Browse Topic: Failure analysis

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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
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
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
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
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
Investigating Thermal Fatigue Cracks in Exhaust Manifolds of Longitudinally Mounted 1.2L 4-Cylinder Engines2026-26-0488To be published on 01/16/2026
This study addresses the challenge of ensuring the durability of closed couple exhaust manifolds in the compact engine bays of modern vehicles, focusing on a longitudinally mounted 1.2L 4-cylinder engine. The original sheet metal Exhaust manifold design failed thermal fatigue bench durability test, requiring a complete redesign to improve strength without changing materials. Initial simulation predictions significantly deviated from physical test results, with repeated cracks observed during accelerated thermal fatigue bench testing, despite simulations predicting a higher number of cycles before failure. This difference highlighted the need for a deeper understanding of the manifold's failure modes, primarily thermal fatigue, and mechanical vibration during engine transients. The design of experiment (DOE) approach was used to find the effect of different parameters e.g., gas temperature, surface temperature, air flow, thermal gradient, on the durability result & also to understand
Krishnan, K.S.Gopala, Mishra, Ashutosh, Yadav, Sanjay Kumar, Kumar, Deepak, Tripathi, Manas, Kumar, Prabhakar
Digital Twin for Motor & MCU incorporating Deep learning AI-ML algorithms for intelligent prognostics for Electric vehicles2026-26-0479To be published on 01/16/2026
As electric vehicles (EVs) become more advanced, so ensuring the reliability of critical components like the motor and Motor Control Unit (MCU) is essential. This paper presents a digital twin model designed to predict failures in motor and MCU components using machine learning. The approach focuses on detecting early signs of failure through real-world data and advanced analytics. We collected thermal and performance data from field vehicles, capturing both normal (healthy) and abnormal (faulty) operating conditions. Using this dataset, we developed and trained an Auto Encoder-based machine learning model that learns what “normal” looks like and flags deviations as potential issues. One key outcome of this study is the successful early prediction of Insulated Gate Bipolar Transistor (IGBT) degradation, where the system identified subtle behavioral changes long before any visible failure symptoms appeared. This digital twin acts as a virtual replica of the physical components
Joshi, Pawan, Pandey, Suchit, KONDHARE, Manish, Upadhyay, Abhay, JaganMoahanarao, Vana, Tank, Prabhu
Test method and set up development for electric parking brake performance and durability validation in vehicle level as per RWUP2026-26-0505To be published on 01/16/2026
The Objective is to develop a testing load case which can assess vehicle electric parking brake (EPB) performance and durability at vehicle level in different project development phases. In current scenario the EPB become one of a primary feature available in many passenger vehicles helps customers to apply this secondary braking system to hold the vehicle when parked. So, it is particularly important to evaluate this feature close to RWUP for the vehicle service life and studying the result before vehicle launch. The test method should be capable of capturing failures related to physical concerns, electrical characteristics, actuation time, gradient vehicle hold, effectiveness during vehicle running and durability. The most important challenge in this test method development is it should simulate the actual sequence followed by user in field on vehicle. A completely automated test set up integrating PLC and COBOT with closed loop feedback developed and discussed in this paper. During
Dhanapal, M R, Vijayakumar, Narayanan, Mahesh, B, B, Venkatasubramanian, Arthanathan, Sankaranarayanan
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-0501To be published on 01/16/2026
Manufacturing tolerances pose considerable challenges in the production of rubber-based components, often leading to dimensional variations that can compromise overall product reliability. These inconsistencies may result in a range of functional issues, including poor sealing, excessive wear, misfit during assembly, and premature failure. Among these components, grommets are especially sensitive due to the complex, non-linear behavior of rubber materials, making precise dimensional control critical to ensure consistent and dependable performance. Even minor deviations in grommet geometry can trigger substantial assembly difficulties. Issues such as misalignment, buckling, insertion challenges, and potential damage to neighboring parts are commonly encountered. These complications typically require multiple rounds of design revisions and physical testing, which extend development timelines and significantly increase production costs. Real-world observations from various automotive
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, Pathan, Eram
Coupled Thermo-Mechanical Simulation Framework for Structural Evaluation of Battery Pack2026-26-0414To be published on 01/16/2026
With the rapid adoption of electric vehicles (EVs), ensuring the structural integrity and thermal safety of lithium-ion battery pack has become a critical priority. Battery failures resulting from mechanical abuse, thermal stress, internal pressure build up or electrical faults may lead to structural failure. To address these challenges, it is essential to understand the coupled thermal and mechanical responses of battery structure under extreme conditions. Thermo-mechanical simulation serves as a powerful tool for predictive safety assessment and design optimization, particularly in addressing thermal propagation and pressure-induced failure events. This study presents a comprehensive coupled thermo-mechanical simulation framework designed to evaluate the structural performance of EV battery enclosures under worst-case thermal and overpressure conditions. The methodology involves high-fidelity three-dimensional modeling of the battery pack enclosure, incorporating realistic material
Bhat, Sadashiv C, Sugumar, Mohanraj
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
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
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
Investigation of Fatigue Durability Failure Mechanisms in High-Pressure Hydraulic Pipes of Power Steering Systems2026-26-0542To be published on 01/16/2026
Abstract—The high-pressure hydraulic pipeline in the power steering system is a vital component for ensuring optimal performance. During warranty analysis, leakage incidents were observed at the customer end within the warranty period. The primary factors contributing to these failures include pipe material thickness, material composition, mechanical properties, and engine-induced vibrations. This study investigates fatigue-related failures through detailed material characterization and Computer-Aided Engineering (CAE) based on real world usage road load data collected. The objective is to identify the root causes by examining the influence of varying pipe thickness on fatigue life. The investigation discovered that crack initiation predominantly occurred on the concave side of bent pipe sections, specifically on the engine-side high-pressure steering line, which is connected to the power steering pump mounted on the engine. Fracture surfaces exhibited characteristics consistent with
Survade, Lalit, Koulage, Dasharath Baliram, Biswas, Kaushik
Study of Style wheel rim failure Due to Rim and disc assembly interference2026-26-0541To be published on 01/16/2026
This study focuses on the investigation of wheel rim failures near weld zone during repeated cornering induced by interference between the rim and disc during the wheel manufacturing assembly process. Strain gauges were employed to capture real-time stress and strain distributions at critical zones during interference fitting. The experimental results revealed that improper interference levels lead to significant stress concentrations, often surpassing the material's elastic limit, initiating micro-crack formation and promoting fatigue failure. Detailed strain analysis indicated that both radial and axial stresses contribute to long-term structural degradation. The study highlights the critical role of dimensional tolerances, surface finishes, and assembly forces in minimizing stress-induced failures. Recommendations are provided for optimizing design and assembly practices to enhance the durability and reliability of automotive wheels.
P, Praveen, DEsigan, Lakshmipathy, K, Chandramohan, C, Santhosh
Development of an Software Algorithm Based Semi-automated Data Acquisition System for Gasoline Vehicle Calibration on Chassis Dynamometer2026-26-0535To be published on 01/16/2026
Vehicle level testing is one of the crucial part of the calibration development. In this, chassis dynamometer is used to collect the vehicle level data. Different engine and vehicle level parameters are logged at various speed and load points covering the entire engine operational zone. This data acquisition is a repetitive activity and covers over 30-40% of the total testing duration. This phase includes base calibration verification, transient development, and emissions-related calibrations, all of which follow a standardized and repetitive sequence. However, these tasks are predominantly performed manually, leading to potential human error and inefficiencies. This paper presents a novel and comprehensive algorithm developed using INCA FLOW software; the first of its kind for this application. Here, crucial vehicle data acquisition activities are identified, mapped into detailed steps. The algorithm introduces a semi-automated, stepwise process for data acquisition during chassis
Kavekar, Pratap Chandrashekhar, Tyagarajan, Sethuramalingam, Agarwal, Nishant Kumar, Shaikh, Wasim, Karadi, Subramanya
Tailgate Stiffness Mitigation and Engineering Strategy for Y-to-Y Tailgate-Mounted Tail Lamp Integration2026-26-0494To be published on 01/16/2026
The tailgate, as the rearmost vehicle opening, plays a pivotal role in defining the rear aesthetic theme while ensuring structural durability and maximizing luggage space. Contemporary automotive design trends highlight an increasing demand for Y-to-Y tailgate-mounted tail lamp configurations, which deliver a bold and dynamic visual appeal. Enhanced by animated lighting features, these designs cater to the preferences of Gen Z customers, becoming a decisive factor in purchasing decisions. However, integrating these complex tail lamp structures introduces significant engineering challenges, including increased X-dimension volume, reduced design space, and intricate mounting schemes constrained by stamping limitations. These factors necessitate the development of innovative joinery strategies and structural definitions to maintain durability targets, including achieving 25,000–30,000 slam cycles without failure, while preserving luggage space. This paper explores a comprehensive approach
Beryl, Joshua, Mohanty, Abhinab, Unadkat, Siddharth, Selvan, Veera
An investigation into the Structural Impacts of Off-Road Manoeuvres on Rear Axle upper Link Mounting Bracket2026-26-0490To be published on 01/16/2026
Multi-link rigid axle suspension is widely used as a rear suspension system for body-on-frame SUVs. The upper link in a multi-link rear suspension plays a critical role in managing the vertical and longitudinal positioning of the axle, while the lower link ensures stability by regulating the axle's movement in the horizontal plane. This coordinated functionality of upper and lower link allows for controlled axle dynamics during compression and rebound, significantly enhancing ride comfort and improving vehicle handling characteristics. This study examines the failure of an upper link mounting bracket on the rear axle of an SUV during off-road events, despite no failures observed in other durability tests. Root cause analysis is conducted on failed samples to determine the specific reasons for failure only in off-road conditions. Additionally, the investigation focuses on understanding the dynamic loads experienced by the upper link during vehicle operation across various durability
J, Akhil, Senthil Raja, T, Ghumare, Dheeraj, Chilakala, Raghavendra, Kundan, Lal, Mohapatra, Durga Prasad
Dimensional Management in Automotive Vehicle Design & Development for Perceived Quality Improvement in Buses2026-26-0447To be published on 01/16/2026
Perceived quality (PQ) is one of the most important factors in engineering signoff as well as customer delight and product improvement (feel, look & touch). The PQ is something related to feel of the product in terms of gap, flushness, fitment and appearance as per the costumer perceptions and expectations. Validate both design and engineering with the perceived quality review. In today's automotive bus industry this is equally applicable. In this paper we have explored the dimensional management scope in improving the PQ requirements and expectations by utilising the dimensional variation analysis (DVA) approach. We have explored & explained the fundamentals of vehicle aggregates fitment process and impact of fitment tolerances as used in DVA model to resolve vehicle packaging issues (critical gaps & clearance variation as per expected no. of vehicles to be manufactured in future at initial stage of the vehicle design). It is further extended into system level DFMEA to include DVA in
Singh, Vinay Kumar, Dewangan, Ved Prakash, Kumar, Rahul, Deep, Amar
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
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
Next Gen Automotive EDS Architecture Design Verification using Real-Time Function Mode Simulation and Failure Condition Analysis2026-26-0454To be published on 01/16/2026
In current automotive electrical design practices, simulation and functional verification of the Electrical Distribution System (EDS) at the design stage are largely absent. Typically, the validation of controller behaviour and EDS wiring is performed only during HIL, SIL, MIL, prototype testing, or physical vehicle trials, often revealing issues late in the development cycle. This delay leads to costly redesigns, prolonged timelines, and increased chances of failure during vehicle integration. Therefore, there is a critical need for an early-stage simulation methodology that ensures robust EDS and controller design, enabling "first-time-right" readiness at the design stage itself. The proposed simulation framework introduces a function mode-based structural approach, where individual vehicle functions are mapped to their corresponding electrical circuits within the vehicle’s wiring system. Resistance values are allocated to specific paths depending on the active function or
Jaisankar, Gokulnath, Warke, Umakant, Chakra, Pipun, Borole, Akash
Simulation Research on Torque Vectoring, Braking, Chassis control Strategies for Electric & hybrid Vehicles using System Simulation2026-26-0423To be published on 01/16/2026
Electric Vehicles and Plug-in Hybrids alleviate the energy crisis but pose a unique challenge for vehicle dynamics. Though significant developments in motor control strategy and energy density management are evolving, we face significant challenges in Torque Management with several ADAS features being integral part of the EV's/xHEV's. It demands high-fidelity physical and control model exchanges between electric-chassis, ride-handling, tire modelling, Steering Assist, powertrain and validate using 0D-1D platform. This paper explicates a unified strategy for improving overall vehicle performance by intelligently distributing and coordinating drive torque to enhance traction, stability, and drivability across diverse operating conditions through the co-simulation. Co-Simulation platform includes physical models in AMESIM, and control strategies integrated in MATLAB/Simulink. The platform features comprehensive representations of digital vehicle that requires detailed modelling of
Eruva, Patrickxavier, Sarapalli Ramachandran, Raghuveeran, Chougule, Sourabh, Natanamani-Pillai, Siva Subramanian, Scheider, Clement, Leclerc, Cedric, Natarajasundaram, Balasubramanian
Accelerating Product Development Life Cycle through Digitalization of Fatigue Life for Structural Components2026-26-0496To be published on 01/16/2026
In today’s competitive market, accelerating product development without compromising durability is critical. Durability is a key benchmark for assessing the quality and reliability of automotive products. To meet rising customer expectations and regulatory demands, the industry must develop vehicles that offer high performance and reduced weight while ensuring safety. A well-engineered vehicle must retain structural integrity and functionality under normal operating conditions and withstand extreme load events without critical failure. Achieving this requires effective Road Load Data Acquisition (RLDA), integrated with robust design practices and efficient validation processes. However, physical RLDA is time-consuming and costly, as it depends on prototype vehicles that are often available only in the later development stages. Failures identified during these late-stage tests can delay the product launch significantly. To address these challenges, this paper introduces a digital
Kokare, Sanjay, Dwivedi, Sushil, Siddiqui, Arshad, Iqbal, Shoaib
Hardware in Loop Validation of Rotary Switch with TFT Display2026-26-0540To be published on 01/16/2026
The increasing complexity of modern automotive drive control systems necessitates the adoption of robust validation methods to ensure functional safety, reliability and customer satisfaction. This paper presents the development and implementation of a comprehensive Hardware-in-the-Loop (HIL) testing framework designed specifically for a specific ECU known as Gear Selection Switch (GSS)/Drive control switch (DCS) system. Hardware-in-the-Loop (HIL) Testing is a simulation-based testing technique where real physical hardware (like an electronic control unit, switch or sensor) is tested by connecting it to a virtual simulation of the rest of the system — instead of testing it inside a real vehicle. Following the analysis of all the field failure incidents reported till date for GSS, detailed root cause investigations were conducted using in-house testing and Ishikawa diagram analysis. A critical failure mode was identified and addressed through targeted mechanical design modification and
Bhuyan, Anurag, Jahagirdar, Shweta, Khandekar, Dhiraj
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
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
A study on the thermal degradation of chlorinated Polyethylene rubber2026-26-0276To be published on 01/16/2026
Elastomeric materials are essential in advanced automotive engineering for mobility, isolation, damping, fluid transfer (cooling, steering, fuel, and brake), and sealing because of their unique physio mechanical properties. Elastomers are commonly used in both static and dynamic components, such as hoses, mounts, bushes, and tires. Engine emission standards and weight optimization have caused higher temperature exposure conditions for automotive components. The steering system uses special purpose elastomers like Chlorinated Polyethylene that can deteriorate under abnormal conditions during vehicle operation or manufacturing process due to the high temperature exposure. Therefore, it is crucial to comprehend the causes and consequences of thermal degradation of elastomers. Thermal degradation is a significant phenomenon that changes the physical and chemical properties of elastomers, which results in a product not meeting functional requirements. This study investigates the thermal
Thiruppathi, Anandhi, Mishra, Nitish, Krishnamoorthy, Kunju
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
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
A systematic debugging methodology for identifying electric vehicle level EMC issues.2026-26-0525To be published on 01/16/2026
Electric vehicles present unique challenges in electromagnetic compatibility testing due to compact packaging, high-frequency switching systems. This paper presents a systematic debugging methodology for identifying radiated emission and radiated immunity issues in these EV platforms. A comprehensive approach is outlined, covering radiated emission measurement; Bulk Current Injection based immunity simulation, and near-field probing techniques. For RI evaluation, BCI testing in the 20 to 400 MHz range is used to simulate radiated threats on the vehicle's power and signal harnesses and handy transmitter near field injections for higher frequency simulation. For RE diagnosis, conducted emission measurements on vehicle harnesses are performed using current probes to capture high-frequency currents. Additionally, near-field electric probes are used at the component to identify dominant noise sources such as DC-DC converters, Motor control unit, and improperly grounded shielding. Case
M, Gokul, Patel, Jinay, Mulay, Abhijit B
BEARING CREEP PREVENTION IN EV TRANSMISSION2026-26-0598To be published on 01/16/2026
As the trend shifts from Internal Combustion Engine (ICE) vehicles to Electric Vehicles (EVs), the operating speeds of prime movers have significantly increased. Commercial EV manufacturers prefer high-speed, low-torque motors coupled with transmissions over low-speed, high-torque motors due to higher efficiency and power density. This combination of high-speed, low-torque motors coupled with transmission is essential for achieving the required gradeability and enhances operational efficiency. However, the increased operating speeds of these EV transmissions have inherently increased the risk of ‘bearing creep’. The “bearing creep” is the phenomenon where unintended relative motion occurs between bearing races and their mounting surfaces, leading to premature wear of mounting surfaces. This issue can lead to a series of failure modes such as increased gear mesh misalignment, bearing damage, seal damage, etc. These problems result into elevated transmission vibrations eventually leading
Bagad, Sachin Sunil, Kanase, Ashish, Hiremath, Satalingayya, Nevarekar, Sandip
Experimental Evaluation of Metro Rail Bogie Frame through Bench Testing2026-26-0561To be published on 01/16/2026
Bogie frame is a main skeleton and structural member in railway system which is carrying all the loads such as Suspensions,Axles,wheels, car body, Motor, Gear box etc. The frame is subjected the exceptional and service stresses in Vertical, Longitudinal, Lateral and twist directions throughout the service life which should be withstand for a life span of 30 years without failure. The purpose of this project is to determine the Structural integrity of the Metro rail bogie frame in consideration with EN13749 standard .This paper is the outcome of bench testing of metro rail bogie frame with the application of multiaxial loading in static and dynamic campaign through which stress data is collected with strain gauge sensors and correlated with the FEA results at design stage. This helps to verify and evaluate the design and validate the quality of metro rail frame as per the requirement specified in EN13749 European standard in early design stages.
Tormal, Uday Bapurao, Sinnarkar, Nitin, Shinde, Vikram
Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application2026-26-0286To be published on 01/16/2026
Quality of the Shear Trimmed edge of HSLA 550 steels is significantly affected by process variations such as Shear Trimming Clearance, trim tolerance, burr height and clamping force. All these parameters largely influence the characteristics of the Shear Affected Zone, a region on sheet metal where it undergoes deformation during the trimming process. The Shear Affected Zone is predominantly vulnerable to failure due to work hardening and the effects of strain rate, induced by the tonnage during the trimming operation. To assess the edge ductility of these materials, Tensile, Fatigue Strength, Die Punch Clearance, Roughness and Hardness Tests are carried out. These tests are crucial for applications that demand high formability and resistance to edge failure. Virtual simulation of edge trimming operation using elastoplastic material models in LS-Dyna have been performed to gain insights into burr formation and damage evolution during shearing. These simulations act as a precursor to
Thota, Badri Vishal, Kashyap, Amit, Bhuvangiri, Jaydev
A Machine Learning Approach to Early-Stage Failure Prediction in Traction Motor Manufacturing2026-26-0281To be published on 01/16/2026
Traction motors technology has, driving the EV industry forward with more efficient, lightweight, and durable solutions. However, despite these advancements, noise testing at the end of the production line remains a critical stage for identifying manufacturing defects in traction motors. Hence early fault detection in traction motors is crucial to ensure safety and reliability of EV. This research contributes a solution that predicts early-fault detection, supporting improved reliability, reduced material cost and minimizing process time in the series production line. To identify the root cause of this problem, historical quality data has been acquired from manufacturing plants to enable efficient analysis. Feature selection was then carried out using embedded and wrapper methods to identify the most important features. These selected features were subsequently used as input for ML models. The best accuracy was achieved using SVC model for early-stage motor failure prediction.
Gaikwad, Pooja, Nangare, Kapilraj, Suryawanshi, Chaitanya
Challenges in Compliance Testing of off-Board Electric Vehicle Chargers: Analysis of Typical Failures and Remedial Measures2026-26-0582To be published on 01/16/2026
As India accelerates the adoption of electric vehicles (EVs) the development of a scalable, reliable, and efficient charging infrastructure becomes critical to ensuring the success of EV adoption. During type testing, the off board AC/DC EV chargers undergo a comprehensive assessment to ensure they meet safety and performance standards required by regulations. The tests examine crucial factors like electrical safety, EMC (electromagnetic compatibility), interoperability, environmental endurance, and mechanical strength. This paper provides information of the mandatory compliance requirements and highlights typical failure modes observed during the validation process of off-board chargers. Emphasis is placed on challenges associated with electrical safety, EMC performance, and interoperability. The objective is to support charger manufacturers to identify potential issues during design and development.
Murumkar, Aditya, Mulay, Abhijit B
SEooC-Based Design Framework for Integrated EV Power Conversion Systems under ISO 26262 Compliance2026-26-0192To be published on 01/16/2026
The rapid integration of electric vehicle (EV) power conversion elements—such as traction inverters, onboard chargers, and DC-DC converters—into unified architectures poses new challenges for ensuring functional safety compliance as per ISO 26262. This paper presents a system-level framework that leverages the Safety Element out of Context (SEooC) approach to design and validate reusable safety-critical components independent of vehicle-specific applications. By defining clear assumptions of use and ASIL decomposition strategies, the proposed method facilitates early-stage fault analysis and verification. The framework integrates model-based development with Hardware-in-the-Loop (HIL) testing and formal verification techniques to validate both control logic and hardware behavior under diverse fault injection scenarios. The result is a scalable, standards-compliant methodology that reduces time-to-market and enhances reliability in integrated EV power electronics platforms. The work
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Experimental Research on MFL Detection Technology for Corrosion Damage of Prestressing Tendons in Bridges2025-99-0203To be published on 12/23/2025
Corrosion of prestressed tendons endangers the safety of bridges, but until now, there has been no effective method to solve the problem of detecting corrosion damage in prestressed tendons of concrete beams. To address this, a magnetic flux leakage detection experimental apparatus for corrosion damage in prestressed tendons based on the principle of magnetic flux leakage inspection has been developed. Using this apparatus, magnetic flux leakage tests were conducted on prestressed tendons after electrochemical corrosion, and the results were compared with simulation analysis to conduct a comparative study. In the experiments, the influence of corrosion severity, corrosion width, and the effect of stirrups on the characteristics of the magnetic flux leakage signals were studied. Magnetic signal feature values were extracted, and a quantification neural network model for corrosion damage was established, which is used to quantify the degree of corrosion damage in prestressed tendons. The
Wang, Peng, Gao, Min, Dong, Lei, Zhu, Junliang
Experimental Investigation of Stress Distribution Characteristics in Surrounding Rock during Unloading in Oblique Upper Crossing Tunnel2025-99-0242To be published on 12/23/2025
The construction technique of oblique upper crossing tunnels with small clear distance is difficult and dangerous. Relying on the existing oblique upper crossing tunnel project of Xinfucun tunnel, an assembly 3D-printed tunnel model was developed, and similar model tests were designed and conducted to examine the stress distribution of the surrounding rock during the unloading process, through varying both tunnel clearances and unloading methods. The results show that the surrounding rock constraint of the lower existing tunnel was reduced when the oblique upper crossing tunnel was unloading. As the clear distance between two tunnels (CDT) increased, the stress diffusion along the outer edge of the tunnel diminished. When CDT exceeded 1.5B, the arch roof stress of the existing tunnel stabilized. The stress growth rate at the bottom of the new tunnel decreased when CDT is greater tahn 2.0B. During the unloading process of the three-step and six-guide-hole method (3S-6HM), the stress
Wu, Hao, Qin, Shuzhen, Li, Guofeng, Dong, Tianwen, Shi, Yongyue
Biocomposite of Euterpe oleracea Mart and Cocos nucifera l. : Sustainable Materials2025-36-0163To be published on 12/18/2025
Euterpe oleracea Mart.Cocos nucifera L.
Dias, Roberto Yuri Costa, Santos Borges, Larissa, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor, Silva de Mendonça, Alian Gomes, Fujiyama, Roberto Tetsuo
Research on SHM Acceleration Data Recovery Method Based on CNN-BILSTM2025-99-0341To be published on 12/17/2025
In the field of bridge structure condition monitoring, sensor systems often have abnormal or missing monitoring data due to environmental interference or equipment abnormalities. This situation may affect the accuracy of structural safety assessment. In this study, combined with deep learning, aiming at the problem of monitoring data completion, a prediction method based on BILSTM is proposed, and a CNN-BILSTM combined model is constructed for acceleration signal prediction. The prediction effects of the three algorithms, LSTM, BILSTM and CNN-BILSTM, were compared horizontally. Through the analysis of the MAX-MAE-RMSE-R2 index system and the fit degree of the prediction curve, it was confirmed that the combined model has better prediction performance. The experiment adopted the monitoring data of the accelerometer of the Hardanger Bridge in Norway as the training test set. Taking the H1E measurement point data as an example, the MAE index of CNN-BILSTM is 4.2% lower than that of BILSTM
Zhang, Xiangyi
Multi-Fault Analysis of Aircraft Main Landing Gear Retraction Hydraulic System2025-99-0301To be published on 12/17/2025
Aiming at the common health performance influencing factors of the aircraft’s main landing gear retracting hydraulic system, based on its hydraulic structure, the landing gear retracting control AMESim hydraulic system model is established to carry out the study of the typical faults of the aircraft landing gear retracting hydraulic system, such as injection of the hydraulic pump internal leakage, hydraulic oil contamination, and leakage of the actuator cylinder. The curve diagrams of the simulation results are analyzed, and the conclusions of the influence of typical faults on the boundary conditions on the pressure and flow of the hydraulic system are drawn. The results of the simulation are analyzed, and the effect of typical fault boundary conditions on the pressure and flow of the hydraulic system is concluded, which provides a reference for the study of parameter optimization, fault analysis, and health management of the landing gear in engineering applications.
Yu, Yahui, Cui, Wenhao
Study on the Wear Resistance of Aggregates Based on Surface Abrasion Characteristics2025-99-0311To be published on 12/17/2025
Abrasion is a primary cause of material failure, and the correlation with mechanical properties is significant. In order to study the aggregate's own wear resistance and surface abrasion mechanism, and to improve the abrasion resistance evaluation system, this paper conducts friction and abrasion tests on four types of aggregate particles, such as basalt, granite, limestone, and bauxite clinker, through the TriboLab test. The friction coefficient change curves of different aggregates are obtained. Subsequently, the three-dimensional reconstruction of the abraded area was carried out based on the white light interference principle. Finally, the quantitative calculation of the wear index between different aggregates was realised. The results obtained from the TriboLab test demonstrate that the friction coefficients of the various aggregates initially increase and subsequently stabilise. Following the stabilisation phase, the values of the friction coefficients are arranged in descending
Liu, Yong, Tian, Tao, Hou, Jianwei, Chen, Geng, Wang, Anping
Identification of Critical Risk Nodes and Vulnerability Analysis in Railway Networks2025-99-042512/10/2025
As the importance of railway networks in regional transportation and economic development continues to grow, identifying critical risk nodes and assessing network vulnerability is crucial for enhancing the stability and resilience of railway systems. This study focuses on the railway network of Shandong Province, constructing a topological model to systematically analyze the structural characteristics of the network, with a particular emphasis on key nodes. To identify these critical risk nodes, four modified weighted indicators were employed, combined with the mean-square deviation TOPSIS method to quantify node importance. The analysis identified Jinan, Linyi, and Yantai as key risk nodes, as they consistently ranked high across multiple indicators. Further vulnerability analysis reveals that the failure of these critical nodes would lead to significant declines in network efficiency and connectivity, with particularly high vulnerability observed when nodes with high weighted
Xu, Chang, Han, Wen, Fan, Hongxian, Dai, Hongna
Research on Thermal Runaway Triggering Methods for Non-Rechargeable Lithium Battery in Civil Aircraft2025-99-040512/10/2025
In aviation industry, compared to traditional batteries (lead-acid and nickel-cadmium batteries), non-rechargeable lithium batteries are usually the primary choice as independent backup power sources for emergency equipment (such as Emergency Locator Transmitter and Underwater Locator Beacon) due to excellent performance, weight/volume advantages and relatively long inspection/maintenance intervals. However, considering higher energy density and more active chemical characteristics, lithium batteries unique failure modes require special consideration in safety analysis. Among these failure modes, thermal runaway is one of the most severe failure modes of non-rechargeable lithium batteries, potentially leading to serious impact such as flame, explosion, and release of toxic and harmful gases/liquid. Therefore, it is necessary to demonstrate the containment of thermal runaway of non-rechargeable lithium batteries through equipment-level testing, and do aircraft-level safety analysis to
Zhang, Xiaoyu, Zheng, Jian, Yang, Dianliang, Sheng, Jiaqian
Mitigating Leak Failures Using Radial Grinding EquipmentTBMG-5433712/01/2025
For any supplier in the medical device manufacturing industry, sustainable success requires an ability and a willingness to bring customers’ ideas to reality. There are often innovative, potentially life-saving projects that are delayed or even abandoned due to limitations on the manufacturing end. However, many specifications that seem impossible to meet can be achieved with persistence, collaboration, and dedication to customers’ ideas.
A Comprehensive Study on Integration of Safety Analysis with Technical Safety Concept to Enhance the Product Safety2025-28-028811/06/2025
This manuscript presents a comprehensive study on the integration of Safety Analyses with Technical Safety Requirements (TSRs) to enhance functional safety in complex automotive systems and off-highway applications. It emphasizes the importance of systematically identifying potential hazards and translating them into precise, actionable TSRs that guide the design, implementation, and validation of safety-critical systems. By aligning safety analysis techniques—such as Fault Tree Analysis (FTA) and Failure Mode and Effects Analysis (FMEA)—with ISO 26262, the study demonstrates how safety goals can be effectively transformed into technical specifications that ensure robust system behavior under fault conditions. Part 1 outlines the use of Failure Modes and Effects Analysis (FMEA) to identify potential failure modes and single point faults across system, subsystems, and components. FMEA assesses the severity, likelihood, and detectability of these failures, guiding the development of
Sowrirajan, Shanmathi Sri, Kumar, M.E.Manoj, Somabathula, Praveen, Sugumar, Ganesh
Optimizing the Structural Finite Element Method based Process to Evaluate the Sustainable Human Accidental Sliding Load of Automobile Airvent Knob Design Made with Thermoplastic PC - ABS2025-28-028911/06/2025
The research work elaborated the structural integrity of airvent by skipping the assembly level snap fit finite element analysis of knob to reduce computational complexity of air vent knob sliding test post stopper. During assembly, the strain based mechanical breakage prediction of airvent sliding knob snaps is investigated in non-prestressed condition. The research work proposes a FEM based analysis approach to evaluate the mechanical breakage load of airvent knob assembly for accidental sliding load. This process skips the assembly level snap insertion load case along with silicone rubber pad compression which could serve as the prerequisite simulation. This prerequisite simulation is computationally expensive and complex to solve due to polymer plasticity and silicone rubber elastomer hyper-elasticity and moving frictional contacts between parts. If the accidental sliding load case without considering pre-tension on snaps is simulated, the load causing mechanical failure in the FEM
Shah, Viren, Wani, Dishant, Miraje, Jitendra
Use of the Sound-intensity Method to Identify Acoustic Leakages from Off Highway Machine Cab2025-28-026711/06/2025
The operator station or “cab” in off Highway equipment plays a critical role to provide a comfortable workspace for the operator. The cab interfaces with several elements of the off-highway equipment which can create gaps and openings. These openings have the potential for acoustic energy leakage, ultimately increasing sound within the cab. During machine operation, noise generated around the cab conducts inside through these leakages resulting in increased sound levels. Acoustic leakages are among the key noise transfer paths responsible for noise inside the cab. Therefore, before considering noise control treatments it is best to first identify and minimize any leakages from joints, corners, and pass-throughs to achieve the required cab noise reduction. In this effort the sound intensity technique is used to detect the acoustic leakages in cab. The commercial test system is used for measuring the sound intensity field over objects. For the cab, an acoustic source is used inside the
Pawar, Sachin M., Mandke, Devendra, Fapal, Anand, Cone, Kerry
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