Browse Topic: Finite element analysis

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Optimizing the Structural simulation process of Automobile Airvent knob design to evaluate the sustainability for human accidental sliding load2025-28-0289To be published on 11/06/2025
The research work elaborated the structural integrity of airvent by skipping the assembly level snap fit analysis of knob to reduce computational complexity of air vent knob sliding test post stopper. During assembly, the strain based mechanical breakage prediction of airvent sliding knob snaps is investigated in prestressed condition. The function of airvent knob is to rotate the vertical fins to divert the air flow as per comfort in intended direction identified by passenger. The airvent knob slides on central horizontal fin on a grove feature provided. Post sliding the knob to extreme end it gets stopped at end of grove feature of H fin. The sliding knob is assembled by compressing it against a silicon rubber elastomer inlay. The compression of inlay produces a constant tension on the knob snaps. The knob assembly has to sustain a passenger accidental and abrupt sliding loads while in stopped condition. The knob snaps in this press fit condition are the weak link in the accidental
Shah, Viren
Virtual load sensor methodology for structural verification2025-28-0269To be published on 11/06/2025
Authors - Swapnil Zalte, Prasad Kulkarni, Abhijeet Aundhe, Shikha Gupta, Shubham Darade Large off-highway vehicles, such as combine harvesters, corn heads, and hinged drapers, are complex machines comprised of multiple interacting subsystems. Consequently, capturing the load path through full vehicle finite element modeling poses significant challenges and can be computationally intensive during the design development process. We primarily employ two structural analysis approaches based on the availability of load inputs: • Full Frame Finite Element Model Setup • Subsystem Finite Element Model Setup Just like virtual verification, physical verification can also be performed at both the full vehicle and subsystem levels. The most critical input for both physical and virtual structural verification is load data. Traditionally, we acquire structural loads induced by ground excitations using wheel force transducers. For subsystem finite element models, interface loads are essential, which
Zalte, Swapnil Suresh, S Kulkarni, Prasad, Gupta, Shikha, Aundhe, Abhijeet, Darade, Shubham
Dynamic Stiffness Simulation Driven Design Changes for Tractor Cab to Mitigate Structure Borne Noise Levels2025-28-0291To be published on 11/06/2025
The dynamic stiffness of mount systems is a critical factor influencing the overall dynamic behavior and vibration isolation capabilities of mechanical assemblies. Effective cab isolation in product design can reduce structure borne noise and tactile vibrations experienced by operators. Detailed dynamic stiffness analysis of mounting brackets coupled with modal analysis using finite element method provide insights into the vibration response and resonant frequencies of components. By systematically varying parameters such as material properties, shape and geometry, the study elucidates the sensitivity of dynamic stiffness to design alternations. This study investigates on dynamic stiffness and their consequential impact on system dynamics on various design alternations by considering the space constraints at mount locations due to components, wiring harness and structural analysis driven solutions. In overall, this paper emphasizes the pivotal role of dynamic stiffness analysis in
Saveenkumar, Valakeerthi, Cone, Kerry, Mandke, Devendra Laxmikant, Fapal, Anand
Optimizing Engine Dynamics & Reliability with Hydraulic Lash Adjusters in Type-5 Valvetrain Systems2025-28-0235To be published on 11/06/2025
The pursuit of optimizing processes and minimizing components has become a central focus in modern powertrain development especially in Off-Highway Vehicles for Sustainable Development. As the automotive industry seeks to upgrade existing engines from older generations with modern technologies, the challenges of integrating advanced valvetrain systems loom large due to their profound impact on engine performance, particularly in terms of timing precision. Among these technologies, Hydraulic Lash Adjusters (HLAs) have emerged as a promising solution, especially in diverse vehicle segments. However, adapting HLAs in Type-5 valve train systems while maintaining existing conditions presents unique challenges. This paper delves into the complexities and benefits of transitioning from mechanically adjusted push rod valve trains to systems controlled by hydraulically operated lash adjusters in a pickup vehicle engine which is an updated tractor engine. Throughout the design and development
John, Shijino Shaji, Bagal, Pratik
Method to determine the instantaneous Temperature rise and current offset for a continuously fluctuating current in a current measurement device.2025-28-0294To be published on 11/06/2025
This research proposes a method to accurately determine the instantaneous temperature rise and current offset in a current measurement device subjected to continuously fluctuating currents, while considering the ambient temperature conditions within an electric vehicle (EV) junction box. The study addresses the critical need for precise current measurements in EVs, where varying loads and environmental conditions can impact the performance and safety of electrical systems. The method involves the development of a comprehensive mathematical model that accounts for the dynamic interplay between the fluctuating current, temperature changes, joule heating and ambient conditions within the EV junction box. By incorporating thermal dynamics and electrical characteristics, the model aims to provide a nuanced understanding of the temperature rise and current offset phenomena. Special emphasis is placed on considering the effects of ambient temperature variations, which play a significant role
r, Sudarshan, Cheran, Abhinav, Rao, Sudarshan, Chandran, Praveen
Computational Fluid Dynamics (CFD) Analysis of Turbocharger Aerodynamics and Thermal Behaviour in Automotive Application2025-28-0229To be published on 11/06/2025
Turbocharging has emerged as a crucial technology for enhancing the performance and efficiency of internal combustion engines (ICEs) in modern vehicles. As the demand for lower fuel consumption and reduced emissions increases, turbochargers enable engine downsizing while maintaining or improving power output. This research work analyses the performance of turbocharging systems, focusing on their working principles, design considerations, performance evaluation, and efficiency optimization in automotive applications. The research begins with an overview of turbocharger fundamentals, detailing key components such as the turbine, compressor, intercooler, and wastegate, along with their respective functions. It examines how exhaust gas energy drives the turbine, which in turn compresses intake air to enhance engine efficiency. Furthermore, this work explores the influence of turbocharger selection on engine power, fuel economy, and emissions. Additionally, this research investigates
Chandrashekar, Aditya, Bhaduria, Abhishek
Structural Evaluation and Improvement of Mobile Vehicle Battery Storage Architecture2025-28-0259To be published on 11/06/2025
Environmental concerns are prompting the global mobility sector to transition towards electrification. Increased research and development in the field of electric vehicles have made them an increasingly efficient and compelling option for reducing greenhouse gas emissions and improving the sustainability of freight transport. Electric vehicles require batteries that offer long range, shorter charging times and high energy efficiency. During long-distance travel, for customer convenience, mobile charging stations have become a trending and highly meaningful solution. For such mobile charging stations, it is essential to ensure the durability and safety parameters of the battery and its structure. For this to happen, it is mandatory that the system possess the strength and stiffness behavior to withstand the various dynamic loads arising from the environment and acting on the vehicle and system. Moreover, the system should maintain a weight that is as low as possible so that it is both
SONARE, PUSHPESH, Ganeshan, Subramanian, Dattawade, Vishal
Fatigue in Plastic Field of AISI 304L on an Engine Component: An Interesting Case on a Pulley for Automotive Application2025-32-0080To be published on 11/03/2025
This study investigates the failure mechanisms of a press-fitted AISI 304L pulley, which is used to drive an engine coolant variable water pump in automotive applications. The analysis focuses on the peculiar loading scheme of the pulley resulting from the innovative water pump design which combines high mean stress from press fitting with cyclic stress from rotating bending loads that exceed the material's yield point. This is coupled with the cyclic material behavior of AISI 304L which exhibit a strong cyclic hardening. This combination significantly influences the stress distribution and fatigue life of the component under cyclic loads combined with material plasticity, ultimately leading to fatigue failure at the pulley-shaft mating surface. Assembly endurance tests were conducted on a specialized test bench, allowing control of pulley bending load. A comprehensive failure analysis, including visual inspection, metallurgical examination, and finite element analysis (FEA) was
Franceschini, Alessandro, Squarcini, Raffaele, Rybicki, Gilles
Study on the Clarification of the Mechanism of Scooter Centrifugal Clutch Squeal2025-32-0022To be published on 11/03/2025
A centrifugal clutch is used in many machines such as scooters, lawn mowers, outboard motor of boats, brush cutters, and so on. It may produce a shrill sound, similar to a brake squeal, when the clutch engages for starting. In this study, we have proved that this shrill sound, in another word, clutch squeal, is caused by the self-excited vibrations of the centrifugal clutch. And we have also clarified that the clutch squeal can be restrained by employing an asymmetrical shape for the clutch housing. The clutch squeal tends to occur when the centrifugal clutch becomes hot due to repetitive starting and stopping, which causes the friction coefficient of the friction material on the clutch shoe to increase. It is presumable that vibration on the clutch housing generated by the self-excited vibrations is the cause of the clutch squeal. In an attempt to clarify the cause of clutch squeal, we first measured the sound pressure of the clutch squeal and the vibration shapes of the clutch
Yamamoto, Kohei, Iwamoto, Tatsuya, Otsuka, Takashi
Dome Profile Optimization and Stress Analysis of Type IV Composite Cylinders using a CLT-based MATLAB Program and FEA Validation2025-28-0374To be published on 10/30/2025
Type IV composite pressure (CP) vessels composed of a plastic liner and composite layers require special design attention to the dome region. The cylindrical portion of the composite cylinder is wrapped with composite layers consisting of the 900 hoop layers and low-angle helical layers, whereas the dome surface carries helical layers only. The winding angle of the helical layers being a constant over the cylindrical portion starts to vary from the cylinder-dome junction toward the boss at the top continuously. Along with the winding angle, the composite thickness also varies continuously resulting in a maximum thickness at the top crown region. The complete analysis and layer-wise stress prediction of Type IV composite cylinders for service pressures up to 70 MPa was analyzed by the Classical Lamination theory (CLT)-based MATLAB program. The MATLAB program developed in this work for the dome initially performs the dome profile generation through the numerical integration of the dome
R. S., Nakandhrakumar, Tandi, Ronak, M, Ramakrishnan, Raja, Selvakumar, Elumalai, Sangeethkumar, Velmurugan, Ramanathan
Structural and thermal behavior prediction of chiller by using CAE simulation2025-28-0396To be published on 10/30/2025
Heat exchangers are critical components in various industrial applications, enabling efficient energy transfer between fluids. Chiller (Plate-type heat exchanger), with its compact design and high thermal performance, have gained significant attention in industries such as HVAC, power generation, and chemical processing. This study presents a comprehensive thermo-structural analysis of a chiller generated due to varying fluctuating temperatures and vehicle vibrations using Computer-Aided Engineering (CAE) tools. The analysis involves modeling the heat exchanger geometry, including the alternate chiller plates, to capture the complex geometries. Advanced simulation techniques such as Computer- Aided engineering (CAE) and Finite Element Analysis (FEA) are employed to investigate the thermal behavior under varying operating conditions, including flow rates, inlet temperatures, and pressure drops. Key parameters like pulsation pressure test, temperature distribution, dynamic stress
Jaiswal, Ankit, Parayil, Paulson
DESIGN AND DEVELOPMENT OF FIBER OPTIC VIBRATION SENSOR FOR AUTOMOBILE APPLICATIONS2025-28-0371To be published on 10/30/2025
Fiber optic sensors are impervious to EMI, which makes them ideal for usage in high-EMI settings like automotive and aerospace applications. These problems might result in expensive repairs and less comfortable driving if they are not fixed right away. In order to lessen this, fiber optic vibration sensors have been developed as a way to detect and analyze vibrations produced by automobile systems by detecting and observing changes in transmitted optical signals. These sensors, which are usually based on fiber optic technology, allow for real-time condition monitoring of the vehicle. Unusual vibration patterns can be identified by installing these sensors in crucial parts like the engine block, gearbox, suspension, or wheels. This allows for early diagnosis and preventative measures. In addition to preventing major malfunctions, this finite element analysis technique increases fuel economy, boosts driver comfort, and guarantees the vehicle’s general dependability. A major development
P, Geetha, Koppala, Neelima, Nagarajan, Sudarson
Finite Element Analysis and Test Validation of New Cummins Agricultural Structural Engine2025-28-0376To be published on 10/30/2025
Cummins Inc. is an American multinational corporation that designs, manufactures, and distributes engines, filtration, and power generation products. This paper presents an overview of the design, analysis and testing carried out by Cummins to demonstrate the capability of a new structural engine for an agricultural tractor application. In general applications, the powertrain assembly is mounted onto a vehicle chassis via vibration isolators. Due to tight packaging constraints in agricultural tractors, leaving no room for the chassis rails. The engine in conjunction with the transmission and a front axle carrier becomes an integral member of the vehicle chassis. This leads to the engine being directly subjected to the wide range of agricultural tractor application specific loads. Multiple analysis lead design (ALD) iterations were carried out using cutting edge CAE software such as Ansys, Dassault Systems fe-safe, and PTC Creo to ensure all elements of the complex acceptance criteria
Pathak, Arun Jyoti
Graphene based solar photonic battery for Aircraft-A Finite Element based 2D Analysis2025-28-0389To be published on 10/30/2025
Over the past one decade, progresses in nanoscience and nano technology have unlocked up novel avenues for the formation of operative photo cells. Currently, metal, polymer and semiconductor nanostructure designs for photovolotaic cells can be built. Considering the optical and electrical mechanisms underlying photovoltaic conversion has also helped from hypothetical and modeling reviews. The great cost and low efficacy of contemporary solar photo voltaic cells avoid solar energy from being used extensively. nanomaterials of one-dimensional (1-D) in particular have made original project potentials for additional efficient solar cells possible because of nanostructured ingredients. These one-dimensional nano structures, which include nanowires, nanorods, and nanotubes, present fantastic opportunities to boost photon concentration, electron transport, and electron gathering in photovoltaic battery. Graphene is a 2D (two-dimension), atomically thin, hexagonal lattice of carbon. The
P, Geetha, Sudarmani, R, c, Venkataramanan, Satyam, Satyam, Nagarajan, Sudarson
Efficient Simulation Methodology for Caliper Rattle Noise Based on a Reasonably Simplified Model and Integrated NVH CAE Approach2025-01-0348To be published on 09/15/2025
Brake caliper rattle noise is difficult to simulate due to its non-stationary, random, and broadband frequency characteristics. Many CAE engineers have adopted rattle vibration as an alternative metric to quantitative noise levels. Previous rattle noise simulations primarily presented relative displacement results derived from normal mode analysis or vibration dB levels rather than actual noise dB levels. However, rattle noise consists of continuous impact noise, which must account for reflections, diffractions, and refractions caused by transient nonlinear contacts and localized vibrations—especially during extremely short contact events. To accurately simulate impact noise, vibration and acoustic characteristics should be analyzed using a simplified structure, given the numerous mechanisms influencing impact noise generation. The rattle noise can be effectively modeled using LS-Dyna, which incorporates both explicit and BEM solvers. The correlation between test results and CAE
Park, Joosang
Development of a Design System for Wheel Bearings Including Prediction Functions for the Finite Element Method Using Lasso Regression and Bayesian Optimization2025-01-0365To be published on 09/15/2025
Wheel bearings play a critical role in providing smooth rotation when vehicles move in straight line and turning motions. Automotive electrification continues to accelerate, emphasizing specific market demands such as lightweighting, lower torque, and quietness. In addition to the above requirements, reduced development timing for automotive programs is required. Recently, the number of bearing manufacturers that utilize Model-Based Development (MBD) have been increasing in order to reduce development time. NTN has developed an integrated calculation automated system which is called Axle Bearing Integrated Calculation System (ABICS) that automates each step of the design processes for third generation hub bearings. After ABICS was released, man-hours per development project were reduced by 80 percent compared to previously used design flows in which each step of the design processes had been performed by a human. In order to further reduce development timing, even more focus has been
Kitada, Tatsuya, Barrett, Rob, Matsubuchi, Hiroki, Suma, Hiroto
A Novel Framework for Elastic Constants and Damping Ratio Optimization of Friction Material in Brake Squeal Simulations2025-01-0350To be published on 09/15/2025
Friction material properties critically impact brake squeal simulation outcomes due to their nonlinear and transversely isotropic behaviors, which vary with load type and direction. To improve the reliability of brake squeal predictions, this study introduces the Transversely-isotropic Elastic Constants Optimization (TECO) method, a novel multi-dimensional constrained optimization framework for refining the elastic constants and damping ratio of friction materials. By integrating experimental testing, finite element analysis (FEA), and an advanced optimization technique - Gradient Response Surface Algorithm (GRA), the TECO method minimizes discrepancies between simulated and experimental data, ensuring accurate characterization of elastic properties. The TECO method offers significant advantages, including flexibility and robustness, making it an effective alternative to ultrasonic measurements and traditional optimization techniques, especially for anisotropic friction lining
Philip, Rony, Muralidharan, Sudharsan, Mohanam, Gopalakrishnan
Evaluation of Switching Effect on Acoustic Noise of an Interior Permanent Magnet Synchronous Motor for a Traction Application14-14-03-001809/09/2025
In recent years, the automotive industry has shown growing interest in the vibroacoustic characteristics of electric propulsion motors. Investigation of such characteristics can open avenues for motor design optimization and refined control strategies to mitigate vibration and acoustic noise in an electric motor. This article presents a comprehensive vibroacoustic analysis of a propulsion interior permanent magnet synchronous motor (IPMSM) under various current excitations generated by the power converter in combination with three different modulation schemes. To evaluate the switching effect from the inverter drive on motor noise, different simulations and processes are performed in ANSYS Workbench and MATLAB/Simulink. The multi-physics noise and vibration workflow, and sampling requirements used for the study are also presented. The simulation results, presented as equivalent radiated power (ERP) waterfall diagrams, show diverse acoustic noise signatures for the different types of
Juarez-Leon, Francisco Alejandro, Sahu, Ashish Kumar, Haddad, Reemon Z., Al-Ani, Dhafar, Bilgin, Berker
Multibody Analysis for Vehicle Dynamics and Durability: Application to a 6x2 Truck and 1+3 Grain Semi-Trailer Combination2025-36-031808/01/2025
The development of modern road implements demands rigorous and comprehensive analyses of various design aspects, including the dynamic behavior of vehicles and the structural durability of their components. Multi-Body System Simulation (MBS) has become an essential tool in developing efficient products, allowing engineers to virtually assess how a truck + semi-trailer combination responds to different operational and loading conditions. By employing models that account for detailed interactions among various vehicle systems -such as suspension, chassis, axles, and fifth wheel-vehicle dynamics can be investigated in complex scenarios. These scenarios replicate real road usage, abrupt maneuvers, and special testing tracks, providing insights into performance under demanding conditions. This approach also facilitates the cascading of loads between systems to conduct durability calculations and estimate the operational lifespan of the implement. This study introduces a development cycle
Justo, Gabriel, Crocoli, Micael, Vigânico, Carlos, Pio, Frederico Nodari
Research on Charging Cables Temperature Field Prediction Based on Finite Element Method and Machine Learning05-18-04-003308/01/2025
With the rapid development of new energy vehicles, high-power charging technology has become an effective way to meet the fast-charging needs of electric vehicles. Temperature control of charging cables is crucial for the safety and efficiency of charging. This article aims to develop finite element method (FEM)-ML to predict the temperature field of the charging cable. First, the initial ambient temperature and maximum current were set as the main influencing factors, and a dataset including various charging parameters and cable temperature fields was built by FEM based on a two-factor, four-level orthogonal design. Then, surrogate models based on the Bayesian optimization (BO) algorithm, multilayer perceptron (MLP) model, and extreme gradient boosting (XGB) model were established to predict the temperature field distribution of high-power charging cables. The results indicated that the XGB model had better prediction performance than the MLP model, with average values of MSE, RMSE
Li, Xilin, Zhan, Zhenfei, Fan, Fuhao, Fu, Yunyou, Shen, Yunlong, Pu, Liangxi, Zhou, Qi, Tang, Weiqin
Design and Analysis of Passive Controlled Plastic Hinge in Two-Post Rollover Protective Structure for Off-Highway Motor Grader Equipment02-19-01-000107/23/2025
Rollover protective structures (ROPS) that absorb energy during vehicle rollovers play a crucial role in providing integrated passive safety for operators restrained by seat belts. These protective structures, integrated into the vehicle frame, are designed to absorb high-impact energy and deform in a controlled manner without intruding into the occupant’s safe zone. This research focuses on the detailed analytical design procedure and performance evaluation criteria of the two-post open ROPS used on motor graders against lateral loads. An experimental test on a standard tubular square hollow section (SHS) column subjected to lateral load has demonstrated a significant correlation between the post-yield behavior of plastic hinge development and energy absorption, compared with results from various formulations adopted in finite element analysis (FEA). To reduce design iteration time and the cost of physical destructive testing, the complete equipment experimental setup is virtually
J., Avinash
Optimisation of Rotor Skewing of a Yokeless and Segmented Armature Axial Flux Machine2025-01-031107/02/2025
This paper presents an optimisation approach for rotor skewing in a Yokeless and Segmented Armature (YASA) design Axial Flux Machine (AFM) for electric vehicle applications. Torque ripple amplitudes are a critical factor influencing the noise, vibration and harshness (NVH) behaviour of electric motors. The focus of this paper is to reduce the torque ripple amplitudes of the dominant harmonics over the entire torque-speed characteristic of the AFM. The principle of the proposed approach is a segmented permanent magnet configuration of the AFM, where individual magnet segments can be circumferentially shifted to achieve optimal skewing configurations. Initial optimisations are performed using 2D finite element (FE) simulations, modelled as linear motors with multiple slices and different numbers of magnet segmentation. However, the accuracy of the 2D FE results is limited due to the lack of interaction between the individual segments and the insufficient representation of three
Müller, Karsten, Maisch, Hannes, De Gersem, Herbert, Burkhardt, Yves
Evaluation of Static and Dynamic Stiffness of Rubber Grommet by Experimental and FEA Method2025-01-027407/02/2025
Vibration control is most important in automotive applications, and generally, rubbers are used to dampen these vibrations due to their inherent nature and low-cost manufacturing methods. Now, to select a rubber material, Shore hardness is considered in engineering applications, but to additionally control the behaviour, we need to understand its static and dynamic stiffness. These values help to determine the vibration isolation obtained by these rubbers. In this paper, we will discuss methods to calculate the static and dynamic stiffness of rubber grommets using experimental methods and FEA modelling. As elastomers have non-linear material properties, various material modelling techniques in FEA are used to capture multiple phenomena like creep, fatigue, and dynamic conditions. Rubber compounding is used in order to improve the physical and chemical properties, which in turn would give desirable linear characteristics. Certain guidelines and thumb rules are used in the rubber
Khamkar, Prasad Subhash, Gaikwad, Vikrant Chandrakant
Closed-Loop Real-Time Simulation of the Thermal and Electromagnetic Behavior in Electric Drive Trains: Optimizing Model Accuracy for Virtual Prototyping2025-01-032007/02/2025
This paper presents a coupled electromagnetic and thermal simulation of Permanently Excited Synchronous Machines (PMSM) in the context of virtual prototyping in a real-time Hardware-in-the-Loop (HiL) environment. Particularly in real-time simulations, thermal influences are often neglected due to the increased complexity of a coupled simulation. This results in inaccurate simulations and incomplete design optimizations. The objective of this contribution is to enable a precise and realistic real-time simulation that represents the electromagnetic as well as the thermal behavior. The electromagnetic simulation is executed used a Field-Programmable Gate Array (FPGA) and parameterized by Finite Element Analysis (FEA) results. The thermal model is based on a Lumped-Parameter-Thermal-Network (LPTN), which is based on physical laws, geometry parameters and material specifications. The simulation results are validated with testbench measurements to ensure the accuracy of the overall model. By
Jonczyk, Fabian, Kara, Onur, Bergheim, Yannick, Lee, Sung-Yong, Strop, Malte, Prochotta, Fabian, Andert, Jakob
Noise, Vibration, and Harshness Countermeasures of Permanent Magnet Synchronous Motor with Viscoelastic Layer Material10-09-04-003106/30/2025
An electric motor exhibits structural dynamic excitation at high frequency, making it particularly prone to noise, vibration, and harshness (NVH) problems. To mitigate this effect, this article discusses a novel countermeasure technique to improve NVH performances of electric machines. A viscoelastic rubber layer is applied on the outer surface of a permanent magnet synchronous motor (PMSM) as vibration damping treatment. The goal is to assess the countermeasure effectiveness in reducing acoustic emissions at different temperatures, through a combination of numerical modeling and experimental validation. A finite element model of the structure is realized, considering a viscoelastic material model for the rubber material, with frequency-dependent loss factor and storage modulus. The numerical model is validated by means of experimental modal tests performed on a house-built cylindrical structure, designed to mimic the geometry of a typical cooling jacket of a PMSM for automotive
Soresini, Federico, Barri, Dario, Ballo, Federico, Manzoni, Stefano, Gobbi, Massimiliano, Mastinu, Giampiero
Nonlinear Finite Element Calculation of Ultimate Breakage Load for Pyro-Inflator Housing2025-01-504506/27/2025
Accurate prediction of the ultimate breakage pressure load for pyro-inflator housing is a critical aspect of inflator development. In this study, the tensile test of a specimen, from its initial shape to fracture, is simulated to verify the material properties of the inflator housing. The numerical results demonstrate high accuracy, with the tensile force–displacement curve, maximum tensile force, necking in the concentrated instability zone, fracture location, and inclined angle all closely matching the experimental data. Following material correlation, the ultimate breakage load of the inflator housing under hydrostatic burst test conditions is calculated using an explicit solver. A stress tensor state analysis method is proposed to define the ultimate load based on the onset of plastic instability in the thickness direction at the top center of the inflator. Compared to experimental results, the accuracy of the ultimate breakage pressure prediction using this method is 99.04%, while
Wang, Cheng
Assessment of the Skull Fracture Prediction Capability of Finite Element Head Models2025-22-000506/16/2025
The development of drones has raised questions about their safety in case of high-speed impacts with the head. This has been recently studied with dummies, postmortem human surrogates and numerical models but questions are still open regarding the transfer of skull fracture tolerance and procedures from road safety to drone impacts. This study aimed to assess the performance of an existing head FE model (GHBMC M50-O v6.0) in terms of response and fracture prediction using a wide range of impact conditions from the literature (low and high-speed, rigid and deformable impactors, drones). The fracture prediction capability was assessed using 156 load cases, including 18 high speed tests and 19 tests for which subject specific models were built. The GHBMC model was found to overpredict peak forces, especially for rigid impactors and fracture cases. However, the model captured the head accelerations tendencies for drone impacts. The formulation of bone elements, the failure representation
Pozzi, Clément, Gardegaront, Marc, Allegre, Lucille, Beillas, Philippe
Commercial Vehicle’s Exhaust Front Pipe Reliability Improvement through Virtual Simulation and Experimental Validation2025-01-020906/16/2025
The exhaust front pipe is a critical structural component in commercial vehicles, ensuring the leak-proof flow of exhaust gases into the exhaust after-treatment system while withstanding engine and frame vibrations. To isolate these vibrations, the front pipe is equipped with a flex connector capable of enduring various displacements at frequencies between 8-25 Hz. The position of the flex connector relative to the engine crank axis significantly impacts its structural reliability over its service life. This paper compares the existing design, which features a horizontally positioned flex connector, with a modified design that positions the flex connector vertically and changes the material from SS-304 to SS-321. Finite element analysis was conducted using Nastran software. The fatigue life of the existing flex connector design is approximately 1015 cycles. In contrast, the improved design demonstrates a fatigue life of 1727 cycles, representing a 70% increase in durability compared to
Chandel, Kushal, Paroche, Sonu, Namdev, Akhilesh, Jain, Shailendra, Patil, Keyur
Numerical Simulation and Parametric Optimization of Engine/Powertrain Mounts: Identifying Key Design Variables to Reduce NVH Noise2025-01-025106/16/2025
Engine and powertrain mounts are vital for isolating vibrations and reducing the transmission of Noise, Vibration, and Harshness (NVH) from the engine to the vehicle structure. Despite technological advancements, addressing NVH issues related to tribological factors continues to pose significant challenges in automotive engineering. This study aims to systematically identify and optimize design parameters of engine/powertrain mounts to minimize NVH levels using CAE tools and parametric optimization techniques in Abaqus and Isight, respectively. The purpose of this research is to investigate the correlation between various design parameters of powertrain mounts and their impact on NVH characteristics. Specific attention is focused on noises such as clunking, banging, or thumping that emerge from the engine bay under dynamic conditions like acceleration, braking, or turning. These sounds often occur as the engine moves excessively due to worn mounts, making unintended contact with other
Ganesan, Karthikeyan, Seok, Sang Ho
Multi-Physics Coupling Analysis of Hybrid Stator Permanent Magnet Vernier Motor for Electric Vehicle Based on Halbach Array14-14-02-001306/11/2025
In order to improve the output torque and power density of the in-wheel motor, a hybrid stator permanent magnet vernier motor (HSPMVM) is proposed based on the traditional single-tooth permanent magnet vernier motor (PMVM-I) and split-tooth permanent magnet vernier motor (PMVM-II). With the help of analytical method and finite element method, the three motors of PMVM-I, PMVM-II, and HSPMVM are compared and analyzed. It is proved that HSPMVM has higher output torque and lower torque ripple, and the amount of permanent magnet is also significantly reduced. In order to further improve the operating performance, the Halbach array is applied to the HSPMVM to form a new hybrid stator Halbach array permanent magnet vernier motor (HSHPMVM). The analysis results show that the HSHPMVM has a significant magnetic concentration effect, the torque is increased by 61.96%, and the torque ripple is reduced by 22.47%. The magneto-thermal two-way coupling analysis of HSHPMVM under rated conditions shows
Xiuping, Wang, Jingquan, Yu, Dong, Xu, Chuqiao, Zhou, Chunyu, Qu
Temperature Effect on the Rattle and Squeak Noise of Automotive Instrument Panel and Console2025-01-504206/10/2025
In order to improve the comfort and perceptive quality of vehicle on the climate conditions worldwide, the temperature effect on rattle and squeak of instrument panel and console is studied under temperatures of −30°C, 23°C, and 60°C. First, the modal accuracy of finite element model is certificated by real vehicle test. The first global mode shapes are reciprocating rotation and reciprocating translation for instrument panel and console, respectively, corresponding to frequencies of 36.6 Hz and 29.6 Hz, which attain about 91% and 92.5% relative to the experiment values. Second, on basis of the “3σ” threshold of 0.27%, an assembly clearance in left instrument panel has non-negligible rattle risk under all temperatures. Another three clearances have no rattle risk but get rattle increase under temperatures of −30°C and 60°C. In addition, the rattle risk is increased around console end clearances at the temperature of 60°C. In other cases, the rattle risk is 0% or can be neglected. Third
Yang, Xiaoyu, Mu, Yongtao
Investigation of Injury Risk Functions of THOR-AV 50th Percentile Male Dummy2025-22-000406/05/2025
This research investigated injury risk functions (IRF) for the THOR-AV 50th percentile male dummy in accordance with ISO TS18506, focusing on areas with design changes. The IRF development utilized a combination of physical tests and finite element (FE) model simulations. For certain postmortem human subject test cases lacking physical dummy tests, the validated Humanetics THOR-AV FE model (v0.7.2) was used to quickly generate data, with the understanding that final IRFs based on full physical test data might offer greater accuracy. Log-logistic, log-normal, and Weibull survival functions were fitted with 95% confidence intervals. The Akaike Information Criterion, Goodman-Kruskal-Gamma, Area under the Curve of Receiver Operating Characteristic, and Quantile-Quantile plot were employed to assess the prediction strength and relative quality of the final IRF selections. Among the three survival distributions, the Weibull distribution provided the best fit. The lumbar Fz was identified as
Wang, Z. Jerry, Hu, George
Evaluation of Occupant Injury Risk in a Transport Aircraft Crash Test Environment02-18-02-001105/16/2025
Researchers at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) previously conducted a full-scale crash test of a Fokker F28 MK1000 aircraft to study occupant injury risks. The goal of the current study was to investigate the injury predictions of the Global Human Body Models Consortium (GHBMC) and Total Human Model for Safety (THUMS) occupant models in the tested aircraft crash condition and explore possible utilization of both human body models (HBMs) in this context. Eight crash conditions were simulated utilizing each of the models. The HBMs were positioned in two postures, a neutral upright posture with hands resting on the legs and feet contacting the floor and a braced posture with head and hand contact with the forward seat back. Head and neck injury metrics and lumbar vertebra axial force were calculated and compared for all simulations. Both HBMs reported similar kinematic responses in the simulated impact conditions. However, the GHBMC
Jones, Nathaniel, Putnam, Jacob, Untaroiu, Costin Daniel
Development of a Generic Nearside Impact Test Fixture for Evaluating In-Vehicle Crashworthiness of Wheelchairs2025-22-000205/13/2025
Current voluntary standards for wheelchair crashworthiness only test under frontal and rear impact conditions. To help provide an equitable level of safety for occupants seated in wheelchairs under side impact, we developed a sled test procedure simulating nearside impact loading using a fixed staggered loading wall. Publicly available side impact crash data from vehicles that could be modified for wheelchair use were analyzed to specify a relevant crash pulse. Finite element modeling was used to approximate the side impact loading of a wheelchair during an FMVSS No. 214 due to vehicle intrusion. Validation sled tests were conducted using commercial manual and power wheelchairs and a surrogate wheelchair base fixture. Test procedures include methods to position the wheelchair to provide consistent loading for wheelchairs of different dimensions. The fixture and procedures can be used to evaluate the integrity of wheelchairs under side impact loading conditions.
Boyle, Kyle, Hu, Jingwen, Manary, Miriam, Orton, Nichole R., Klinich, Kathleen D.
Proposed Reformulation of Brain Injury Criteria (BrIC) Using Head Rotation-Induced Brain Injury Thresholds Simulated and Derived Directly from A Subhuman Primate Finite Element Model2025-22-000305/13/2025
Recent studies have found that Brain Injury Criteria (BrIC) grossly overpredicts instances of real-world, severe traumatic brain injury (TBI). However, as it stands, BrIC is the leading candidate for a rotational head kinematics-based brain injury criteria for use in automotive regulation and general safety standards. This study attempts to understand why BrIC overpredicts the likelihood of brain injury by presenting a comprehensive analysis of live primate head impact experiments conducted by Stalnaker et al. (1977) and the University of Pennsylvania before applying these injurious conditions to a finite element (FE) monkey model. Data collection included a thorough analysis and digitization of the head impact dynamics and resulting pathology reports from Stalnaker et al. (1977) as well as a representative reconstruction of the Penn II baboon diffuse axonal injury (DAI) model. Computational modeling techniques were employed on a FE Rhesus monkey model, first introduced by Arora et al
Demma, Dominic R., Tao, Ying, Zhang, Liying, Prasad, Priya
Structural Strength Evaluation of the Lightweight Frame of Bus Passenger Seat with High-Tensile Material and Analysis of the Importance of Independent Variables by Regression02-18-04-002205/10/2025
This study aims to develop a lightweight bus passenger seat frame by conducting structural nonlinear finite element analysis (FEA) on various thickness combinations of seat frame components to identify the optimal configuration. The thicknesses of critical structural members that primarily bear the load when force is applied to the seat frame were selected as independent variables, while stress on each component and compliance with ECE R14 seatbelt anchorage displacement regulations were set as dependent variables. A regression analysis was performed to calculate the importance of each component and analyze the influence of each design variable on the dependent variables. Strain gauges were attached to critical areas of the actual seat frame to conduct a seatbelt anchorage test, and simulations under identical conditions were performed using the nonlinear FEA software (LS-DYNA) to validate the reliability of the analysis results. The optimized seat frame exhibited a maximum stress of
Ko, Yeong Gook, Cho, Kyu Chun, Lee, Ji Sun, Kang, Ki Weon
Influence of Strain Rate Effect on Mechanical and Crashworthiness Properties of CFRP Composite Structures05-19-01-000205/06/2025
Composite materials are increasingly utilized in industries such as automotive and aerospace due to their lightweight nature and high strength-to-weight ratio. Understanding how strain rate affects the mechanical and crashworthiness properties of CFRP composites is essential for accurate impact simulations and improved safety performance. This study examines the strain rate sensitivity of CFRP composites through mechanical testing and finite element analysis (FEA). Experimental results confirm that compressive strength increases by 100%–200% under dynamic loading, while stiffness decreases by up to 22% at a strain rate of 50 s−1, consistent with trends observed in previous studies. A sled test simulation using LS-Dyna demonstrated that the CFRP crash box sustained an average strain rate of 46.5 s−1, aligning with realistic impact conditions. Incorporating strain rate–dependent material properties into the FEA model significantly improved correlation with experimental crashworthiness
Badri, Hesam, Jayasree, Nithin Amirth, Loukodimou, Vasiliki, Omairey, Sadik, Bradbury, Aidan, Lidgett, Mark, Page, Chris, Kazilas, Mihalis
High-Fidelity NVH Model Development for Electric Motors Using Deep Learning and Machine Learning Algorithms2025-01-012305/05/2025
Electric motor whine is a significant source of noise in electric vehicles (EVs). To improve the noise, vibration, and harshness (NVH) performance of electric propulsion systems, it is essential to develop a physics-based, high-fidelity stator model. In this study, a machine learning (ML) model is developed using an artificial neural network (ANN) method to accurately characterize the material properties of the copper winding, varnish, and orthotropic stator laminate structure. A design of experiments (DOE) approach using Latin hypercube sampling of parameters is implemented after evaluating alternative surrogate models. A finite element (FE) model is constructed using the nominal stator design parameters to train the ANN model using 121 DOE variables and 72,000 data points. The ML-trained ANN model is then verified to predict the driving point frequency response function (FRF) spectrum with reasonable accuracy. Subsequently, modal tests are conducted on the electric stator, and the
Rao, Bhyri Rajeswara, GSJ, Gautam, He, Song
Evaluation of Material Damping Ratio of 2-Wheeler Electronic Ignition Switch Module to Enhance its Finite Element Model Physics for Harmonic Response2025-01-010905/05/2025
The proposed work performs the detailed investigation of material damping ratio for different Electronic Ignition Switch Module (EISM) used in two-wheeler automobiles. A Finite Element Method (FEM) based simulation model has been developed. The simulation is performed by matching the failure areas of critical components in the assembly with physical sinusoidal vibration based shaker table test. The results (particularly breakage) have been reproduced by utilizing different damping ratios for the assembly. The damping ratio parameter is further utilized to perform FEM based harmonic response analysis for different EISM and evaluate critical structural breakage zones. The breakage zones predicted by simulation are found to be aligned with breakage zones depicted by shaker table sinusoidal test results. The simulation outcomes are validated, specifically considering the damping ratio parameter. The FEM based harmonic response analysis has been performed for a particular acceleration
Shah, Viren, Kalurkar, Shantanu, Kumar, Rahul, Kushari, Subrata, Miraje, Jitendra, D, Suresh, Parandkar, Parag
Study on the Aspiration Properties of Glassrun Seal System under Time-Varying Pressure Difference2025-01-003005/05/2025
When a vehicle is driven at high speed, there exists intricate flow pattern and vortex shedding at the side window area with intense pressure fluctuation. A significant dynamic pressure difference between the vehicle's exterior and interior can render the side window sealing system vulnerable to aspiration. This susceptibility can lead to the generation of leakage noise, adversely affecting acoustic comfort in the vehicle's cabin. This paper delves into the aspiration properties of glassrun seal system under time-varying pressure difference. A nonlinear finite element model of the glassrun seal was established to simulate the quasi-static deformation of the sealing strip during installation process, which aims to obtain the deformed geometric shape and residual stress after this process. Then, the exterior flow field of the glassrun sealing area of a simplified vehicle model was calculated with CFD simulation to obtain the hydrodynamic pressure excitation acting on the outer surface of
Li, Hanqi, He, Yinzhi, Zhang, Lijun, Zhang, Yongfeng, Yu, Wuzhou, Jiang, Zaixiu, Blumrich, Reinhard, Wiedemann, Jochen
Horn Sound Digital Validation for ECE-R28 Regulation Compliance2025-01-000805/05/2025
Every vehicle has to be certified by the concerned governing authority that it matches certain specified criteria laid out by the government for all vehicles made or imported into that country. Horn is one of the components that is tested for its function and sound level before a vehicle is approved for production and sale. Horn, which is an audible warning device, is used to warn others about the vehicle’s approach or presence or to call attention to some hazard. The vehicle horn must comply with the ECE-R28 regulation [1] in the European market. Digital simulation of the horn is performed to validate the ECE-R28 regulation. In order to perform this, a finite element model of a cut model of a vehicle, which includes the horns and other components, is created. Fluid-structure coupled numerical estimation of the sound pressure level of the horn, with the appropriate boundary conditions, is performed at the desired location as per the ECE-R28 regulation. The simulation results thus
Ramachandran, Balachandar, Raveendran, Roshin, Mondal, Arghya
Numerical Analysis of Variable Cross Section Weather-Strip Contact Sealing Performance & Stick Slip Behavioral Study2025-01-013505/05/2025
This study focuses on the numerical analysis of weather-strip contact sealing performance with a variable cross-sectional design, addressing both static and dynamic behaviors, including the critical issue of stick-slip phenomena. By employing finite element modeling (FEM), the research simulates contact pressures and deformations under varying compression loads, DCE (Door Closing Efforts) requirements, typical in automotive applications. The analysis evaluates how changes in the cross-sectional shape of the weather-strip affect its ability to maintain a consistent sealing performance, especially under dynamic vehicle operations. The study also delves into stick-slip behavior, a known cause of noise and vibration issues, particularly improper/ loosened door-seal contact during dynamic driving condition. This study identifies key parameters influencing stick-slip events, such as friction coefficients, material stiffness, surface interactions, sliding velocity, wet/dry condition
Ganesan, Karthikeyan, Seok, Sang Ho, Sun, Hyang Sun
Comprehensive Analysis and Optimization of Door Closing Sound Quality of a Heavy Truck2025-01-006605/05/2025
Based on the objective and subjective experiment and finite element analysis, the influencing factors on the door closing sound quality of a heavy truck is analyzed and optimized. Results show that the loudness and sharpness can be reduced by increasing stiffness and damping of the door. The sound quality can be enhanced by increasing the pressure release area, which can decrease the air pressure resistance of dooring closing. By adding holes on the inner liner and changing the pressure release location, the dooring closing air pressure resistance is reduced from 289 Pa to 181 Pa. In terms of the rebound sound, the sound level is positively related to the door closing force. Increasing the protrusion height and decreasing the stiffness of the vibration absorber of the handle can improve the rebound sound quality. Optimizing the absorbers on both ends of the handle and adding damping material can decrease the loudness by 47.8%, reduce the cavity sound, reduce the rattle and improve the
Wang, Jian, Zhang, Yongshen, Feng, Lei, Xie, Chenhao, Lin, Jiewei, Sun, Changchun
Navigating Evolving Vehicle NVH Challenges with Application of Emerging Technologies in Artificial Intelligence and Machine Learning2025-01-013005/05/2025
The multifaceted, fast-paced evolution in the automotive industry includes noise and vibration (NVH) behavior of products for regulatory requirements and ever-increasing customer preferences and expectations for comfort. There is pressing need for automotive engineers to explore new and advanced technologies to achieve a ‘First Time Right’ product development approach for NVH design and deliver high-quality products in shorter timeframes. Artificial Intelligence (AI) and Machine Learning (ML) are trending transformative technologies reshaping numerous industries. AI enables machines to replicate human cognitive functions, such as reasoning and decision-making, while ML, a branch of AI, employs algorithms that allow systems to learn and improve from data over time. The purpose of the paper is to show an approach of using machine learning techniques to analyze the impact of variations in structural design parameters on vehicle NVH responses. The study begins by executing the Design of
Miskin, Atul R., Parmar, Azan, Raj, Sonia, Himakuntla, Uma Maheswar
Experimental Characterization of a Steel Spring Mount Using Virtual Point Transformation2025-01-004605/05/2025
The application of virtual point transformation for determining the transfer dynamic stiffness of a helical coil spring is demonstrated in this experimental study. Rigid fixtures are attached to both ends of the spring, and frequency response functions are measured using impact hammer excitations. These frequency response functions are transformed into virtual points, analogous to a node in finite element analysis, with six degrees of freedom. The six degrees of freedom transfer dynamic stiffness is then extracted using the inverse substructuring method, which eliminates the need to account for fixture dynamics. The results are validated by a direct measurement approach. Additionally, the study investigates the effect of liquid applied sprayed damping coatings on the spring's transfer dynamic stiffness, revealing that the coating significantly reduces vibration amplitudes at the surge frequencies. This suggest that the springs effective damping properties are enhanced.
Neihguk, David, Herrin, D. W., de Klerk, Dennis
A Theoretical and Experimental Investigation of NVH of In-Wheel Reducer and Motor Drive System2025-01-000605/05/2025
To enhance the power density of the system and reduce production costs, the high-speed electric drive system featuring integrated design and control is poised to be the future development trend. However, the high speeds of motors and gear reducers can lead to challenges such as system reliability and issues related to NVH. This paper specifically addresses the NVH concerns associated with the in-wheel reducer and motor drive system (IWRMDS). First, a bench test scheme is established, and vibration and noise tests are conducted under a range of conventional operating conditions. The results indicate that at a torque of 200 Nm and a speed of 5500 rpm, the noise sound pressure level reaches 86.2 dB, highlighting significant vibration and noise issues within the system. Subsequently, Operational Deflection Shape (ODS) testing and analysis are performed on the system. It was discovered that the IWRMDS exhibits a relatively rich modal frequency spectrum, with the breathing mode being the
Huang, Chao, Xiong, Lu, Meng, Dejian, Gong, Yu, Guo, Han, Zhang, Mengyuan
Process to Simulate Active Tuned Mass Dampers to Reduce Interior Noise during Cylinder De-Activation Events2025-01-011005/05/2025
During cylinder deactivation events, high amplitude torque pulsations are generated at the crankshaft of the engine over a wide frequency range creating a potential risk for noise, vibration and harshness (NVH) performance of the vehicle. As passive tuned mass dampers are effective only in a narrow frequency range, active tuned mass dampers (ATMD) have become a popular choice to mitigate the risk. Often, engineers rely on finite element (FE) models of vehicle structures to make design decisions during the early stages of vehicle development. However, there is limited literature on the simulation of ATMD using FE techniques. Consequently, several details related to the ATMD design are decided through physical testing at the latter stages of vehicle development which is not ideal. To address these issues, a novel methodology to simulate an ATMD during cylinder deactivation events using FE technique is presented here. In this study, an ATMD based on force feedback control method was
Maddali, Ramakanth, Mogal, Akbar Baig, Haider, Syed, Jahangir, Yawar
NVH Analysis and Optimization of Electric Drive System in Over Modulation and Six-Step Regions2025-01-008205/05/2025
Pulse width modulation (PWM) and the corresponding modulation index (MI) value are of critical importance to the performance of electric drive systems for electric vehicle applications. For interior permanent magnet (IPM) machines, operating in overmodulation (OVM) and six-step modes increases the voltage output beyond the linear region, allowing the motor to achieve higher torque and power with reduced inverter loss. However, the resulting distorted current waveforms and higher current ripple harmonics lead to a notable increase in the motor noise. A multi-disciplinary approach has been developed to analyze the NVH performance of a three-phase 8-pole IPM motor when it operates in the OVM and six-step regions at high speed. The PWM current ripple harmonics induced by voltage-source inverters are predicted using different MIs and subsequently validated through experiments. The current ripple data are used for the prediction of dynamic electromagnetic (EM) forces in the OVM and six-step
He, Song, Chang, Le, Gong, Cheng, Zhang, Peng, GSJ, Gautam
Noise Analysis and Optimization of Thermal Management Integrated Module2025-01-008105/05/2025
Thermal Management Integration Module (TMIM), which comprises components such as water pumps, runner boards, brackets, sensors, etc., is a multifunctional integrated component for electric vehicles. However, the water pump generates an excitation over a wide range of frequencies due to a wide range of speed variations. This excitation causes the TMIM to vibrate and generate noise. In this study, a TMIM that generates noise is studied and analyzed. Using the TMIM of an electric vehicle as a case study, a full-vehicle experimental test was conducted, revealing that the noise originates from the integration module. The finite element method is used to analyze the cause of noise generation. Given the characteristics of the TMIM, which comprise many components, high integration, and a complex structure, this paper simplifies the bracket, heat exchanger, sensor, and other components using the centralized mass point method. The modal state of the TMIM is obtained by impact hammer testing the
Xu, Shenao
Modeling Snap-Fit Stiffness for Improved BSR Predictions in Automotive Design2025-01-008905/05/2025
Squeak and Rattle (S&R) issues present significant challenges in the automotive industry, negatively affecting the perceived quality of vehicles. Early identification of these issues through rigorous testing protocols—such as auditory assessments and dynamic simulations—enables the development of more robust systems while optimizing resource use. Finite Element Method (FEM) simulations are crucial for identifying S&R issues during the design phase, allowing engineers to address potential problems before the creation of physical prototypes. By developing high-fidelity virtual models and accurately simulating flexible connections, these simulations effectively capture rattle effects, enhancing prediction reliability. Traditional snap stiffness calculations typically employ a cantilever-based formulation, which is suitable for simple snap-fit designs but insufficient for more complex geometries that require enhanced stiffness. To address this limitation, the proposed methodology utilizes
Rao, Sohan, Elangovan, Pranesh, Reddy, Hari
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