Browse Topic: Optimization

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Preliminary Design and Analysis of Dual Throat Fluidic Thrust Vectoring Nozzle for Supersonic Aerospace Application2026-28-0106To be published on 02/12/2026
The project investigates the performance characteristics of dual-throat nozzle used for fluidic thrust vectoring (FTV) in supersonic aircraft applications, offering a potential alternative to mechanical vectoring methods. Fluidic thrust vectoring provides benefits such as reduced weight, lower radar signature, and improved manoeuvrability and control. Computational methods are used to study the effects of geometric and operational parameters, including nozzle pressure ratios and secondary injection rate and injection angle, on thrust-vectoring efficiency and system dynamics. The study aims to develop optimized design configurations and validate using computational models.
Suresh, Vignesh, M, Akash, SENTHILKUMAR, NIKIL, Sundararaj, Senthilkumar, A, Garry Kiristen, Singh, Swaraj
A Nature-Inspired Optimization Approach for Vienna Rectifier Control in EV Fast Charging Applications: Performance Comparison with NPC and Swiss Topologies2026-28-0112To be published on 02/12/2026
The growing adoption of electric vehicles (EVs), particularly those utilizing High Voltage battery systems, demands fast-charging infrastructure that ensures high efficiency and power quality. This study proposes a Golden Jackal Optimization (GJO)-based control strategy for a Vienna rectifier used exclusively in a High Voltage EV fast-charging system. Unlike conventional systems that incorporate an additional DC-DC converter stage, the proposed architecture utilizes only the Vienna rectifier for AC-DC conversion, thereby reducing system complexity and improving overall reliability. The GJO algorithm, inspired by the cooperative hunting behavior of golden jackals, is employed to optimize the switching control parameters of the Vienna rectifier, enhancing system performance in terms of efficiency, power factor correction (PFC), and total harmonic distortion (THD). A detailed comparative analysis is performed between the Vienna rectifier, Swiss rectifier, and Neutral-Point Clamped (NPC
R, Mohammed Abdullah, N, Kalaiarasi
Statistical Optimization of Wire Arc Additive Manufacturing Parameters Using Taguchi Methodology2026-28-0035To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is an emerging metal additive manufacturing process known for its high deposition rates and cost-effectiveness in fabricating large-scale components. However, the quality of the final build is highly sensitive to process parameters such as wire feed rate, travel speed, voltage, and current. In this study, the Taguchi method is employed to statistically optimize key WAAM process parameters with the aim of improving surface finish and mechanical integrity of the deposited parts. An L9 orthogonal array was used to design experiments, and signal-to-noise (S/N) ratios were analyzed to identify optimal parameter settings. Analysis of variance (ANOVA) was performed to determine the significance of each factor on the selected output responses. The results demonstrated that specific combinations of process parameters can significantly reduce surface roughness and enhance bead geometry. The optimized settings obtained through the Taguchi approach provide a
PN, Vani
Multi-Objective Optimization of WAAM for Sustainable Production of Automotive-Grade Components2026-28-0030To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) has emerged as a promising technology for fabricating large-scale metal components with reduced material waste and lead time, aligning with the goals of sustainable manufacturing. This study presents a multi-objective optimization approach for WAAM to enhance both the manufacturing efficiency and sustainability of automotive-grade components. Key process parameters such as travel speed, wire feed rate, and current were systematically varied to evaluate their impact on dimensional accuracy, mechanical performance, and energy consumption. A statistical design of experiments framework was employed, and multiple performance objectives were optimized simultaneously using suitable decision-making techniques. The results demonstrate that optimized WAAM settings not only meet structural and functional requirements for automotive applications but also contribute to material and energy savings. This approach supports the integration of sustainability into
Pasupuleti, Thejasree
Statistical Modeling of Wire Arc Additive Manufacturing Parameters Using Regression Analysis2026-28-0024To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is gaining prominence for fabricating large metal components due to its high deposition rate and cost-effectiveness. However, the quality and performance of WAAM-fabricated parts are strongly influenced by process parameters such as wire feed rate, travel speed, arc voltage, and current. This study presents a statistical modeling approach using regression analysis to predict the effects of these key parameters on critical output responses, including bead geometry, surface roughness, and material deposition rate. Experiments were designed using a structured methodology, and the collected data were analyzed to develop linear and multiple regression models. The accuracy and reliability of the models were evaluated using statistical metrics such as R² and p-values. The results demonstrate that regression-based models can effectively predict WAAM outcomes, enabling process optimization and quality control. This approach provides a valuable tool for
Pasupuleti, Thejasree
Structural Redesign and Functional Integration of an Electrohydraulic Brake Valve for Enhanced Performance and Manufacturability2026-28-0002To be published on 02/12/2026
The Electrohydraulic Brake Valve (EBV) is a critical component in full-power brake systems, particularly in heavy-duty and off-highway vehicles, where precise braking control and system reliability are paramount. This paper presents a comprehensive cost and weight optimization initiative focused on the EBV housing, which currently accounts for approximately 75% of the total assembly weight due to its bar-machined construction. The project involved a complete redesign of the EBV housing with the dual objective of reducing mass and enhancing functionality. Key improvements include the integration of sensor ports for real-time pressure monitoring, a dedicated provision for nameplate mounting to support customer traceability, and a transition to a cast-based design optimized through advanced core modeling. Material substitution and structural simplification were explored to further improve manufacturability and cost-efficiency. Finite Element Analysis (FEA) was employed to validate the
R, Thangarajan
Design and Development of Integrated Brake and Bull Cage System for Enhanced Tractor Performance and Sustainability2026-28-0005To be published on 02/12/2026
Conventional tractor transmission systems feature separate Brake and Bull Cage housings, with brakes often being proprietary components and Bull Cage designed by the Original Equipment manufacturer (OE). To optimize design and performance, an innovative integrated system was developed, combining an in-house braking system with a unitized Bull Cage assembly. This robust design reduces part count, eliminates proprietary dependency (except for friction liners), and enhances performance. Virtual simulations performed under RWUP conditions demonstrated enhanced strength and stiffness in the integrated design. In this Integrated Brake & Bull Cage assembly (IBCA) , the braking layout was reconfigured from a 4+1 friction design to a 3+2 configuration which improved balancing, enhancing customer braking experience and increasing contact area by 11%. This adjustment extends friction liner life and boosts mechanical advantage by 7.5%, significantly improving tractor stability and performance
Dumpa, Mahendra Reddy, Dhanale, Swapnil, Perumal, Solairaj, Gomes, Maxson, Redkar, Dinesh, Savant, Kedarnath, V, SARAVANAN
Evolution of a Novel Hybrid Stab-Link for a Born Electric Sports Utility Vehicle2026-28-0001To be published on 02/12/2026
The present study details the design evolution and failure analysis of a novel hybrid stabilizer bar link (stab link) developed for the front suspension of a born electric sports utility vehicle (SUV) platform characterized by higher gross vehicle weight (GVW), increased wheel travel, and constrained packaging space. To address these challenges, a unique hybrid stab link was designed featuring dual plastic housings at both the metal ball joint ends, connected by a steel tube, and achieving a 30% weight reduction while offering enhanced articulation angles for extremely lower turning circle diameter (TCD) of the vehicle, compared to the conventional stab link. The unique hybrid stab failed under complex loading conditions during accelerated durability testing (ADT), prompting a comprehensive investigation. The failure analysis included road load data acquisition across various stab bar diameter configurations evolved during suspension tuning, different stabilizer link designs evolved
SELVENDIRAN, P, J, Ramkumar, NAYAK, Bhargav, M, Sudhan, Patnala, Avinash
Parameter Selection Strategies for High-Performance WAAM Structures in Automotive Engineering2026-28-0033To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) has gained traction as an advanced fabrication technique for producing large, structurally demanding components in the automotive industry. Achieving high-performance WAAM structures requires precise control and selection of key process parameters, which directly influence mechanical strength, dimensional accuracy, and surface quality. This study investigates the effect of critical process variables—including wire feed rate, travel speed, current, voltage, and inter-layer cooling time—on the structural integrity of WAAM-fabricated components designed for automotive use. A systematic experimental approach, supported by statistical modeling and optimization tools, was employed to identify parameter combinations that yield optimal results. The outcomes demonstrate improved microstructural uniformity, reduced residual stresses, and enhanced tensile properties in the fabricated parts. The findings serve as a foundation for developing robust parameter
V, Aravind
Selection and Optimization of Process Parameters in Wire Arc Additive Manufacturing for Automotive Structural Applications2026-28-0039To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) has emerged as a promising technology for fabricating large, complex metal structures with reduced material wastage and improved design flexibility. In the automotive sector, WAAM offers significant potential for producing lightweight and high-strength components, particularly for structural applications. However, the quality and performance of WAAM-fabricated parts are highly dependent on the careful selection and optimization of process parameters such as wire feed rate, travel speed, arc voltage, current, and inter-pass temperature. This review focuses on the systematic evaluation of key process parameters influencing the mechanical properties, surface integrity, dimensional accuracy, and microstructural characteristics of WAAM-produced structures intended for automotive applications. The study also explores various optimization techniques—such as Taguchi, response surface methodology (RSM), and artificial intelligence (AI)-based approaches
V, Aravind
Galvanic Corrosion Susceptibility Analysis and Mitigation strategies in Automotive Battery Packs2026-28-0018To be published on 02/12/2026
As electric vehicles continue to revolutionize transportation, ensuring the reliability of their powertrain systems and battery packs has become a critical focus. One key challenge is galvanic corrosion, which occurs when dissimilar metals in contact are exposed to an electrolyte, such as seashore moisture or road salt used in snow or ice zones. This corrosion can weaken structural components, compromise electrical conductivity, and reduce the lifespan of critical systems. Common areas at risk include metallic joints within battery enclosures, busbars, cooling systems, and electrical connectors. Environmental factors such as high humidity and temperature fluctuations further amplify the issue, making it a pressing concern for manufacturers. This paper aims to systematically identify critical galvanic joints within electric powertrain systems and battery packs and provide effective strategies to mitigate corrosion risks. Preventative measures include choosing compatible materials with
NARAIN, ADITYA, Venugopal, Sivakumar, Gopalan, Vijaysankar, Varatharajan, Senthilkumaran
Methodology for Shower Water Management in Electric Car Applications2026-28-0068To be published on 02/12/2026
All automotive vehicles with enclosed compartments must pass the Shower test standard - IS 11865 (2006). One of the most severe and critical areas of water leakage is “Water entry into HVAC opening”. Excess water flow in high-pressure conditions and seepage during long-time low-pressure conditions could potentially have a significant impact on water entry inside the HVAC suction cutout and subsequently into the cabin. The study clearly indicates that for making leak proof HVAC opening (suction interface), it is crucial for the structure of BIW Plenum, Trim Applique and its sealing components to be robust enough to effectively collect and divert the water during shower test condition. This robustness is necessary to ensure leakage prevention thru HVAC cutout in varying rain scenarios during customer usage of the vehicle. A systematic approach is followed for assessing leak tightness of the HVAC area. 1. CFD simulation performed to verify the flow path of water during shower test. It is
Gunasekaran, Mohanraj, NAMANI, Prasad, Ramaraj, Rajasekar, Junankar, Ashish, Raju, Kumar
Parameter Optimization for Improved Surface Finish in WAAM-Fabricated Steel Structures2026-28-0023To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is a cost-effective and scalable metal additive manufacturing technique widely used for fabricating large metallic components. However, surface finish remains a critical challenge, especially for structural applications where post-processing needs to be minimized. This study focuses on optimizing key process parameters to improve the surface finish of ER70S-6 steel structures fabricated using the WAAM process. Experiments were designed using a statistical approach to systematically vary parameters such as wire feed rate, travel speed, voltage, and inter-pass cooling time. Surface roughness was measured using standard metrology tools, and the results were analyzed to identify the most influential parameters. An optimized parameter set was proposed based on the experimental outcomes, leading to a significant reduction in surface roughness without compromising the structural integrity of the deposited material. The findings contribute to enhancing
PN, Vani
TOPSIS-Based Multi-Criteria Optimization of WAAM Parameters for Automotive Component Fabrication2026-28-0026To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) can make huge, complicated metal parts quickly and cheaply, making it popular in the automobile sector. This study uses TOPSIS, a multi-criteria decision-making method, to improve WAAM process parameters such wire feed rate, travel speed, and current. Automotive applications need surface roughness, deposition rate, and dimensional precision, which WAAM-fabricated components must meet. TOPSIS normalizes and ranks experimental findings to find parameter combinations that perform best across many quality metrics. The results show that integrated optimization improves component quality and consistency, making WAAM a feasible and economical sustainable vehicle manufacturing option.
Pasupuleti, Thejasree
AI-Driven Process Optimization in Wire Arc Additive Manufacturing of Nickel Alloys Using ANFIS2026-28-0025To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is gaining significance in recent years as a process for additive manufacturing that produces large and complex components with high deposition rates at economically feasible rates. Nickel-based alloys, praised for their unique features, like mechanical strength, corrosion resistance, and thermal stability, find widespread application in the aerospace, marine, and energy sectors. However, achieving the desired surface finish, dimensional precision, and mechanical performance of WAAM nickel alloy structures is a continuing challenge because of the complex interactions occurring between the process parameters. The study presents an experimental analysis conducted to establish the effect of important process parameters of WAAM-wire feed rate, travel speed, welding current, interpass temperature-on the quality indicators such as surface roughness, dimensional accuracy, and hardness. For the purpose of prediction and process control, the Adaptive Neuro
Natarajan, Manikandan
Coupled Thermo-Mechanical Simulation Framework for Structural Evaluation of Battery Pack2026-26-0414To be published on 01/16/2026
With the rapid adoption of electric vehicles (EVs), ensuring the structural integrity and thermal safety of lithium-ion battery pack has become a critical priority. Battery failures resulting from mechanical abuse, thermal stress, internal pressure build up or electrical faults may lead to structural failure. To address these challenges, it is essential to understand the coupled thermal and mechanical responses of battery structure under extreme conditions. Thermo-mechanical simulation serves as a powerful tool for predictive safety assessment and design optimization, particularly in addressing thermal propagation and pressure-induced failure events. This study presents a comprehensive coupled thermo-mechanical simulation framework designed to evaluate the structural performance of EV battery enclosures under worst-case thermal and overpressure conditions. The methodology involves high-fidelity three-dimensional modeling of the battery pack enclosure, incorporating realistic material
Bhat, Sadashiv C, Sugumar, Mohanraj
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
Balancing global and local formability properties through Nb microalloying2026-26-0303To be published on 01/16/2026
David Martin, CBMM Asia Bernardo Barile, CBMM Europe BV Caio Pisano, CBMM Europe BV Automotive high strength steels have specific microstructure-dependent forming characteristics. Global formability is generally associated with high uniform strain values which imply good drawability and stretch forming properties driven by pronounced work hardening. Local formability on the other hand is often measured by various fracture strain values—generally higher in single phase steels. In this respect, the so-called ‘local/global formability map’ concept has been established not only to provide a comprehensive methodology to characterize existing automotive steels but also to enable improvement strategies toward more balanced forming characteristics. Niobium (Nb) microalloying is a powerful tool to achieve both property improvement in general and property balance in particular. More than two decades of research has demonstrated that Nb-induced microstructural optimization is applicable to HSLA
Barile, Bernardo
Digital Twin for Motor & MCU incorporating Deep learning AI-ML algorithms for intelligent prognostics for Electric vehicles2026-26-0479To be published on 01/16/2026
As electric vehicles (EVs) become more advanced, so ensuring the reliability of critical components like the motor and Motor Control Unit (MCU) is essential. This paper presents a digital twin model designed to predict failures in motor and MCU components using machine learning. The approach focuses on detecting early signs of failure through real-world data and advanced analytics. We collected thermal and performance data from field vehicles, capturing both normal (healthy) and abnormal (faulty) operating conditions. Using this dataset, we developed and trained an Auto Encoder-based machine learning model that learns what “normal” looks like and flags deviations as potential issues. One key outcome of this study is the successful early prediction of Insulated Gate Bipolar Transistor (IGBT) degradation, where the system identified subtle behavioral changes long before any visible failure symptoms appeared. This digital twin acts as a virtual replica of the physical components
Joshi, Pawan, Pandey, Suchit, KONDHARE, Manish, Upadhyay, Abhay, JaganMoahanarao, Vana, Tank, Prabhu
Determination of Acrylonitrile Content in Nitrile Butadiene Rubber Vulcanizates by Py-GCMS Techniques2026-26-0546To be published on 01/16/2026
Nitrile Butadiene Rubber (NBR), a copolymer of butadiene and acrylonitrile is known for its superior resistance to hydrocarbon oil, low gas permeability and excellent thermal stability. It is extensively used in seals, O-rings, conveyor belts and pneumatic tires. It is worth mentioning that these performance attributes are predominantly influenced by acrylonitrile content. While solid-state 13C Nuclear Magnetic Resonance (NMR) is an established technique for structural characterization of rubber vulcanizates, its high cost and accessibility limits its application in routine industrial analysis. This study aims to develop Pyrolysis-Gas Chromatography/Mass Spectrometry (Py-GCMS) as a robust, precise, cost-effective alternative to determine acrylonitrile content in NBR vulcanizates. This research demonstrates and establish a method to determine the acrylonitrile (ACN) content in finished rubber vulcanizates through pyrolysis gas chromatography-mass spectrometry (Py-GCMS). This method
Samanta, Rajyasree, Ghosh, Debojit, Anjana, Kanhaiya, Sen, Amit, Guria, Biswanath, Chanda, Jagannath, Samui, Barun, Ghosh, Prasenjit, Mukhopadhyay, Rabindra
Simulation Based Approach to Optimize Electric Vehicle Battery Thermal System2026-26-0376To be published on 01/16/2026
The performance and longevity of Li-ion batteries in electric vehicles are significantly influenced by the cell temperature. Hence, efficient thermal management techniques are essential for battery packs. Simulation based optimization approaches can enhance these techniques during early product development and life cycle. In this work, a method to optimize the battery thermal system comprising of cooling plate and external insulation is described. The first part is to optimize the cell heat extraction by the cooling plate. The heat transfer coefficient of the coolant is a parameter which can indicate the thermal efficiency of a cooling plate. At the same time, it's important to keep the coolant pressure drop within a reasonable limit. A 1D simulation methodology is described to optimize the cooling channel height based on pressure drop and heat transfer coefficient targets. This methodology is based on empirical correlations and multi-objective pareto optimization. The advantage of
U, Reghunath, P S, Shebin
Accelerating engine auxiliaries’ development by deploying ML techniques in CFD virtual verification2026-26-0374To be published on 01/16/2026
The automotive and off-road industries are heavily investing in research and development (R&D) to improve both physical and virtual verification and validation techniques. Recent software and hardware advancements have extended these techniques from simple component evaluations to complex system assessments such as involving multi-physics scenarios. Despite the benefits of virtual validation tools like structural analysis and computational fluid dynamics (CFD), they often come with high development costs, particularly in CFD applications. Virtual verification methodology, especially when combined with data science, offer significant advantages over traditional physical methods by enhancing computer-aided engineering (CAE) efficiency and reducing resource consumption which can greatly improve product design and validation efficiency across many industries. The success of machine learning applications depends on effective data processing, adequate computational resources, and the right
Jadhav, Mitali, Kumbhar, Appaso, Tirumala, Bhaskar, Nisha, Kumari
Optimized Panel Design for Reducing Seal Squeak and Chucking in Door & Body Seals2026-26-0341To be published on 01/16/2026
Quieter cabins in an automobile are the new era, they provide customers with pleasurable driving experience. Squeak and Rattle are spoil sport for any OEM that aim to improvise customer driving experience. Their nonlinear nature makes it difficult to formulate design frontloading methods. The issue of seals rubbing against the body & door interface is a clear sign of seal squeak & seal chucking. Seals are applied with anti-friction coatings to avoid stick slip phenomena between EPDM and painted panel. Primary root cause for seal squeak is coating erosion. The challenge lies in determining whether the body or the closure side contributes to the seal issue. This paper presents a distinctive approach for identifying the seal squeaking noise and enriches on the new modelling methods for seal interaction with door and body interfaces using FE software. The proposed method was able to highlight the locations along the door-body interface for squeak noise. The approach for reducing the
H, Ravishankar, C M, Mithun, Michael Stephan, Navin Estac Raja, Mohammed, Riyazuddin
Analysis and optimization of noise and vibrational performance of an e-axle2026-26-0340To be published on 01/16/2026
As the electric mobility landscape evolves, there is a growing emphasis on addressing the Noise, Vibration, and Harshness (NVH) challenges associated with electric drivetrains. The absence of an IC engine in EVs shifts the focus to other noise contributors such as gear meshing, electric machine operation, and structural vibrations. Despite the known influence of micro-geometry on gear dynamics, current optimization practices often rely on empirical adjustments or standard guidelines without fully utilizing advanced computational methods to predict and optimize NVH performance. There exists a pressing need for a systematic approach to analyse and optimize gear micro-geometry to reduce noise and vibration in high-speed e-axle applications. This research aims to bridge that gap by investigating the relationship between micro-geometry optimization and NVH characteristics of an e-axle. Through detailed modelling and optimization techniques, this research aims to identify optimal gear micro
Ankit, Priyadarshi, Kulkarni, Krishna, Momin, Vaseem
Development of a Systematic Methodology for Identifying and Mitigating Squeak & Rattle Issues in Automotive Seating Systems2026-26-0333To be published on 01/16/2026
The automotive industry constantly strives to enhance vehicle safety, comfort, and customer satisfaction. One of the critical aspects influencing these factors is the mitigation of Buzz, Squeak, and Rattle (BSR) issues, which can significantly impact perceived vehicle quality and user experience. This paper focuses on the BSR challenges specifically encountered in two key components: seat headrests and latch & striker mechanisms. Seat headrests, designed to provide comfort and safety, often face BSR issues due to component misalignment, material incompatibility, or wear and tear during usage. Vibrations and movement, especially during vehicle operation, exacerbate these problems, leading to acoustic disturbances that detract from the overall ride quality. Similarly, latch and striker in seat system is prone to squeaks and rattles due to improper fitment, environmental conditions, or mechanical stress. These issues not only compromise the auditory experience but may also raise concerns
Deole, Sameer Shrikant, Rahman, Shafeeq, Mohammed, Riyazuddin, Shah, Prashant
Nexifi11D: A Comprehensive Multidimensional Framework for Futuristic Manufacturing Ecosystems2026-26-0282To be published on 01/16/2026
The manufacturing sector is undergoing a paradigm shift driven by hyper-connectivity, sustainability imperatives, and accelerated digital transformation. Conventional systems, however, remain constrained by their focus on isolated optimizations—such as predictive analytics, IoT-enabled sensing, or workforce scheduling—without providing an integrated operational perspective. To address this fragmentation, Nexifi11D is introduced as a comprehensive, multidimensional framework that consolidates 11 critical dimensions of manufacturing into a unified ecosystem. Nexifi11D advances beyond traditional Industry 4.0 architectures by seamlessly integrating intelligent algorithms, immersive simulation technologies, IoT infrastructure, and predictive systems within a scalable, interoperable mesh. The framework breaks down silos across key manufacturing domains—such as sustainability, cost, operations, and workforce—enabling holistic, data-driven, and proactive decision-making. Each integrated
Kumar, Rahul, Singh, Randhir
A Novel Approach to Deep Drawing Using Hybrid System and Pneumatic-Assisted Forming2026-26-0301To be published on 01/16/2026
ABSTRACT: This paper presents a novel Plunger-Integrated Hybrid System aimed at enhancing the efficiency and performance of deep drawing operations in metal forming processes. The proposed hybrid system strategically combines the mechanical strength of metals with the elastic flexibility of polymers, specifically polyurethane rubber, to improve formability and reduce spring-back, two critical challenges in conventional sheet metal forming. A novel two-stage forming technique is employed, an initial drawing operation using a larger radius with polyurethane rubber, followed by final radius formation using the same rubber in conjunction with a pneumatic cylinder. This integrated approach ensures uniform force distribution via the embedded plunger, significantly minimizing forming defects and enhancing the dimensional accuracy of the final components. The solution has been validated using Finite Element (FE) simulation methods, confirming its capability to produce high-quality parts
Chava, Seshadri Reddy, Singh, Prakhar, Dhanajkar, Narendra, Roy, Amlan, Raju, Gokul
Optimizing Stick Slip Performance in Automotive Interiors by Material Selection, Additives, and Design Strategies2026-26-0325To be published on 01/16/2026
The automotive industry is highly competitive, especially in terms of design and perceived quality. The use of hard plastics with a high gloss finish is driven by styling trends and the push towards zero gaps, making interfaces critical. In-cabin mood lighting is another feature being offered as a theme for interiors. Dashboard or cockpit designs often incorporate a significant amount of polycarbonate-acrylonitrile butadiene styrene (PC-ABS) and polycarbonate (PC). These materials provide strength and design flexibility but have the disadvantage of material incompatibility when used together, leading to stick-slip phenomena. Traditionally, felt tapes were used as interface isolation to solve this problem, but this increased manufacturing costs and assembly complications. The study focuses on the stick-slip phenomenon and material interface modifications. Specifically, it examines selecting the right surface finish on one side of the PC & PC-ABS interface to change adhesion and friction
Mohammed, Riyazuddin, R, Prasath, Rahman, Shafeeq
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
Comparative Analysis of Charger Identification Methods in Electric Truck Routing Algorithms2026-26-0206To be published on 01/16/2026
Optimizing Vehicle Routing is a key application for determining the most effective sequence of locations in electric trucks. This optimization not only enhances operational efficiency but also minimizes energy consumption and reduces overall costs. A critical aspect of Optimal Vehicle Routing is identifying charging stations along the route, particularly for electric vehicles with specific range requirements. The availability of these charging stations are crucial for maintaining the continuity of operations and preventing delays. This paper explores multiple methods for charger identification, simulating and comparing their effectiveness. The primary parameter for comparison is the execution time of the algorithm, which directly impacts the feasibility of real-time applications in logistics. The results of this study provide insights into the efficiency of different charger identification methods within the Optimal Vehicle Routing framework. By analysing execution times, the paper
Bhat, Adithya, Prasad P, Shilpa, Kolakar, Rakshita, Myers, Michael, Klein, Fischer, Shrivastava, Himanshu
Durability Validation of Full Vehicle Structures Using Strain Correlation and RLDA-Based Simulations2026-26-0523To be published on 01/16/2026
Durability validation of full vehicle structures is crucial to ensure long-term performance and structural integrity under real-world loading conditions. Accurate strain correlation between physical testing and finite element (FE) simulations plays a key role in the validation, ensuring reliable predictions of vehicle durability. In this paper, a comprehensive methodology for strain correlation on a full vehicle subjected to torture track testing is implemented. Strategic placement of strain gauges is determined through a combination of static analysis, modal analysis, and identification of critical stress regions in the FE model. Strain gauges were installed on key structural locations of a prototype to capture strain responses under severe loading environments. Simultaneously, vehicle wheel loads were recorded on the torture track to build a detailed Road Load Data Acquisition (RLDA) dataset at critical hard points, Loads measured in terms of wheel loads (WFT) are fed to MBD model to
Jaju, Mayur, Dokhale, Sandeep, Gadre, Nilesh, Patil, Sanjay
A method of selectively elevating a Seamless Switch Integrated in Fabric2026-26-0596To be published on 01/16/2026
This research presents the construction and working principle of Selectively Elevated Seamless Fabric Switch technology aimed at advancing automotive interior design through enhanced aesthetics, functionality, and user experience by providing a tactile surface that is available for operation only during the activated, elevated state. Traditional mechanical switches often suffer from issues such as dust and water ingress, accidental activation, and a fragmented visual profile. The proposed system integrates concealed controls sandwiched with a fabric surface, with switches selectively elevated only upon user interaction. The design incorporates conductive fabric layers and electromagnetic actuation to achieve seamless integration with vehicle interiors while maintaining responsive tactile feedback. The input provided for activating the switch can be a signal such as gesture or proximity of the user’s finger. Upon activation the switch is selectively elevated and ready for operation due
Mohunta, Sanjay, Panchal, Girish, Puthran, Shaunak
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 strategic approach to the selection of switchgear and busbars for EV battery packs2026-26-0165To be published on 01/16/2026
With the rising adoption of electric vehicles (EVs), the need for robust and efficient power distribution systems has become increasingly important. This paper outlines a strategic method for selecting switchgear and busbars in EV battery packs, emphasizing key factors such as safety, energy efficiency, thermal control, and future scalability. Proper optimization of these components can significantly improve performance, minimize power losses, and ensure durability under demanding operating conditions. The design and selection of battery conducting components, such as switchgears and busbars, are typically based on the maximum continuous and peak current capabilities of the EV battery pack. While this approach ensures that the components can withstand extreme conditions, it often leads to over-engineering, resulting in unnecessary costs and added weight. However, this method overlooks the dynamic power demands of the vehicle, which fluctuate based on driving conditions and usage. Real
Soman, Anu, satheesh, Goutham, K, Mathankumar
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
Simulation driven design of robust Crank-train systems for elevated In-cylinder combustion pressure2026-26-0400To be published on 01/16/2026
The need for increased in-cylinder pressure to meet the higher engine rating and stringent emissions norms requires special attention on the Main moving components torsional behaviour and the bearing performance. The work presented in this paper utilizes the 1D and 3D simulation potential of AVL EXCITE for the assessment of design changes required in Crank-Train system for the increased in-cylinder pressure from 170bar to 220bar. The key feature of the executed work was that all the design changes were accommodated with minimal changes in packaging / layout interfaces. The given work was executed on 6-Cylinder Turbocharged In-cylinder with Type V valve-train configurations. Initial brain storming & 0d calculation helped in understanding the design optimization required in each and every crank-train parts. Considering the guidelines available in terms of L/d ratio for the bearing, connecting rod length, the overall linkage specification was set up for starting with design work for
Khandelwal, Meha, Kaundabalaraman, Kaarthic, Rathi, Hemantkumar
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, Ravi, Abhikrishna, Maheshwari, Pankaj, Kumar, Mandeep
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
Optimizing Busbar Design by Investigating Critical Parameters and Their Influence on Electrical and Thermal Behaviors for Reliable Electric Vehicle Battery Packs.2026-26-0474To be published on 01/16/2026
With the rise of EVs, researchers are focusing on optimizing busbar design to meet the demands of high energy density, fast charging, and compact battery packs. The busbar design starts with selecting the cross-sectional area based on current-carrying capacity and material type. The width matches or exceeds the battery cell terminal size, while the length is optimized based on space constraints. The research also highlights the risk of busbars to oxidation and corrosion, which increases resistance and decreases thermal conductivity for which Plating and coating techniques are applied to improve surface hardness, durability, and thermal conductivity while minimizing heat loss. Using simulations and experimental validation, the study examines three key design parameters: weld diameter, electrical resistance, and contact resistance. A detailed analysis investigates how weld diameter influences electrical resistance and temperature rise, as well as the impact of contact resistance between
Nogdhe, Yogesh, Singh, Shobit Kumar, Paul, Jibin, Mishra, Mukesh, Menon, Praveen
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-0501To be published on 01/16/2026
Manufacturing tolerances pose considerable challenges in the production of rubber-based components, often leading to dimensional variations that can compromise overall product reliability. These inconsistencies may result in a range of functional issues, including poor sealing, excessive wear, misfit during assembly, and premature failure. Among these components, grommets are especially sensitive due to the complex, non-linear behavior of rubber materials, making precise dimensional control critical to ensure consistent and dependable performance. Even minor deviations in grommet geometry can trigger substantial assembly difficulties. Issues such as misalignment, buckling, insertion challenges, and potential damage to neighboring parts are commonly encountered. These complications typically require multiple rounds of design revisions and physical testing, which extend development timelines and significantly increase production costs. Real-world observations from various automotive
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, Pathan, Eram
Automated evaluation of drive file simulation accuracy2026-26-0528To be published on 01/16/2026
In the area of structural durability testing using servo-hydraulic actuators, developing drive files for the actuators is a major step. Testing outcomes depend on ensuring the simulation accuracy of each drive file. These drive files are developed in an iterative process for different test track surfaces at different road and load combinations till the time we achieve better correlation. Evaluation of simulation accuracy of the drive files is an extensive manual review process, making it time-consuming and resource-intensive. To address this challenge, an application has been developed to automate the comparison of actuator signals with predefined target signal files. This tool enables quick and accurate analysis of each drive file in a test run, facilitating a comprehensive review of signal deviations. Each test run has thousands of drive files based on road-load mix and actuator settings. This application helped us significantly optimize the simulation workflow by reducing the manual
Soni, Yash, Katake, Vrishali, Mullapudi, Dattatreyudu, Chaskar, Mithun
Optimizing Vehicle Dynamics: A Methodology for Reducing Correlation Gaps2026-26-0091To be published on 01/16/2026
In the highly competitive automotive industry, final design decisions are often made early in the product development cycle. However, physical prototypes may exhibit deviations from nominal specifications due to design tolerances, manufacturing tolerances, stiffness element fitment, and other noise factors. These deviations can lead to significant performance discrepancies (correlation gaps) between real-world performance and the digital twin representation created during the design phase. Repeatedly measuring all system parameters to account for these differences can be both costly and impractical. This research aims to bridge the gap between digital and physical models by identifying key system parameters from system characteristic data generated through controlled dynamic testing. Specifically, dynamic load cases are conducted using a 4-poster test rig, where vehicle responses are recorded at various suspension locations under controlled conditions. By analyzing these target
Verma, Rahul Ranjan, Goli, Naga Aswani Kumar, Prasad, Tej Pratap
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
Effects of Battery Integration in modal behaviour of Electric Two Wheeler Frame2026-26-0310To 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
A Performance-driven Numerical Approach for Optimizing the Plenum Opening Area of Cowl Box2026-26-0461To be published on 01/16/2026
There is a scarcity of research in literature regarding the determination of Plenum Opening Area of cowl box. The area of the plenum opening in the cowl box significantly affects the airflow rate in fresh airflow modes, such as face and defrost modes, as well as issues related to water ingress. Primarily, the size of the plenum opening is determined by the necessary HVAC airflow rate. This study aims to investigate how the plenum opening area impacts both airflow discharge and the water ingress issue in the HVAC module. A novel approach is introduced in this research to determine the optimal plenum opening area of the cowl box, taking into account both airflow rate and water ingress concerns. The ANSYS FLUENT software is utilized to analyze airflow discharge in both face and defrost modes, while the SPH (Smooth Particle Hydrodynamics) based Preonlab tool is employed for water ingress analysis. Airflow discharge is evaluated for various plenum opening sizes in both modes, and the area
Baskar, Subramaniyan, Mahesh, A, Gopinathan, Nagarajan
Design Optimization of Hydrogen Engine Vanity Cover for PSHA Compliance using CFD leakage analysis2026-26-0263To be published on 01/16/2026
Abstract: The integration of hydrogen (H2) as a fuel source in internal combustion engines (ICE) necessitates stringent design measures to mitigate leakage risks and ensure operational safety. This study focuses on the design optimization of vanity cover for hydrogen engines which only serves the purpose for hiding fuel system, wire harness & engine aesthetic else there is no engineering function like sealing, load factor associated with it. This paper addresses the challenges and risks of using Vanity cover on Internal combustion engines, if fuel joints inside the cover start leaking and forms hydrogen cloud which if not ventilated or diluted properly will have safety risk considering low ignition of hydrogen. Computational fluid dynamics (CFD) analysis is carried out to assess and control hydrogen leakage through fuel rail connections, injector interfaces and associated high pressure fuel system components. Detailed modelling of hydrogen flow behavior, diffusion characteristics of
Veerbhadra, Swati Ashvinkumar, Sahu, Abhay Kumar, Singh, Rahul
Determination of part tolerances for reduced variation in suspension level performance by using Multi-objective Robust Design Optimization (MORDO)2026-26-0381To be published on 01/16/2026
Competition in automotive industry is fierce and manufacturers must meet the needs of their costumers to maintain or increase their market. It is important for Original Equipment Manufacturers (OEMs) to create affordable vehicles with better driving experiences, comfort for occupants and safety for costumers. Suspension architecture plays critical role in vehicle ride, handling and stability behavior and is directly connected with driving experience. Incorrectly positioned hardpoints can significantly affect the performance of a vehicle. Consequently, recommended tolerances for suspension hardpoints positioning are made to avoid deterioration of Kinematics and Compliance (K&C) parameters. Therefore, part level tolerance design is critical in vehicle development to minimize production cost and reduce vehicle performance deviation. In present paper, Multi-objective Robust Design Optimization (MORDO) has been adopted to determine the maximum acceptable part tolerance values without
Pathak, Jugal, Ganesh, Lingadalu
Accurate Component Load Prediction with Hybrid Test – FEA Approach.2026-26-0366To be published on 01/16/2026
Knowing accurate loads acting on the structure is still a main pain area for analyst. Accurate fatigue analysis through FEA is still a difficult task because of uncertainties associated with component load profile. Even for known duty cycle, approximation involved in measurements and load cascading techniques (MBD simulation models) put limits on accuracy of component load prediction. Small error in loads can lead to very large error in fatigue life calculations. Various researches proposed various innovative alternate means for accurate component load prediction and published in literature over past few decades. Author has explored and developed hybrid Test-FEA approach to estimate component loads based on robust strain-load transformation and pseudo inverse technique. This approach is based on effective use of strain transformations along with accurately measured strain data to calculate accurate load histories. The accuracy of load estimates depends upon number of factors such as
Pratap, Rajat, Apte, Sr., Amol, Babar, Ranjit
Early Prediction of CNG Filling Time using Artificial Intelligence for Design Optimization2026-26-0662To be published on 01/16/2026
The CNG fuel system is a critical component in vehicle development and typically includes large-volume gas cylinders (up to 800 liters). As these vehicles often operate over long distances daily, frequent refueling is necessary, making a short gas filling time highly desirable. Currently, CNG filling time is evaluated after prototype development to determine the refueling duration. If the filling time is excessive, design changes to the fuel system are required, leading to significant cost and time penalties and causing delays in the vehicle product development cycle. By integrating AI/ML technology, a mathematical model has been developed based on various influencing parameters. This model will predict CNG gas filling time across all commercial vehicle platforms at the initial Zero design release gateway. This early prediction will enable further optimization to improve gas filling time. The goal of this research work to optimising the filling time for various platform before physical
Choudhary, Aditya Kant, Petale, Mahendra, Dutta, Surabhi, Bagul, Mithilesh
Study of Style wheel rim failure Due to Rim and disc assembly interference2026-26-0541To be published on 01/16/2026
This study focuses on the investigation of wheel rim failures near weld zone during repeated cornering induced by interference between the rim and disc during the wheel manufacturing assembly process. Strain gauges were employed to capture real-time stress and strain distributions at critical zones during interference fitting. The experimental results revealed that improper interference levels lead to significant stress concentrations, often surpassing the material's elastic limit, initiating micro-crack formation and promoting fatigue failure. Detailed strain analysis indicated that both radial and axial stresses contribute to long-term structural degradation. The study highlights the critical role of dimensional tolerances, surface finishes, and assembly forces in minimizing stress-induced failures. Recommendations are provided for optimizing design and assembly practices to enhance the durability and reliability of automotive wheels.
P, Praveen, DEsigan, Lakshmipathy, K, Chandramohan, C, Santhosh
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