Browse Topic: Analysis methodologies

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Improvement of rCF behaviour through the introduction of NF2026-37-0039To be published on 06/09/2026
The use of recycled carbon fibres (rCF) allows for reduction of emissions impacting energy and resource requirements. A major drawback of using rCF composites is the discontinuous nature of the fibres as this limits the performance and applications. The present investigation aimed to overcome some of these limitations by manufacturing hybrid composites by combining rCF and natural fibres (NF). One of the key observations was a significant change in the failure mode of hybrid samples under various loading scenarios, where the composite did not shatter but rather failed in a controlled manner. Initial results also showed an overall improvement impact properties in comparison to plain rCF. Similar performance was observed in other tests. Research was focused on determining the most effective ply sequencing under different types of loading and understanding the effect of the ply sequence on the failure mechanisms. It was determined that depending on the application, the layups does effect
Hnatyk, Dawid, Chrysanthou, Andreas, De Vuyst, Tom, Ismail, Sikiru
THERMO-STRUCTURAL ANALYSIS OF GRID FINS FOR RE-ENTRY MODULES2026-26-0749To be published on 06/01/2026
Grid fins are lattice structures employed as aerodynamic control surfaces to achieve the required static stability of re-entry modules during atmospheric descent. Grid fins help to stabilize the re-entry modules by counteracting aerodynamic instabilities, especially when the module is moving through the atmosphere at high speeds. Each panel within the grid fin functions as an individual fin, generating lift and drag forces that enhances the overall stability of the re-entry module. In contrast to conventional fins, grid fins incorporate a distinctive waffle-like pattern or grid pattern configuration, offering superior aerodynamic performance in supersonic regimes and enabling compact storage through folding during launch followed by deployment at the time of exigency. The separation of re-entry modules from their launch vehicles is typically executed using high-thrust, fast-acting solid rocket motors (SRMs) which provide the impulsive force needed for clean detachment. The primary
Mali, Somanath Nandu, Sundar Raj, R, Sundaresan, MK, R, Suresh
Integrating Human Factors and Predictive Modeling for Enhanced Aviation Safety: A Data-Driven Approach to Risk Mitigation and System Design2026-26-0795To be published on 06/01/2026
The evolution of the aviation industry from manual control to highly automated and autonomous systems has brought human factors to the forefront of safety, design, and operational efficiency. This paper presents an integrated analysis combining machine learning techniques with statistical modeling to assess the impact of human-system interaction on aviation incident outcomes. The first phase of this research involved a longitudinal dataset covering aircraft design evolution, training programs, and incident records. Using classification algorithms, including XGBoost, the study achieved an accuracy of 81.82% in predicting incident likelihood. Performance metrics such as F1-scores (0.85 for “Incident” and 0.78 for “No Incident”) highlighted the model’s robustness in identifying risk patterns associated with human factors and system complexity. In the second phase, 50 plus detailed aviation incident reports were analyzed using logistic regression, t-tests, and Cook’s Distance to identify
Valiyaparambil, Praveen
Investigation of Acoustic Fill Effect of a Launch Vehicle Payload Fairing2026-26-0759To be published on 06/01/2026
The payload fairing of a launch vehicle is subjected to extremely high acoustic loads, with peak levels occurring during lift-off and transonic aerodynamic regimes. The external acoustic field penetrates the fairing, producing intense internal sound pressure levels that can challenge the integrity of spacecraft components. Accurate characterization of the vibroacoustic behaviour of the payload fairing and its enclosed cavity is therefore essential to ensure spacecraft survivability. The internal acoustic field is governed by the coupled dynamics of the fairing structure and the spacecraft configuration, making it critical to quantify the acoustic environment for different payload arrangements. This study presents a detailed vibroacoustic analysis of a payload fairing with multiple spacecraft configurations to evaluate the resulting internal sound pressure distribution. Vibroacoustic finite element analysis (FEA) is employed in the low frequency range, while statistical energy analysis
S R, Arun Raj, Jayan, Mahind, George, P
Sensitivity Analysis of Geometric Imperfections in Aerospace structures2026-26-0738To be published on 06/01/2026
Launch vehicle structures are designed to withstand flight loads ensuring design adequacy after thorough structural assessment. In general, Preliminary FE model assumes perfect geometry of structures for analysis without considering profile imperfections arising during course of fabrication. These deviations, occurring during manufacturing, can significantly reduce the structure's load capacity. Traditional analysis often relies on simplified or theoretical imperfection models, which are different from "fabricated" hardware, leading to either underestimation or over estimation of margin for structural design loads. This paper presents a robust methodology for a cylindrical structure by directly incorporating measured manufacturing deviations into the finite element (FE) model. Thin-walled cylindrical structures, particularly those with complex stiffening patterns like isogrid panels, are sensitive to geometric imperfections. The subject hardware exhibited significant non-conformances
Sharma, Amit, Singh, Nishant, Xavier, Shijo, R, Suresh
Automated Flight Maneuver Recognition for Intelligent Flight Simulator2026-26-0713To be published on 06/01/2026
The rapid growth in the number of aircrafts and pilots emphasizes the need for an AI-enabled training framework that can offer precise, automated examination of flight maneuvers, thereby optimizing the pilot’s training efficiency and minimizing iterations of the conduct of flight maneuvers thereby reducing the training time of the pilot for a flight. This paper introduces a novel hybrid methodology to intelligently detect manoeuvres performed during a flight using signal processing and machine learning techniques. A general framework is developed that can be used for all kinds of flight phases and aircraft types. The framework is implemented in a two-step approach. Firstly, Continuous Wavelet Transform (CWT) of the signals of interest for different manoeuvres are generated, to find the time at which a manoeuvre happens during a sortie. CWT looks at the energy levels in the transformed signal and uses smart thresholding technique to pick out only the parts with high energy, to extract
Sahu, Akash, C, Poornima, C, Aravindh, Kaliyari, Dushyant, TK, Khadeeja Nusrath
Finite Element Approach for Fatigue Life Prediction of Threaded Bolts with Experimental Validation2026-26-0745To be published on 06/01/2026
Predicting the fatigue life of threaded bolts is crucial in aerospace and mechanical assemblies where cyclic loading can cause early joint failure. Previous research conducted experiments to develop S-N curves for high-strength bolts under different pretension and temperature conditions (Zhang et al. 2024). However, there are a very few numerical methods that can replicate these results, especially for bolts with screw threads. In this work a finite element analysis (FEA) methodology is developed to predict the fatigue performance of threaded bolts under axial loading and validated using the experimentally derived Series-1 S-N data for M20 high-strength bolts. The approach includes detailed FEA modelling (3D solid) with explicit thread geometry to capture local stress distributions under cyclic tensile loading. Peak stress amplitudes are employed to estimate fatigue life by applying the Basquin relation and the Series-1 S-N curve. The results are compared with the calculated fatigue
K R, Lesanth, S, Suhail Ahmed, C, Arunvetrivel, P, Krishnakumar, P S, Premkumar, Vasantharaj, C
Hybrid Physics-Informed Neural Network and PID Control for Fault-Tolerant Autonomous Multi-copters2026-26-0770To be published on 06/01/2026
This paper addresses the critical challenge of fault-tolerant control in autonomous multi-copters, particularly under conditions of one or two rotor failures a scenario that often leads to severe instability and a complete loss of directional control due to unbalanced torque and resultant autorotation. Existing advanced control strategies, including optimal approaches such as LQR, typically require precise system modeling and state estimation, which are difficult to achieve in real-world, dynamic failure scenarios. Alternative methods like fuzzy logic, sliding mode control, and gain-scheduling either lack robust generalization or are impractical for enumerating all possible failure cases. In this work, a hybrid control framework integrating Physics Informed Neural Networks (PINN) with a standard PID controller is proposed for fault-tolerant operation of autonomous multi-copters subject to multiple actuator failures. PINNs incorporate governing physical laws as regularization in their
Charapalle, Samruddhi, Venugopalan, Nandagopalan, Nerkundram Muralidharan, Arun, Sundararaj, Laveen
Influence of Boundary Conditions on Dynamic Characterization of Launch Vehicle Structures with Closely Spaced Modes2026-26-0730To be published on 06/01/2026
Dynamic characterization tests play a critical role in launch vehicle applications, as they provide the frequencies and mode shapes required for refining Finite Element Models (FEM) and ensuring structural integrity. While such tests are often routine when mode shapes in orthogonal planes are well separated, practical challenges arise when modes are closely spaced. In these cases, careful test planning and execution become essential to obtain reliable results. A key factor influencing test outcomes is the boundary condition of the test article. Although free-free suspension, achieved through very low-frequency support, is theoretically ideal, it is often impractical. As a result, most dynamic characterization tests are performed with a base-fixed condition, where the properties of the supporting structure can influence the measured response. For structures with asymmetry limited to a single axis, mode shapes are typically expected to align along that axis; however, deviations may occur
Panda, Ajay Kumar, Avirah, Nohin K, Shaikh, Altafhusen
Assessment of Injection Gate Location effects on Mechanical Performance of Short Fiber Reinforced Plastic Components using Digimat2026-26-0746To be published on 06/01/2026
The mechanical performance of short fiber-reinforced plastic (SFRP) components is highly sensitive to fiber orientation, which is significantly influenced by the injection gate location during the molding process. Traditionally, gate placement decisions are driven by warpage minimization strategies, often overlooking mechanical performance under diverse load cases. This research introduces an automated workflow within Digimat-MS that integrates injection gate optimization into the early design phase, leveraging Integrated Computational Materials Engineering (ICME) principles. The proposed methodology enables engineers to upload either of Marc, Abaqus or Ansys input decks, select a component of interest, assign material cards, and define gate scenarios. A Design of Experiments (DOE) is then executed locally or remotely, allowing Digimat to simulate and evaluate multiple gate configurations. The system aggregates results and identifies optimal gate locations based on the initiation of
Kauthale, Tanmay, Madhavan, Vinay, Soni, Ganesh
An Integrated Digital Engineering Framework for Parametric Design and Finite Element Analysis of Aerospace Systems2026-26-0735To be published on 06/01/2026
Digital engineering initiatives in aerospace demand more than conventional finite element analyses; they require integrated, traceable, and systematic workflows that shorten iteration cycles, enable rapid trade-off studies, and ensure verification across the design process. FEAST (Finite Element Analysis of Structures)—an indigenous finite element software developed by VSSC, ISRO—provides structural analysis capabilities, but its native command structure is not directly compatible with automated, iterative design exploration. This limitation creates a gap between solver functionality and the needs of modern model-based engineering, where efficiency, reproducibility, and scalability are critical. To address this gap, a unified workflow is proposed that links parametric geometry modeling, load-case management, solver execution, and results visualization in a seamless manner. The framework automates repetitive pre- and post-processing tasks, enables systematic evaluation of alternative
Gupta, Shivangi, T J, Raj Thilak, P, Deepak
Porosity Matters: Multiscale Simulation of Composite Panel Performance in Aerospace Structures2026-26-0731To be published on 06/01/2026
Porosity in carbon fibre reinforced polymers (CFRP) remains a critical concern for aerospace engineers, as even minor voids introduced during manufacturing can undermine the reliability of structural components. This work explores the influence of interply porosity on composite panel behaviour, employing a multiscale simulation approach that bridges material characterisation and full-scale structural analysis. The study begins with virtual coupon testing using Digimat-VA and Digimat-MF, enabling the prediction of material allowables and the assessment of defect variability. Homogenised material properties derived from these simulations are then applied to detailed panel models constructed in MSC Apex, ensuring accurate representation of layup and orthotropic behaviour. The workflow can support a range of structural load cases, allowing for the evaluation of stiffness, buckling, or other relevant scenarios as dictated by aerospace certification requirements. Nonlinear finite element
Savane, Vishal, Kumar, Rajat
Novel material architecture for enhanced high cycle fatigue life in turbofan engine fan blades2026-26-0748To be published on 06/01/2026
High Cycle Fatigue (HCF) is a critical failure mode in turbofan blades, primarily driven by resonance phenomena when the blade’s natural frequency aligns with engine-induced excitations. Traditional approaches to mitigate HCF often involve geometric modifications or damping treatments, which can adversely affect aerodynamic performance or increase component weight. This study explores alternative methodologies to strategically alter the natural frequency of turbofan blades while maintaining aerodynamic efficiency and structural integrity. A novel material architecture is proposed, consisting of a dual-metallic configuration with a high-stiffness core and a lightweight, fatigue-resistant outer shell. This design enables precise tuning of the blade’s dynamic response by leveraging the contrasting mechanical properties of the core and outer materials. The dual-metallic structure shifts the natural frequency away from critical excitation zones, thereby reducing the risk of resonance
S, Ravivarman, Inamdar, Prachi, De, Rohit
Hybrid Digital Twin for Aero-Engine Bearing Prognostics: A Physics-Informed Machine Learning Approach to RUL Prediction2026-26-0718To be published on 06/01/2026
Unscheduled maintenance due to the failure of critical components, such as aero-engine rolling element bearings, is a leading cause of costly Aircraft-on-Ground (AOG) events; consequently, current time-based maintenance practices are inefficient and prone to risk. This paper develops a resource-efficient Hybrid Digital Twin (HDT) model for an engine bearing, focusing on the dynamic prediction of spall growth due to Rolling Contact Fatigue (RCF), thereby enabling a condition-based maintenance paradigm. The HDT architecture integrates two core models: (1) a physics-informed model that uses established life and fatigue theory to define initial degradation thresholds and constrain the failure envelope, and (2) a data-driven Recurrent Neural Network (RNN) (specifically, an LSTM) for dynamic degradation rate modeling. The methodology utilizes a Monte Carlo simulation coupled with RCF progression equations to generate a large, synthetic run-to-failure dataset under varying operational loads
Mohamed, Abbas
Design and Multi-Faceted Validation of UAV Arm Clamps, Landing Gear and Motor Mounts via Generative Design in Autodesk Fusion 3602026-26-0734To be published on 06/01/2026
The reliability of the entire airframe is essential for Unmanned Aerial Vehicles (UAVs) deployed in critical surveillance and disaster management missions. Performance cannot be compromised, as even minor structural weaknesses can impact flight stability and mission success. This work introduces a thorough "design–simulate–build–test" process that combines advanced simulation, additive manufacturing, AI-driven generative design, and experimental validation to construct an assembly of high-performance UAV structural components. Motor mounts, arm clamps and landing gear were among the important structural components of a custom UAV that were redesigned using the suggested technique. With the use of Autodesk Fusion 360's generative design tools, every component was tailored for Fused Filament Fabrication (FFF) additive manufacturing. Their mechanical performance was first predicted through a detailed Finite Element Analysis (FEA) framework. To experimentally validate these simulations
Krishna Bansal, Vaibhav
Estimation of dynamic responses at internal points of a nested sub-structure with two-level Craig-Bampton reduction2026-26-0747To be published on 06/01/2026
Dynamic analyses of large and complex structural assemblies usually employ sub-structure coupling or Component Mode Synthesis (CMS) methods. The most widely used CMS method for dynamic analyses is the Craig-Bampton (CB) method. The displacement transformation of the CB method employs fixed-interface normal modes and interface constraint modes as the component modes. Dynamic analyses utilizing Craig-Bampton-reduced sub-structure matrices will provide information about dynamic responses at interface degrees-of-freedom (DOFs) and at generalized DOFs corresponding to fixed interface normal modes. However, physical responses at internal DOFs cannot be obtained directly from these analyses. In order to extract dynamic responses at selected internal DOFs, Output Transformation Matrices, which define a relation between responses at component modes and at internal DOFs, are used. In this paper, an approach to estimate and validate the internal point dynamic responses in a nested sub-structure
Ramachandran, Nirmal
Effect of Fluid Flow/Time Duration on Static Voltage Generation for Aerospace Hose Assembly2026-26-0757To be published on 06/01/2026
Static electricity is an electrical imbalance on the surface of a material that can interact with other components made of the same or different materials. Fluid (hydrocarbons) flow within the hose assembly generates static voltage due to the friction caused by fluid flow in pipes, which needs to be appropriately quantified and dissipated. Accumulation of such static charge may lead to sudden discharge, resulting in spark generation. Spark generation around fuel flow might lead to system failure and failure in aircraft engines. Experiments were conducted to analyze the static voltage generated in the hose assembly with a fixed hose assembly length due to fuel flow, with the objective of achieving acceptable voltage levels to avoid ESD (electrostatic discharge) failure. The procedure includes fuel flow rate monitoring and voltage measurement. The testing revealed that the curvature of the hose affects the readings, highlighting the importance of consistent meter alignment. Using a
Waghmare, Shashank
Directional Stiffness Decoupling in Meta-Wheels via Three-Dimensional Discrete Curved Spokes15-19-01-00054/22/2026
Meta-wheels—non-pneumatic wheels whose performance is governed by structural geometry rather than internal pressure—offer new opportunities for directional stiffness control. Yet achieving independent tuning of longitudinal, lateral, and vertical stiffness within a single wheel architecture has remained challenging due to the inherent coupling in conventional radial and planar curved spokes. In this study, we introduce a three-dimensional (3D) discrete curved-spoke design that provides explicit geometric control through two independent parameters: the in-plane curvature angle (α) and the out-of-plane inclination angle (β). Using spoke-level and full-wheel finite-element (FE) simulations, supported by a simplified cantilever-beam analytical model, we show that these two geometric parameters govern stiffness in fundamentally different ways. The curvature angle α serves primarily as a geometric softener, reducing stiffness in all directions while maintaining a high top-loading ratio (TLR
Han, Heeseung, Liu, Zhipeng, Ju, Jaehyung
Real Turbulent Flow in Vehicle Aerodynamics: Overview of On-Road Measurements and Turbulence Generation in Wind Tunnels2026-01-50294/22/2026
Flow conditions on the road are quite different from the conditions used to develop vehicle aerodynamics. However, a significant amount of statistical data now exists that describes realistic road conditions. Some of these on-road flow characteristics can be replicated in wind tunnels. This paper reviews technical facilities designed to simulate on-road flow characteristics, such as turbulence intensity, turbulent length scales, and flow angle distribution. Reconstruction of a flow field that matches real road conditions is made possible by using active or passive turbulence generators within the wind tunnel. This review provides a comprehensive overview of these facilities, offering readers key insights into the challenges involved in replicating real-world flow conditions in wind tunnels.
Vondruš, Jan, Vančura, Jan
Engine Cooling Fan Structural AnalysisJ1390_202604 (Current)4/13/2026
Three levels of fan structural analysis are included in this practice: a Initial structural integrity. b In-vehicle testing. c Durability (laboratory) test methods. The initial structural integrity section describes analytical and test methods used to predict potential resonance and, therefore, possible fatigue accumulation. The in-vehicle (or machine) section enumerates the general procedure used to conduct a fan strain gage test. Various considerations that may affect the outcome of strain gage data have been described for the user of this procedure to adapt/discard depending on the particular application. The durability test methods section describes the detailed test procedures for a laboratory environment that may be used depending on type of fan, equipment availability, and end objective. The second and third levels build upon information derived from the previous level. Engineering judgment is required as to the applicability of each level to a different vehicle environment or a
Cooling Systems Standards Committee
Strain-Based Fracture Assessment of Tailor Welded Blanks under Complex Loading Conditions2026-01-02314/7/2026
Tailor Welded Blanks are critical for automotive lightweighting yet prone to premature failure due to differential thickness and strength across the weld. This study utilized digital image correlation (DIC) to analyze the maximum in-plane principal Hencky strain (E₁max) and axial strain (εₐₓₐₗ) of TWBs under complex loading conditions, including biaxial and plane-strain states. Twelve distinct material stack-ups were tested to evaluate the impact of material difference on formability. Results indicated that differential properties significantly altered strain distribution, often forcing localization onto the thinner or softer sheet. While UHSS welds provided high load capacity with limited ductility, combinations using HSLA or IF substrates were susceptible to early localization and unstable fracture. Comparative heatmaps illustrate strain evolution across all samples, providing spatial insights beyond conventional force–displacement analysis. Metallurgical characterization confirmed a
Aminzadeh, Ahmad, Sheng, ZiQiang, Huang, Lu, McCarty, Eric, Biro, Elliot
The ML FMEA in Action: Lessons from Applications of Machine Learning Safety2026-01-00794/7/2026
Introducing machine learning (ML) into safety-critical systems presents a fundamental challenge, as traditional safety analysis techniques often struggle to capture the dynamic, data-driven, and non-deterministic behavior of learning-enabled components. To address this gap, the Machine Learning Failure Mode and Effects Analysis (ML FMEA) methodology was developed as an open-source framework tailored to ML-specific risks. This paper reports on the maturation of ML FMEA from an initial conceptual framework to a proven, practice-driven methodology. We make four primary contributions. First, we extend the ML FMEA pipeline with two new stages: a “Step Zero” for problem definition and system-level hazard analysis, and a “Step 5” for constructing ground truth or reward signals. Autonomous vehicle and humanoid robot applications are presented to illustrate the practical application and safety benefits of these additions. Second, we introduce tailored Severity, Occurrence, and Detection
Schmitt, Paul, Shinde, Chaitanya, Diemert, Simon, Pennar, Krzysztof, Seifert, Bodo, Poh, Justin, Lopez, Jerry, Mannan, Fahim, Mohammed, Majed, Chalana, Akshay, Wadhvana, Neil, Wagner, Michael
Integrated Welding Simulation and Experimental Characterization of Weld-Metal and Heat-Affected-Zone Strength in AA6063-T62026-01-02304/7/2026
In the context of automotive lightweighting and efficient manufacturing, welding is a key joining method for aluminum body structures due to its maturity, versatility, and cost effectiveness. This study investigates MIG butt welding of AA6063-T6 sheets using a sequential thermo-mechanical finite element model with a double-ellipsoid heat source. Thermocouple histories and macroscopic metallography of the weld-pool morphology are used to validate the predicted temperature field, and post-weld deformation measured by a coordinate measuring machine is compared with the simulation to confirm overall model reliability. Hardness mapping across the joint partitions the material into weld metal (WM), heat-affected zone (HAZ), and base metal (BM). Miniature tensile specimens extracted along the weld provide local mechanical properties, from which linear strength–hardness relations are established. Building on these results, a five-material equivalent strength model covering WM, HAZ-I, HAZ-II
Shao, Jiyong, Meng, Dejian, Xiang, Yao, Gao, Yunkai
Development and Validation of a Self-Propelled Trailer: A Standards-Based Approach to Enhancing Compact Vehicle Towing2026-01-00554/7/2026
This paper presents a structured test plan for the development and validation of a Self-Propelled Trailer (SPT), an emerging concept designed to enhance the towing capacity of compact, fuel-efficient vehicles. Unlike conventional trailers, the proposed system integrates electric propulsion and autonomous sensing to actively assist the towing vehicle, reducing engine load and improving both safety and fuel economy. The methodology employs a Design Failure Mode and Effects Analysis (DFMEA) to systematically identify potential risks, while incorporating Society of Automotive Engineers (SAE) standards to guide environmental durability testing (dust, water ingress, gravel impact) and dynamic performance evaluations (gradeability, braking, and stability). A comprehensive set of test procedures is outlined to validate system reliability, robustness, and compliance with established towing requirements. The study demonstrates how powered trailer technology can extend the practical use of
Reilly, Carter, Peters, Diane, Zadeh, Mehrdad
A CFD Based Multi-Physics Modeling Approach to Predict Vent Gas Flow Paths Due to Can Melting during Prismatic Cell Thermal Runaway2026-01-04074/7/2026
As the automotive industry increasingly adopts high-energy-density batteries, ensuring vehicle safety against catastrophic thermal runaway (TR) has become paramount. Predicting the complex failure sequence of prismatic cells, requires high-fidelity simulation tools that can capture tightly coupled physical phenomena. This paper presents a comprehensive, three-dimensional multi-physics Computational Fluid Dynamics (CFD) framework designed to simulate the entire TR event. The simulation originates with a multi-step Arrhenius chemical kinetics model to calculate the heat and gas generated by the primary exothermic reactions. This process drives a rapid increase in internal temperature and pressure, which is resolved by the model’s fluid dynamics solver. The initial vent opening is triggered when this internal pressure exceeds a predefined mechanical burst threshold, simulating a realistic seal rupture. Concurrently, a Conjugate Heat Transfer (CHT) analysis calculates the temperature
Mukherjee, Swarnava, Schlautman, Jeff, Srinivasan, Chiranth
Effective Prediction of the Mechanical Properties of Glue-Laminated Motor Stator Core with Consideration of Glue Disposition2026-01-01774/7/2026
This study presents an effective predictive methodology for determining the mechanical properties of glue-laminated motor cores, with explicit consideration of glue disposition, including bonding pattern, configuration, location, and coverage. In laminated stator cores, glue bonding and stacking processes jointly govern the mechanical integrity of the lamination stack. Practical production bonding schemes are typically nonuniform and localized, leading to spatial variations in stiffness and to locally anisotropic, orthotropic material behavior. These effects influence both the in-plane and through-thickness stiffness of the stator core. They can significantly affect the accuracy of structural simulations, such as NVH responses of high-speed traction motors and e-drive systems. Given the constituent material properties of the electrical steel laminations and the glue, this work distinguishes the governing mechanisms underlying the equivalent core properties. The in-plane stiffness is
Nie, Zifeng
Development of Automotive Hood Using Multi-Material Double Injection Molding – An Overview2026-01-04764/7/2026
This paper presents the multidisciplinary development of a hybrid automotive hood manufactured using double-shot injection molding with overmolded brackets. Conventional steel and aluminum hoods, while structurally reliable, pose challenges in terms of weight reduction, pedestrian head protection, and manufacturing cost. Composite and thermoplastic alternatives supported by computational analysis and advanced molding processes provide opportunities to address these challenges. Finite element analysis (FEA) was employed to evaluate torsional and bending stiffness, locking load, and crashworthiness, while pedestrian headform simulations following ECE R127 and EEVC WG17 guidelines were conducted to assess compliance with safety regulations. Adhesion and bonding strength of overmolded polymer–polymer interfaces were studied to validate manufacturing feasibility. Results confirm that hybrid hoods fabricated using multi-material double-shot molding can achieve weight reductions of up to 30
Ganesan, Karthikeyan, Seok, Sang Ho, Jo, Hyoung Han
Kissing Bonds Inspection by Comparing Natural Frequencies Using Digital Holography2026-01-02074/7/2026
Accurate detection and evaluation of kissing bonds in composite materials is essential to ensure the integrity of the component structure, but traditional NDT (non-destructive testing) methods struggle to identify imperfect bonds and zero-volume debonds. In this study, a vibration analysis method based on holography was applied to detect kissing bonds by monitoring the changes in natural frequencies of the same sample before and after fatigue loading. Both pristine and kissing bond samples were tested under identical conditions, and their vibration characteristics (natural frequency, amplitude, and mode shape) were measured using holography. The experimental results show for the intact sample exhibited no changes in natural frequency amplitude or mode shape after fatigue loading, confirming that the applied fatigue test did not affect the integrity of its adhesive layer. In contrast, for the sample with a kissing bond, after fatigue loading, the natural frequency decreased by up to 22
Gao, Zhongfang, Fang, Siyuan, Gerini-Romagnoli, Marco, Yang, Lianxiang
Acoustic Improvements to a Passenger Service Unit Panel with Core Filler and Facesheet Patches using Topology Optimization2026-01-05114/7/2026
Passenger comfort is becoming the forefront of luxury private jets where noise needs to be kept to a minimum. One source of structure-borne noise is the vibration of the Passenger Service Unit (PSU) panel. These vibrations originate from the outer skin, excited by turbulent boundary layer, and are transmitted through the fuselage frame to the PSU panel. This panel resides overhead of passenger seating, it is composed of a corrugated honeycomb core sandwiched between thin face-sheets. This paper presents a systematic approach to improve the vibro-acoustic performance of a honeycomb core sandwich structure by employing core filler and facesheet patches. Topology Optimization (TO) is used to determine the optimal layouts of these design modifications. The vibro-acoustic performance of the PSU panel with facesheet patches and core filler is evaluated using a frequency response analysis in the commercial finite element solver OptiStruct. The effectiveness of vibration reduction will be
Russo, Connor, Whetstone, Isobel, Patel, Anuj, Wotten, Erik, Kim, Il Yong
A Study on Fail-Safe and Limp-Home Strategies for Electric Drive Failures in P1-P2 (P)HEVs2026-01-04274/7/2026
Hyundai Motor Company’s TMED-II hybrid system adopts a P1–P2 parallel motor layout, which improves power distribution flexibility but increases reliance on electric drive components. Failures in motors, inverters, or other power electronics can critically affect drivability and safety, making robust Fail-Safe strategies essential. This study proposes a three-stage, sequential Limp-Home strategy for P1–P2 HEVs under P2 motor system failure. Unlike conventional methods that open the main relay and rely solely on the engine, the proposed approach keeps the high-voltage (HV) system active whenever possible to maintain performance, safety, and comfort. Stage 1 – P1 motor-based State of Charge (SOC) control: Keeps the main relay closed and uses the P1 motor to maintain SOC within set limits. Overcharge is mitigated by operating the motor in discharge mode, and overdischarge is mitigated through regenerative operation. Engine torque is adjusted to match motor torque demand, preserving launch
Rho, Jeongwon, Park, Sangcheol, Oh, Sung Hwan
Analysis of Failures Due to Ant Entry in Automotive Electronic Components and Integration of Learnings in Design2026-01-01934/7/2026
Automotive electronic components are exposed to different environmental conditions, and these conditions may impact the functioning of the components, leading to failures in vehicles globally. These failures often create inconvenience for customers across OEMs. Addressing failures requires measures that incur extra costs. One of the environmental factors is insect entry inside the components. This Quality research paper aims to address the need for revision in design standards due to failures caused by Ant entry. The increase in integration of technology in vehicles has led to an increase in the use of electronic components such as switches, control modules, and controllers. Vehicles are often parked in open areas (under trees, open grounds, basements or construction sites) and are in close vicinity to Ant nests or feeding areas. Ants may be drawn to the warmth and shelter provided by vehicle engine bays and wiring compartments. In some cases, especially in tropical regions, ants have
Marwah, Ramnik, Dasgupta, Saikat, Upadhyay, Siddharth, Joshi, Rohit, Taneja, Bhavnesh, Bose, Sushant, Sharma, Pankaj, Garg, Vipin
A Vehicle-Integrated Validation Method for Weather-Strip Sealing Performance in Automotive Closure Systems2026-01-02004/7/2026
Weather-strip sealing systems are critical to automotive closure performance, influencing water- and dust-tightness, aerodynamic noise control, and overall NVH quality. Conventional validation often relies on flat or straight JIG-based tests that inadequately represent the curved, angled, and non-uniform geometries of real closures such as doors, tailgates, hoods, roofs, and fixed or movable glass. This disparity limits the predictive accuracy of sealing performance in actual vehicles. This study proposes a vehicle-integrated validation framework that mirrors true geometric and contact conditions. The methodology combines finite element analysis (FEA) of both flat JIG and full-vehicle CAD geometries with experimental JIG tests, establishing a baseline for pressure distribution, compression load, and sealing contact behavior. A comparative analysis highlights significant deviations between flat-section predictions and vehicle-specific closure profiles. Results demonstrate that the
Ganesan, Karthikeyan, Seok, Sang Ho
Testing of Rigid Two- and Three-Wheeled Vehicle Pitch-Over Threshold Models2026-01-05384/7/2026
The phenomenon of bicycle pitch-over is simple in concept, yet determining threshold criteria for pitch-over has yet to be well established, particularly with respect to determining whether or not a bicycle’s front wheel will roll over a particular obstacle or not. Two prior SAE papers have laid out two different analytical approaches to predict this threshold – the Moment-Inversion and Brach Pitch-Over Threshold models - and this paper proposes a modification to the Moment-Inversion model to account for tire deflection. Testing began by measuring the center of gravity locations and moments of inertia for a bicycle with weights and training wheels and for a test rider on a bicycle and tricycle. These physical measurements were used to calculate the predicted pitch-over height for each system for each model. The test systems were then ridden over a series of progressively taller square edge obstacles until they transitioned from rolling over to stopping or pitching over. From this
Sweet, David Michael, O'Brien, Nathan, Bretting, Gerald
AI Powered Failure Mode and Effect Analysis in Safety Critical Industry2026-01-01064/7/2026
This paper presents the first systematic examination of Large Language Model (LLM) capabilities for automating the development of Failure Mode and Effects Analysis (FMEA) utilizing architectural diagrams as input. Although prior research has examined LLMs for FMEA tasks, our methodology incorporates innovative aspects, such as the direct analysis of architectural diagrams for component extraction, prediction of failure modes, causes, estimation of risk and a human-in-the-loop (Hu-IL) validation framework. We examine the capability of general-purpose LLMs to accurately automate the creation of FMEA by formulating a methodology that extracts components and signals from architectural diagrams, conducts automated component classification, and produces a comprehensive FMEA form sheet encompassing Severity, Occurrence, and Detectability (S/O/D) scoring. Our methodology is grounded in structured prompt engineering theory, utilizing scope bounding techniques to reduce hallucination while
Diwakaruni, Sundara Sasi Koushik, Krishnamurthy, Anunay
Understanding Adversarial Transferability in Vision-Language Models for Autonomous Driving: A Cross-Architecture Analysis2026-01-01704/7/2026
Vision-language models (VLMs) are increasingly used in autonomous driving because they combine visual perception with language-based reasoning, supporting more interpretable decision-making, yet their robustness to physical adversarial attacks, especially whether such attacks transfer across different VLM architectures, is not well understood and poses a practical risk when attackers do not know which model a vehicle uses. We address this gap with a systematic cross-architecture study of adversarial transferability in VLM-based driving, evaluating three representative architectures (Dolphins, OmniDrive, and LeapVAD) using physically realizable patches placed on roadside infrastructure in both crosswalk and highway scenarios. Our transfer-matrix evaluation shows high cross-architecture effectiveness, with transfer rates of 73–91% (mean TR = 0.815 for crosswalk and 0.833 for highway) and sustained frame-level manipulation over 64.7–79.4% of the critical decision window even when patches
Fernandez, David, MohajerAnsari, Pedram, Salarpour, Amir, Pese, Mert D.
High Strain Rate Behaviors of Fiber Reinforced Composites in Principal and Off-Axis Directions2026-01-01754/7/2026
Materials can exhibit significantly different mechanical behaviors compared to quasi-static conditions at high strain rates (> 100 s-1). High strain rate tests using setups such as SHPB (Split-Hopkinson Pressure Bar) can provide, in a practicable manner, the stress-strain relations for a material at high strain rates. Such properties are vitally needed for activities such as simulation-driven impact safety design of composite structures deployed in the form of automotive body parts and assembly, and other sub-systems. Although the behaviors of isotropic and ductile materials such as various metallic alloys appear to have been extensively studied and reported in literature, dependence of mechanical properties of fiber-reinforced composites especially in different off-axis directions are extremely difficult to come across. To fill up this void, a detailed experimental study has been carried out on high strain rate mechanical characterization of a laminated orthotropic glass/epoxy
Bawa, Prashant, Deb, Anindya, Barui, Ananya, Zhu, Feng
Curb Impact: Non-linear Structural FE Analyses in Multibody Dynamics Models2026-01-02194/7/2026
In a few extreme customer abuse load cases such as curb impact and potholes, automotive structures see non-linear (plastic) deformations as well as large rigid body motion. The load cases can be simulated by a few tools: crash analysis tools such as LS-Dyna, non-linear structure analysis tools, or multi-body dynamics (MBD) analysis tools like Ansys Motion. The three simulation tools have pros and cons, respectively. In this study, a curb impact simulation was performed using the multi-body dynamic approach with nonlinear structural analysis capabilities included in Ansys Motion. The tool demonstrated the simulation was completed faster than other MBD tools due to smartly recycling the system Jacobian matrix when structural deformation was not significant. The results were compared with structural analysis and correlated reasonably well. The post-impact suspension alignment changes can also be simulated for reviewing design requirements. This approach proposes a new way to simulate
Hong, Hyung-Joo, Kim, Wangoo
Bias and Uncertainty in the Time, Position, and Speed Data of Consumer-Grade GPS Devices2026-01-05444/7/2026
The goal of this study is to quantify the accuracy (bias) and precision (uncertainty) of the time, position, and speed data acquired by a range of consumer-grade devices (4 bike computers, 5 watches, 1 application on 3 smart phones, and a camera) that access Global Positioning System (GPS) satellite signals. We acquired data at each device’s maximum sampling rate (typically 1 Hz) during 207 minutes (twelve sessions of ~17 min) over 61.6 km of road cycling. The time and position data from these devices were compared to real-time kinematic (RTK) data acquired using a differential GPS system, and speed data from these devices were compared to a high-resolution wheel speed sensor synchronized to the RTK data in order to statistically estimate the bias and 95th percentile confidence intervals of the uncertainty of the devices’ data. Overall, we found the position and speed data from the devices generally lagged the reference by 4 s or less, although the lags between the speed and position
Booth, Gabrielle R., Mitchell, Alan L., Siegmund, Gunter P.
From Algorithm to Engineering Judgment: Navigating Topology Optimization’s Limits in Crash Applications2026-01-01894/7/2026
The non-linear nature of crash scenarios has led to many designs being developed through extensive trial and error based on the intuitions of the design engineer. As such, effectively utilizing topology optimization for crash applications offers opportunities to provide major improvements in cost, weight, and passenger safety. Topology optimization is known for creating stiff, lightweight structures, however its application to crash scenarios must be handled carefully. Compliance minimization, the most common optimization objective, can yield misleading designs that prioritize undesirable qualities when developing structures for crash applications. In this paper, the design process of a passenger seat assembly subject to sequentially applied enforced displacement, and crash deceleration loads is discussed. Due to the conflicting nature of compliance minimization and enforced displacement, the design was split into two types of regions; sacrificial, which are regions manually designed
Orr, Mathew, Shi, Yifan, Lee, Jake, Gray, Savannah, Park, Taeil, Wotten, Erik, LeFrancois, Richard, Huang, Yuhao, Patel, Anuj, Kim, Hansu, Burns, Nicholas, Jalayer, Shayan, Grant, Robert, Kok, Leo, Hansen, Eric, Kim, Il Yong
A Novel Spot Joint Finite Element for Rapid Stress Analysis of Fasteners in Automotive Structures2026-01-01824/7/2026
Due to the spot weld and mechanical fastener share the similar characteristics to join sheets together with differences in deformation behavior around joint region, a novel spot joint element (user-defined element) consists of regular Mindlin shell elements and equations for different kinematic constraints is proposed to simplify the spot joint representation in lightweight automotive structures. The novel spot joint element can not only provide accurate deformation behavior around joint region but also output mesh-insensitive structural stresses at virtual nodes with the use of traction-based structural stress method for fatigue failure analysis. In this investigation, the structural stress distributions around joint circumference in the lap-shear specimens with spot weld or fastener are first calculated to validate the accuracy of the novel spot joint element. Then, the structural stresses along different cross-sections emanating from joint are also calculated for the specimens with
Wu, Shengjia, Zhang, Lunyu, Dong, Pingsha
Effects of Obstacle Height and Vehicle Roll Behavior on Electric Vehicle Side Impact Safety2026-01-04054/7/2026
Electric vehicles (EVs) face unique safety challenges under pole side impact conditions, largely due to the presence of floor-mounted battery packs. Existing regulatory test procedures, such as FMVSS 214, primarily address occupant injury using full-height cylindrical obstacles. These procedures were originally developed for internal combustion vehicles (ICVs). However, real-world roadside crashes frequently involve obstacles of varying heights, such as guardrails, curbs, and median bases. While these obstacles pose limited risk to the passenger compartment, they can intrude into the battery pack and trigger thermal runaway. This study investigates the influence of obstacle height on EV pole side impacts. Finite element simulations of a commercially available sedan were conducted against rigid obstacles of different heights. Results reveal a non-monotonic trend of battery intrusion governed by the interplay between rollover dynamics and structural stiffness. Theoretical analyses were
Ma, Chenghao, Xing, Bobin, Zhou, Qing, Xia, Yong
Elucidation of Flow Mechanisms Modulating Vehicle Wind Noise by Using Large-Scale CFD Simulation2026-01-06144/7/2026
In vehicle development, noise reduction is critical for ensuring passenger comfort. As electric vehicles become prevalent and engine noise is minimized, wind noise becomes more noticeable. Modulated wind noise, which causes a sense of fluctuation due to atmospheric turbulence, wind gusts, and preceding vehicle wakes, can cause significant discomfort. This noise is characterized as a high frequency sound above 1 kHz, modulated at low frequencies owing to the wind velocity and direction fluctuating at several Hz. The mechanisms behind wind noise modulation are not fully understood, and no established countermeasures have been developed. This is because wind noise perceived through the side window is primarily caused by the A-pillar vortex and door mirror wake, which coexist as complex turbulent flows around the vehicle. Therefore, identifying the source of modulated wind noise around vehicles under fluctuating wind conditions is difficult. This study aims to identify the source of the
Tajima, Atsushi, Hirata, Takumi, Ikeda, Jun, Kamiwaki, Takahiro, Wakamatsu, Junichi, Tsubokura, Makoto
Computational Modeling and Optimization of Shape Memory Polymer-Based Energy Absorbers2026-01-05734/7/2026
Shape memory polymers (SMPs) provide tunable thermomechanical properties and enable the design of recoverable crash structures for automotive applications. This paper introduces a computational framework for the design and optimization of SMP-based crash absorbers with periodic auxetic microstructures. First, a finite element (FE) model is developed and validated against experimental data regarding crushing and recovery behavior. A parametric study is then performed by varying key microstructural features, including wall thickness, cell size, and cell shape. Structural performance is evaluated in terms of specific energy absorption (SEA), peak force, and recoverability. To efficiently explore the high-dimensional design space, surrogate models based on machine learning are constructed, and multi-objective optimization is carried out to identify Pareto-optimal designs that balance competing objectives. The parametric study indicated that geometric parameters strongly influenced energy
Zhu, Yingbo, Zhu, Feng, Deb, Anindya
Optimizing Custom Hybrid Solutions for Low-Volume Specialist Equipment2026-01-04794/7/2026
Off-road vehicles are typically powered by diesel engines, sized to cover the highest peak loads in their dutycycles. Such applications can be designed with downsized engines, using hybridization to supplement engine power with electrical power for short periods. However, many applications are low-volume and specialized, making it impractical to deploy heavy engineering resources to optimize each one. For this reason, manufacturers tend to produce maid-of-all-work vehicles to cover every situation. This paper demonstrates the benefits of custom hybridization for specialist applications, and addresses the lack of accessible software tools for evaluating such opportunities. Analysis is applied with a fast, low-cost, Concept-based software tool named “ePOP Concept”, suited to original equipment manufacturers (OEMs) who seek to provide custom low-volume vehicles. It allows many different powertrain architectures to be evaluated rapidly at the product planning stage, and can be quickly set
De Salis, Rupert, Fons, Daniel
Design and Simulation Analysis of an Integrated Honeycomb-Filled Front Bumper for a Special Vehicle2026-01-04754/7/2026
In frontal collisions of automobiles, the bumper beam at the front of the vehicle plays a crucial role in absorbing energy and protecting the vehicle body during a collision. To enhance the collision resistance of a specific type of special vehicle with a non-load-bearing body structure, this paper focuses on this type of vehicle and conducts a study on the design and collision performance of an integrated vehicle front bumper - anti-collision beam structure based on aluminum alloy additive manufacturing technology. A novel bumper structure is proposed, which integrates the front bumper and the front anti-collision beam of the vehicle and is integrally formed using aluminum alloy additive manufacturing technology. This integrated structure is directly connected to the vehicle frame. Firstly, based on the appearance of the special vehicle body and the form of the front anti-collision beam of traditional passenger vehicles, an integrated design of the vehicle front bumper- anti-collision
王, Xufan, Yuan, Liu-Kai, Zhang, Tangyun, Wang, Tao, Zhang, Ming, Wang, Liangmo
Advancing Safe Battery Design through Experimental Cell Characterization of Thermal, Electrical and Mechanical Properties2026-01-04084/7/2026
Lithium-ion batteries are critical to Electric Vehicles (EV) and grid-scale energy storage. Safe design of battery systems relies on accurate simulation of thermal runaway under electrical, thermal, and mechanical abuse. A predictive battery simulation requires characterization of electrical, thermal, and mechanical properties at the full cell and cell-component levels. In this study, a commercial cell from an EV was disassembled, and tested to support both homogenized and detailed computational models. At the cell level, electrical properties were characterized using Hybrid Pulse Power Characterization (HPPC) testing to assess the cell’s power capability. Full cell compression tests were conducted to characterize mechanical behavior under deformation and used to develop a multi-physics homogenized cell model. On the other hand, detailed cell modeling that includes different component layers could help users understand localized cell integrity under mechanical deformation. At the
Challa, Vidyu, Rostami-Angas, Masoud, kong, Kevin, Wang, Leyu, Reichert, Rudolf, Kan, Cing-Dao
Application of Reliability Growth Methods in Conjunction with Design for Reliability Framework to Validate Heavy Truck Design2026-01-01374/7/2026
Why field campaigns in the automotive industry have been going up over the years despite the strong development of technical knowledge, computational design tools and techniques to secure higher reliability standards since early stages of development phases? Uncertainties created by product complexity have been a factor that affects the ability of the manufacturers to prevent design failures before the product launch. Another factor is the shorter product development time, less test time to validate the product means that the new design will not have enough exposure to the real truck application and so some failures may not be able to be detected during the project. To deal effectively with uncertainties this study shows an application of reliability growth techniques in conjunction with DfR- Design for Reliability framework to validate the truck design in the customer application. The Crow - AMSAA method is applied to measure the reliability growth of the complete vehicle in various
Coitinho, Marcos
Backward Fuzzy Driving Control for 6×4 Off-Road Vehicles2026-01-01484/7/2026
Off-road autonomous vehicle systems must be able to operate across unstructured and variable terrain while avoiding obstacles. This presents significant challenges in vehicle and control system design, especially for less conventional platforms such as 6×4 vehicles. While forward driving autonomy has developed and matured in recent years, effective reverse navigation remains an under-explored area of vehicle co-design. Reversing 6×4 vehicles have limited rear steering authority, an extended wheelbase, and asymmetric traction, which introduce complex dynamics into any control system that is used. To address this need, a robust and experimentally validated fuzzy logic control architecture for 6×4 reverse navigation was developed during the course of this project. This architecture incorporates both near-field and long-range path data with adaptive outputs controlling steering and velocity based on a rule base that covers the whole vehicle state space. This method has low computational
Dekhterman, Samuel R., Sreenivas, Ramavarapu S., Norris, William R., Patterson, Albert E., Soylemezoglu, Ahmet, Nottage, Dustin
Integrated Effects of Suspension Geometry and Tire Pattern Design on Vehicle Pull Reduction under Acceleration in High-Performance and Electric Vehicles2026-01-05934/7/2026
Vehicle pull under acceleration is a phenomenon commonly observed in high-performance vehicles and electric vehicles (EVs), primarily arising asymmetric driveshaft angles, drivetrain architecture, and suspension geometry. In addition to these mechanical factors, tire characteristics, particularly the tire lateral force generated at the contact patch, significantly influence this effect. The lateral force is intricately tied to the dynamics of the contact patch and the geometric design of the tire tread pattern. This study investigates the relationship between tread pattern geometry and vehicle pull under acceleration, emphasizing the role of tire lateral force variations. By employing finite element (FE) simulation, lateral force response variations (dfy/dfx) resulting from tread block deformation were analyzed. Based on these simulation, a robust analytical methodology for tread pattern evaluation and optimization was established. The developed tread pattern characteristic parameter
Yoon, Youngsam, Jang, Dongjin, Kim, Hyungjoo, Lee, Jaekil
Application of Fatigue Damage Criteria to CAE-Based Fatigue Life Prediction of a Welded Chassis Component2026-01-02324/7/2026
In recent years, computer-aided engineering (CAE) has become an essential practice in design and durability analysis of industrial components such as weldments. The current analytical trend for CAE-based fatigue life prediction of weldments includes procedures based on design guidelines, mesh-sensitive methods (e.g., local strain-life approach) and mesh insensitive methods (e.g., Volvo and Verity methods). As an inherent characteristic of weldments, the geometry of the weld is often simplified in failure analysis and important hotspots such as start/stop of the weld beads are not considered in the design process. However, such critical locations cannot be avoided in complex welded structures. Therefore, incorporating main geometrical details of the weld can improve the accuracy of critical regions identification and damage calculation using mesh-sensitive CAE-based methodologies. Herein, a framework for life prediction of welded components including the weld geometry is discussed and
Razi, Ahmad, Kim, Dooyoung, Park, Jaehong, Youk, Wansoo, Fatemi, Ali
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