Alloy wheels are essential safety components in two-wheeled vehicles. This study details the finite element analysis (FEA) used to simulate and evaluate the wheel and tire performance under the double mass impact load specified by the AIS-073 (Part-1) standard. The impact is carried out by dropping a striking mass along with a main mass onto the alloy wheel–tire assembly, as per the standard. The alloy wheel is modeled using a three-dimensional finite element model with elastic-plastic material behavior, and the tire is modeled with its internal elements (e.g., carcass, belt, etc.). The prediction of wheel impact failure is based on the total plastic work of the ductile fracture mechanism. The validity of results is confirmed by comparing the predicted permanent lateral rim deformation against the measured lateral deformation from a corresponding physical test.

Minz, Jai Shankar, Singh, Sanjay Kumar, Nirala, Deepak Kumar

Design and Multi-Faceted Validation of UAV Arm Clamps, Landing Gear and Motor Mounts via Generative Design in Autodesk Fusion 360

2026-26-0734

6/1/2026

This study presents a comprehensive methodology for optimizing critical UAV structural nodes—specifically Arm Clamps, Landing Gear, and Motor Mounts—using Generative Design (GD) tailored for Fused Filament Fabrication (FFF) with PLA+. Traditional “plate-and-standoff” UAV constructions often utilize orthogonal geometries that induce stress concentrations and fail to leverage the geometric freedom of additive manufacturing. Furthermore, reliance on expensive CNC machining or injection molding creates supply chain bottlenecks for custom or short-run UAV production. While FFF offers geometric freedom, applying it to structural airframe parts introduces challenges regarding anisotropy, layer adhesion, and material brittleness. This research optimizes these components for standard commercial 3D printers by strictly enforcing manufacturing constraints, including a 40-degree maximum overhang and a 0.4 mm nozzle size, to ensure printability without internal support structures. A significant

Krishna Bansal, Vaibhav

Estimation of Dynamic Responses at Internal Points of a Nested Sub-Structure with Two-Level Craig-Bampton Reduction

2026-26-0747

6/1/2026

Dynamic responses at critical locations of a spacecraft due to excitations expected during the ascent phase of a launch vehicle mission are usually estimated through a Coupled Loads Analysis (CLA) using the structural dynamic finite element model of the launch vehicle coupled with that of the spacecraft. Generally, the full physical structural dynamic model of a spacecraft has lakhs of degrees-of-freedom (DOFs). Coupling such a model with a similar model for the launch vehicle results in exorbitantly high computational costs for CLA. Hence, dynamic analysis of such 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. Conventionally, a full launch vehicle CLA involves one level of CB-reduction wherein a reduced-order dynamic model of the spacecraft is first generated using the fixed-interface CB-method. This reduced-order model is

Ramachandran, Nirmal

Porosity Matters: Multiscale Simulation of Composite Panel Performance in Aerospace Structures

2026-26-0731

6/1/2026

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 behavior, employing a multiscale simulation approach that bridges material characterization and full-scale structural analysis. The study begins with virtual coupon testing using Digimat-VA and Digimat-MF, enabling the prediction of material allowable and the assessment of defect variability. Homogenized material properties derived from these simulations are then applied to detailed panel models constructed in MSC Apex, ensuring accurate representation of layup and orthotropic behavior. 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

Thermo-Structural Analysis of Grid Fins for Re-Entry Modules

2026-26-0749

6/1/2026

Grid fins are non-conventional aerodynamic lifting and control surfaces which are made of a frame supporting lifting surfaces positioned in the form of a lattice structure. Grid fins are also called as lattice fins and are used as control surfaces in launch vehicles, crew escape systems, missiles etc. to achieve static stability. Each panel of the grid fin acts as fin and it produces force which increases stability of the vehicle. For a crew escape system module, grid fins are used as a passive aerodynamic control surfaces to achieve static stability. Grid fins are positioned at the end of crew escape system module to provide required static margin by increasing moment arm. 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 in stowed position during launch followed by deployment at the time of exigency. In case of an

Mali, Somanath Nandu, Sundar Raj, R, Sundaresan, MK, R, Suresh

An Integrated Digital Engineering Framework for Parametric Design and Finite Element Analysis of Aerospace Systems

2026-26-0735

6/1/2026

Digital engineering practices in aerospace increasingly require closely connected and traceable analysis workflows rather than isolated finite element tasks. Traditional FEA methods remain effective, but they involve considerable manual effort during pre- processing and post-processing, making rapid iteration difficult. Finite Element Analysis of STructures (FEAST), an indigenous finite element analysis software developed by Vikram Sarabhai Space Centre (VSSC) ISRO, offers structural analysis capabilities through a command-based architecture, yet its manual operation limits its use in automated studies. This work develops a flexible scripting-driven framework that links geometry creation, load-case definition, solver execution, and result interpretation within a unified digital engineering pipeline. The framework automates repetitive tasks, incorporates Design of Experiments (DoE) for systematic parameter variation, and supports sensitivity and automation studies. Its performance is

Gupta, Shivangi, T J, Raj Thilak, P, Deepak

Conceptual Design of CFRP Sandwich Structures Interfacing Cryogenic Tankages in Rockets

2026-26-0761

6/1/2026

The study proposes the use of Carbon Fiber Reinforced Plastic (CFRP) sandwich composites configurations for structures interfacing cryogenic tankages. To address the design challenge posed by high thermal contractions in metallic tanks after cryogenic propellant filling, the study incorporates slits near the tank interfaces. Additionally, to minimize the transfer of cryogenic temperatures into these interfacing parts, the sandwich structure features interface end attachment made of thermally insulating Glass Fiber Reinforced Plastic (GFRP) material. Analytical and Finite Element (FE) studies were conducted on a typical cylindrical cryogenic intertank structure to demonstrate the proof of concept. These studies included analytical design using MATLAB based codes, parametric analyses with simplified shell element models and detailed 3D sector models using solid elements. The parametric studies assessed the effects of the number and dimensions of slits to achieve an optimal design, while

Bhalerao, Sandesh Popat, Gupta, Yogesh Kumar, Madhukumar, P.

Investigation of Acoustic Fill Effect of a Launch Vehicle Payload Fairing

2026-26-0759

6/1/2026

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 behavior 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 is employed in the low frequency range, while statistical energy analysis is

S R, Arun Raj, Jayan, Mahind, George, P

Sensitivity Analysis of Geometrical Imperfections in Aerospace Structures

2026-26-0738

6/1/2026

Launch vehicle structures are designed to withstand flight loads while fulfilling their intended functional requirements. Most of these structures use cylindrical geometries and employ stiffened configurations—such as isogrid, orthogrid, or skin-stiffened designs—comprising multiple long panels to efficiently carry dominant compressive loads. Traditional FE analyses generally use simplified or idealized imperfection models, which often do not represent the imperfections present in actual hardware and therefore tend to over/under-predict load-carrying capacity based on the initial assumed imperfection level. In reality, long stiffened panels are highly sensitive to geometric imperfections introduced during manufacturing. These include spring-back effects from roll bending as well as deviations accumulated during assembly. Such manufacturing-induced variations can significantly diminish the effective load-bearing capability of the structure. The subject hardware—an isogrid cylindrical

Sharma, Amit, Singh, Nishant, Xavier, Shijo, R, Suresh

Novel Material Architecture for Enhanced High Cycle Fatigue Life in Turbofan Engine Fan Blades

2026-26-0748

6/1/2026

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

Influence of Boundary Conditions on Dynamic Characterization of Launch Vehicle Structures with Closely Spaced Modes

2026-26-0730

6/1/2026

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

Finite Element Approach for Fatigue Life Prediction of Threaded Bolts with Experimental Validation

2026-26-0745

6/1/2026

Predicting the fatigue life of threaded bolts is crucial in aerospace and mechanical assemblies where cyclic loading can cause early joint failure. Existing studies, like [1], have created S-N curves for high-strength bolts under different pretension and temperature conditions through experimentation. However, there are few numerical methods that can replicate these results, especially for bolts without pretension. This study develops and validates a finite element analysis (FEA) methodology to predict the fatigue performance of pretensioned threaded bolts under axial loading, using the experimentally derived Series-2 S-N data for M20 high-strength bolts with pretension. The approach employs a detailed 3D solid model with explicit thread geometry and a two-step transient structural analysis. This first simulates the bolt tightening process to establish a realistic preload, followed by the application of a service tensile load. Local stress distributions are analyzed to extract peak

K R, Lesanth, S, Suhail Ahmed, C, Arunvetrivel, P, Krishnakumar, P S, Premkumar, Vasantharaj, C

Reliability Program Standard Implementation Guide

JA1000/1_201205 (Historical)

5/26/2026

The importance of reliability in design engineering has significantly grown since the early 1960’s. Competition has been a primary driver in this growth. The three realities of competition today are: world class quality and reliability, cost-effectiveness, and fast time-to-market. Formerly, companies could effectively compete if they could achieve at least two of these features in their products and product development processes, often at the expense of the third. However, customers today, whether military, aerospace, or commercial, have been sensitized to a higher level of expectation and demand products that are highly reliable, yet affordable. Product development practices are shifting in response to this higher level of expectation. Today, there is seldom time, or necessary resources to extensively test, analyze, and fix to achieve high quality and reliability. It is also true that the rapid growth in technology prevents the accumulation of historical data on the field performance

G-41 Reliability

Reliability Program Standard Implementation Guide

JA1000/1_202108 (Current)

5/26/2026

G-41 Reliability

Research on Hole Enlargement Process and Modeling Optimization for Type III Hydrogen Storage Tanks

2026-99-0720

5/15/2026

The global automotive industry is accelerating its transition toward low-carbon solutions, with hydrogen fuel cell vehicles offering core advantages of zero emissions and extended range. Their critical component is the Type III fiber-wound hydrogen storage tank, whose performance directly impacts vehicle operational safety and driving range. This technology has now achieved widespread adoption. However, two significant challenges persist in the dome region of these tanks: first, modeling accuracy is difficult to control due to dynamic variations in thickness and winding angles; second, fiber thickness buildup frequently occurs near the pole holes. These issues compromise both the design reliability and manufacturing quality of hydrogen storage tanks. Therefore, this study adopted a combined approach of theoretical analysis and numerical simulation. First, based on composite mechanics theory and calibrated with experimental data (Tensile, Compression, and Shear Tests on NOL and

Wang, Jianguo, Zhang, Qian, Cao, Xuewen, Zheng, Xuanxuan, Li, Jiajie

Autonomous Navigation Strategy and Docking Mechanism for Intelligent Chassis Module of Split Flying Vehicle

2026-99-0743

5/15/2026

In response to the problems of urban traffic congestion and the limited expansion of infrastructure, this paper conducts two core research focusing on the intelligent chassis system of split-type flying vehicle. Firstly, an autonomous navigation strategy for the intelligent chassis module is proposed based on chassis module Navigation 2 architecture, which fuses LIDAR and IMU positioning to plan paths using the A* global planning algorithm on a global cost map, and update the local cost map in real time with sensor data. It is orchestrated by the BT Navigator using a behavior tree, with failures handled by the Recovery Server, to achieve autonomous driving across multiple waypoints. In simulation and closed-field experiments, the system can stably reach the preset target points. The positioning accuracy and trajectory tracking performance can meet the design requirements. Secondly, a mechanical slide rail-type docking structure adapted to the split flying vehicle architecture is

Zhao, Wenyu, Shi, Qin, Jiang, Cong, He, Zejia

Fatigue Resistance of High-Pressure Hydrogen Storage Vessels with Aluminum Liner

2026-99-0731

5/15/2026

Although carbon fiber-reinforced aluminum-lined hydrogen storage vessels (Type III) exhibit outstanding specific strength and specific stiffness, the constraints imposed by their design parameters on fatigue performance and ultimate load-bearing capacity remain incompletely elucidated. We propose a fatigue life prediction method for high-pressure vessels that couples progressive damage in the fiber composite with cumulative damage in the metallic liner, aimed at forecasting the fatigue performance of Type III pressure vessels under cyclic loading. Furthermore, a finite element analysis systematically investigates the influence of key design parameters, for nominal pressure, liner diameter and liner thickness, on fatigue performance and ultimate load-bearing capacity. Results indicate that fatigue life significantly decreases with increasing nominal pressure and liner diameter, with nominal pressure exerting a more pronounced effect. Notably, altering the autoclave pressure alone cannot

Bi, Zhihai, Zhang, Qian

Research on a Lightweight Assistive Manipulator for Insulated Short-Stick Live-Line Operations in Distribution Networks

2026-99-0732

5/15/2026

With the continuous economic development and the rapid advancement of urbanization, the stable operation of distribution networks has become a key factor in ensuring the reliability of power systems. In response to the problems of high risk, high labor intensity, and low efficiency in distribution network operations, this paper designs an auxiliary operation mechanical arm for distribution networks. This auxiliary operation mechanical arm is fixed on the working bucket of an insulated boom truck. The main body is a two-degree- of-freedom SCARA mechanical arm that moves in a plane, and the end is connected to a three-degree-of-freedom end effector through a flange to cooperate in completing the pitch, deflection, axial feed, and clamping of insulated rods, achieving coarse positioning in the plane and precise positioning of the target. The auxiliary mechanical arm operation platform adopts a fully insulated design. The platform is made of glass nylon material, and the edges are rounded

Wang, Jingjie, Chen, Zhenning, Feng, Yu, Wu, Shaolei, Zhang, Yuxi, Dou, Hang, Wang, Wei

Modification and Validation of a Finite Element Model of a Pedestrian Dummy

09-14-01-0012

5/4/2026

Aims of the research This study aims to modify the lower body (the pelvis, thigh, and leg) of the mid-sized male pedestrian dummy FE model by considering the latest version of the physical dummy and to evaluate both the accuracy by comparing test results of the past studies and the biofidelity specified in SAE J2782 in both component and full-scale validations. Methods 1 Component validation The validation of the modified pelvis model was performed in dynamic lateral compression simulations. The sacrum and the pubis force-deflection responses of the iliac or the acetabulum impact were measured. The modified thigh and leg models were evaluated in a dynamic 3-point lateral bending simulation, measuring the force-deflection responses. The results from the simulations were compared with test results and the biofidelity requirements. 2 Full-scale validation The whole-body model was updated by incorporating these modified component models. The model of the generic buck developed for the

Asanuma, Hiroyuki, Gunji, Yasuaki, Mori, Fumie, Nagashima, Akiko

Assessing Injury Prediction with Human Body Models: Application to Rib Fracture Risk Prediction Using SAFER HBM

09-14-01-0023

5/4/2026

As a consequence of the introduction of mathematical human body models (HBMs) in consumer information programs, there is an increased need for reliable methods that can demonstrate and build trust in the capability of HBMs to predict human response and injury risk in crashes. Therefore, a framework for validation of strain-based injury prediction is proposed. The framework comprises stepwise validation with the final step to validate the utility of risk predictions by means of the area under the curve (AUC) combined with Brier scores. SAFER HBM V11.1.0 previously validated at component and body part levels was selected for the demonstration of the final step of the framework to validate the capability to predict fracture risk in frontal, oblique, and lateral loading. For frontal loading, five postmortem human surrogate (PMHS) test series with 43 PMHS (age range: 19–88 years) were reconstructed. The predicted rib fracture risk for 2+ and 3+ fractured ribs was compared to the number of

Pipkorn, Bengt, Niranjan Poojary, Yash, Osth, Jonas, Larsson, Karl-Johan, Iraeus, Johan

Directional Stiffness Decoupling in Meta-Wheels via Three-Dimensional Discrete Curved Spokes

15-19-01-0005

4/22/2026

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

Loss Model and Finite Element Analysis Thermal Model of a Production Fast Charging Battery Module

2026-01-0123

4/7/2026

Accurate modeling of battery temperature rise during fast charging is challenging due to uncertainty around cell heat generation and the thermal characteristics of the materials and interfaces which make up the battery pack. High fidelity thermal models are critical to attaining the best battery pack design, since they enable a multitude of cooling and packaging approaches to be considered prior to building a prototype. In this study, a 3D finite element analysis (FEA) thermal model of a production fast charging battery module is created. A loss model is parameterized as input for the FEA model. A key part of the loss model is the entropic heating coefficient (EHC), which is the change of open circuit voltage with respect to temperature. The EHC is measured by waiting for the cell voltage to reach steady state at various temperatures in 5% and 10% state of charge intervals over its capacity. This is then corrected numerically by accounting for unwanted discharge or rebounds. The EHC is

Thornton, Jack, Kollmeyer, Phillip, Panchal, Satyam, Gross, Oliver

Failure Analysis and Improved Design of a Cycloidal Rotor Pump for Automotive Applications

2026-01-0184

4/7/2026

Cycloidal rotor pumps are widely used in industries such as automotive and aerospace due to their advantages of compact structure, large displacement per unit volume, and low flow pulsation. With the development of new energy vehicles, rotor pumps are required to operate stably for extended periods under higher speeds, higher pressures, and harsher conditions, placing greater demands on their reliability. Addressing the specific problem of fracture failure of the inner rotor in a certain cycloidal rotor pump during bench testing, this paper first conducted a theoretical analysis of the inner rotor's metallographic structure. The metallographic results indicated that the inner rotor fracture was unrelated to material quality but was instead caused by the improper positioning of the slot on the pump's inner rotor, making the slot root the weakest part of the entire rotor material. Furthermore, sharp corners existed on the inner slot surface, leading to significant stress concentration at

Li, Meng, Xie, JIa, Qin, Gongyu, Yang, Hanming, Wang, Liangmo

Integrated Welding Simulation and Experimental Characterization of Weld-Metal and Heat-Affected-Zone Strength in AA6063-T6

2026-01-0230

4/7/2026

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

Effective Prediction of the Mechanical Properties of Glue-Laminated Motor Stator Core with Consideration of Glue Disposition

2026-01-0177

4/7/2026

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 Overview

2026-01-0476

4/7/2026

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 Holography

2026-01-0207

4/7/2026

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 Optimization

2026-01-0511

4/7/2026

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 Vehicle-Integrated Validation Method for Weather-Strip Sealing Performance in Automotive Closure Systems

2026-01-0200

4/7/2026

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

Curb Impact: Non-linear Structural FE Analyses in Multibody Dynamics Models

2026-01-0219

4/7/2026

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

A Novel Spot Joint Finite Element for Rapid Stress Analysis of Fasteners in Automotive Structures

2026-01-0182

4/7/2026

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 Safety

2026-01-0405

4/7/2026

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

Modelling and Analysis of Rolling Truck Tire over Dry and Snow-Covered Surfaces Using Advanced Computational Techniques

2026-01-0591

4/7/2026

This paper presents a novel approach to modelling and analyzing a 315/80R22.5 sized truck tire running over dry and snow-covered surfaces. The tire is modelled using Finite Element Method (FEM) in ESI Virtual Performance Solutions (VPS) software. The tire model consists of various parts representing the tread, under tread, carcass, sidewalls and beads in addition to the rim. The tire model is then verified in both static and dynamic domains against experimental data. The experimental results were conducted over a dry surface at a high-speed test track in Hällered, Sweden, at a constant travelling speed of 80 km/h, and a constant vertical load of 26 kN with sensors depicting both temperature and inflation pressure changes throughout a 40-minute run. A tire temperature model is developed, and the simulation results are correlated with the measured temperature of the tested tires. In addition, the rolling resistance variation with speed, temperature and inflation pressure is predicted and

Opatha, Dillon, Oijer, Fredrik, El-Sayegh, Zeinab, El-Gindy, Moustafa

Automotive Crash Dynamics Modeling Accelerated with Machine Learning

2026-01-0568

4/7/2026

Crashworthiness assessment is a critical aspect of automotive design, traditionally relying on high-fidelity finite element (FE) simulations that are computationally expensive and time-consuming. This work presents an exploratory comparative study on developing machine learning-based surrogate models for efficient prediction of structural deformation in crash scenarios using the NVIDIA PhysicsNeMo framework. Given the limited prior work applying machine learning to structural crash dynamics, the primary contribution lies in demonstrating the feasibility and engineering utility of the various modeling approaches explored in this work. We investigate two state-of-the-art neural network architectures for modeling crash dynamics: MeshGraphNet, a graph neural network that is widely employed in physics-based simulations, and Transolver, a transformer-based architecture with a physics-aware attention mechanism designed to maintain linear computational complexity with respect to geometric

Nabian, Mohammad Amin, Chavare, Sudeep, Akhare, Deepak, Ranade, Rishikesh, Cherukuri, Ram, Tadepalli, Srinivas

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