Browse Topic: CAD, CAM, and CAE

Items (3,022)
Find
Low-speed steering returnability analysis and improvements through mathematical modeling and CAE simulation for SUV2026-26-0573To be published on 01/16/2026
In driving, steering serves as the input mechanism to control the vehicle's direction. The driver adjusts the steering input to guide the vehicle along the desired path. During maneuvers such as parking or U-turns, the steering wheel is often turned fully from lock to lock and then released. It is expected that the steering wheel quickly returns to its original position. Steering returnability is defined as the ratio of the difference between the steering wheel position at lock to lock and the steering wheel angle after 3 seconds of release, to the steering wheel angle at the lock position, under steady-state cornering conditions at 10 km/h. Industry standards dictate that the steering system should achieve 75% returnability under these conditions within 3 seconds. Achieving proper steering returnability characteristics is a critical aspect of vehicle design. Vehicles equipped with Electric Power-Assisted Steering (EPS) systems can more easily meet returnability targets since the
Singh, Ram Krishnan, ahire, Manoj, JAIN, PRIYA, Vellandi, Vikraman, SUNDARAM, RAGHUPATHI, Paua, Ketan
Virtual Reality in Assembly Simulations : Outpacing Tecnomatix Process Simulate for Faster Time-to-Market2026-26-0398To be published on 01/16/2026
Virtual Reality (VR) technology is emerging as a transformative solution in manufacturing industry. It offers significant advantages over traditional tools like Tecnomatix Process Simulate (PS) in assembly and ergonomic simulations. Analysis using PS is time consuming and lacks real time human interaction as it relies on detailed modelling and sequential workflows, which will delay the identification of assembly no-build conditions and ergonomic issues. This paper evaluates the time and cost saving potential of VR in assembly processes and explores its role in minimizing the need for physical prototypes across various stages of vehicle development. VR provides interactive environments, enabling interaction with 3D models and real-time collaboration with various teams across the globe. This leads to faster identification of assembly process flaws, quicker iteration cycles, and a reduced need for physical prototypes in the station development process for the lines. VR allows individuals
Nagendran, Rakesh Kumar
Standardized design principles and emerging opportunities for AI-integrated CAD systems.2026-26-0632To be published on 01/16/2026
Artificial Intelligence (AI) in the automotive industry is growing and transforming in different segments of the industry. Still there is a significant gap persisting in the standardization of design principles and the incorporation of manufacturing constraints in system. However current development in AI CAD systems is isolated and non-parametric way, in contrary the conventional way of CAD methodology is knowledge based and systematic parametric steps which is agile to the iterative improvement. Hence it will be challenging in integration and adoption of these AI CAD systems in the well-established product development cycle. The research focuses on identifying the scope of AI integration which includes generative design, automated error detection, and design pattern-dependent learning systems, but also stresses the importance of standardized policies to address fundamental questions of system coherence, uniformity, and broad applicability. This research paper studies the adoption of
Shaikh, Taha, Harel, Samarth, Kumar, Akarsh, Venkitachalam, Muthukumar, SHAH, BHUMIKA, Chakraborty, Pinka
Evaluation of Thermo-Mechanical behavior of brake discs in vehicles using Multidisciplinary approach2026-26-0433To be published on 01/16/2026
The objective of this paper is to evaluate the thermal performance of the brake discs in the design stage of its life cycle by developing a methodology to replicate the dynamometer testing using multi-disciplinary Finite Element Analysis (FEA) methods. A simulation workflow was formulated in which Computational Fluid Dynamics (CFD) was used to create temperature and velocity dependent Heat Transfer Coefficients (HTC) which were in turn used in Computer Aided Engineering (CAE) to do a thermo-mechanical analysis. With this workflow various designs of the brake discs were analyzed. A sensitivity study was done to determine critical design features that affected its thermal performance. A final design was fixed that met both the weight and thermal performance targets. This design was evaluated in dynamometer testing, and 95% correlation was achieved. Thus, the developed simulation workflow ensured that a first-time right brake disc can be finalized in the design stage, which will meet the
Balaji, Praveen, K, Karthikeyan, S, KESAVPRASAD, S Kangde, Suhas, REDDY, JAGADEESWARA
Predictive Simulation Framework for Tyre Curb Impact Durability Assessment and Design Optimization2026-26-0396To be published on 01/16/2026
Tyre structural durability validation is a critical aspect of automotive design, considering the worsening road conditions. One of the key validation tests for assessing structural integrity is the curb impact test, which evaluates the tyre's ability to withstand sudden and concentrated impacts. Typically, this process involves physical testing of preliminary tyre samples, followed by iterative modifications to the tyre's construction to meet durability requirements. However, this approach often compromises ride performance, necessitating a more efficient and predictive methodology. To address this challenge, a frugal simulation-based prediction methodology has been developed to evaluate tyre curb impact durability before vehicle-level testing. This allows for the optimization of tyre design parameters early in the development process, ensuring structural performance while minimizing ride and handling (R&H) tuning iterations. By reducing the number of iterations, the methodology
Sundaramoorthy, Ragasruoban, LENKA., VISWESWARA
A procedure for validation of full vehicle CAE models with physical tests for passive safety applications2026-26-0411To be published on 01/16/2026
With the fast development of computational analysis tools and capacities during the past ten years, complex and substantial computer-aided engineering (CAE) simulations are now economically possible. While the cost of crash tests has risen steadily, the fidelity and complexity, which numerical simulations could address, has multiplied keeping the cost of computational analysis more stable. The use of CAE simulations complements physical testing, accelerating the product development process, reducing cost, and ensuring safe and more optimized designs. The fundamental goal of CAE is a significant reduction in the number of physical tests conducted during the product development process. However, validating the CAE model with physical tests is essential to ensure accuracy and reliability. Simulations performed using a validated CAE model could be used to make decisions like airbag deployment or high voltage shutdown without an actual physical test. This paper discusses validating an
UPENDRAN, ANOOP, Knuth, Joseph, krishnappa, Giri, Punnaiappan, Arunsankar
Optimization of a Positive Displacement Type Supercharger Using Response Surface Modeling (RSM)2026-26-0429To be published on 01/16/2026
Air suction in a naturally aspirated engine is a crucial influencing parameter to dictate the specific fuel consumption and emissions. For a multi-cylinder engine, a turbocharger can well address this issue. However, in a single or two-cylinder engine, the usage of turbocharger is not recommended, due to the lack of availability of continuous exhaust energy pulses. A supercharger solution comes handy in this regard for a single or two-cylinder engine. In this exercise, we explore the possibility of the usage of a positive displacement type supercharger, to enhance the air flow rate of a single cylinder, naturally aspirated, diesel engine for genset application, operating at 1500 rpm. The supercharger parametric 3D CAD model was prepared in Creo, with (a) Generating radius, (b) depth of blower and (c) clearance between lobes & lobe and casing, being treated as three parameters. The optimum supercharger design was expected to (a) generate a boost pressure of minimum 0.4 bar (gauge), (b
Satre, Santosh Dadasaheb, Mukherjee, Nalini, Rajput, Surendra, Nene, Devendra
Automated Parameterization of CAE Model Based on Test Data Response Bands2026-26-0436To be published on 01/16/2026
This study presents a data-driven approach aimed at enhancing the correlation between physical test data and Computer-Aided Engineering (CAE) simulations, with an emphasis on adapting the standard CAE model's response to minimize any gaps relative to the response of a given test specimen. Leveraging historical test data, machine learning techniques are used to categorize responses into distinct bands, effectively capturing the inherent variability observed in real-world scenarios. This categorization step recognizes patterns across a wide range of test data, forming the foundation for closely matching and adapting CAE models to new, unseen hardware data. In typical automotive simulation workflows, tuning a standard CAE model to match new hardware test data involves iterative parameter adjustments and simulations. This process can be time-consuming and often lacks predictive insight into the necessary modifications. The approach developed in this study addresses this challenge by
Khopekar, Maria, Arya, Bibhu, Sridhar, Raam, Mohan, Pradeep, Kurkuri, Mahendra
Innovative Friction Locking Mechanism for High Voltage Busbar Connections in EV Batteries2026-26-0155To be published on 01/16/2026
In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also reduces heat generation, addressing common issues associated with traditional screw-based connections. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency. This study presents the design methodology, performance
Venkatesh, Murali, Raghu, Arun, Bhramanna, Amol
Fatigue Life Prediction Methodology for Vehicle Suspension System and correlation with Physical Test2026-26-0459To be published on 01/16/2026
Fatigue Analysis is a safety critical area in design engineering for load bearing members. The design of a durable suspension system forms the foundation of vehicle architecture. The challenge lies in accurately predicting fatigue in critical areas to reduce field failures, primarily due to the absence of a validated methodology for fatigue calculation. This study provides an overview of fatigue assessment for Knuckle assembly/Rear Twist Beam based on digital Road Load/test Data for Finite Element Analysis (FEA) process for design development. This study makes use of Computer Aided Engineering (CAE) solvers such as Optistruct for model setup and fatigue tool such as nCode/FEMFAT for Fatigue Analysis. The methodology used for Fatigue estimation of rear suspension components such as Rear Twist Beam and Knuckle assembly is based on Digital Road Load Data/duty cycle loads applied to the suspension components at the hard point location at assembly level. The fatigue process used for
Kokare, Sanjay, Nagapurkar, Tejas, Iqbal, Shoaib
Master Complexity of Version Management in SDM by AI-Driven Assistance2026-26-0439To be published on 01/16/2026
Simulation-driven product development involves numerous CAE model iterations, where each version represents a critical difference. Usually, these multiple model versions are generated by hundreds of simulation engineers working in teams distributed across the globe, making functional collaboration a key for effective product development. To manage vast amounts of CAE data generated by engineers working simultaneously on a project, it is imperative to have a robust version management system to track changes in the CAE data. A robust version management is the backbone of an effective simulation data management (SDM) system. It involves capturing and documenting model changes at every design iteration. An accurate documentation of the model changes is crucial as it helps in understanding the model evolution and collaboration among engineers. However, documenting is usually considered a boring and tedious task by many engineers. This often leads to bad change documentation, which in turn
Thiele, Marko, Sharma, Harsh
Virtual Prototyping: Accelerating Traction Motor Development for Commercial Electric Vehicles2026-26-0152To be published on 01/16/2026
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 key dimensions were calculated on the basis of the permanent-magnet field theory, and the 2D finite element method (FEM) model of the IPM motor using Ansys MotorCad electromagnetic simulation tool. The influence of geometrical parameters on the performances of traction motor are evaluated based on FEM. The temperature distribution of the motor under rated operating condition and the condition of maximum speed were also analyzed. 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 IPMSM motor
Murty, V. Shirish, Rathod, Sagarkumar, Gandhi, Nikita, Tendulkar, Swati, Kumar, Kundan, Thakar, Dhruv, Sethy, Amanraj
A Data-Centric Approach to Identify Optimal NVH simulation Tools and Solvers2026-26-0356To be published on 01/16/2026
The world is rapidly evolving towards a data-driven paradigm, with widespread adoption of tools and techniques such as Artificial Intelligence, Machine Learning, Digital Twins, and Cloud Computing. In the automotive sector, vast amounts of data are being generated through both physical and digital test evaluations. Among these, Computer-Aided Engineering (CAE) stands out as one of the largest contributors to data generation, as physical testing is often cost-prohibitive due to the need for prototypes and complex test setups. The field of Automotive Noise, Vibration, and Harshness (NVH) is advancing exponentially, driven by stringent regulatory norms and growing customer demand for comfort. Digitally advanced techniques are playing a pivotal role in revolutionizing NVH processes. Data generation via CAE tools has become an integral part of engineers' daily operations, with the selection of appropriate CAE software and solvers being critical. This choice impacts factors such as user
Hipparge, Vinod, masurkar, Nikita, Arabale, Vinand, Billade, Dayanand
Developing Advanced CAE Model for Door Glass Regulator Operating Noise Reduction through TEST/CAE Correlation2026-26-0311To be published on 01/16/2026
The importance of performance improvement and weight optimization using CAE in the early design stages of vehicle development has been continuously increasing over the past two decades. And, the accuracy of CAE models plays key role, more efforts are required to improve it. Representation of exact physical model in CAE is still a big challenge for achieving an accurate TEST vs CAE correlation. In this research, the procedure and application of door system model correlation were described to reduce the glass regulator operating noise. The function of a regulator in door system is to open and close the glass. The regulator under improper design creates unwanted noise and discomfort to the passenger. In current door CAE Model, we are unable to identify this real time problem. Therefore, this paper discusses how to correlate door system model according to the assembly stage based on modal correlation and it helped in calculating accurate glass regulator operating noise. As a result, the
PANUGANTI, NARESH KUMAR, Choi, Seungchan
Optimisation of frontal impact force scheme to accelerate the target setting process for development of front-end structures in vehicles.2026-26-0001To be published on 01/16/2026
A passenger vehicle's front-end structure's structural integrity and crashworthiness are crucial to ensure compliance with various frontal impact safety standards (such as those set by Euro NCAP & IIHS). For a new front-end architecture, design targets must be defined at a component level for crush cans, longitudinal, bumper beam, subframe, suspension tower and backup structure. The traditional process of defining these targets involves multiple sensitivity studies in CAE. This paper explores the implementation of Physics-Informed Neural Networks (PINNs) in component-level target setting. PINNs integrate the governing equations into neural network training, enabling data-driven models to adhere to fundamental mechanical principles. The underlying physics in our model is based upon a force scheme of a full frontal impact. A force scheme is a one-dimensional representation of the front-end structure components that simplifies a crash event's complex physics. It uses the dimensional and
Gupta, Ishan, Bhatnagar, Abhinav, Kumar, Ayush
Investigation of Fatigue Durability Failure Mechanisms in High-Pressure Hydraulic Pipes of Power Steering Systems2026-26-0542To be published on 01/16/2026
Abstract—The high-pressure hydraulic pipeline in the power steering system is a vital component for ensuring optimal performance. During warranty analysis, leakage incidents were observed at the customer end within the warranty period. The primary factors contributing to these failures include pipe material thickness, material composition, mechanical properties, and engine-induced vibrations. This study investigates fatigue-related failures through detailed material characterization and Computer-Aided Engineering (CAE) based on real world usage road load data collected. The objective is to identify the root causes by examining the influence of varying pipe thickness on fatigue life. The investigation discovered that crack initiation predominantly occurred on the concave side of bent pipe sections, specifically on the engine-side high-pressure steering line, which is connected to the power steering pump mounted on the engine. Fracture surfaces exhibited characteristics consistent with
SURVADE, LALIT, Koulage, Dasharath Baliram, Biswas, Kaushik
Optimization of Electric Drive Unit Mounting for Vibration Isolation in EV Powertrains Using Multibody Dynamics2026-26-0080To be published on 01/16/2026
With growing significance of electric vehicles (EVs), their powertrains—while naturally quieter than internal combustion engine (ICE) powertrains—pose new NVH (Noise, Vibration, Harshness) challenges. These are triggered mainly from high-frequency disturbances caused by electric motors and gear interactions. Isolation of such excitations is essential for securing cabin refinement and customer expectations for acoustic comfort. This paper offers a simulation-based approach to optimal placement of the electric drive unit (EDU), which houses the electric motor and gearbox, with the objective of reducing vibration transfer to the chassis of the vehicle. The methodology explores the effect of spatial mount repositioning under actual dynamic load conditions through multibody dynamics (MBD) modeling and integrated optimizer using advanced multibody dynamics simulation software – Virtual Dynamics. The suggested workflow helps in effective investigation of mount positioning within packaging
Mane, Prashant, Shah, Swapnil, Back PhD, Arthur, Pinjari, Abrar, Emran, Ashraf, Mane PhD, Shrikala
Advanced Defect Detection Techniques Using AI, CAD Data, and Computer Vision2026-26-0644To be published on 01/16/2026
In area of modern manufacturing, ensuring product quality and minimizing defects are utmost important for maintaining competitive advantage and customer satisfaction. This paper presents an innovative approach to detect defect by leveraging Artificial Intelligence (AI) models trained using Computer-Aided Design (CAD) data. Traditional defect detection methods often rely on physical inspection, which can be time-consuming and prone to human error. The conventional method of developing an AI model requires a physical part data , By utilizing CAD data, the time to develop an AI model and implementing it to production line station can be saved drastically . This approach involves the use of AI algorithms trained on CAD models to detect and classify defects in real-time. The field trial results demonstrate the effectiveness of this approach in various industrial applications, highlighting its potential to revolutionize defect detection in manufacturing.
Kulkarni, Prasad Ramesh, Sahu, Dilip, Joshi, Chandrashekhar, Khatavkar, Akshay, Poddar, Shivani, Deep, Amar
Efficient simulation modelling technique using automatic mesh and contact interface generation2026-26-0392To be published on 01/16/2026
Computer-Aided Engineering (CAE) users often follow traditional meshing and contact generation processes, which are time-consuming, repetitive, and heavily dependent on user experience and perspective. The method described herein presents a system for generating a mesh and contact interfaces that ensures standardized and consistent output for a model. The system stores multiple mesh configurations, each containing a set of predefined geometric features to create standard meshes for users. The process begins by receiving data for a CAD model of an object and capturing user input through a graphical user interface. Users specify several parameters, including the desired body type, global mesh size, and a selected mesh configuration from the available options. Using these inputs, the system generates a mesh for the model, incorporating the selected mesh configuration’s geometric features along with the specified body type and size. The contact generation process offers several key
DABADGAONKAR, ANAND, Kamble, Amardeep
Strategic Design of Intake Systems for Crafting a Sporty Acoustic Signature in Passenger Vehicles2026-26-0328To be published on 01/16/2026
In pursuit of a distinct sporty interior sound character, the present study explores an innovative strategy for designing intake systems in passenger vehicles. While most existing literature primarily emphasizes exhaust system tuning for enhancing vehicle sound quality, the current work shifts the focus toward the intake system’s critical role in shaping the perceived acoustic signature within the vehicle cabin. In this research work, target cascading and settings were derived through a combination of benchmark and structured subjective evaluation study and aligning with literature review. Quantitative targets for intake orifice noise was defined to achieve the desired sporty character inside cabin. Intake orifice targets are engineered based on signature and sound quality parameter required at cabin. Systems are designed by using advanced CAE techniques, Specific identified acoustic orders were enhanced in the intake system to reinforce the required signature in acceleration as well
Sadekar, Umesh Audumbar, Titave, Uttam, Patil, Jitendra
Investigating the Effect of Aperture Flange Curvature on Tailgate Seal Bulb Height: A CAE-Based Approach2026-26-0416To be published on 01/16/2026
Water leakage is a common issue in vehicles, especially during water testing. It often occurs due to a gap between the seal bulb and the closure panel. This gap can result from variations in flange angle, flange curvature, closure surface, or seal bulb height. This study focused on how flange curvature affects seal bulb height and sealing performance. A Computer-Aided Engineering (CAE) method was used, supported by tests on physical samples. Multiple simulations were done using different flange curvatures. Results showed that with a constant flange angle of 150°, increasing the flange radius reduced seal bulb deformation. The optimal radius was 250 mm, where the bulb compression was 1.1 mm. Sharp or tight flanges caused the bulb to deform more, reducing contact and sealing force. To reduce this deformation, a hollow tube was inserted inside the seal bulb. The hollow tube used had an internal diameter of 10 mm and an external diameter of 12 mm. With the hollow tube, the optimum flange
Kumar, Saurav, Neelam, Rajat, Chowdhury, Ashok, Panchal, Girish, Lathwal, Sandeep
Multi-Model Analysis of O-Ring Compression and Relaxation Force Predictions Using Machine Learning and CAE Simulations2026-26-0466To be published on 01/16/2026
O-rings play a critical role in ensuring leak-proof seals in a wide range of engineering systems. Accurate prediction of their compression and relaxation behavior under various material and geometric configurations is essential for optimal design and reliability. This study presents an analysis of machine learning techniques to predict two key performance outputs, compression force and relaxation force (after 10 minutes) trained on computer-aided engineering (CAE) simulation data. The experimental setup was represented in CAE simulation and the results were compared with experimental data conducted at ZF test facilities. Simulation results correlated well with the experimental data (deviation was less than the 5%). To create a dataset for training machine learning (ML) models, realistic ranges for the input parameters such as hardness and geometrical parameters were determined, and simulation data were generated using design of experiments (DOE). Multiple ML models were developed and
Kosgi, Durgaprasad, Alva, P Pancham, Dangeti, VenkataKrishna Pavan
Road noise improvement of a passenger vehicle through end-to-end CAE-Simulation using Transfer Path Analysis (TPA) approach2026-26-0431To be published on 01/16/2026
Refined NVH performance of a vehicle is a mark of premium quality. Achieving the desired NVH performance in different vehicle operating conditions is always a Herculean task and early stage “CAE design recommendations” play crucial role in overall vehicle design development. This becomes tougher when the program is very much cost, weight and timeline sensitive. This paper explores simulation approach for addressing a major noise issue for a vehicle running at a constant speed on a rough road. The first and the most critical step is to identify the exact root cause of the issue. Hence, we propose a detailed full vehicle level “contribution analysis (CA) + transfer path analysis (TPA)” methodology (everything done through the simulation) and then go for the design recommendations to improve the performance. We used road excitation power spectral density (PSD) as the input at all the four wheels (spindle locations) calculated through MBD software. The first step i.e. contribution analysis
Mahajani, Mihir, Nascimento, Fabio, ADINARAYANA REDDY, KODIDELA, Matyal, Mahantesh, Tenagi, Irappa, Sardar, Chenna
Simulation-Driven Load Spectrum Prediction_ Virtual RLDA for Chassis and Suspension System2026-26-0095To be published on 01/16/2026
In the rapidly evolving and highly competitive automotive industry, manufacturers are under immense pressure to bring products to market quickly while meeting customer expectations. As a result, optimizing the product development timeline has become essential. Structural integrity analysis for chassis and suspension systems lies in the accurate acquisition of operational load spectra, conventionally executed through Road Load Data Acquisition (RLDA) on instrumented vehicles subjected to proving ground excitation. At this point, RLDA is mainly used for final validation and fine-tuning. If any performance shortfalls, such as premature component failure or durability issues, are discovered, they often trigger design revisions, prototype rework, and additional testing This study proposes a Virtual Road Load Data Acquisition (vRLDA) methodology employing a high-fidelity full-vehicle multibody dynamic (MBD) representation developed in Adams Car. The system is parameterized and uses high
Goli, Naga Aswani Kumar, PRASAD, TEJ PRATAP
Experimental and Numerical Investigation of Modal Behaviour in Electric Two-Wheeler Frames2026-26-0310To be published on 01/16/2026
This research investigates the dynamic characteristics of an electric two-wheeler chassis through a combined experimental and numerical approach. The study commences with the development of a detailed CAD model, which serves as the basis for Finite Element Analysis (FEA) to predict the chassis's natural frequencies and mode shapes. These numerical simulations offer initial insights into the structural vibration behaviour crucial for ensuring vehicle stability and rider comfort. To validate the FEA predictions, experimental modal analysis is performed on a physical prototype of the electric two-wheeler chassis using impact hammer excitation. Multiple response measurements are acquired via accelerometers, and the resulting data is processed to extract experimental modal parameters. The correlation between the simulated and experimental mode shapes is quantitatively assessed using the Modal Assurance Criterion (MAC). This matrix provides a measure of the consistency and similarity between
Das Sharma, Aritrya, Iyer, Siddharth, Prasad, Sathish, Anandh, Sudheep
Material-Optimization in Rib-Stiffened Polymer structures: A Computational & Analytical Study2026-26-0498To be published on 01/16/2026
Background The demand for lightweight yet rigid polymer components continue to drive innovation in structural design, particularly for applications requiring optimal stiffness-to-weight ratios. This study examines an alternative rib-stiffening approach for polypropylene plates, where conventional single-rib geometries are reconsidered in favor of parallel micro-rib configurations. While single ribs have been extensively studied, the potential benefits of distributed rib architecture remain less explored, particularly regarding their combined bending and shear performance. Key objective: This study systematically evaluates how parallel rib configurations influence mechanical performance in polypropylene plates, with specific focus on:  Bending stiffness preservation through optimized moment of inertia distribution  Shear resistance enhancement via controlled rib spacing  Coupled effect of the bending and shear resistance Prior art and their limitations: Current literature primarily
Sreejith, M P, Jain, Deepak, Maheshwari, Pankaj, Kumar, Mandeep, Ravi, Abhikrishna
Development of Vibration Fixtures for Automotive Testing: A Combined Analytical and FEA-Based Approach2025-28-025811/06/2025
Vibration testing is an essential component of automotive product development, ensuring that components such as engines, transmissions, and electronic systems perform reliably under various operating conditions. The adoption of electronics in the automotive industry, particularly during the 1950s and 1960s, marked a shift in vibration testing approaches, moving from primarily low-frequency tests to methods that could address high-frequency vibrations as well. This evolution highlights the need for effective vibration fixture designs that can simulate real-world conditions, enabling manufacturers to detect potential weaknesses before products are integrated into vehicles. A key aspect of vibration testing is the identification of resonant frequencies within components. The coupled mass-spring-damper system, for example, can exhibit multiple resonances characterized by a Bode Diagram, where the Q factor technique is utilized to assess damping levels. Accurate vibration analysis can be
Shinde, Pramodkumar, Shah, Viren
Optimizing Engine Dynamics with Hydraulic Lash Adjusters in Type-5 Valvetrain Systems2025-28-023511/06/2025
For the diesel engines first designed & developed before 2000s, push-rod type valvetrains with mechanical valve lash adjustment were common. For one such legacy diesel engine, first developed for tractors and now applicated for on road vehicles, having push-rod valvetrain architecture & mechanical valve lash adjustment (Type-5 valvetrain system) with flat follower tappet, integrating HLAs for enhancing the NVH & serviceability presented certain challenges. This paper delves into the challenges faced in the design & development phase of HLA integration project on a four-cylinder diesel engine. For integration of HLA, first, the packaging evaluation of valvetrain assembly was done followed by oil flow assessment and necessary changes in the oil pump and circuit. Then, valve lift profile optimizations were done since the ramp rate & seating velocity requirements are different for valvetrains with mechanical lash and HLAs. Numerous iterations were performed for cam-profile design to
John, Shijino Shaji, Bagal, Pratik
Development of CAE Technology for the Design Support of Piston Pin Circlip2025-32-001511/03/2025
This study focuses on the technology for establishing design criteria for the piston pin circlip (hereinafter referred to as "circlip"), which is a component that holds the engine piston pin. During the development of high-revving engines, failure of the piston sometimes becomes a problem, and the main factors are fatigue failure of the piston and falling of the piston pin. The falling of the piston pin is caused by the circlip disengaging from the groove by the inertial force due to the vertical motion of the piston. The circlip is compressed to the size of the piston circlip groove and assembled to the piston. Therefore, in order to prevent the circlip from falling out, it is necessary to compress it more and increase the reaction force acting on the groove. However, this measure raises concerns about the deterioration of the ease of assembly of the circlip. Therefore, it is necessary to establish evaluation criteria that prevent the circlip from disengaging and deterioration of its
Ishizuka, Atsushi, Watanabe, Naoto
Optimum Bore-to-Stroke Ratio for a Flathead Uniflow Two-Stroke SI Engine and its Impact on Different Fuels2025-32-002411/03/2025
This numerical study investigates a spark-ignited, two-stroke engine employing uniflow scavenging, flathead cylinder head design, and an exhaust valve system to identify the optimal bore-to-stroke (B/S) ratio for maximizing brake efficiency at fixed displacement. A single-cylinder prototype engine was constructed, and its experimental data validated a 1D GT-SUITE simulation model. This validated model was then utilized to simulate a full-scale, 1.5-liter displacement, horizontally opposed four-cylinder engine with supercharger-assisted boosting, intended for small aircraft propulsion. The simulations explored a range of B/S ratios from undersquare (0.7) to oversquare (1.5), maintaining a consistent brake power output of 60 kW at 3000 rpm and lambda 0.9. Results showed that increasing the B/S ratio enhanced brake efficiency from 26.0% at B/S=0.7 to 27.0% at B/S=1.5, largely due to reduced frictional losses attributed to shorter stroke and lower piston speeds, decreased heat transfer
Zanchin, Guilherme, Hausen, Roberto, Fagundez, Jean Lucca, Lanzanova, Thompson, Martins, Mario
Development of Temperature Sensor for Automotive2025-28-039410/30/2025
The work presents a micro-electromechanical system (MEMS) temperature sensor that has been designed using COMSOL Multiphysics 6.0 software for use in predicting the temperature of automotive parts. Due to its versatility, the shape of this design employs a meander, and this involves joule heating physics. It clearly shows the variation of resistance with temperature. For this design, Nitinol nano material is used because of the following advantages: Enhanced Shape Memory Effect, Superior Super elasticity, Increased Surface Area, Increased Surface Area, Improved Biocompatibility, Tunable Properties, Enhanced Mechanical Properties. Nitinol having high strength to weight ratio find its application in aerospace industry. This sensor works based on the principle of temperature dependence of resistance; that is, the resistance of the material increases or decreases based on temperature. It is observed that Nitinol has low von Mises stress, proving the safety nature of the material in
P, Geetha
Integrated Topology, Shape and Size Optimization-Application in Automotive Design and Manufacturing2025-28-037510/30/2025
CAE (Computer Aided Engineering) optimization plays a pivotal role in various industries to gain a competitive edge. CAE optimization is essential in several industries, such as automotive, aerospace and consumer electronics, etc., concentrating on enhancing component structural design. The process helps in addressing complex design challenges, including weight reduction, material usage efficiency and operational effectiveness. This paper presents applications for an integrated form shape, size and topology optimization approach of structural systems by using CAE tools. For the present study, CAD (Computer Aided Design) was prepared using CATIA V5 followed by meshing in Hyper-mesh 2022.3 version software. Optistruct was used as a solver tool. Modal analysis was performed to extract the natural frequencies of vibration and respective mode shapes. According to the results of the frequency response function study performed on the automobile air conditioning condenser, based on low-stress
Mehra, Akanksha, Parayil, Paulson
Prediction of Compressor Torque due to Swash Angle Change by Using Multi Body Simulation2025-28-040110/30/2025
Compressor is one of rotating component in AC system and function of the compressor is to increase the pressure of refrigerant and circulate the refrigerant across the system. Swash plate compressor is generally used in automotive AC application due to its light weight and compact size. Torque required to operate the compressor is very important and Compressor torque for specific capacity need to be evaluated based on simulation result. For this, simulation tools are effectively used Modeling and simulation are the key enablers to improve the design and development process. They are extensively used throughout the development cycle. MBD based simulation is more commonly used which gives better understanding of the movement of kinematic part. Reaction forces from the result will help in providing information for the CAE analysis. Many parameters like reaction forces, torque and power varying with shaft angle of rotation is predicted using MBD and result is analyzed. Rigid and Flexible
Parayil, Paulson
Development of Capacitive Pressure Sensor for Automotives2025-28-038710/30/2025
Measurement plays a crucial role in the precise and accurate management of automotive subsystems to enhance efficiency and performance. Sensors are essential for achieving high levels of accuracy and precision in control applications. Rapid technical advancements have transformed the automobile industry in recent years, and a wide range of novel sensor devices are being released to the market to speed up the development of autonomous vehicle technology. Nonetheless, stricter regulations for reliable pressure sensors in automobiles have resulted from growing legal pressures from regulatory bodies. This work proposes and investigates a tribo electric nano sensor that is affected by a changing parameter of the separation distance between the device's primary electrode and dielectric layers. The system is being modeled using the COMSOL multiphysics of electrostatics and the tribo-electric effect. Open circuit electric potential and short circuit surface charge density are two of the
P, Geetha, K, Neelima, Sudarmani, R, C, Venkataramanan, Satyam, Satyam, Nagarajan, Sudarson
Structural and Thermal Behavior Prediction of Chiller by Using CAE Simulation2025-28-039610/30/2025
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 analysis
Jaiswal, Ankit, Parayil, Paulson
Determination of Optimum Refrigerant Charge Quantity in ICEVs and EV Using 1D CAE2025-28-038410/30/2025
In both Internal Combustion Engine Vehicles (ICEVs) and Electric Vehicles (EVs), the refrigerant charge is essential for efficient climate control and energy consumption. An accurate refrigerant charge allows the system to regulate cabin temperature effectively and optimizing energy use. In ICEVs, this prevents the wastage of engine power. In EVs, it preserves battery life by minimizing energy drain by the climate control systems. Undercharging or Overcharging has adverse effects on the Heat Ventilation Air-Conditioning (HVAC) systems and the energy usage associated with it. Undercharging leads to poor cabin cooling which reduces heat absorption by refrigerant whereas overcharging leads to higher energy consumption by compressor, and potential damage to components, which can lead to wear, leaks, and system failures. Hence it is crucial to use optimum refrigerant charge quantity in Mobile Air-Conditioning (MAC) system both in ICEVs and EVs. Previous work on refrigerant charge
Shah, Geet, Jaiswara, Prashant, Kulkarni, Shridhar, Jaybhay, Sambhaji, vangala, Sai krishna, M, Chandru
Finite Element Analysis of Structural Strength of Traction Rod of Subway Vehicle Bogie Based on ANSYS2025-99-001410/17/2025
The research object of this paper is the bogie traction rod of urban rail transit vehicles in China. In order to better analyze the structural strength of bogie traction rod, we use advanced computer aided design and analysis software. Modeling software we use Solid Works to build a 3D model of the bogie traction device, which helps us to understand its structure and working principle more intuitively. The simulation analysis software uses ANSYS to carry on the static analysis of the subway bogie traction device, and establishes the finite element model, through simulation and calculation to predict the various situations and problems that the traction device may encounter in the actual operation.
Yue, Danfei, Lun, Jianlong, Ruan, Chijian, Tang, Simin, Yang, Zekun
Analyzing Aircraft Antenna Placement and Performance with Unified Modeling and Simulation25AERP10_0610/01/2025
Reliable antenna performance is crucial for aircraft communication, navigation, and radar detection systems. However, an aircraft's structure can detune the antenna input impedance and obstruct radiation, creating a range of potential problems from a low-quality experience for passengers who increasingly expect connectivity while in the air, to violating legal requirements around strict compliance standards. Determining appropriate antenna placement during the design phase can reduce risk of costly problems arising during physical testing stages. Engineers traditionally use a variety of CAD and electromagnetic simulation tools to design and analyze antennas. The use of multiple software tools, combined with globally distributed aircraft development teams, can result in challenges related to sharing models, transferring data, and maintaining the associativity of design and simulation results. To address these challenges, aircraft OEMs and suppliers are implementing unified modeling and
Posture Prediction Data Used for Manikin Placement in Ground Vehicle Design2025-01-047209/16/2025
The objective of this effort is to create a methodology to posture and position equipped manikins in Computer-Aided Design (CAD) software for ground vehicle workstation design. A collaborative effort is taking place to evaluate the current practices used to posture and position both physical and digital human representations. The goal of the group is to determine how best to utilize posture and position data to update positioning procedures. Data from the Seated Soldier Study and follow-on studies is being utilized to develop statistical models using multivariate analysis methods. Design is the first area of focus across the broader design-develop-evaluate process. The products to address this need are parametric CAD accommodation models with imbedded Digital Human Models (DHMs). Developing updated positioning procedures for each of the manikins will provide a traceable justification for positioning manikins based on Soldier data.
Huston II, Frank, Zielinski, Gale, Reed, Matthew
Towards Effective SCR System Optimization: A 3D-CFD and Experimental Study Enabling Faster Deposit Formation Risk Assessment2025-24-008709/07/2025
Selective Catalytic Reduction (SCR) is a key technology for reducing nitrogen oxides (NOx) emissions in diesel engines. In this process, a urea-water solution (UWS) is injected upstream of the catalyst to generate ammonia, which reacts with NOx to form nitrogen. However, liquid urea can adhere to system walls, undergoing secondary reactions that lead to the formation of solid deposits. These deposits must be minimized to ensure the long-term durability and efficiency of the system. Computer-Aided Engineering (CAE) simulations play a crucial role in optimizing SCR performance during the design phase. However, accurately predicting deposit formation requires detailed chemical modelling, which is computationally expensive and introduces uncertainties related to reaction mechanisms definition. To address this challenge, simplified CAE approaches are needed to assess deposit formation risks while maintaining computational efficiency. This study presents an improved Deposit Risk Index (DRI
Bianco, Andrea, Prestifilippo, Mattia, Robino, Cristina, Petrafesa, Giovanni, Postrioti, Lucio, Buitoni, Giacomo
Validation of a Suspension Lifter Bracket through a Test Bench2025-36-030608/01/2025
In the Brazilian market, the 6x2 configuration for commercial vehicles is widely used. These vehicles feature a driven rear axle and a non-driven axle. For the non-driven axle, it is common to use a lifter system that allows the axle to be lifted when the vehicle is running empty. This system provides benefits such as reduced fuel consumption, lower tire wear, and reduced toll costs when charges are based on the number of axles in contact with the ground. Given these advantages, the system has a high demand, making it mandatory to perform a durability test prior to its market implementation. This paper will present the validation methodology for the lifter system bracket. To achieve this, the following stages will be discussed: CAE, instrumentation, data acquisition, test bench concept, test execution and results.
Leme, Cristiano, da Costa Rodrigues, Gilson, Figueiredo, Guilherme Galvão, de Souza Maria, Heitor Cunha, Pires, Luciano Rogério
Optimizing Engine Coolant Hose Joint Performance through Taguchi Design of Experiments and Computer-Aided Engineering Analysis2025-01-505007/15/2025
This article presents a design of experiments (DOE) approach to analyze automobile engine coolant leakage from hose joints. The data includes force measurement at hose joints through physical validation and computer-aided engineering (CAE) simulation results. The proposed approach involves utilizing digital validation data, which simulates the entire experiment using CAE. The novelty of this approach lies in its reliance on digital validation data rather than conventional physical measurements, thus providing cost and time savings for the organization. In this study, the authors investigated the force at the coolant hose joint, which results in oil leakage as the response variable. Nine independent factors were evaluated in this experiment. The study concluded through the identification of critical parameters and opposed regression model to predict force at hose joints.
Koulage, Dasharath Baliram, Mondal, Kanchan, Manerikar, Dattatray Shriniwas
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
Automation and Optimization of the Design and Development Process for a Formula Student Racing Car Suspension2025-01-027007/02/2025
The design, development, and optimization of modern suspension systems is a complex process that encompasses several different engineering domains and disciplines such as vehicle dynamics simulation, tire data analysis, 1D lap-time simulation, 3D CAD design and structural analysis including full 3D collision detection. Typically, overall vehicle design and suspension development are carried out in multiple iterative design loops by several human specialists from diverse engineering departments. Fully automating this iterative design process can minimize manual effort, eliminate routine tasks and human errors, and significantly reduce design time. This desired level of automation can be achieved through digital modeling, automated model generation, and simulation using graph-based design languages and an associated language compiler for translation and execution. Graph-based design languages ensure the digital consistency of data, the digital continuity of processes, and the digital
Borowski, Julian, Rudolph, Stephan
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
100+ Years of Noise and Vibration in the Auto Industry2025-01-007105/05/2025
Over the past 30 years concerns about noise & vibration have become more critical in the design and manufacture of the automobile. Tools, both in physical testing and computer aided engineering have and continue to develop permitting more refined designs. Today’s customer can be very discerning when it comes to vehicle noises and vibrations. However, this is not a new concern for automotive customers or manufactures. This paper highlights the drive from automotive manufacturers to promote quiet, smooth and vibrationless operation of their products as well as some of the advances in vehicle component design over the past 100+ years. This is not an exhaustive study, but rather the intent is to bring to light the long history of noise and vibration in the automotive industry and its importance to the customers even in the infancy of the auto industry.
Kach, Raymond, Thompson, James
Brake Noise CAE Enhancement with the Synergy between Design of Experiments and Machine Learning2025-01-012405/05/2025
The digitalization of industrial systems has led to increased data availability. Machine learning (ML) methodologies are now commonly used for data analysis in industrial contexts. Not all contexts have abundant data; sometimes data collection can be scarce or expensive. Design of Experiments (DOE) is a technique that provides an informative dataset for ML analysis when data are limited. It involves systematically designing experiments to collect relevant data points with regression models. Disc brake noise is a challenging problem in vehicle noise, vibration, and harshness (NVH). Different noise events occur under various operating conditions and across frequencies (1-16 kHz). To enhance computer-aided engineering (CAE) techniques for brake noise, ML is used to generate additional data. Sequential experimentation in DOE aligns well with ML’s ability to continuously learn and improve as more data become available. DOE is applied in CAE to collect data for training ML models. ML helps
Song, Gavin, Sridhar, Gurupriya, Vlademar, Michael, Venugopal, Narayana
The DANA EV NVH Laboratory2025-01-000705/05/2025
A cutting-edge EV powertrain NVH laboratory has been established at Dana Incorporated’s world headquarters in Ohio, significantly enhancing its capabilities in EV powertrain NVH development. This state-of-the-art, industry-leading facility is specifically designed to address diverse NVH requirements for EV powertrain development and validation processes. This capability substantially reduces development time for new drivetrain systems. Key features of the laboratory include a hemi-anechoic chamber, two AC asynchronous load motors, an acoustically isolated high-speed input motor, and two battery emulators capable of accommodating both low and high-voltage requirements. The NVH laboratory enables engineers to evaluate system performance and correlate results with digital twin models. This capability supports the optimization of NVH characteristics at both the system and component levels, as well as the refinement of CAE models for enhanced design precision. This paper details the design
Cheng, Ming-Te, Zugo, Chris
Designing Rubber Flaps for Resonance Management: High-Frequency Tuning in Electric Vehicles Using AI/ML Approaches2025-01-012505/05/2025
High-frequency whine noise in electric vehicles (EVs) is a significant issue that impacts customer perception and alters their overall view of the vehicle. This undesirable acoustic environment arises from the interaction between motor polar resonance and the resonance of the engine mount rubber. To address this challenge, the proposal introduces an innovative approach to predicting and tuning the frequency response by precisely adjusting the shape of rubber flaps, specifically their length and width. The approach includes the cumulation of two solutions: a precise adjustment of rubber flap dimensions and the integration of ML. The ML model is trained on historical data, derived from a mixture of physical testing conducted over the years and CAE simulations, to predict the effects of different flap dimensions on frequency response, providing a data-driven basis for optimization. This predictive capability is further enhanced by a Python program that automates the optimization of flap
Hazra, Sandip, Khan, Arkadip
Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions2024-32-003804/18/2025
The arc welding process is essential for motorcycle frames, which are difficult to form in one piece because of their complex shapes, because a single frame has dozens of joints. Many of the damaged parts of the frames under development are from welds. Predicting the strength of welds with high reliability is important to ensure that development proceeds without any rework. In developing frames, CAE is utilized to build up strength before prototyping. Detailed weld shapes are not applicable to FE models of frames because weld shapes vary widely depending on welding conditions. Even if CAE is performed on such an FE model and the evaluation criteria are satisfied, the model may fail in the actual vehicle, possibly due to the difference between CAE and actual weld bead geometry. Therefore, we decided to study the extent to which the stresses in the joint vary with the variation of the weld bead geometry. Morphing, a FE modeling method and design of experiment method, was utilized to
Hada, Yusuke, Sugita, Hisayuki
Items per page:
1 – 50 of 3022