Browse Topic: Finite element analysis

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Analysis of the biofidelity of aPLI under low-speed collision conditions2026-01-0551To be published on 04/07/2026
Abstract: With the increasing popularity of automotive active safety systems, the probability of collisions between vehicles and pedestrians has gradually decreased. Among them, the AEB system, as an important part of active safety systems, can actively intervene to avoid collisions in advance. However, in actual road traffic conditions, there are still situations where the AEB system cannot completely avoid collision accidents, and the impact speed between pedestrians and vehicles may drop to below 40 kph. However, the aPLI legform impactor, which is widely used in pedestrian protection evaluations in various regions, has a standard impact speed of 40 kph in the test procedure. The response of the aPLI to low-speed collisions and the resulting pedestrian leg injuries is still unclear. Based on finite element simulation, this study compared the kinematic responses and injury responses of the aPLI impactor with human body models (THUMS and GHBMC) under 5 different speeds (20kph, 25kph
Sun, Bowen, YE, BIN, LONG, YONGCHENG, Zhan, Zhenfei, shi, Xinxin, jun, yin
Lightweight design of a seat module assembly for a robotic arm amusement ride system using topology optimization2026-01-0481To be published on 04/07/2026
This paper presents a methodology to design a lightweight seat module assembly (SMA) for a robotic arm amusement ride, often used in dark rides. Typical SMA designs begin with a welded metal frame, and the exterior shell serves only as a non-structural cover, resulting in stress concentrations and excess weight. The proposed methodology introduces a bottom-up process that integrates topology optimization at the outset, enabling the outer shell to function as a primary load path and subsequently identifies the ideal configuration for internal secondary framing by utilizing manufacturing constraints. This approach is further enhanced by adopting fiber-reinforced polymers as the structural material, leveraging their high stiffness-to-weight ratio to replace conventional metallic designs. Multiple manufacturing-specific interpretations of the optimized design were explored to evaluate feasibility, including extrusion and tubing based approaches. Finite element analysis of the final design
Pooler, Claire, Hronowsky, Benjamin, Chai, Kevin, Shi, Yifan, Park, Taeil, Lo, David, Kim, Il Yong
Anisotropic mechanical property simulation of fiber reinforced PEEK using composite theory and comparison to experimental results2026-01-0256To be published on 04/07/2026
The mechanical properties of 3D printed composites have been shown to vary due to the manufacturing infill direction due to artifacts from the printing process. PEEK (Polyether Ether Ketone) and PEEK reinforced with carbon fiber were studied for these experiments because they are widely used for their high strength properties. 3D printed composites that behave with anisotropic characteristics have been evaluated under Laminate Composite Theory (LCT), which can be used to determine the mechanical properties of these 3D printed composites. By changing the orientation of the extruded strands in a 3D printed part, the structure can be optimized in a specific orientation for specific loading conditions, and LCT can be applied for simulating mechanical responses. Three point bending tests were performed on rectangular 3D printed samples and compared to a 3D simulation using LCT for a similar bending load. This allows for the use of LCT in combination with a finite element software such as
Bradley, Coilin, Garcia, Jordan, Sibley, Brian
Thermal Finite Element Modelling and Prediction of Laser Welded Battery Packs2026-01-0385To be published on 04/07/2026
Battery modules consist of battery cells electrically joined at the terminals by conductive busbars. Laser welds are the most consistent and controllable process to create these connections on a large scale due to their control over power, laser width, speed, wobble, and overlap, and their quality is critical to battery pack performance. Tuning these parameters for an application typically requires weld trials to reach desired weld width, penetration, and strength without overheating the battery cell and weakening the dielectric insulators around the terminals. Poorly welded cells in a module can result in increased electrical resistance, causing greater joule heating and accelerated cell aging, and poorly welded modules can lead to uneven aging and unpredictable performance. To better understand the laser welding process, a modelling approach was developed to predict weld properties to reduce production time, costs, and potential cell damage. The 3D finite element model was calibrated
Contreras, Luis, Hoffmeyer, Matthew, Abidin, Zainal
Integrated Welding Simulation and Experimental Characterization of Weld-Metal and Heat-Affected-Zone Strength in AA6063-T62026-01-0230To be published on 04/07/2026
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
Simulation verification and design guide for P1+P2 hybrid built-in damper system2026-01-0006To be published on 04/07/2026
Among the hybrid system methods, the TMED (Transmission mounted electric device) method is divided into the TMED-1 system driven by the existing mass-produced P0+P2 motor and the TMED-2 system driven by the P1+P2 motor. It is known that the TMED-2 method improves power and fuel efficiency by about 10% or more compared to the TMED-1 due to the intervention of the P1 motor, and that carbon emissions can be reduced due to the improvement of engine thermal efficiency. However, the TMED-2 system is a structure that replaces the P0 motor with the P1 motor to improve power performance and transmission efficiency. The P1 motor is disadvantageous in terms of mountability due to its longer overall length compared to the P0. To solve this problem, the existing external damper system was designed and shaped to be assembled into the inner space between the P1 and P2 motors (built-in damper system), thereby securing mountability. The main development item that our company is currently researching is
Sun, Hyang Sun, GANESAN, KARTHIKEYAN
Effective Prediction of the Mechanical Properties of Glue-Laminated Motor Core with consideration of glue disposition and stacking factor.2026-01-0177To be published on 04/07/2026
This study presents a practical approach for predicting the mechanical properties of glue-laminated motor cores, with a particular focus on the influence of glue disposition patterns and coverage rate, to enable more accurate material modeling and reliable NVH and other general structural analysis. Since glue bonding and lamination stacking are essential for ensuring the structural integrity of motor stator cores, variations in glue implementation introduce significant changes in both in-plane and out-of-plane stiffness properties. To address this, a homogenization framework based on the unit-cell method, considering detailed glue application information, is employed. The laminated structure is idealized as an orthotropic material, and the variation of in-plane properties in different directions is considered. Unlike simplified coverage-rate models, the proposed method incorporates localized glue distribution patterns—such as teeth, core back iron, and edge-concentrated regions like
Nie, Zifeng
Accurate Prediction of the Mechanical Properties of Welded/Interlocked Motor Core for Reliable NVH Analysis2026-01-0241To be published on 04/07/2026
Accurate prediction of the mechanical properties of welded and interlocked motor cores is critical for reliable NVH analysis of electric drives. Unlike glue-laminated cores, which rely on adhesive bonding and exhibit relatively uniform stiffness distributions, welded or mechanically interlocked laminations introduce strong local discontinuities due to spot welds, contacts, or interlocking features. These connections significantly alter the load transfer paths across laminations, resulting in anisotropic stiffness behavior and localized stress concentrations that cannot be accurately captured by homogenization approaches developed for glue-laminated cores. To address this, a refined unit-cell (RVE) modeling framework is proposed, which explicitly incorporates welded or interlocked regions as discrete mechanical connections within the periodic lamination structure. The framework accounts for variations in weld spacing/size, interlaminar contact, and interlock geometry, enabling the
Nie, Zifeng
Lightweight Wheel Design Through Shape Optimization with Structural Constraints2026-01-0504To be published on 04/07/2026
The wheel rim is an annular, thin-walled structure featuring complex geometry and is subjected to multiple load cases, including radial, rotary, and impact scenarios. Achieving an optimal balance between mass reduction and structural performance remains a significant challenge in modern vehicle wheel design. Aero-efficient vehicles demand lightweight backbone wheels capable of accommodating aerodynamic covers without compromising handling, steering precision, or overall performance. In this study, shape optimization is applied to an 8-spoke truck wheel with the goal of minimizing mass while enhancing lateral stiffness and ensuring that stress constraints are satisfied under all critical load cases. A three-dimensional finite element model is developed and evaluated under realistic radial, rotary, and impact loading conditions representative of industry validation tests. The optimization process fine-tuned the spoke geometry using symmetric shape domains and carefully defined
Yoo, Dong Yeon, Adduri, Phani, Chakravarty, Rajan
Modelling and Analysis of Rolling Truck Tire over Dry and Snow-Covered Surfaces Using Advanced Computational Techniques2026-01-0591To be published on 04/07/2026
This paper presents a novel approach to modelling and analyzing a 315/80R22.5-sized truck tire under snow-covered road conditions. 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 27 kN with sensors depicting both temperature and inflation pressure changes throughout a 40-minute run. A tire thermal 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 analyzed
Opatha, Dillon, Oijer, Fredrik, El-Sayegh, Zeinab, El-Gindy, Moustafa
Analyzing Fastened Joints in Hydraulic Dampers using Simulation and Experimental Methods2026-01-0585To be published on 04/07/2026
The main purpose of this study is to develop and validate an accurate calculation model for an unorthodox hydraulic damper piston joint, enabling reliable torque specification and clamp behavior without full prototype iteration. The joint features a bolted interface with a laminated shim stack of many thin disks with varying outer diameters. Analysis of such unorthodox joints are uncommon in literature, making the effects of load distribution truncation in the member stack due to varying outer diameters and surface contact effects between thin members during compression and torquing difficult to quantify. The model discussed in this paper is based on frustum load distribution combined with annular-plate bending and elastic-foundation effects to capture the effects of washer cupping. Concrete outputs of the calculator include member load distribution, bolt and member stiffnesses, torque-to-preload relationships, including friction factors and a variable effective-bearing-diameter, and
Dresen, Gabriel S., Vollmar, Race, Roy Chowdhury, Sourav
Risk analysis of occupant injuries with different lower limb postures during vehicle frontal impact2026-01-0572To be published on 04/07/2026
To investigate the biomechanical characteristics of injuries sustained by occupants with different lower limb postures during frontal impact, the human body finite element models- THUMS AM50 under standard sitting posture and sitting posutres with 100° calf bend, 90° calf bend, and crossed legs were analyzed in the frontal impact at 56 km/h. Injury biomechanical analysis demonstrates that the occupant under the sitting posture with crossed legs has the highest overall injure risk, e.g, the highest HIC (Head Injury Critirion) value, peak value of head accerelation, VC (Viscous Crterion) values, strain of the thracic organs, stress of pelvic cortical bone and knee ligments, and so on. In summary, different lower limb postures can affect the overall risk of occupant injury: the smaller the calf flexion angle and the more complex the leg posture, the higher the risk of overall injury. In the future study it is necessary to strengthen the protection of occupants in non-standard seating
Li, Dongqiang, jiang, Yejie, Tan, Chun, Li, Yanyan, HeQuan, Wu, Jiang, Binhui, Zhu, Feng
Automotive Crash Dynamics Modeling Accelerated with Machine Learning2026-01-0568To be published on 04/07/2026
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
High frequency finite element approach for structural components in automotive industry2026-01-0491To be published on 04/07/2026
Typical Computer Aided Engineering support in automotive industry is focused on using finite elements analysis to support vibrations and acoustics. The virtual methods have multiple advantages compared to physical test in terms of time to produce results and the cost of multiple iterations been assessed is lower in the CAE models. Particularly in vibrations finite element models have proved to be reliable to correlate with testing in the case of low frequencies. High frequencies are challenging for CAE predictions and low frequency models show a limitation to perform vibration analysis, the results usually tend to deviate from the testing. This investigation covers the work done with finite element models specially prepared to analyze high frequency vibrations of structural components in a body in prime.
Alvarez, Ezequiel, Alonso, Liliana
Effective design method for lightweight suite of seats considering crashworthiness and cost2026-01-0493To be published on 04/07/2026
This paper presents a methodology for designing and evaluating lightweight, crashworthy aircraft seats that meet 21g crash safety standards and injury criteria. Four seat classes—economy double, economy single, single premium, and business—were developed using a modular design strategy focused on part commonality (family of parts) and manufacturability. A shared family of structural components was implemented across all seat types, with dimensional modifications applied only, when necessary, due to differences in seat width or height. In such cases, the same material systems and design principles were used to ensure consistency and reduce manufacturing complexity. The designs were evaluated using finite element simulations to verify performance under aerospace crash conditions. Each seat configuration was validated against regulatory crashworthiness criteria and injury thresholds, including pelvic, lumbar, and femur compressive forces, as well as head injury criteria (HIC) values. The
Gray, Savannah, Orr, Mathew, Shi, Yifan, Park, Taeil, Lee, Jake, Wotten, Erik, LeFrancois, Richard, Huang, Yuhao, Patel, Anuj, Kim, Hansu, Burns, Nicholas, Jalayer, Shayan, Grant, Robert, Kok, Leo, Hansen, Eric, Kim, Il Yong
Collapse Strength and Crush Space Analysis in Lateral Side Pole Impact of an Electric Vehicle2026-01-0472To be published on 04/07/2026
High Voltage Battery (HVB) protection in lateral pole impact is very important due to severe nature of the impact. Unlike frontal impacts, vehicles have limited range of space and capacity to absorb kinetic energy in lateral side impacts. Nowadays, computer aided engineering (CAE) using finite element analysis (FEA) is utilized routinely to simulate high-speed crash events of varied type, including side pole impact. These CAE applications focus on the analysis and design of HVB when the vehicle structure is well developed. CAE methods are time consuming and are not suited during the pre-program stage when the structure is only in a concept stage and not even a reasonable CAD is available/developed in any sense to use these methods. There is no analytical tool available to understand how to define the characteristics of the structure that surrounds and protects the HVB. The primary motive of this publication is to help with this aspect of vehicle planning/development. Needless to state
Alavandi, Bhimaraddi, Midoun, Djamal, Frank, Randy
Development of Automotive Hood Using Multi-Material Double Injection Molding2026-01-0476To be published on 04/07/2026
Introduction: The automotive hood is a critical closure component that must meet structural, safety, and styling requirements. Traditional metal hoods are increasingly being replaced or supplemented by polymer-based designs due to advancements in material technology and manufacturing methods. Among these, multi-material double injection molding presents a promising alternative to reduce production time and cost while achieving performance compliance. Aim: This study aims to develop an automotive hood using a hybrid plastic combination through a double-shot injection molding process. The focus is on evaluating the structural feasibility of such designs under regulatory and OEM-defined stiffness and crashworthiness performance targets. Purpose: The objective is to investigate the compatibility of different thermoplastic materials for outer and inner skin layers in achieving structural rigidity, impact resistance, and manufacturing efficiency. The approach targets the consolidation of
GANESAN, KARTHIKEYAN, Seok, Sang Ho, Jo, Hyoung Han
Design and Simulation Analysis of an Integrated Honeycomb-filled Front Bumper for a Special Vehicle2026-01-0475To be published on 04/07/2026
In frontal collisions of automobiles, the bumper beam at the front of the vehicle plays a crucial role in absorbing energy and protecting the vehicle body during a collision. To enhance the collision resistance of a specific type of special vehicle with a non-load-bearing body structure, this paper focuses on this type of vehicle and conducts a study on the design and collision performance of an integrated vehicle front bumper-impact beam structure based on aluminum alloy additive manufacturing technology. A novel bumper structure is proposed, which integrates the front bumper and the front impact beam of the vehicle and is integrally formed using aluminum alloy additive manufacturing technology. This integrated structure is directly connected to the vehicle frame. Firstly, based on the appearance of the special vehicle body and the form of the front impact beam of traditional passenger vehicles, an integrated design of the vehicle front bumper-impact beam structure is carried out and
王, Xufan, Yuan, Liu-kai, Zhang, tangyun, Wang, Tao, Zhang, Ming, Wang, Liangmo
Dynamic Characterization and Viscoelastic Modeling of Polymer Foams for Automotive Applications2026-01-0236To be published on 04/07/2026
Viscoelastic behavior of polymeric materials serves as a critical indicator of their internal structure and chemical composition, offering valuable insights into energy absorption and dissipation mechanisms. This study focuses on the dynamic characterization of polymer foams through both experimental and numerical approaches, aiming to accurately capture their time and frequency dependent mechanical response. Experimental investigations include uniaxial tension and uniaxial compression, which characterize hyperelastic or instantaneous behavior of the material. Stress relaxation tests and Dynamic Mechanical Analysis (DMA) characterize the dependence on time, frequency and temperature. A combination of these tests is effectively utilized to create viscoelastic material models that can describe the material response as a function of time, frequency and temperature containing a viscous and an elastic part. This paper presents dynamic characterization of polymer foams in finite element
M, Gokula Krishnan, Lin, Chunfu, Savic, Vesna
Curb Impact: Non-linear structural FE analyses in Multibody Dynamics Models2026-01-0219To be published on 04/07/2026
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 crash analysis tools such as LS-Dyna or multi-body dynamics analysis tools like Ansys Motion. The crash analysis has a better representation of structural compliances including large deformation with large rigid body motion. However, it requires a well-defined FE model and suspension multi-body models in detail. Furthermore, it takes a long time to get a result. On the other hand, the multi-body dynamics approach is very quick to get a result, while it has a limitation of representing structural compliance. The limitation is true in representing structural non-linearity such as large deformation associated with plastic yielding. In this study, a curb impact simulation was performed using the multi-body dynamic approach with nonlinear structural analysis capabilities included in
Hong, Hyung-Joo, Kim, Wangoo
In-situ Decoupling and Stiffness Optimization of Resiliently Coupled Assemblies Using FRF-Based Substructuring2026-01-0227To be published on 04/07/2026
Road shake remains one of the most critical NVH challenges in light- and heavy-duty body-on-frame trucks, directly shaping ride comfort and perceived vehicle quality. At the heart of this issue are the body mounts, which govern the transfer of vibration between frame and body. Optimizing these mounts for improved road shake performance is therefore a key objective in NVH engineering. Traditionally, such optimization has relied on finite element analysis (FEA). While highly accurate, FEA—especially when performed with commercial solvers such as NASTRAN—demands enormous computational resources, with complete simulations often requiring hundreds of hours. Each design iteration multiplies this cost, restricting the pace and efficiency of NVH development. Recent methods such as response surface modeling (RSM) and machine learning (ML) have aimed to reduce the burden, yet they remain dependent on large libraries of pre-computed FEA data, inheriting much of the same expense and inflexibility
Haider, Syed, Abbas, Ahmad, Jahangir, Yawar, Maddali, Ramakanth
Hybrid Computational Tire-Sand Interaction: A Tractive Effort and Rolling Resistance Analysis2026-01-0213To be published on 04/07/2026
This paper investigates the performance of a computational radial passenger car tire over winter road sand at different operating conditions. An experimental direct shear-strength test was conducted using winter road sand to obtain the density, internal friction angle and cohesion. A simulated direct shear-strength test was then validated in a Finite Element Analysis (FEA) software called Virtual Performance Solution (VPS) using a Smoothed-Particle Hydrodynamic (SPH) technique to model the sand. Once the sand was validated against physical testing data the sand was layered atop an icy road surface to understand the influence sand has on tractive effort and rolling resistance performance. With modelled and validated winter road sand and a Continental CrossContact LX Sport tire size 235/55R19, testing conditions were set up. The tire-sand interaction was simulated using a node-to-segment contact algorithm with edge treatment on a low friction surface for both the tire-road and the sand
Fenton, Erin, El-Sayegh, Zeinab
Development of Full Articulation Subsystem FEA Model for Validating Vehicle Suspension Durability2026-01-0190To be published on 04/07/2026
Vehicle durability is a cornerstone of automotive engineering, directly impacting customer satisfaction, brand reputation, and warranty costs. Traditionally durability validation of suspension systems often rely on virtual validation of individual components (an approach which can overlook complex non-linear system interactions) and followed by expensive full vehicle physical tests which happen very late in the vehicle development phase, which often results in correlation gap between virtual and physical realms, resulting in components redesigning and production delays. This paper presents a more efficient, high-fidelity, full-articulation suspension subsystem finite element (FE) model development specifically for durability assessments. This integrated model enables comprehensive block cycle durability assessments, providing a holistic understanding of system behavior and eliminating the inefficiencies of analyzing components in isolation. This methodology yields significant
Bavgi, Sai Kiran
Novel Steel Tubular Side Sill Reinforcement Design and Validation for Enhanced Crash Performance in EVs2026-01-0478To be published on 04/07/2026
Increased use of Electrical vehicles (EVs) brings in unique structural design challenges particularly in Side Impact scenarios when the battery pack is near the sill region therefore elevating the possibility of Electrical Module penetration and triggering thermal runway event resulting from the crash. Thus, Electric Vehicles present unique structural design challenges. This study intends to evaluate a novel tubular structure design for side sill reinforcement and its performance benefits over a traditional aluminum side sill reinforcement currently commonly utilized for battery protection in EV vehicles body components. The proposed Steel side sill design mainly focuses on structural rigidity and improved load transfer during side pole impact crash cases and address manufacturing complexity and cost reduction opportunity. Multiple iterations for Steel side sill reinforcement design were carried out using finite element analysis with software like LSDYNA Hyper works to propose optimal
Kusnoorkar, Harsha, Khutorsky, Alex, Penumetsa, Vivek, Koraddi, Basavaraj
A Study on the Relationship between Impact Conditions and Head Injury Criterion (HIC) in Powered-Two-Wheeler to Car Crashes2026-01-0571To be published on 04/07/2026
Road Traffic crash statistics highlight the importance of reducing fatalities among Powered-Two-Wheeler (PTW) riders, and suggest the necessity of a robust method to evaluate PTW crashworthiness performance. The objective of this study is to clarify the relationship between impact conditions and the Head Injury Criterion (HIC) to establish a fundamental basis for determining representative crash configurations for safety. A total of 1,272 PTW-front to car-side impact simulations were conducted by using production car and PTW models. HIC was used as a metric indicating likelihood of head injury. Velocities, impact angle, and impact locations were varied to create response surfaces. The surfaces were evaluated in terms of their accuracy in identifying the representative impact conditions. In addition, head trajectories were analyzed to clarify the kinematics until head impact. The Finite Element (FE) simulations produced the following findings. - The HIC distribution by Head Impact
Yanaoka, Toshiyuki, GUNJI, Yasuaki, Zulkipli, Zarir Hafiz, Matsushita, Tetsuya, Carroll, Jolyon, Puthan, Pradeep, Mohd Faudzi, Siti Atiqah, D-Wing, Kak, Miyazaki, Yusuke
Numerical Investigation of Low Velocity Impact Perforation in Natural–Synthetic Hybrid Composites for Automotive Applications2026-01-0246To be published on 04/07/2026
The increasing demand for sustainable and lightweight materials in the automotive industry has accelerated interest in natural fiber reinforced polymer composites. However, their limited impact resistance restricts application in structural and crash-relevant components. This work presents a numerical investigation of the low velocity impact (LVI) and perforation behavior of jute (J) and flax natural fiber reinforced epoxy composites (N) and their glass fiber (G) hybrid forms with synthetic fiber reinforced epoxy laminates (S), using LS-DYNA. A finite element model, developed with a discounted ply approach and MAT54 damage model, was first validated against published experimental data for glass/epoxy laminates, showing strong correlation in peak load and energy absorption. The validated model was then extended to simulate bidirectional natural fiber and hybrid laminates under 2–10 J impacts, replicating typical energy levels relevant to low-speed collisions and road debris impacts in
Mache, Ashok, Pingulkar, Harshad, Ambhore, Nitin, Hujare, Pravin, Salve, Aniket
Acoustic simulation for a vehicle audio system across the full audible frequency2026-01-0226To be published on 04/07/2026
Audio system is an important part of vehicle cabin for various purposes. In vehicle development process, it need be tuned for optimal acoustic performance. Traditionally, this process is performed physically on vehicles. In this paper, a methodology is developed to simulate the acoustic performance of the audio system across the full audible frequency range. To quantify the effectiveness, the p/v acoustic transfer functions of the sound pressures at passengers’ ears over the voltage inputs are measured for 12 different speakers in a production vehicle. As the sound perceived by the passengers depends on both the source and the path, the effort of the numerical study mainly concentrates on two aspects: characterization of the loudspeaker parameters and representation of cabin environment. The speaker parameters are characterized from the sound radiation data measured in 2pi chamber. To represent the vehicle cabin, pure finite element model is applied under 1k Hz while a hybrid FE-SEA is
Yang, Wenlong, Patra, Suresh, Hawes, David, Shorter, Phil
Bridging Simulation and Reality: A New Validation Approach for SUV Tailgate Weather-Strip Sealing Performance2026-01-0200To be published on 04/07/2026
Weather-strip sealing performance is critical in modern SUVs for preventing the intrusion of noise, dust, and water, directly affecting cabin comfort and NVH quality. Traditionally, experimental validation of sealing efficiency has been conducted using flat or straight JIG setups, which do not accurately represent the complex contact conditions found in actual vehicle assemblies. Components such as tailgates, doors, hoods, roofs, and bumpers typically interface with the weather-strip through curved, angled, or non-uniform surfaces, resulting in a mismatch between lab-based results and real-world performance. This study addresses the limitations of conventional flat JIG testing by proposing a more vehicle-integrated validation methodology that mirrors actual contact geometries and sealing behavior. The objective is to reduce the disparity between laboratory results and in-vehicle sealing performance, enabling more reliable design decisions and early-stage NVH optimization. The approach
GANESAN, KARTHIKEYAN, Seok, Sang Ho
Kissing Bonds Inspection by Measuring and Comparing Natural Frequencies Using Digital Holography2026-01-0207To be published on 04/07/2026
Accurate detection and evaluation of kissing bonds in composite materials is essential to ensure the integrity of the structure, but traditional NDT methods are often ineffective when dealing with zero-volume defects or disbonds. In this study, a vibration analysis method based on digital holography was used to detect kissing bonds by comparing the vibration mode shapes and corresponding natural frequencies of defective and intact samples. The mode shapes observed with the holography were highly consistent with the results of a linear finite element method simulation, validating the capability and accuracy of digital holography when measuring vibrational characteristics. In this study, three composite aluminum plate samples were prepared: a defect-free sample, a sample with a 30 mm-diameter kissing bond, and a sample with a 60 mm-diameter kissing bond, both located in the center of the respective plates. Controlled contamination of the bond area was used to induce kissing bond defects
Gao, Zhongfang, Fang, Siyuan, Gerini-Romagnoli, Marco, Yang, Lianxiang
Jute-Polyester Trim as a Novel Vehicle Upper Interior Head Impact Safety Countermeasure2026-01-0567To be published on 04/07/2026
A significant fraction of annual global human mortality is caused by severe head injuries resulting from vehicle crashes. In order to ensure upper interior head impact safety in vehicles, stiff upper body pillars are covered with plastic trims often along with internal countermeasures such as fin-type monolithic ribs. In the study being reported here, a consistent Computer-Aided Engineering (CAE) procedure employing explicit nonlinear finite element analysis has been demonstrated for predicting headform impact safety of a steel A-pillar component covered with a novel jute-polyester trim. Using simulation as mentioned combined judiciously with test data and physical reasoning, a number of jute-polyester trim configurations are considered by varying the number of jute plies, and packaging space between trim and A-pillar inner panel. Additionally, jute-polyester trims with internal ribs are considered. The current study reinforces the potential of a jute polymer composite as a vehicle
Karthika, M R, Deb, Anindya, Zhu, Feng
A Helical Compression Spring Fracture under Impact Velocity in Pump Operation by Theoretical Study and FEA2026-01-0271To be published on 04/07/2026
Helical compression springs have been used widely in various industries from automotive, aerospace and heavy-duty industries to electronics and medical devices. In the automotive industry, they appear in many places such as suspension, valvetrain, etc., especially in the discharge check valve of Gasoline Direct Injection (GDI) pump, which is the subject of study due to a recent fracture in lab testing. A theoretical study is conducted first to establish equation governing spring dynamic motion under impact velocity, which can be in high magnitude with surging shock wave along spring axis. A new spring shock wave equation is developed for spring axial motion coupled with coil torsional effect. This newly derived shock wave equation has a broad term than the classic spring formula found in engineering book. In the paper, it proves that the classic spring shock wave equation is only a special case for the new general wave equation discovered. Also, a formula on spring shock wave
Pang, Michael L., GUNTURU, SRINU, Norkin, Eugene
Optimization of Active–Passive Integrated Evaluation Weighting for Pedestrian Protection2026-01-0577To be published on 04/07/2026
Pedestrians, as the most vulnerable road users, largely determine the severity of traffic accidents through the extent of their injuries. Traditional vehicle safety evaluations have primarily emphasized passive safety. However, with the widespread implementation of active safety technologies such as Automatic Emergency Braking (AEB), passive-only assessments no longer adequately reflect a vehicle’s true pedestrian protection performance.This study employed finite element models of a sedan and an SUV to analyze changes in pedestrian head and lower limb injury metrics before and after AEB intervention, thereby quantifying the associated injury-mitigation benefits. The results show that AEB reduced the maximum head injury value (HIC15) by about 50%, lowering the proportion of severe head injuries from 0.217 to 0.118. Conversely, braking-induced pitch effects increased the proportions of severe femur and tibia bending moment injuries to 0.235 and 0.294, respectively, making them higher
shi, Xinxin, YE, BIN, Liu, Yu, Zhan, Zhenfei, Sun, Bowen, Zhao, yuanyi, zhu, lei
Computational Modeling and Optimization of Shape Memory Polymer-Based Energy Absorbers2026-01-0573To be published on 04/07/2026
Shape memory polymers (SMPs) provide tunable thermomechanical properties and enable the design of recoverable crash structures for automotive applications. This paper introduces a computational framework for the design and optimization of SMP-based crash absorbers with periodic auxetic microstructures. A finite element (FE) model is developed and validated against experimental data reported in the literature. The model is used to simulate crushing and recovery behavior under different temperature conditions. A parametric study is performed by varying key microstructural features, including wall thickness, cell size, and cell shape. Structural performance is evaluated in terms of specific energy absorption (SEA), peak force, and recoverability under axial crush loading. To efficiently explore the high-dimensional design space, surrogate models based on machine learning are constructed, and multi-objective optimization is carried out to identify Pareto-optimal designs that balance
Zhu, Yingbo, Zhu, Feng, Deb, Anindya
Integrated Effects of Suspension Geometry and Tire Pattern Design on Vehicle Pull Reduction under Acceleration in High-Performance and Electric Vehicles2026-01-0593To be published on 04/07/2026
Torque steer is a phenomenon that is more prominently observed in high-performance vehicles and electric vehicles (EVs). This phenomenon occurs primarily due to asymmetric driveshaft angles, drivetrain structure, and suspension geometry. Additionally, tire characteristics, particularly lateral force (Tire Lateral Force), also play a significant role in affecting torque steer. Tire lateral force is strongly influenced by the contact patch dynamics and the geometric design of the tire tread pattern. This study focuses on analyzing the impact of tire tread pattern geometry on the relationship between torque steer and tire lateral force in such vehicles. Specifically, lateral force response variations (dfy/dfx) resulting from tread pattern block deformation were derived through finite element (FE) simulations. These simulations enabled the establishment of an analytical method for tread pattern evaluation and optimization. The developed characteristic parameter was validated by comparative
Yoon, Youngsam, Jang, Dongjin, Kim, Hyungjoo, Lee, Jaekil
Impact of Core Glue Coverage and Stacking Factor on Glue-laminated Motor Material Properties and Its NVH Behavior2026-01-0439To be published on 04/07/2026
The influence of core glue coverage and stacking factors on the mechanical properties of core material is investigated in this study. As these structural attributes of the motor directly affect the mechanical behavior of the e-drive system, such as the NVH and durability performance, their influence on NVH is also analyzed under electromagnetic loads. With the unit-cell method previously proposed for predicting laminated motor core material properties, the material used in the finite element analysis (FEA) model for the glue-laminated motor core is homogenized over the laminations and idealized macroscopically as a transversely isotropic material. A numerical FEA method to quantify the effect of the glue coverage rate and stacking factor in a statistical or averaged sense to establish their relationship with the linear transversely isotropic properties. The glue is assumed to be evenly distributed over the lamination plane, and changes in the in-plane and out-of-plane elastic modulus
Nie, Zifeng
Influences of Process Parameters on Residual Stress and Tensile Performance of Riveted Joints2026-01-0183To be published on 04/07/2026
The mechanical integrity and performance of riveted joints critically influence the reliability and safety of automotive structures. To investigate the effect of residual stress on the tensile behavior of riveted joints, this study firstly established a finite element model of the riveting process using Abaqus software. The model was validated using the thick-walled cylinder theory, and the distribution of residual stress around the rivet hole was subsequently analyzed. Orthogonal experiments were subsequently conducted to examine the influence of key process parameters including rivet spacing, hole diameter, and upset head height on tensile performance, yielding simulation results for both radial residual stress and maximum tensile load. Based on the finite element analysis results, XGBoost and Kriging surrogate models were established using four key parameters as input variables, namely rivet spacing, hole diameter, upset head height, and arrangement pattern, with radial residual
Shen, yunlong, Zhan, Zhenfei, Tang, Weiqin, Yang, Yutong, Xiao, yong, HUANG, SHIYAO
Application of Fatigue Damage Criteria to CAE-Based Fatigue Life Prediction of a Welded Chassis Component2026-01-0232To be published on 04/07/2026
In recent years, computer-aided engineering (CAE) has become an essential practice in design and durability analysis of industrial components such as weldments. The current analytical trend for CAE-based fatigue life prediction of weldments includes procedures based on design guidelines, mesh-sensitive methods (e.g., local strain-life approach) and mesh insensitive methods (e.g., Volvo and Verity methods). As an inherent characteristic of weldments, the geometry of the weld is often simplified in failure analysis and important hotspots such as start/stop of the weld beads are not considered in designing process. However, such critical locations cannot be avoided in complex welded structures. Therefore, incorporating main geometrical details of the weld can improve the accuracy of critical regions identification and damage calculation using mesh-sensitive CAE-based methodologies. Herein, a framework for life prediction of welded components including the weld geometry is discussed and
Razi, Ahmad, Kim, Dooyoung, PARK, Jaehong, YOUK, Wansoo, Fatemi, Ali
Modelling and Analysis of Complex Shaped Cracks2026-28-0048To be published on 02/12/2026
This study provides an extensive analysis through finite element analysis (FEA) on the effects of fatigue crack growth in three different materials: Structural steel, Titanium alloy (Ti Grade 2), and printed circuit board (PCB) laminates based on epoxy/aramid. A simulation of the materials was created using ANSYS Workbench with static and cyclic loading to examine how the materials were expected to fail. The method was based on LEFM and made use of the Maximum Circumferential Stress Criterion to predict where cracks would happen and how they would progress. Normalizing SIFs while a crack was under mixed loading conditions was achieved using the EDI method [84]. We used Paris Law to model fatigue crack growth using constants (C and m) for the materials from previous studies and/or tests. For example, in the case of titanium Grade 2, we found Paris Law constants with C values from 1.8 × 10-10 to 7.9 × 10-12 m/cycle and m values from 2.4 to 4.3, which illustrate differing effects of their
T, Lokesh, Bhaskara Rao, Lokavarapu
Structural Redesign and Functional Integration of an Electrohydraulic Brake Valve for Enhanced Performance and Manufacturability2026-28-0002To be published on 02/12/2026
The Electrohydraulic Brake Valve (EBV) is a vital component in full-power brake systems for heavy-duty and off-highway vehicles, providing precise hydraulic pressure modulation through electrical control. Traditionally, EBV housings are manufactured using bar-machined components, which offer durability but contribute significantly to the overall weight and cost of the assembly. In response to increasing demands for lightweight and cost-effective solutions, this study presents a targeted design optimization of the EBV housing. The redesigned housing adopts a casting-based geometry, integrates sensor ports for pressure monitoring, and includes a nameplate mounting provision for customer identification. Material substitution and structural simplification were employed to enhance manufacturability and performance. Finite Element Analysis (FEA) was used to validate the mechanical integrity of the new design under operational conditions. The optimized EBV assembly achieved a weight reduction
R, Thangarajan
Vibration Analysis of Rectangular and Circular Plates with Fixed Edges: Analytical and Computational Validation2026-28-0108To be published on 02/12/2026
This study presents a comparative investigation of the vibration characteristics of rectangular and circular plates with fixed edges using analytical, numerical, and computational approaches. Analytical models based on classical plate theory were employed to calculate natural frequencies and mode shapes, while finite element analysis (FEA) was performed in a CAE tool to provide high-fidelity simulation results. A detailed mesh convergence study confirmed numerical stability, with frequency variations below 1% between successive refinements. Analytical predictions showed excellent agreement with simulation results for lower modes, with errors as low as 0.25% for the rectangular plate and 2.65% for the circular plate. However, higher modes exhibited significant deviations, with errors reaching up to 29.01% for rectangular and 181.52% for circular geometries, highlighting the limitations of closed-form solutions in capturing complex vibrational behavior. Python-based computational tools
N, Suhas, R, Sanjay, Bhaskara Rao, Lokavarapu
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 02/12/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a 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 glass fiber reinforced polyamide based thermoplastic composite (PA66GF), we have adopted a novel approach of determining non-linear Chaboche Non-Linear Kinematic Hardening (NLK) model parameters from monotonic uniaxial temperature dependent tensile test data of PA66GF. 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 PA66GF, here von Mises yield criteria
Basu, Parichay, Srinivasappa, Naveen
Improve Safety Balance between Women and Men in Frontal Crashes through Parametric Human Modeling and Adaptive Design Optimization2025-22-00101/23/2026
Objective: Previous studies have reported disparity in injuries between male and female drivers in the risk of certain types of injuries in frontal crashes that may be due to a myriad of sex-related differences, including body size, shape, anatomy, or sitting posture. The objectives of this study are 1) to use mesh-morphing methods to generate a diverse set of human body models (HBMs) representing a wide range of body sizes and shapes for both sexes, 2) conduct population-based frontal crash simulations, and 3) explore adaptive restraint design strategies that may lead to enhanced safety for the whole population while mitigating potential differences in injury risks between male and female drivers Method: A total of 200 HBMs with a wide range of body sizes and shapes were generated by morphing the THUMS v4.1 midsize male model into geometries predicted by the statistical human geometry models. Ten male and ten female HBMs were selected for population-based simulations. An existing
Sun, Wenbo, Hu, Jingwen, Lin, Yang-Shen, Boyle, Kyle, Reed, Matthew, Sun, Zhaonan, Hallman, Jason
A High-Fidelity Transient Fluid-Structure-Interaction Methodology for Evaluation of Rear Bumper Flutter of a Vehicle2026-26-04101/16/2026
The present work demonstrates a transient Fluid-Structure-Interaction (FSI) based numerical methodology for estimation of aerodynamic-induced flutter of the rear bumper of a Sports Utility Vehicle (SUV). Finite Volume Method (FVM) based High-fidelity transient full vehicle aerodynamic simulations were conducted for the estimation of the transient aerodynamic load. Subsequently, by mapping this transient aero load onto the surface of the rear bumper, Finite Element Method (FEM) based dynamic structural simulations were performed to predict its response. The results obtained through simulations were then compared against experimental wind tunnel test data of a prototype car with modified bumper for the specific test-case. The pressure and the time series data of rear bumper deflection were captured at multiple probe locations from wind tunnel experiments at 140 and 200 kmph. The distribution of pressure on the rear surfaces of the car was well captured by the aerodynamic simulation at
Choudhury, Satyajit, Yenugu, Srinivasa, Walia, Rajat, Zander, Daniel, Gullapalli, Atchyut, Balan, Arun, Astik, Pritesh
Virtual Prototyping: Accelerating Traction Motor Development for Commercial Electric Vehicles2026-26-01521/16/2026
This paper presents the virtual prototyping of traction motor in commercial EV to make an early prediction of the performance parameters of the machine without spending an enormous cost in building a physical structure. A 48/8 slot-pole configuration of IPMSM is used to demonstrate the electromagnetic and thermal co-simulation in ANSYS MotorCad. The core dimensions were determined using permanent-magnet field theory. From those, a two-dimensional finite-element (2D FEM) model of the interior permanent magnet (IPM) motor was simulated using Ansys Motor-CAD electromagnetic simulation tool. The influence of geometrical parameters on the performances of traction motor are evaluated based on FEM. The temperature distribution have been analyzed under steady and transient operating conditions. Alongside, the effects of saturation, demagnetization analysis, and the impact of PM flux linkage on inductances are also considered in this paper. At last, the simulation and analytical results of the
Murty, V. Shirish, Rathod, Sagarkumar, Gandhi, Nikita, Tendulkar, Swati, Kumar, Kundan, Thakar, Dhruv, Sethy, Amanraj
A Fluid-Structure- Interaction based Methodology to Evaluate Aero-Thermal Performance of Deformable Air Guides2026-26-03641/16/2026
The present work demonstrates a Fluid-Structure Interaction (FSI) based methodology that couples a Finite Volume Method (FVM) and Finite Element Method (FEM) based tools to estimate air guide deformation, thereby predicting accurate aerothermal performance. The method starts with a digital assembly step where the assembly shape and the induced stress due to assembly is predicted. A full vehicle Aerodynamic simulation is performed to extract the surface pressure on the air guide which is then used to estimate the extent of deformation of the air guides. Based on the extent a subsequent Aerodynamic simulation may be carried out to predict thermal efficiency. Comparison against pressure data and deflection data extracted from the wind tunnel experiments of vehicles has shown reasonable match demonstrating the accuracy and usefulness of the method.
Gadasu, Ravishastri, Choudhury, Satyajit, Umesh, Acharya Vaibhav, Kumar, Saravanan, Yenugu, Srinivasa, Zander, Daniel, Beesetti, Siva, Hattarke, Mallikarjun
Fatigue Failure Analysis for Automotive Transmission2026-26-05771/16/2026
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 generates 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
Effect of Pipe Bending by Rotary Tube Bending Process on Durability of Frame Structure2026-26-03701/16/2026
Automobile frames, particularly trellis frame structures, are engineered for superior dynamic performance, with stiffness being a paramount consideration1. These frames frequently utilize welded tubes, a manufacturing process made more complex by the necessity of bending tubes to precise angles to meet packaging and assembly requirements2. This bending, however, induces residual stresses that can substantially compromise the frame's durability3. This investigation employs a detailed finite element simulation to analyse the structural deformation and residual stresses that arise during the bending of Cold Electric Welded (CEW) annealed round pipes4. A comprehensive 3D mechanical model, incorporating realistic tooling and contact interactions, was developed to accurately simulate shape change, ovality, and wall thickness redistribution during the bending process5. CEW pipes, unlike their Electric Resistance Welded (ERW) counterparts, possess minimal initial forming stresses, and the
Rajwani, Ishwar, Khare, Saharash
AI-Driven Digital Twin for Enhanced Suspension Assembly Testing in Automotive Vehicles2026-26-04451/16/2026
This paper presents the development and implementation of a digital twin (DT) for the suspension assembly of automotive vehicles—an essential subsystem for assessing vehicle performance, durability, ride comfort, and safety. The digital twin, a high-fidelity virtual replica of the physical suspension system, is constructed using advanced simulation methodologies, including Finite Element Analysis (FEA), and enriched through continuous integration of empirical test data. Leveraging machine learning techniques, particularly Artificial Neural Networks (ANNs), the DT evolves into a dynamic and predictive model capable of accurately simulating the behaviour of the physical system under diverse operational conditions. The primary aim of this study is to enhance the precision and efficiency of suspension testing by enabling predictive maintenance, real-time system monitoring, and intelligent optimization of test parameters. The digital twin facilitates early detection of potential failures
Sonavane, Pravinkumar, Patil, Amol
Utilization of an Improved Hardening Model for Finite Element Analysis and Experimental Correlation of a Tractor ROPS Structure2026-26-04041/16/2026
In recent years, virtual validation using finite element analysis (FEA) has become a key step in designing an agricultural tractor roll over protective structure (ROPS). With the advancement of computation power and ability of finite element solver to handle bigger models; a higher fidelity model can be built to improve virtual validation accuracy. More & more advanced material model can be used to improve accuracy of the results. Along with ROPS, its mounting chassis and mounting bolts can also be validated. Virtual validation at the design phase not only saves time of new product development cycle; but also optimizes the weight & cost of the design. In this paper, majorly two material model has been used to analyze a real-life tractor ROPS, its mounting chassis and bolts. For the ROPS, conventional isotropic hardening model has been used using bilinear and piece-wise multilinear stress-strain curve. Additionally kinematic hardening model has been used using advanced multi-component
Pandey, Manoj Kumar, Kumar, Arun, Redkar, Dinesh, Thirugnanam, Vivekanndan, Magendran, G, MANI, SURESH
Integrated Evaluation of Pre-Crash Braking and Crash Injury Outcomes Using Human Body Models and ATDs2026-26-00191/16/2026
Traditionally, occupant safety research has centered on passive safety systems such as seatbelts, airbags, and energy-absorbing vehicle structures, all designed under the assumption of a nominal occupant posture at the moment of impact. However, with increasing deployment of active safety technologies such as Forward Collision Warning (FCW) and Autonomous Emergency Braking (AEB), vehicle occupants are exposed to pre-crash decelerations that alter their seated position before the crash. Although AEB mitigates the crash severity, the induced occupant movement leads to out-of-position behavior (OOP), compromising the available survival space phase and effectiveness of passive restraint systems during the crash. Despite these evolving real-world conditions, global regulatory bodies and NCAP programs continue to evaluate pre-crash and crash phases independently, with limited integration. Moreover, traditional Anthropomorphic Test Devices (ATDs) such as Hybrid III dummies, although highly
Pendurthi, Chaitanya Sagar, THANIGAIVEL RAJA, T, Kondala, Hareesh, Sudarshan, B.Sudarshan, Nehe, Vaibhav, Rao, Guruprakash
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