved BSR performance, cost saving and perceived quality. This new concept has the rear wiper motor assembly which accommodates the nozzle also thereby making it a single unified assembly with reduced system complexity. This concept eliminates the complex hose routing of washer system for rear wiping which is usually packaged at spoiler or HMSL. It also helps in improved spray coverage and reduced dry wiping which in turn enhances system reliability with clean & quiet operation. This integrated nozzle concept is much more compact than the available products in the market with minimum number of end items. Also, this design comes with non-return valve which ensures there is no delay in the spray execution. And it improves the cleaning efficiency by maintaining consistent fluid pressure. This concept comes with
Dhage, Prashant, K, Nagarajan, G, Sabari Rajan
Thermo-Mechanical Fatigue Assessment of Cylinder Heads Using Advanced Simulation Techniques2026-26-0465To be published on 01/16/2026
Thermo-mechanical fatigue (TMF) is a critical durability concern for cylinder heads in internal combustion engines, particularly under severe cyclic thermal and mechanical loads. TMF-induced damage often initiates in geometrically constrained regions with high thermal gradients and can significantly reduce component life. As performance demands increase, understanding and mitigating TMF becomes essential to ensure the structural integrity and long-term reliability of engine components. This study presents a simulation methodology for evaluating thermo-mechanical fatigue (TMF), a temperature-dependent low-cycle fatigue (LCF) mechanism that arises from repeated thermal expansion and contraction under mechanical constraints, leading to cyclic plastic deformation and damage. The methodology consists of two key phases. Phase I involves global finite element (FE) simulations—both thermal and structural—to obtain temperature and displacement fields under rated and idle engine conditions
Ghotekar, Sunil, Kumbhar, Dipak Madhukar, Pendse, Ameya
A Data-Centric Approach to Identify Optimal NVH simulation Tools and Solvers2026-26-0356To be published on 01/16/2026
The world is rapidly evolving towards a data-driven paradigm, with widespread adoption of tools and techniques such as Artificial Intelligence, Machine Learning, Digital Twins, and Cloud Computing. In the automotive sector, vast amounts of data are being generated through both physical and digital test evaluations. Among these, Computer-Aided Engineering (CAE) stands out as one of the largest contributors to data generation, as physical testing is often cost-prohibitive due to the need for prototypes and complex test setups. The field of Automotive Noise, Vibration, and Harshness (NVH) is advancing exponentially, driven by stringent regulatory norms and growing customer demand for comfort. Digitally advanced techniques are playing a pivotal role in revolutionizing NVH processes. Data generation via CAE tools has become an integral part of engineers' daily operations, with the selection of appropriate CAE software and solvers being critical. This choice impacts factors such as user
Hipparge, Vinod, Masurkar, Nikita, Arabale, Vinand, Billade, Dayanand
Accurate Component Load Prediction with Hybrid Test – FEA Approach.2026-26-0366To be published on 01/16/2026
Knowing accurate loads acting on the structure is still a main pain area for analyst. Accurate fatigue analysis through FEA is still a difficult task because of uncertainties associated with component load profile. Even for known duty cycle, approximation involved in measurements and load cascading techniques (MBD simulation models) put limits on accuracy of component load prediction. Small error in loads can lead to very large error in fatigue life calculations. Various researches proposed various innovative alternate means for accurate component load prediction and published in literature over past few decades. Author has explored and developed hybrid Test-FEA approach to estimate component loads based on robust strain-load transformation and pseudo inverse technique. This approach is based on effective use of strain transformations along with accurately measured strain data to calculate accurate load histories. The accuracy of load estimates depends upon number of factors such as
Pratap, Rajat, Apte, Sr., Amol, Babar, Ranjit
Value-Engineered Design Optimization of a Reinforced Plastic Bracket to Meet Natural Frequency Targets in Passenger Vehicles.2026-26-0355To be published on 01/16/2026
The transition from metal to plastic in the design of engine mount brackets marks a pivotal step toward sustainable and value-driven automotive engineering. This study investigates the optimization of plastic engine mount brackets, focusing on material selection, structural performance, and alignment with NVH (Noise, Vibration, and Harshness) targets. Recycled polymer composites were chosen for their favorable mechanical properties, environmental resilience, and contribution to circular economy goals. The primary objectives were weight reduction, cost-effectiveness, and manufacturability, without compromising structural integrity or long-term durability. A combination of Finite Element Analysis (FEA), CAE-based durability simulations, modal analysis, and comprehensive vehicle-level validation was conducted to assess dynamic performance. Results demonstrated that the optimized plastic brackets not only satisfy critical natural frequency and durability requirements but also offer a
Hazra, Sandip, Gupta, Deepak, Khan, Arkadip, Gite, Yogesh
Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly2026-26-0302To be published on 01/16/2026
This research paper investigates the failure of an isolator clip used in the seat slider assembly, which guides and restricts the sliding motion of the tooth bracket within the seat. The component is made of C80 high-carbon spring steel, known for its high strength. According to the manufacturing process details, zinc plating was applied to the component for corrosion protection, as confirmed by EDS analysis. A fractographic examination of the failed part revealed a brittle, intergranular fracture morphology with visible cracks. Certain areas also exhibited micro-void coalescence, indicating a dimpled fracture surface. The primary failure mode was intergranular (IG) fracture. The delayed fracture was attributed to intergranular fracture mechanisms, micro-void coalescence, and the high strength of the steel, which made the component susceptible to hydrogen embrittlement. Hydrogen embrittlement occurs when hydrogen atoms become trapped along the grain boundaries, where they form hydrogen
Saindane, Mehul Kishor, Bali, Shirish
Vibration modelling of high-pressure fuel lines driven by pressure pulsation.2026-26-0319To be published on 01/16/2026
When the flow of fluid within a high-pressure line is abruptly halted, pressure pulsations are generated. This phenomenon is known as the water hammer effect. This may lead to significant stress and, in the worst-case scenario, result in various types of failures within the highly pressurized system. Similar issue is observed in diesel high pressure fuel line where pressure is well above 1600 bar. Due to multiple injection on off event, pressure pulsation gets created inside high pressure fuel lines (HPFL) which leads problems such as high strain on high pressure fuel lines, mechanical damage, uneven fuel injected quantity, vibration beyond specification limits for rail pressure sensor or in worst case extreme noise. Due to pressure pulsation, fluid will have its own natural frequency, and resonance occurs when it interacts with structural frequency. In this work, A comparative FEA analysis is conducted to evaluate strain in two distinct high-pressure fuel lines, with pressure
Bawache, Krushna Ramesh, Sethy, Girija Kumari
Evaluating the Suitability of ADC12 for Sand Casting: Filling, Solidification, and Mechanical Properties2026-26-0296To be published on 01/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Singh, Gajendra, Doddamani, Mrityunjay
Numerical Investigation of Cowl Water Drainage in Automotive Design2026-26-0393To be published on 01/16/2026
Motivation Improper drainage of cowl water (accumulated at the base of the windshield) leads to critical issues in automotive design. Early-phase evaluation of drainage efficiency is critical to avoid costly late-stage design revisions and warranty issues. Traditional physical testing methods are often time-intensive, costly and limited in scope. Therefore, leveraging simulation-driven optimization enables proactive prediction of failure modes and accelerates robust design validation. The Problem Inadequate cowl drainage causes: 1. HVAC system degradation due to moisture ingress (mold growth, blower motor failure). The accumulated water can also enter the cabin. 2. Rust and corrosion in the cowl panel, windshield frame, and adjacent electronics due to accumulation of stagnant water Methodology We investigated multiple design strategies to enhance cowl drainage performance. The following approaches were studied by using STAR-CCM+: 1. Multiphase volume of fluid (VOF) Simulation - To
Mathew, Ronnie, Ibrahim, Sayyaf, Nikumbh, Nayan
Comprehensive Technology Framework for effective and early leveraging of test assets2026-26-0527To be published on 01/16/2026
The automotive industry is going through a tremendous technological change and its impact on the way we test the functionalities that we offer to the end consumer is continually evolving. This includes the ever-growing need to embed software-based functions to support more and more end user functionality, while at the same time retaining existing and well-established functions, all within short development timelines. This presents both opportunities and challenges, with greater potential for reuse or leverage of test assets, although the actual percentage of leverage on real world projects is practically less than anticipated for a multitude of reasons. As part of paper, we collate the various factors which effect the practical leverage of test assets from one project to another, including various workflows and the interaction across components amongst applications lifecycle management systems. Through this paper, we would describe the current practices of basis analysis in isolation
Venkata, Parameswaran, Kulkarni, Apoorva, RAJARAM, Saravanan, Ganesh, Chamarthi
Conceptual Crash Analysis in Automotive Applications with Reduced Computational Effort2026-26-0451To be published on 01/16/2026
In the realm of automotive safety engineering, the demand for efficient and accurate crash simulations is ever-increasing. As finite element (FE) modeling of components becomes increasingly detailed and the availability of advanced material models improves, crash simulations for full vehicles can become time-consuming. Evaluating the crash performance of any vehicle subsystem requires full vehicle simulations at the industry level, which are complex and time-consuming. This paper introduces a novel methodology for replicating full vehicle crash simulations using Principal Component Test (PCT) cut-model level. Adapting PCT simulations, a significant reduction in computational time and resource usage is achieved, thereby optimizing CPU cluster performance. The proposed method has been successfully implemented across various crash load cases, including frontal 100 percent overlap, 40 percent overlap, small overlap crash, side impact, rear impact, underbody impact and low speed impact
Moncayo, David, Malipatil, Anand, Prasad, Rakesh, Kunnath, Allwin
Analysis of Engagement Probability for Dog Clutch Geometry Parameters in Heavy-Duty Automated Mechanical Transmissions.2026-26-0437To be published on 01/16/2026
This study presents a simulation-based approach to estimate the dog clutch engagement probability maps under different vehicle operating conditions. The developed probability function incorporates multiple critical parameters including initial speed differential between engaging components, application of countershaft brake, number of tooth in dog clutch, friction coefficients at tooth interfaces, applied actuation force, dog tooth geometry, and component inertia. Using MATLAB and Simulink, comprehensive simulation models were developed to analyze engagement dynamics and produce detailed probability maps at different vehicle speeds. The present work effectively outlines optimal operational zones for successful engagement while identifying critical regions prone to tooth clash and engagement failure. The effect of tooth geometry on engagement probability has been investigated to study its effect on the optimal mismatch speeds. The resulting engagement maps serve as valuable diagnostic
Khan, Mohammad Adeeb, Khan, Nuruzzama Mehadi, Koona, Rammohan
FATIGUE FAILURE ANALYSIS FOR AUTOMOTIVE TRASNMISSION2026-26-0577To be published on 01/16/2026
A fatigue failure in the transmission input shaft was identified during a bench-level endurance test under 2nd gear loading conditions. The test transmission’s input shaft comprises fixed 1st, reverse, and 2nd gears, with the remaining gears mounted as floating. The shaft was subjected to cyclic torsional loads, and failure occurred after a defined number of cycles. Metallurgical analysis revealed a brittle fracture surface with crack initiation at the outer surface, propagating to core in a helical pattern, ultimately resulting in complete shaft fracture. To monitor and replicate the failure, the test setup was instrumented with a Reilhofer Delta Analyzer for early fault detection. TTL signals from accelerometers mounted on the transmission and a bench speed sensor were fed into the system, which generated FFT spectra and trend indices. A warning alarm triggered upon deviation in the trend index, indicating premature damage initiation. The test was subsequently halted for component
Kushwaha, Rakesh, Patel, Hiral, Navale, Pradeep
Condition-Based Monitoring for Prompt Identification of Component Failures to Safeguard the Entire System.2026-26-0576To be published on 01/16/2026
Condition-based monitoring (CBM) has emerged as a transformative approach in predictive maintenance, enabling the proactive identification of potential component failures. It offers numerous advantages like Cost Savings, Increased Equipment Lifespan, RCA of failed parts, Optimized Resource Utilization, Reduced Disruptions, Enhanced Reliability and Safety and many more making it a vital approach for effective maintenance and operational efficiency. This paper presents a comprehensive methodology for monitoring and analyzing vibration trends to predict and prevent the breakdown of critical components in IC Engine in its testing phase. The good part here is that this methodology is not just limited to IC Engine but can be applied across wide range of industries and mechanical systems as from the literature and past vibration data, it was observed that before any such failure engine vibration increases. If the engine is stopped at that moment, it can be preserved, allowing for further
Gupta, Gaurav, Verma, Vivek
Advancing Welding Excellence through Numerical Simulation Based Approach: A Multi Pass Welding Case Study on Cast Iron Coupons2026-26-0457To be published on 01/16/2026
The Automotive industry extensively uses cast iron for its exceptional mechanical performance and cost-effectiveness. However, repair welding or assembly of cast iron components remain highly challenging due to the material’s high carbon content, inherent brittleness, rapid thermal conductivity, and complex microstructural transformations. Multi-pass welding exacerbates these challenges by subjecting materials to repeated thermal cycling, accumulating residual stress, and inducing distortion – all of which potentially degrade the integrity of welded joints. A comprehensive understanding of welded joint behavior is essential to effectively mitigate these effects. Finite element analysis (FEA) serves as a powerful tool, enabling accurate prediction of thermal profiles, phase transformations, residual stress development, and resulting deformations. These valuable insights are critical for optimizing welding processes and enhancing overall joint quality. This study investigates and
Vidhate, Digambar, Nalawade, Rahul, Dabhadkar, Mandar, Vaidya, Abhijit, Ammasi, Vinoth, Rajagopalan, Sridhar
Influence of Impact Configuration on Rear Compartment Intrusion and Structural Countermeasures2026-26-0462To be published on 01/16/2026
Rear seat survival space intrusion pattern during severe rear-impact collisions is strongly influenced by the impact configuration. The relative contributions of rear seat pan forward intrusion versus rear seatback intrusion vary depending on the nature of the collision. In underride impacts, the rear wheels are pushed forward into the occupant survival space from below, causing the rear seat pan to move forward and upward relative to the vehicle interior. Conversely, override impacts tend to produce direct seatback intrusion into the rear compartment. This study employed a validated finite element model of a production vehicle, obtained from the NHTSA website, to simulate various types of rear compartment intrusions under different impact configurations. The analysis also evaluated structural countermeasures aimed at reducing occupant survival space intrusion. The results demonstrate that underride impacts primarily drive the forward motion of the rear wheels into the structure
Thorbole, Chandrashekhar, Vhanaje, Manoj G, Eknath Chopade, Santosh
Machine learning model to predict Chest Injury during Thorax Impact on Human Body Models2026-26-0665To be published on 01/16/2026
In recent years, virtual models have been handy in predicting potential injury risk to occupants in vehicle crashes. Virtual models offer detailing of occupant anthropometry and closest possible bio-fidelity over existing test devices. This study focuses on the assessment of chest deflections in frontal thorax impacts using virtual human body models of a few anthropometries and transforming the assessment of injuries of broader range of anthropometries (population). The study utilizes machine learning models to enable injury assessment across a broader range of body types. The study has taken a standard test scenario (Kroell load case) having frontal blunt thoracic impact. The load case is replicated in LS-DYNA and finite element human body models (HBMC) of 05th Female and 50th Male are used. The simulation setup replicates the boundary conditions as per literature, the responses necessary to measure chest deflection were validated & recorded. The outputs from the simulations and data
Sridhar, Raam, Arya, Bibhu, Divakar, Prajwal, R, Udhaya Kumar, Bhutki, Prasad, Kumar, Devendra, Kurkuri, Mahendra, Mohan, Pradeep
Powering the Future: Addressing Power Architecture Bottlenecks in Next Gen Automotive Platforms2026-26-0688To be published on 01/16/2026
As the automotive industry moves from conventional function oriented embedded ECU-based systems to Code-driven system, the core electrical and electronic (E&E) architecture is also being redesigned to support more software-driven functionality. Modern and centralized architectures promise scalability and software-driven flexibility, but they also introduce significant challenges in power distribution-an area that remains underexplored despite its critical role in overall vehicle safety and performance. Our paper aims at the adoption of the traditional power distribution approach for Next Gen vehicle architecture. It requires a fresh look at how power is distributed. In a novel E&E architecture, a single power harness supplies battery voltage to each zone. If there's a failure or voltage drop, it can affect multiple functions within that zone at once, and management of voltage regulation, thermal dissipation, and EMI/EMC compliance becomes crucial. Adding to the complexity, safety
Borole, Akash, Warke, Umakant, Chakra, Pipun, Jaisankar, Gokulnath
Reverse Engineering and Digital Twins in Powertrain Design: Enhancing Performance and Sustainability2026-26-0065To be published on 01/16/2026
This study explores the application of reverse engineering (RE) and digital twin (DT) technology in the design and optimization of advanced powertrain systems. Traditional approaches to powertrain development often rely on legacy designs with limited adaptability to modern efficiency and emission standards. In this work, we present a methodology combining 3D scanning, computational modeling, and machine learning to reconstruct, analyze, and enhance internal combustion engines (ICEs) and electric vehicle (EV) drivetrains. By digitizing physical components through RE, we generate high-fidelity DT models that enable virtual testing, performance prediction, and iterative improvement without costly physical prototyping. Key innovations include a novel mesh refinement technique for scanned geometries and a hybrid simulation framework integrating finite element analysis (FEA) and multi-body dynamics (MBD). Our case study demonstrates a 12% increase in thermal efficiency for a retrofitted ICE
Bernikov, Mark Alexandrovich, Kurmaev, Rinat
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-0280To be published on 01/16/2026
This paper presents a comprehensive numerical methodology for simulating the coupled process-structure behavior of short glass fiber-reinforced, injection-molded thermoplastics. The approach integrates elastoplastic and anisotropic material characteristics using three engineering tools: Moldflow, Digimat, and ABAQUS. It accounts for fiber orientation and injection molding defects, linking to thermo-mechanical performance. This method enables accurate virtual modeling of real-time injection-molded components by transferring anisotropic data from Moldflow to ABAQUS. In this study, short fiber orientation and potential injection molding defects such as weld lines and residual stresses are discussed using Moldflow simulation. Besides, Digimat is employed as an interface tool to facilitate the transfer of Moldflow simulation results, namely fiber orientation and material behavior in the allied configurations directly into ABAQUS. This integration enables the evaluation of thermo-mechanical
T, Kalinga, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Johnson-Cook model calibration for brittle materials under impact loads2026-26-0367To be published on 01/16/2026
In the assessment of parts subjected to impact loading, the current process relies on static analysis, which overlooks the significant influence of high strain rate on material hardening and damage. The omission of these effects hinders accurate impact simulations, limiting the analysis to comparative studies of two components and potentially misidentifying critical hot spot locations. To address these limitations, this study emphasizes the importance of incorporating the effects of high strain rate in impact simulations. By utilizing the Johnson-Cook material calibration model, which includes both material hardening and damage models, a more comprehensive understanding of material behavior under dynamic loading conditions can be achieved. The Johnson-Cook material hardening model accounts for the strain rate sensitivity of the material, providing an accurate representation of its behavior under high strain rate conditions. This allows for improved prediction of material response
Pratap, Rajat, Apte, Sr., Amol, Babar, Ranjit, Dudhane, Karan, Poosarla, Shirdi Partha Sai, Tikhe, Omkar
EVALUATION OF DRIVELINE NVH PERFORMANCE USING LINEAR DYNAMIC FINITE ELEMENT SIMULATION2026-26-0322To be published on 01/16/2026
Automotive driveline design plays an important role in the NVH characteristics of the overall vehicle. Driveline systems are an integral part of delivering torque from the engine/transmission to the tires which propel the vehicle and drivelines often experience a wide frequency of excitation which poses unique NVH challenges. With the increasing trend in the automotive industry to introduce turbocharged engines with fewer cylinders while delivering the same torque / power, the driveline systems are excited with increased lower frequency torsional vibration in addition to other vibrations transmitted from powertrain and road. In this paper, we address the key design consideration for developing an optimal driveline system with consideration to NVH while keeping durability and other functional requirements in perspective. We consider the example of a front wheel drive-based vehicle architecture with independent suspension. The effect of fundamental prop shaft frequency to determine
Joshi, Atul Kamalakarrao, Subramanian, MANOJ
Study, design, electro-chemical testing and validation of fuel cell fixture of single cell assembly towards custom stationary application.2026-26-0265To be published on 01/16/2026
Fuel cell - as name suggests, it generates energy from fuel (Hydrogen). A three-input system produces three different outputs: electrical energy, heat, and pure water. Fuel cell can produce decent power depending on design of active area and possible current density. Overall required power output which is generated by a series of cells stacked together. The design once meets all the required performance parameters at single cell level, can be extrapolated to stack level design. The present work elaborates successful testing and validation of a compact, light weigh single cell fuel cell fixture. Further the design will be scaled to a fuel cell stack design with a capacity of 5 kW to cater various stationary application such as back-up/ stand-alone power generator for remote location. The same design philosophy will also be implemented in fuel cell stack design for automobile applications. The membrane electrode assembly (MEA) is heart of the fuel cell which produces the output while
Pandit`, Abhishek Rajshekhar, Chougule, Abhijeet, Khot, Ranjit, Chaudhari, Shirish
Q-Series Child Dummy FE model development and validation for child occupant safety assessment in Automotive crashes2026-26-0390To be published on 01/16/2026
The Ministry of Road Transport and Highways (MoRTH), Government of India has established BHARAT NCAP to provide a fair, meaningful, and objective assessment of the crash safety performance of cars. This program evaluates vehicles across three key areas, including Child Occupant Protection (COP). A critical component of the COP assessment involves dynamic testing using Q-series child dummies representing a 1½-year-old (Q1.5) and a 3-year-old child (Q3). As per the BHARAT NCAP protocol these dummies are placed in the second-row outboard seating position within Child Restraint Systems (CRSs) and subjected to two primary dynamic impact tests: Offset Deformable Barrier (ODB) conducted at speed of 64 km/hr. and Mobile Deformable Barrier (MDB) Side Impact tests conducted at 50 km/hr. The dynamic assessment of these child dummies is primarily focused on the head, neck, and chest regions to evaluate the effectiveness of the CRSs and overall vehicle safety system in protecting young occupants
Khopekar, Maria, Lakshminarayana, Apoorva, Mohan, Pradeep, Kurkuri, Mahendra
Dual-Stage Compressor Bracket NVH Optimization for High-Performance 4x4 Electric Vehicles2026-26-0327To be published on 01/16/2026
The increasing demand for high-performance 4x4 electric vehicles (EVs) has necessitated advancements in Noise, Vibration, and Harshness (NVH) optimization, particularly in critical components such as compressor brackets. This study focuses on the NVH optimization of a dual-stage compressor bracket, comparing its performance against a conventional single-stage design. The dual-stage bracket is evaluated for isolation effectiveness, modal frequency alignment, and overall NVH performance, while ensuring compliance with stiffness and durability targets. Through finite element analysis (FEA) and experimental validation, the dual-stage bracket demonstrates superior vibration isolation, achieving a 30% reduction in transmitted forces compared to the single-stage design. Modal analysis reveals that the dual-stage configuration effectively shifts critical frequencies away from operational ranges, reducing resonance risks. Additionally, the dual-stage design meets stringent stiffness
Hazra, Sandip, Tangadpalliwar, Sonali
A fluid-structure- interaction based methodology to evaluate aero-thermal performance of deformable air guides2026-26-0364To be published on 01/16/2026
An air guide in a car directs fresh air onto the Heat Exchangers (HXs) to facilitate efficient thermal management. It is of paramount importance that the air guide creates a proper sealing and prevents any leakage of the incoming fresh air. It is achieved in two ways – 1) In the design condition, the air guide is manufactured in a way so that it overlaps/intersects with the surrounding components 2) the air-guide is made flexible with a highly elastic rubber seal at the edge. When the air-guide is assembled, the rubber portion of the air-guide deforms to produce a proper fit leading to a sealed air-intake pathway. At high-speed condition as well as high airflow conditions by the radiator fan during idling/stationary, like DC charging – incase of BEV, etc., the air guide encounters high pressure. Being elastic and flexible, these conditions make the air guide susceptible to deformation with potential leakage of incoming air. Digital evaluation of the air guide deformation at different
Gadasu, Ravishastri, Choudhury, Satyajit, Umesh, Acharya Vaibhav, Kumar, Saravanan, Yenugu, Srinivasa, Zander, Daniel, Beesetti, Siva, Hattarke, Mallikarjun
Development of a Lightweight Front-End Structure Using Injection Molding Technology2026-26-0304To be published on 01/16/2026
This paper presents the development of a lightweight, functionally integrated Front-End Module (FEM) utilizing plastic-metal hybrid injection molding technology. The objective is to achieve modularization, part consolidation, weight reduction, and cost efficiency. The proposed design integrates multiple components into a single module which makes assembly faster and easier. A mounting strategy with fixation features was integrated into the structure to effectively support various components.To ensure structural performance, component-level Finite Element Analysis (FEA) was performed, including static strength, bending and torsional stiffness, hood retention tests, and modal analysis. Ribbing patterns were optimized to meet design stiffness targets while minimizing weight. Moldflow analysis was carried out to evaluate manufacturability, focusing on gate design, weld lines , warpage, and flow balance. Necessary design corrections were implemented prior to tool development to ensure
Srivastava, Sanjay, Thakoor, Shruti Ghanshyam, Sonkusare, Shailesh
Experimental Frequency-Based Substructuring for Full-Vehicle NVH Characterization in Electric Vehicles2026-26-0309To be published on 01/16/2026
Electric vehicles introduce new NVH challenges due to high-frequency excitations from e-motors and associated electronics. These excitations, often in the kilohertz range, are primarily transmitted as structure-borne noise and require advanced experimental methods for accurate characterization and mitigation. Traditional simulation approaches are insufficient to capture the true dynamic behavior of complex components under operational boundary conditions. This study presents a fully experimental Frequency-Based Substructuring (FBS) methodology applied to a complete electric vehicle. Frequency Response Functions (FRFs) of individual subsystems—such as the e-motor, mounting system, inverter housing, and body connection points—are measured and transformed using Virtual Point Transformation to obtain consistent six-degree-of-freedom representations. These Virtual Point models are assembled into a full-vehicle system to investigate the structure-borne transfer paths to the vehicle interior
Kohlhofer, Daniel, Pingle, Pawan Sharad, de Klerk, Dennis
Advanced Welding Process Simulation for Prediction and Control of Distortion and Residual Stresses in Automotive Sheet Metal Component Assembly2026-26-0412To be published on 01/16/2026
Welding simulations are transforming industrial manufacturing by enabling a predictive and first-time-right approach for process development. Advanced techniques such as Finite Element Analysis (FEA) help in accurate prediction of temperature distribution, residual stress, distortions and potential defects prior to physical welding which in turn support for addressing key challenges associated with Heat Affected Zones (HAZ) like distortion, fitment issues and post-weld cracking. Early integration of simulation in the development cycle significantly reduces lead time, enhances durability, and improves manufacturing efficiency. This study presents a simulation-based product development approach to mitigate post-weld crack generation issues in a complex multiple weld configuration of an automotive sheet metal assembly. The methodology adopts a two-stage framework: first, identifying the root cause of crack generating through baseline weld simulation; and second, implementing design
Nalawade, Rahul, Deshmukh, Kishor Pandurang, Vidhate, Digambar, Prakash, Ved, Dabhadkar, Mandar Mukund
Advanced Sensor less Machine Learning Technique for Early Detection of Engine Oil Degradation2026-26-0656To be published on 01/16/2026
Maximizing vehicle uptime and reducing maintenance costs are critical objectives in modern automotive systems, making efficient resource utilization a top priority. One key factor is engine oil degradation, which directly affects engine performance, longevity, and overall vehicle efficiency. Current Conventional oil monitoring approaches are real time based on dedicated sensors—can be inefficient, costly, or poorly adapted to varying usage conditions. While earlier studies have explored sensor-based or chemical analysis methods for oil health monitoring, these solutions often lack scalability and cost-effectiveness for widespread adoption. This paper introduces a Machine Learning-based Engine Oil Degradation Detection System that operates non-intrusively using existing vehicle CAN signals, requiring no additional sensors. Key engine parameters such as RPM, Torque, Gear Position, Engine Power, Coolant Temperature, and Odometer readings are trained with tri-bological properties
Dusane, Mangesh, Tade, Vilas, Iqbal, Shoaib
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