Browse Topic: Manufacturing

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ALTERNATE CATALYST FOR DOC IN A CATALYTIC CONVERTER2026-28-0016To be published on 02/12/2026
Emission norms have become much more stringent to reduce emissions from vehicles. Diesel engines in particular are the predominant contributors to higher emissions. Diesel Oxidation Catalyst (DOC) in diesel engine catalytic converter systems is the crucial component in reducing harmful emissions such as Carbon Monoxide (CO) and unburnt Hydrocarbons (HC). DOCs often rely on expensive noble metals like platinum or palladium and rhodium as catalyst materials,significantly inflating the cost of emission control units. The proposed idea is to explore MnOxCeO₂ (Manganese Oxide-Cerium Oxide) as an alternative catalyst to traditional DOC materials, with the goal of delivering effective oxidation performance while reducing overall system cost. MnOx-CeO₂ catalysts are promising due to their good low-temperature activity, oxygen storage capacity, and redox behaviour, which are beneficial for diesel engines operating under varied conditions. These properties help improve the oxidation of CO and HC
C, Jegadheesan, T, Karthi, Rajendran, Pawan, Muruganantham, Kowshiik, S, Vaitheeshwaran
Concurrent Scheduling of Machines and AGVs with Alternative Machines in Automobile Manufacturing Using Black Widow Spider Optimization2026-28-0095To be published on 02/12/2026
Automobile manufacturing environments demand high-performance scheduling strategies to synchronize machine operations with material handling systems such as Automated Guided Vehicles (AGVs). This paper lays down a formal framework for machines and Automated Guided Vehicles (AGVs) simultaneous scheduling with alternative machines in a multi machine Flexible Manufacturing System (FMS) to produce best optimal sequences for minimization of makespan. This simultaneous scheduling problem is highly complex in nature as it involves selection of machines, job-operations’ sequencing on machines, assignment of AGVs to job-operations and associated trip operations such as AGVs’ dead heading trip and loaded trip times. This paper introduces a nonlinear Mixed Integer Programming (MIP) formulation to model the machines and AGVs combined scheduling with alternate machines and employing a Black Widow Spider Optimization Algorithm (BWOA) based on the hunting behavior of black widow spiders for this
Mareddy, Padma Lalitha, Siva Rami Reddy, Narapureddy, Surya Prakash, RVNR, Katta, Lakshmi Narasimhamu
Simultaneous scheduling of machines, tool transporter and tools in a multi machine FMS with alternative routing using crow search algorithm in Automotive Manufacturing2026-28-0089To be published on 02/12/2026
In modern automobile manufacturing systems, achieving high efficiency in production scheduling is crucial for cost reduction and delivery optimization. This paper addresses the integrated scheduling problem of machines, Tool Transporters (TT), and tools with consideration of alternate machines in a multi-machine Flexible Manufacturing System (FMS) considering tool transfer times to minimize makespan, specifically within an automobile production context. Due to economic constraints, only a single copy of each tool type is maintained, stored centrally in a shared Central Tool Magazine (CTM), which serves multiple CNC machining centers involved in automobile component manufacturing. The problem is to select machines and assignment of tools to job-operations, job-operations’ sequencing on machines, corresponding trip operations including the dead heading trip and loaded trip times of tool transporter for makespan minimization. This paper introduces a nonlinear Mixed Integer Programming
Mareddy, Padma Lalitha, Natarajan, Manikandan, Katta, Lakshmi Narasimhamu, Siva Rami Reddy, Narapureddy
Mechanical Performance & Vibration Analysis of Hybrid Composite Plates Composed of E - Glass and Areca Fibers2026-28-0073To be published on 02/12/2026
This study investigates the vibration characteristics of hybrid composite laminated plates made from E-glass and areca fibers, targeting applications that demand both mechanical performance and environmental sustainability. The motivation stems from the growing interest in replacing synthetic fibers with natural alternatives in structural applications, particularly for lightweight and vibration-sensitive components. Areca fiber, an abundant and biodegradable natural material, was combined with high-strength E-glass fiber to form hybrid laminates using the Vacuum Assisted Resin Transfer Moulding (VARTM) process. Three distinct composite plates were fabricated with different stacking sequences and filler variations using epoxy resin and brake lining powder. The mechanical integrity and vibrational behavior of these plates were then studied using experimental modal analysis. The tests were conducted under three boundary conditions: fully clamped (C-C-C-C), two-edge clamped (C-F-C-F), and
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, R G, Ajay Krishna, Ng, Bhavan
Modelling and Analysis of Complex Shaped Cracks2026-28-0048To be published on 02/12/2026
This study offers a thorough analysis using finite element methods (FEA) to examine how fatigue cracks grow in three different materials: Structural steel , Titanium alloy (Ti Grade 2), and epoxy/aramid-based printed circuit board (PCB) laminates. Using ANSYS Workbench, we ran simulations under both static and repeated loading to understand how these materials fracture. The approach was based on Linear Elastic Fracture Mechanics (LEFM), employing the Maximum Circumferential Stress Criterion to predict where cracks might start and how they could spread. Also, the Equivalent Domain Integral (EDI) method helped us calculate the Stress Intensity Factors (SIFs) when cracks are under mixed loading modes. We modeled the growth of fatigue cracks using the Paris Law, relying on material-specific constants (C and m) drawn from previous studies and experimental tests. For example, titanium Grade 2 showed Paris Law constants with C values between 1.8 × 10⁻¹⁰ and 7.9 × 10⁻¹² m/cycle, and m values
T, Lokesh, Bhaskara Rao, Lokavarapu
Genetic algorithm based optimization of Chaboche kinematic hardening parameters along with the validation of FE model through characterized crack initiation2026-28-0086To be published on 02/12/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a low voltage (LV) connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for thermo-plastic composite material Ultramid A3U44G6, we have adopted a novel approach of determining non-linear Chaboche Kinematic Hardening (CKH) model parameters from monotonic uniaxial temperature dependent tensile test data of Ultramid A3U44G6. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for Ultramid A3U44G6, here von Mises yield
Basu, Parichay, Srinivasappa, Naveen
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
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
Experimental Investigation of Process Parameter Effects in WAAM of Nickel-Based Alloys2026-28-0027To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is an evolving discipline in metal additive manufacturing characterized by rapid deposition, cost-effectiveness, and centrality to the near-net-shape fabrication of large-scale components. This study will concentrate on WAAM application to deposit nickel alloys, which find extensive use in aerospace, power generation, and marine industries, due to their good mechanical strength, corrosion resistance, and thermal stability. However, some drawbacks in WAAM processing of nickel alloys include thermal distortion, porosity, and residual stress. The research looks at how key WAAM process parameters, including wire feed rate, travel speed, current, and interpass temperature affect geometric accuracy, surface integrity, and mechanical performance of the fabricated components. Microstructural characterization was done using optical microscopy, and hardness distribution was measured as an indication of mechanical uniformity throughout the builds. It is
Natarajan, Manikandan
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
Sustainable Machining of Aluminium Alloys: Experimental Insights into WEDM Process Optimization2026-28-0034To be published on 02/12/2026
The most advanced mathematics transforms aluminum alloys into one of the most highly intricate materials into practically any engineering application based on the mechanical properties of ductility and low fatigue sensitivity. The use of aluminum alloys permeates critical industries like aerospace and automotive, besides being strong contenders in other high-performance applications. Their inherent corrosion resistance certainly gives an edge to aluminum alloys for applications in rigorous service environments. Conventional manufacturing processes would not successfully create components with some geometrical complexity; hence, advanced machining processes are being developed. Among them is Wire Electrical Discharge Machining (WEDM), which is increasingly being adopted within the EDM family, as it efficiently machines hard and complex shapes at high accuracy. The present investigation deals with WEDM of aluminum alloy using Taguchi's design of experiments approach, while focusing on
Natarajan, Manikandan
Effect of Minimum Quantity Lubrication during Machining of Incoloy 800H Using Vegetable Oil Enriched With Nano Particles2026-28-0038To be published on 02/12/2026
In this experimental work an effort has made to investigate the machining of difficult to machine Incoloy 800H super alloy. Cryogenically treated textured cutting inserts and vegetable oil enriched with nano particles were used for this study. The turning experiments were performed with different parameters such as Cutting speed, feed rate and depth of cut. Surface Roughness, Cutting Force, Tool-Tip Temperature and Power were the output responses considered. Grey Relational Analysis (GRA) and Analysis of Variance (ANOVA) analysis were used to optimize the machining parameters and to find the most influencing machining parameter on the output responses. The results showed that the optimal machining conditions considered were cutting speed at 35 m/min, feed rate at 0.06 mm/rev and depth of cut at 0.5 mm for the multiple-characteristic performances and it was improved by 3.86 % with this approached method. Also, Tool-tip temperature and Power were reduced during machining with cryo
Natarajan, Manikandan
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 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
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
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
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
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
Advancing Welding Excellence through Numerical Simulation Based Approach: A Multi Pass Welding Case Study on Cast Iron Coupons2026-26-0457To be published on 01/16/2026
The Automotive industry extensively uses cast iron for its exceptional mechanical performance and cost-effectiveness. However, repair welding or assembly of cast iron components remain highly challenging due to the material’s high carbon content, inherent brittleness, rapid thermal conductivity, and complex microstructural transformations. Multi-pass welding exacerbates these challenges by subjecting materials to repeated thermal cycling, accumulating residual stress, and inducing distortion – all of which potentially degrade the integrity of welded joints. A comprehensive understanding of welded joint behavior is essential to effectively mitigate these effects. Finite element analysis (FEA) serves as a powerful tool, enabling accurate prediction of thermal profiles, phase transformations, residual stress development, and resulting deformations. These valuable insights are critical for optimizing welding processes and enhancing overall joint quality. This study investigates and
Vidhate, Digambar, Nalawade, Rahul, Dabhadkar, Mandar, Vaidya, Abhijit, Ammasi, Vinoth, Rajagopalan, Sridhar
AI-Driven Predictive Methodology for Bolt Integrity in Vehicle Durability Testing2026-26-0648To be published on 01/16/2026
The application of AI/ML techniques to predict truck tailgate bolt loosening represents a major innovation for the automotive industry, aligning with the principles of Industry 4.0. Traditional physical testing methods are both expensive and time-consuming, often identifying issues late in the development process and necessitating costly design changes and prototype builds. By harnessing AI/ML, manufacturers can now analyze tailgate slam and bolt preload data to accurately forecast potential bolt loosening issues. This predictive capability not only enhances quality and safety standards but also significantly reduces the costs associated with tooling and builds. The AI/ML tool described in this paper can simulate a variety of load conditions and predict bolt loosening with over 90% accuracy, considering factors such as changes in loads, bolt diameters, washer sizes, and unexpected masses added to the tailgate. It provides valuable design insights, such as recommending optimal bolt
Sivakrishna, Masani, Das, Mahat, Singh, Abhinav, Karra, Manasa, Shienh, Gurpreet, Luebke, Amy
Early prediction of relaxation voltage & detection of state of battery for functional safety2026-26-0166To be published on 01/16/2026
During parking condition of vehicle, state of the battery is uncertain as it goes through the relaxation process. In such scenarios the battery voltage may exceed the functional safety limits. If we cross the functional safety limits it is hazardous to the driver as well as the occupant. In this case relaxed voltage plays a crucial role in identifying the safe state of the battery. To estimate the relaxed cell voltage there are methods such as RC filter time constat modeling and relaxation voltage error method. The problem with these solutions is the waiting time and accuracy to determine the relaxation voltage. In this manuscript a solution is proposed which ensures the above problem gets reduced. To achieve the reduction of relaxation voltage estimation time, a python sparse identification of nonlinear dynamics (PySindy) is used which identifies and fits an equation model based on observing the battery characteristics at different SOC and temperatures. The implementation is done and
Pandey, Priyanshu, Nilajkar, Ankur, Panda, Abinash
Optimizing Suspension Joint Reliability: Overcoming Bolt Loosening and Torque Variability in Automotive Production2026-26-0492To be published on 01/16/2026
In modern automotive manufacturing, ensuring the integrity of suspension joints under real-world driving conditions is a critical aspect of vehicle safety and performance. These joints endure substantial transverse loads and large vibrations due to irregular road surfaces, dynamic manoeuvres, and varying environmental factors. As a result, bolt loosening becomes a significant concern, compromising joint integrity and overall vehicle reliability. This paper delves into the challenges associated with maintaining joint integrity, specifically focusing on pre-load determination, torque application, and production-related issues. The pre-load generated during torquing is the primary factor that ensures a suspension joint remains securely fastened under dynamic road conditions. This pre-load is derived using road load data acquisition (RLDA) inputs, which capture the forces acting on the joint during actual driving scenarios. RLDA inputs provide critical insights into the forces experienced
Kumar, Sabeesh, Vasant Kumar, Jesse Daniel, Mishra, Harshit, Senthil Raja, T, Nayak, Bhargav, M, Sudhan, Namani, Prasad, Vibhute, Shekhar
Effect of pipe bending by rotary tube bending process on durability of frame structure2026-26-0370To be published on 01/16/2026
For Original Equipment Manufacturers (OEMs), ensuring the overall quality of two-wheeler frames hinges on robust process capability and meticulous design considerations. A comprehensive Computer-Aided Engineering (CAE) simulation approach, integrating manufacturing processes and design elements, is vital for achieving optimal durability. This study focuses on developing such an approach through detailed finite element analysis of Cold Electric Welded (CEW) annealed round pipes used in frame construction. We simulate the bending process, capturing structural deformation and residual stresses. A 3D mechanical model with realistic tooling geometries and contact interactions accurately represents shape changes, ovality, and wall thickness redistribution. Unlike Electric Resistance Welded (ERW) pipes, CEW pipes, due to annealing, offer a stress-free initial state, allowing precise deformation analysis. Simulation results demonstrate significant geometric alterations in the bend zone
Rajwani, Ishwar, Khare, Saharash
A study on the thermal degradation of chlorinated Polyethylene rubber2026-26-0276To be published on 01/16/2026
Elastomeric materials are essential in advanced automotive engineering for mobility, isolation, damping, fluid transfer (cooling, steering, fuel, and brake), and sealing because of their unique physio mechanical properties. Elastomers are commonly used in both static and dynamic components, such as hoses, mounts, bushes, and tires. Engine emission standards and weight optimization have caused higher temperature exposure conditions for automotive components. The steering system uses special purpose elastomers like Chlorinated Polyethylene that can deteriorate under abnormal conditions during vehicle operation or manufacturing process due to the high temperature exposure. Therefore, it is crucial to comprehend the causes and consequences of thermal degradation of elastomers. Thermal degradation is a significant phenomenon that changes the physical and chemical properties of elastomers, which results in a product not meeting functional requirements. This study investigates the thermal
Thiruppathi, Anandhi, Mishra, Nitish, Krishnamoorthy, Kunju
OPTIMIZER SUNSHADE PACKAGING WITH HALF ALUMINIUM CASSET AND METAL PULL BAR2026-26-0597To be published on 01/16/2026
The automotive industry is advancing rapidly with the integration of cutting-edge technology, aesthetics, and performance. One area that has remained relatively underexplored in the pursuit of sleek, minimalistic interiors is the Sunshade packaging in door trim system. Traditional sunshade design, often bulky and are increasingly incompatible with the trend towards compact. Car sunshade is a shield that is placed on a car side window, and it is used for regulating the amount of light entering from the car window and improves the passenger comfort inside the cabin. Car Interior components specifically plastic and seats based on thermal stress properties. When we exposed these parts direct contact with sunlight, humidity and ambient temperature above threshold limit then interior plastic parts can start softening and melt after that they emit harmful chemical which is caused to anemia and poor immune systems. So, Sunshade protection not only serve to protect passenger comfort inside car
Palyal, Nikita, D, Gowtham, Bhaskararao, Pathivada, Bornare, Harshad, Ritesh, Kakade
Design optimization of jounce bumper support ring based on RWUP loading2026-26-0514To be published on 01/16/2026
Title: Challenges faced during design and manufacturing of POM (Polyoxymethylene) ring in Macpherson strut suspension. Abstract: Designing and manufacturing a POM (Polyoxymethylene) ring for a MacPherson strut suspension system brings a unique set of challenges due to the high-performance and durability demands for Indian road application. POM ring along with bump used in the shock absorber is designed to absorb the strong shock coming from the road inputs when suspension travel reached to the maximum limit there by absorbing the impact energy and preventing it from transferring it to the body. A bump stopper for a suspension of a vehicle is made of poly urethane (PU) and POM ring (Polyoxymethylene). The bump stopper forms of a bellows shape during the absorption of impact energy. Bellow or wrinkle in which concaves and convexes are repeated is formed on the outer surface of the bump stopper. POM ring is placed in the concaves of bump stopper which will define load, deflection
Koritala, Ashok Kumar, Malekar, Amit, Kulkarni, Purushottam, S, Sivashankar, Mishra, Harshit, Ganesh, Mohan Selvakumar, Patnala, Avinash, J, Ramkumar, Nayak, Bhargav, M, Sudhan
Optimization of the Rodip CED Process Suitability through Strategic Fixture System for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-0486To be published on 01/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is latest technology used by Automotive Manufacturers for higher quality corrosion protection in new generation Automobiles. This process involves multiple 360-degree rotation of automotive body in white (BIW) which exert higher hydrostatic forces on large surface panels like Hood. For maintaining consistent gaps & flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel Hood panel while undergoing through this CED process. This study investigates the enhancement of hood panel alignment through strategic optimization of support rod placement and quantity within the Ro-dip CED system. By conducting experimental trials and computational simulations, the research identifies critical deformation points and evaluates the impact of varying support rod configurations on dimensional stability. The outcome results demonstrate that positioning support rods at
Tile, Vikrant, Unadkat, Siddharth, Askari, Hasan, Jadhav, Devidas
Tailgate Stiffness Mitigation and Engineering Strategy for Y-to-Y Tailgate-Mounted Tail Lamp Integration2026-26-0494To be published on 01/16/2026
The tailgate, as the rearmost vehicle opening, plays a pivotal role in defining the rear aesthetic theme while ensuring structural durability and maximizing luggage space. Contemporary automotive design trends highlight an increasing demand for Y-to-Y tailgate-mounted tail lamp configurations, which deliver a bold and dynamic visual appeal. Enhanced by animated lighting features, these designs cater to the preferences of Gen Z customers, becoming a decisive factor in purchasing decisions. However, integrating these complex tail lamp structures introduces significant engineering challenges, including increased X-dimension volume, reduced design space, and intricate mounting schemes constrained by stamping limitations. These factors necessitate the development of innovative joinery strategies and structural definitions to maintain durability targets, including achieving 25,000–30,000 slam cycles without failure, while preserving luggage space. This paper explores a comprehensive approach
Beryl, Joshua, Mohanty, Abhinab, Unadkat, Siddharth, Selvan, Veera
Failure Analysis of Dissimilar Metal Weld Joint of an Air Spring Bracket within an Automotive Active Seat Suspension System2026-26-0487To be published on 01/16/2026
In modern four-wheelers, seat suspension systems play a crucial role in enhancing occupant comfort by mitigating the effects of road unevenness and vibrations. Among these systems, active suspension mechanisms offer advanced performance through complex assemblies involving welded, riveted, and bolted joints. This study investigates the failure of an air spring bracket - a critical component of a pneumatic active suspension system - manufactured by Gas Metal Arc Welding (GMAW) of two dissimilar ferrous materials which are likely to be SAPH440 and S355J2. These different materials were used based on mechanical properties required to perform by their particular part. System level validation tests were conducted to ensure the reliability of the seat suspension system. The one of the validation tests is continuous cyclic fatigue test which is carried out on the complete seat assembly. However, during vibration / cyclic endurance testing, premature failures were observed near the weld joints
Patale Jr, Reshma, Pinjari, Jayant Namdev, Bali, Shirish
Evaluating the Suitability of ADC12 for Sand Casting: Filling, Solidification, and Mechanical Properties2026-26-0296To be published on 01/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Singh, Gajendra, Doddamani, Mrityunjay
Vehicle interior material emissions and contributions in passenger vehicle cabin air quality2026-26-0287To be published on 01/16/2026
Polymer compounds used in the manufacturing of automotive interiors are formulated with various kind of additives, pigments, fillers, and resins. These compounded polymers are prone to the emission of chemicals called volatile organic compound (VOC) over a period of usage, temperature exposure etc. VOCs include a variety of chemicals, some of which may have short term adverse health effects like nausea, headache, vomiting, and long-term adverse health effects like cancer, even death if beyond the permissible limits. Studies indicates the concentrations of many VOCs are consistently higher in indoors (up to ten times higher) than outdoors and hence these chemical emissions are required to be controlled within the defined limits. This paper is focused on the identification part and material, evaluation against the recommended test (Odor/Fogging/VOC/Carbonyl compound emissions) and development of materials used inside the car cabin. This study further provides the guidelines for the
Shukla, Sandeep Kumar, Balaji, K V, Varatharajan, Senthilkumaran
Wireless Mobile charger Packaging in Pecuilar Rear Door Trim Profile.2026-26-0270To be published on 01/16/2026
Abstract A mobile wireless charger is a device that charge a smartphone or other compatible gadgets without the need for physical cables. Principle of wireless mobile charger system based on inductive coupling phenomena. The main objective of this paper aims to address the challenge of packaging wireless mobile charger in peculiar door trim profile keeping overall functionality and aesthetic appearance of door trim intact. This paper deals with integration of a wireless charging system within the door trim of a vehicle to provide convenience and advanced functionality. The objective is to pack a wireless charger in door trim meeting the ergonomic target and equilibrium state stability while maintaining sleek and minimalist design of the door trim. The study focuses on innovative packaging solutions related to space optimization in door despite multiple challenges involved. Major challenge lies in packing the unit amidst complex mechanisms such as window regulators, speakers, structural
Palyal, Nikita, D, Gowtham, Bhaskararao, Pathivada, Kumarasamy, Raj Ganesh, Bornare, Harshad
Incorporation of strain hardening and sheet thinning effects during forming process for an accurate prediction of buckling loads on sheet metal axle parts2026-26-0391To be published on 01/16/2026
In this competitive automotive world, shorter development time and quicker time to market for new models are vital to product success. This can be achieved by digitalization, thereby avoiding over-design of parts and the need for physical prototypes, resulting in cutting down on material and development efforts respectively. In this study, the deviation of load carrying capacity of chassis sheet metal axle links in comparison with hardware testing and simulation results were investigated. A multi-step forming simulation is carried out, which involves simulating all stages of the forming process to accurately predict the plastic strains leading to material strain hardening and thickness distribution leading to thinning. The forming simulation is performed using the anisotropic material model Banabic-Barlat-Comsa (BBC) to capture the anisotropy effects. This model uses several coefficients to precisely characterize the yield surfaces, considering both uniaxial and biaxial yield stresses
R B, Govind, Selvaraj, Nirmal Velgin
Predictive Analysis and Risk Management of Nickel-Plated Aluminum Automotive Parts Exposed to Harsh Environmental Conditions2026-26-0305To be published on 01/16/2026
Aluminium is widely used across various industries due to its lightweight properties, high strength-to-weight ratio, and cost-effectiveness. However, its susceptibility to corrosion, particularly in harsh environmental conditions, presents challenges to its long-term durability and performance. To mitigate these issues, nickel plating was applied as a protective measure, creating a barrier to minimize aluminums' direct exposure to corrosive environments and enhance its resistance to degradation. In this study, nickel-plated aluminum was subjected to controlled corrosion testing under simulated real-world conditions, including high humidity, saline atmospheres, and industrial pollutants. The primary objective was to evaluate the effectiveness and longevity of nickel plating as a corrosion prevention method. Periodic observations and measurements were conducted to monitor material changes, such as surface degradation and corrosion product formation. The findings highlight the critical
Narain, Aditya, Venugopal, Sivakumar, Gopalan, Vijaysankar, Varatharajan, Senthilkumaran
Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly2026-26-0302To be published on 01/16/2026
This research paper investigates the failure of an isolator clip used in the seat slider assembly, which guides and restricts the sliding motion of the tooth bracket within the seat. The component is made of C80 high-carbon spring steel, known for its high strength. According to the manufacturing process details, zinc plating was applied to the component for corrosion protection, as confirmed by EDS analysis. A fractographic examination of the failed part revealed a brittle, intergranular fracture morphology with visible cracks. Certain areas also exhibited micro-void coalescence, indicating a dimpled fracture surface. The primary failure mode was intergranular (IG) fracture. The delayed fracture was attributed to intergranular fracture mechanisms, micro-void coalescence, and the high strength of the steel, which made the component susceptible to hydrogen embrittlement. Hydrogen embrittlement occurs when hydrogen atoms become trapped along the grain boundaries, where they form hydrogen
Saindane, Mehul Kishor, Bali, Shirish
Enhancing Factory Modelling: Integrating Drone Technology and Automated Post Processing Systems2026-26-0307To be published on 01/16/2026
The growing environmental, economic, and social challenges have spurred a demand for cleaner mobility solutions. In response to the transformative changes in the automotive sector, manufacturers must prioritize digital validation of products, manufacturing processes, and tools prior to mass production. This ensures efficiency, accuracy, and cost-effectiveness. By utilizing 3D modeling of factory layouts, factory planners can digitally validate production line changes, substantially reducing costs when introducing new products. One key innovation involves creating 3D models using point cloud data from factory scans. Traditional factory scanning processes face limitations like blind spots and periodic scanning intervals. This research proposes using drones equipped with LiDAR (Light Detection and Ranging) technology for 3D scanning, enabling real-time mapping, autonomous operation, and efficient data collection. Drones can navigate complex areas, access small spaces, and optimize factory
Narad, Akshay Maruti, C H, Ajheyasimha, Vijayasekaran, Vinothkumar, Fasge, Abhishek
Virtual Paint Shop: Automotive E-coating Process2026-26-0365To be published on 01/16/2026
The automotive paint shop is one of the most energy-intensive processes in vehicle manufacturing. This drives automotive OEMs to continuously improve production efficiency and reduce operational costs through digital twin technologies. Additionally, the push for shorter time-to-market emphasizes the need for simulation-based manufacturing processes—such as virtual testing and CAE simulations—to enable faster, data-driven decision-making early in the product development cycle, ultimately reducing cost and development time. Among the various stages in the paint shop, two of the most critical are: 1. Electro-dip coating (E-coating), also known as Electro-Deposition coating, which applies a corrosion-resistant primer to the Body-in-White (BIW). 2. Oven curing, which ensures the primer is properly bonded and cured for long-term protection and finish quality. To optimize these processes, a Dip-Drain-E-Coating simulation was developed using Siemens Simcenter STAR-CCM+. This simulation
Gundavarapu, V S Kumar, P, Vivekaanandan, Garg, Manish, Navelkar, Tanay, BS, Balachandran
Comprehensive evaluation and development of a single cylinder engine vehicle for refinement of NVH characteristics2026-26-0308To be published on 01/16/2026
The scale of worldwide population presents its own set of difficulties, especially in densely populated cities. Almost every individual has some form of personal transport, which leads to congestion and limited parking space. Automotive manufacturers are scaling down the size of vehicles to resolve these issues to some extent. This paper is based on the NVH development of a single-cylinder diesel engine vehicle. It provides an insight into the comprehensive vehicle level NVH refinement approaches adopted. The NVH characteristics of the benchmark two-cylinder diesel and baseline vehicle were measured and analyzed for target setting. The performance of each subsystem, such as engine mounting, vehicle structure, intake and exhaust, was evaluated, and gap analysis was performed against set targets. It was found that the engine mounting system and vehicle structure were inefficient in isolating the excitation forces. The design and location of the mounting system was evaluated using CAE and
Ghale, Guruprasad Chandrashekhar, Baviskar, Shreyas, Bendre, Parag, Kamble, Pranit, Bhangare, Amit, THAKUR, SUNIL, Kunde, Sagar, Wagh, Sachin
UNIQUE HYBRID PANORAMIC HEADLINER CLIP WITH HIGH TOLERANCE TO REPLACE DUAL LOCK FASTENERS2026-26-0299To be published on 01/16/2026
Mounting strategies for vehicles with panoramic sunroofs remains a challenge owing to its high complexity to balance cost, performance and assembly efficiency. Achieving efficient and reliable headliner mounting solutions is one of the conundrums where cost optimization must go together with uncompromised performance. Traditional methods like Dual Lock Fasteners (DLFs), have set high benchmarks for robustness but at the cost of increased manufacturing complexity and expense. In pursuit of a more economical and production-friendly alternative, various plastic clip designs were explored. However, these solutions posed significant challenges during validation due to the stringent requirements for mounting feasibility, tolerance management, and long-term durability This paper introduces a novel hybrid plastic-metal clip solution that addresses those challenges comprehensively. The new design achieves precise tolerance control, ensuring reliable headliner installation under varying Body-in
D, Gowtham, Kumarasamy, Raj Ganesh, Shoeb, Mohd, Chauhan, Aarti
Safety Locking and alert system for Container trailers with Geo fencing2026-26-0273To be published on 01/16/2026
The Container trailer is used worldwide to transport goods & materials especially e-commerce applications with valuable materials. These container trailers are presently locked with a mechanical locking system and often broken and unlocked by unauthorized people. During transportation time, the driver stops for natural calls, food or any other breakdown, the attempt is made to steal the materials. Many cases were known only after damages are done. It has become a serious issue nowadays in the transportation industry. To avoid these problems, we have designed and developed a system that operates pneumatically with digital locking control. The system is designed to ensure proper safety by rigid mechanical locking. It is actuated by a pneumatic system consisting of Directional control valve & pneumatic cylinders. The lock and unlock inputs are given through digitally and the digital controller provides the appropriate input to solenoid operated direction control valve. Based on the
kumaran, Rajasekar
Development of a GUI-Based Pitch Sequence Optimization Tool for Tyre Noise Reduction2026-26-0330To be published on 01/16/2026
Minimizing tyre noise is essential for enhancing ride comfort, especially in electric vehicles where the absence of engine noise makes tyre-generated sound more prominent. This work presents the development of a GUI-based pitch sequence optimization tool to support tyre design engineers in generating acoustically optimized tread sequences. The tool operates in two modes: without constraints, where the pitch sequence is optimized freely to reduce tonal noise levels; and with constraints, where specific design rules are applied to preserve pattern consistency and manufacturability. This tool plays a pivotal role in the tire development process, serving as one of the key evaluation criteria for tread pattern approval before mould fabrication. By enabling engineers to generate balanced, low-noise pitch sequences that align with both acoustic targets and engineering constraints, the tool facilitates faster design iterations and smooth integration with downstream processes. Its successful
Sampathraghavan, Lakshmi, Ramarathnam, Krishna Kumar, Mantripragada PhD, Krishna Teja, Ramachandran, Neeraj
Packaging the HPTS Airbag in a Second-row bench seat2026-26-0033To be published on 01/16/2026
Seats of modern cars should necessarily meet the regulatory safety norms along with aesthetics and comfort. In the existing passenger cars prevailing across the Indian subcontinent, the measure of safety has been a challenging one. The stringent regulatory norms thereby make the Airbag very promising. In the domain of automotive safety, certain features hold exceptional importance, with airbags taking a forefront position. Their fundamental objective is to provide an advanced level of safety for both the driver and passengers in the unfortunate event of a collision. This is accomplished through the automatic deployment of an inflatable airbag, engineered to swiftly respond during a crash and furnish the necessary sophisticated cushioning to enhance overall passenger safety. The technology has been practiced widely upon a many vehicles seat. However, the present work highlights a novel approach of packaging the HPTS air bag in second row seat. This Air bag unit is fitted in the seat
Buradkar, Rajat, Bose, Karthik, Jadhav, Deepika, Balakrishnan, Gangadharan
Hypoid Gear Performance Redefined: Addressing Scoring and Whine Noise Concerns2026-26-0078To be published on 01/16/2026
Rear drive vehicles transfer power to the rear wheels through the Gear Carrier Assembly, which is fit at the central section of the Rear Axle. The Gear Carrier Assembly includes hypoid ring and pinion gears, set at the heart of the system. However, gear scoring and whine noise frequently emerge as critical challenges, leading to reduced durability and compromised performance of the vehicle. This study focuses on the design and process improvements aimed at addressing these concerns while enhancing the overall performance and reliability of hypoid gears. Design enhancements include macro geometry refinements, material upgrades, and modifications in the heat treatment process. These changes improved key mechanical properties such as contact stress, bending strength, impact strength, and motion transmission error (MTE). Process optimizations involved precise control over carburizing, hardening, and quenching temperatures, as well as adjustments in quenching pressure. These measures
Praveen, Abhinav, Deshpande, Praveen, Jain, Saurabh Kumar, Parmar, Mayur, Karle, Nilesh, Kanagaraj, Pothiraj, Pagar, Pawan
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
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
Multi-Material Front Structures: A Pathway to Safer and More Sustainable Vehicle Design2026-26-0456To be published on 01/16/2026
Frontal crash structures play a vital role in occupant safety, but traditional designs often involve a trade-off between structural strength and weight efficiency. In the pursuit of safer and more sustainable mobility, this study explores a physics-based methodology that leverages the principle of dynamic equilibrium to guide the integration of dissimilar materials in front-end vehicle structures. Specifically, we examine a novel configuration wherein aluminum High pressure die cast (HPDC) is introduced in swan neck region of the front longitudinal member, while retaining steel in the frontal crush zone. This arrangement aims to redistribute crash loads and control deformation mechanisms, enabling improved energy absorption without compromising structural integrity. To evaluate the proposed strategy, a series of detailed finite element simulations were conducted using LS-DYNA, a widely adopted tool for vehicle crash analysis. The results reveal that the dynamic equilibrium approach
Revanth, Goshika, Bhagat, Milind, Joshi, Vikas, Mankhair, Abhijit, Sudarshan, B.Sudarshan, Kollipara, Jahanavi
Transforming Manufacturing: Increasing Throughput and Reducing production Complexity with Digital Twins2026-26-0449To be published on 01/16/2026
In traditional manufacturing, increasing production line capacity often involves physical trials, leading to downtime, high costs, and operational risks. This paper presents a bidirectional digital twin developed for the Fischertechnik Smart Factory Kit, enabling real-time simulation and validation of production line modifications before actual deployment. The digital twin integrates with a Siemens PLC to mirror real-world operations, capturing live production data and visualizing key parameters like cycle time and machine utilization in a 3D environment. Engineers can test various optimization scenarios adjusting conveyor speeds, optimizing robot paths, and modifying buffer sizes to enhance efficiency. The best-performing configurations are identified based on throughput, cycle time, and resource utilization, and validated changes are automatically deployed to the PLC, ensuring seamless implementation. Beyond capacity optimization, this solution improves overall production efficiency
Kumar, Rahul, Singh, Randhir
Considerations for Vulnerability Management in the Automotive Industry2026-26-0626To be published on 01/16/2026
With the emergence of Software-Defined Vehicles (SDVs), more complex software and connectivity technologies are introduced to support new advanced use cases such as phone as a key, smart parking and vehicle management. However, complex software functionality and external connectivity also increase the attack surface of vehicles and its ecosystem. In this paper, we first perform a classification of recent automotive cybersecurity attacks. We further perform an analysis of these attacks and associated vulnerabilities considering the application of best practices of vulnerability management approaches including Common Vulnerability Scoring System (CVSS), Exploit Prediction Scoring System (EPSS), and Stakeholder-Specific Vulnerability Categorization (SSVC). CVSS is a standardized framework used to assign severity scores to known vulnerabilities and helps organizations prioritize vulnerability remediation based on severity. EPSS is a predictive model that estimates the probability of a
Oka, Dennis Kengo, Vadamalu, Raja Sangili
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