Browse Topic: Manufacturing

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Sustainable Machining of Aluminium Alloys: Experimental Insights into WEDM Process Optimization2026-28-0034To be published on 02/01/2026
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 Shot Peening on the Fatigue Life of Polylactic Acid Parts in Automobiles2026-28-0032To be published on 02/01/2026
Polylactic Acid (PLA), is a biodegradable thermoplastic and most widely used materials in automobiles also inherent fatigue performance limitations and its deployment in demanding load-bearing automobile applications. Shot peening, a well-established surface treatment known to significantly enhance the fatigue life of metallic materials, presents a potential post-processing strategy to improve the durability of polymers. The proposed work investigation into the effects of controlled shot peening pressure on the various behavior of injection molded PLA specimens. The outlined methodology encompasses the fabrication of PLA samples conforming to ASTM standards, the application of shot peening using precisely defined parameters, comprehensive characterization of the resulting surface modifications (including roughness, hardness, morphology, and systematic uniaxial fatigue testing according to ASTM D7791. Fatigue tests will generate fatigue behavior and fatigue life (by varying number of
Ranganathan, Soundararajan
Modelling and Analysis of Complex Shaped Cracks2026-28-0048To be published on 02/01/2026
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
Influence of varying shoulder profiles in pin-less tool on friction stir welding of thin plates2026-28-0028To be published on 02/01/2026
This study explores the thermal and mechanical characteristics of Friction Stir Welding (FSW) using pin-less tools with varied shoulder geometries to weld 2 mm dissimilar plates. FSW is a solid-state joining technique known for minimizing weld defects and enhancing joint integrity, particularly in the applications requiring high precision and low thermal distortion. Using simulation-based analysis via ANSYS, three custom-designed tool profiles are considered (i.e) spiral, concentric, and diamond tip, were evaluated. The rotational speeds considered are 500, 1000, and 3000 rpm at a constant traverse speed of 90 mm/min. The 3D models of the FSW tool with required shoulder profiles and thin plates are developed using Solid works. The tool and plates are characterized using tungsten carbide and aluminium-magnesium for workpieces. The simulations focused on key field variables including, temperature distribution, residual stress, and deformation on the welded plates. Results indicated that
Nelson, N Rino
TOPSIS-Based Multi-Criteria Optimization of WAAM Parameters for Automotive Component Fabrication2026-28-0026To be published on 02/01/2026
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
Machinability Evaluation of WAAM-Fabricated Alloys Using Wire EDM and Parameter Optimization Techniques2026-28-0036To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) is increasingly utilized for fabricating near-net shape metal components due to its high deposition rates and cost-effectiveness. However, post-processing of WAAM-fabricated parts, especially to achieve precise dimensions and surface finish, is essential. Wire Electrical Discharge Machining (WEDM) presents an effective solution for such requirements due to its ability to machine hard-to-cut materials with high precision. This study investigates the machinability of WAAM-fabricated alloy specimens using WEDM by analyzing key output responses such as material removal rate (MRR), surface roughness (Ra), and kerf width. Taguchi and other optimization techniques were employed to identify the optimal combination of WEDM parameters including pulse-on time, pulse-off time, peak current, and wire feed. Experimental results demonstrated that specific parameter settings significantly enhance machinability while maintaining structural integrity. The findings
Bangaru, Haritha
ALTERNATE CATALYST FOR DOC IN A CATALYTIC CONVERTER2026-28-0016To be published on 02/01/2026
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
Effect of Minimum Quantity Lubrication during Machining of Incoloy 800H Using Vegetable Oil Enriched With Nano Particles2026-28-0038To be published on 02/01/2026
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
Experimental Investigation of Process Parameter Effects in WAAM of Nickel-Based Alloys2026-28-0027To be published on 02/01/2026
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
AI-Driven Process Optimization in Wire Arc Additive Manufacturing of Nickel Alloys Using ANFIS2026-28-0025To be published on 02/01/2026
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
Parameter Optimization for Improved Surface Finish in WAAM-Fabricated Steel Structures2026-28-0023To be published on 02/01/2026
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
Surface Integrity and Process Efficiency studies on Wire EDM Parameters for Machining Hastelloy Components for automobile parts2026-28-0037To be published on 02/01/2026
Hastelloy, a high-performance nickel-based alloy, is widely used in aerospace, chemical, and marine industries due to its exceptional corrosion resistance and mechanical strength. However, its superior properties also make it difficult to machine using conventional processes. Wire Electrical Discharge Machining (WEDM) offers a non-conventional approach to accurately machine Hastelloy components with minimal thermal damage. This study focuses on optimizing key WEDM process parameters pulse-on time, pulse-off time, peak current, servo voltage, and wire feed to enhance surface quality and material removal rate. A Taguchi L9 orthogonal array was used to design experiments, and analysis of variance (ANOVA) was applied to identify the most significant factors affecting performance. The results revealed that optimized settings led to a notable reduction in surface roughness and improved cutting efficiency. The study provides a strategic framework for the effective machining of Hastelloy
Bangaru, Haritha
Selection and Optimization of Process Parameters in Wire Arc Additive Manufacturing for Automotive Structural Applications2026-28-0039To be published on 02/01/2026
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
Tuning structural and optical properties of Cu2ZnSnS4 thin films via annealing temperature2026-28-0015To be published on 02/01/2026
Cu2ZnSnS4 thin films, a promising material for solar cell absorber layers, have been effectively deposited onto soda-lime glass substrates using the chemical spray pyrolysis method. During this deposition method, the films have been deposited at a substrate temperature of 375 °C. The films are deposited with a spray rate of 10 ml/min to achieve uniform film formation. After the deposition of these films, to improve the crystallinity of the films and increase the sulfur content, the as-deposited films were annealed in a sulfur-rich atmosphere. Annealing was carried out at a two-zone vacuum tubular furnace at 500 - 550 °C. The as-deposited films are found to be rich in tin and deficient in sulfur. After annealing, there is a noticeable improvement in the Cu2ZnSnS4 phase formation and crystallinity. However, films annealed at the higher temperature of 550 °C showed signs of zinc loss in the deposited films. X-ray diffraction analysis confirmed the formation of the kesterite structure
M, Pavan Sai Reddy, Kumar, YB Kishore
Investigation of Wear and Friction Characteristics of 3D printed PLA and PLA–Carbon Fiber Composites against a Tribometer Counter Part Surface2026-28-0031To be published on 02/01/2026
PLA (poly Lactic Acid) carbon fiber composites is most widely used in industrial applications especially in automotive, consumer electronics sector due to low cost prototyping and durability. In this proposed work, investigation on PLA and PLA+CF 3D printed samples are taken for wear and friction testing with same material counterpart. This experiment helps to analyze wear and friction resistance by applying material interaction between part on pin, counterpart on disc with varying applied load of 5,10,15 to 20N and sliding velocity of 1m/s and 3m/s. At first designing the required prototype (Part sample, counterpart disc) with material as PLA, PLA+CF. The unique of the research, tested samples are 3D printed pin and counterpart disc, both are same material. Each sample subject to 4 different load and 2 different sliding velocity. In this work we use two materials namely PLA, PLA+CF composite material. In this work PLA and PLA Carbon Fiber materials are comparatively analysed where PLA
Ranganathan, Soundararajan, Karthickkumar, S, Alwin Jones, J
Experimental Optimization of WEDM for Post Processing of Wire Arc Additive Manufactured Alloys2026-28-0041To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) is widely adopted for producing large-scale metal components due to its high deposition rates and material efficiency. However, WAAM-fabricated parts often exhibit poor surface finish and dimensional inaccuracies, necessitating precision post-processing. Wire Electrical Discharge Machining (WEDM) offers a suitable solution for finishing such components, especially those made from hard-to-machine alloys. This study presents an experimental investigation into the optimization of WEDM process parameters such as pulse-on time, pulse-off time, peak current, and wire feed for post-processing WAAM-fabricated alloys. Using a Taguchi design of experiments and statistical analysis, the influence of each parameter on surface roughness, material removal rate (MRR), and dimensional accuracy was evaluated. The optimized parameters yielded improved surface integrity and machining efficiency, making WEDM a reliable post-processing technique for enhancing the
Pasupuleti, Thejasree
Experimental and Predictive Study on WEDM of Aluminium Alloys Using Taguchi and ANFIS2026-28-0040To be published on 02/01/2026
The attributes of aluminium alloys are acknowledged in the varied usage of these alloys because they have excellent mechanical properties and good ductility while being less vulnerable to fatigue. These alloys are widely applied in engineering disciplines. The aerospace and automotive industries are important industries using these alloys, and many other progressive engineering applications continue to embrace the use of these alloys. Their resistance to corrosion makes them even better suited for usage in some harsh environments. Unfortunately, producing parts with very complicated geometries through conventional machining techniques is still a challenge. To try to solve this limitation, there have been several advanced machining processes. Among them is Wire Electrical Discharge Machining (WEDM) - a specific form of Electrical Discharge Machining (EDM) for an effective solution for complex and hard-to-machine components. In this study, efforts have been made to study the WEDM process
Natarajan, Manikandan
Statistical Modeling of Wire Arc Additive Manufacturing Parameters Using Regression Analysis2026-28-0024To be published on 02/01/2026
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
Statistical Optimization of Wire Arc Additive Manufacturing Parameters Using Taguchi Methodology2026-28-0035To be published on 02/01/2026
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 02/01/2026
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
Multi-Objective Optimization of WAAM for Sustainable Production of Automotive-Grade Components2026-28-0030To be published on 02/01/2026
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
The Impact of Color Correlated Temperature (CCT) on Automotive Headlights Performance and Driver Perception2026-26-0130To be published on 01/16/2026
Automotive lighting has been evolved from simple incandescent lamps to advanced LED based AFS and ADB functions. These lighting play crucial role in road traffic enhancing better visibility and safety to driver as well as other road users. Today’s Automotive Headlights use different light sources viz., Halogen, HID (Xenon), LED, and Laser each emitting light at different correlated color temperatures (CCT), measured in Kelvin (K). Color temperature not only influences visibility but also impacts the amount and perception of glare experienced by other drivers. The study was undertaken to evaluate the effect of correlated color temperature of automotive headlamps on driver visibility and comfort during night driving conditions. The experiment was conducted in a controlled laboratory environment using headlamps with different CCTs ranging from 3000K to 6500K. Participants from various age groups and genders were involved to capture diverse perceptions. Studies confirm that both CCT and
Patil, Mahendra G., Kirve, Jyoti, Parlikar, Padmakumar
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
A Dynamic Cybersecurity Benchmarking Framework for Automotive Cyber-Physical Systems2026-26-0612To be published on 01/16/2026
As the automotive industry accelerates towards greater connectivity and automation, ensuring robust cybersecurity has become a critical priority, especially in emerging markets like India. This paper introduces a comprehensive framework designed to assess and enhance the cybersecurity of production-ready vehicles, with a particular focus on addressing the unique challenges posed by both domestic and international markets. The proposed system combines advanced threat modeling, vulnerability assessment, and dynamic evaluation techniques to continuously monitor and quantify a vehicle’s cybersecurity posture throughout its lifecycle. In the Indian context, where the automotive market is rapidly evolving and the adoption of connected and automated vehicles is on the rise, the need for tailored cybersecurity measures is particularly pressing. By evaluating the impact of cyber threats on safety, data privacy, financial risks, and vehicle functionality, the system generates a detailed
Shah, Ravindra, Awasthi, Vibhu Vaibhav, Karle, Ujjwala
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
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
For CNG and FFV fuel application robustness improvement of Exhaust Valve2026-26-0125To be published on 01/16/2026
Today, globally, automotive manufacturers are striving to meet the increasing demand for fuel economy, high performance, and silent engines. The fundamental approach to achieving these requirements is through designing low friction mechanisms, resulting in less wear and higher durability. The demand for CNG vehicles has surged exponentially in recent years, prompting increased government focus on alternative fuels such as CNG and hydrogen. These dry fuels lack lubricating properties, unlike conventional fuels like petrol, diesel, and biofuels, which are wet and liquid. Consequently, the operations and failures associated with these fuels differ. The materials and designs of engine parts, such as fuel lines, ECU, exhaust valves, and cylinder heads, vary depending on the fuel used. This study discusses the countermeasures adopted to address the high seat and guide wear in cylinder heads and valves. The investigation focuses on material, design, and manufacturing process improvements
Poonia, Sanjay, KUMAR, CHANDAN, Sharma, Shailender, khan, Prasenjit, Bhat, Anoop, P, Prasath, Neb, Ashish
Manufacturing process advancement in CNG Exhaust Valve to prevent seat wear issue2026-26-0278To be published on 01/16/2026
Exhaust Valve CNG market share increased in India in recent years demanding for more durable and reliable CNG Engine. While in current scenario durability is one of the major concerns for CNG engine. Major issue faced in CNG powertrain is high wear at Exhaust valve CNG face due to excessive wear. In Current practice T400 Sintered material layer is deposited at Valve face which is very critical to achieve less wear at valve face. Due to manufacturing variability high level of variation is found mechanical properties of T400 deposit which is very critical for Exhaust Valve CNG performance. In this paper all important process parameters are discussed for achieving consistent Exhaust Valve CNG T400 deposit quality. Each process parameter detail impact on T400 material is studied and explained to achieve consistent quality of T400 deposit leading to robust design of Exhaust Valve CNG.
Poonia, Sanjay, KUMAR, CHANDAN, Kundu, Soumen, kumar, prabhakar, Vats, Rajesh, khan, Prasenjit, Sharma, Shailender
Jerk evaluation criteria for pedestrian head impact on Windshield and technological requirement to meet the criteria2026-26-0023To be published on 01/16/2026
The safety of vulnerable road users, particularly pedestrians, cyclists, and motorcyclists, is a paramount concern in automotive design and regulation. In India, the situation is particularly alarming, with pedestrians being the second highest victims of road accidents, as evidenced by over 32,825 reported pedestrian accidents and 4,836 cyclist fatalities in 2022, excluding two-wheeler motorcyclists. On a global scale, the prevalence of such incidents has prompted European countries to introduce new regulatory requirements, such as ECE R127.03. This regulation encompasses the evaluation of pedestrian head form impacts on windshields, assessing the typical behavior of glass through jerk criteria following initial contact, in conjunction with the existing Head Injury Criterion (HIC) evaluation for pedestrian head forms. These criteria are meticulously designed to ensure that both acceleration and jerk remain within safe limits to reduce the severe injury to head of vulnerable road users
Kumar, Ritik, A, Rajesh
A systematic debugging methodology for identifying electric vehicle level EMC issues.2026-26-0525To be published on 01/16/2026
Electric vehicles present unique challenges in electromagnetic compatibility testing due to compact packaging, high-frequency switching systems. This paper presents a systematic debugging methodology for identifying radiated emission and radiated immunity issues in these EV platforms. A comprehensive approach is outlined, covering radiated emission measurement; Bulk Current Injection based immunity simulation, and near-field probing techniques. For RI evaluation, BCI testing in the 20 to 400 MHz range is used to simulate radiated threats on the vehicle's power and signal harnesses and handy transmitter near field injections for higher frequency simulation. For RE diagnosis, conducted emission measurements on vehicle harnesses are performed using current probes to capture high-frequency currents. Additionally, near-field electric probes are used at the component to identify dominant noise sources such as DC-DC converters, Motor control unit, and improperly grounded shielding. Case
M, Gokul, Patel, Jinay, Mulay, Abhijit B
Road noise improvement of a passenger vehicle through end-to-end CAE-Simulation using Transfer Path Analysis (TPA) approach2026-26-0431To be published on 01/16/2026
Refined NVH performance of a vehicle is a mark of premium quality. Achieving the desired NVH performance in different vehicle operating conditions is always a Herculean task and early stage “CAE design recommendations” play crucial role in overall vehicle design development. This becomes tougher when the program is very much cost, weight and timeline sensitive. This paper explores simulation approach for addressing a major noise issue for a vehicle running at a constant speed on a rough road. The first and the most critical step is to identify the exact root cause of the issue. Hence, we propose a detailed full vehicle level “contribution analysis (CA) + transfer path analysis (TPA)” methodology (everything done through the simulation) and then go for the design recommendations to improve the performance. We used road excitation power spectral density (PSD) as the input at all the four wheels (spindle locations) calculated through MBD software. The first step i.e. contribution analysis
Mahajani, Mihir, Nascimento, Fabio, ADINARAYANA REDDY, KODIDELA, Matyal, Mahantesh, Tenagi, Irappa, Sardar, Chenna
Post-EOL Cybersecurity Validation for Automotive Production ECUs2026-26-0608To be published on 01/16/2026
ISO/SAE 21434 emphasizes comprehensive cybersecurity risk management throughout the automotive lifecycle. However, specific guidance on validating cybersecurity measures at the production level remains limited. This paper addresses the gap in production-stage validation, particularly after End-of-Line (EOL) flashing, which includes configurations of security hardware and software protection (e.g., UCB confirmation, JTAG, and P-flash password settings). Problem articulation: Current automotive cybersecurity validation methods, despite adherence to ISO/SAE 21434, lack specific procedures for the production stage. The existing system-level validation using the ASPICE V-model (e.g., SWE.6, SYS.5) does not ensure the integrity and functionality of cybersecurity features in the final manufactured unit post-EOL flashing. This gap poses a risk of vulnerabilities being introduced during the EOL process, compromising critical security measures. Proposed solution: To mitigate the cybersecurity
Chakraborty, Sucheta, Kulanthaisamy, Nagarajan, Sankar, Ganesh
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-0280To be published on 01/16/2026
This paper presents a comprehensive numerical method intended at developing a coupled process structure simulation that integrates both elastoplastic and anisotropic material behavior for short glass fiber-reinforced injection-molded thermoplastics. Three engineering tools, namely Moldflow, Digimat, and ABAQUS are used in the current numerical methodology to assess material anisotropy and its influence on thermo-mechanical characteristics. The simulation incorporates fiber orientation concerns as well as potential injection molding defects known as weld lines, linking with thermo-mechanical simulations. The behavior of real injection-molded components is computationally represented by the ability to transfer data from injection molding software (Moldflow) to structural software (ABAQUS). Besides, integrating with multi-scale modeling software Digimat as an interface tool, the results of the Moldflow simulations, such as fiber orientations and weld-line properties transmitted directly
T, KALINGA, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Optimizing rattle behaviour in metal-plastic interfaces for EV tail lamp assemblies2026-26-0332To be published on 01/16/2026
The seamless and sleek design of connected tail lamps adds a visually striking element to the car's exterior. It aligns with contemporary automotive trends and gives the vehicle a premium and futuristic appearance. Automakers use these lamps as a design signature to establish brand identity. Connected tail lamps improve visibility for drivers behind the vehicle. The assembly of connected tail lamps can pose several challenges, especially due to their complex design and integration requirements. Metal-plastic creak is a common concern in electric vehicles (EVs), often noticeable when driving on uneven roads. This primarily results from stick-slip behaviour at the interface of metal and plastic components, intensified by improper alignment. When the designed geometric dimensioning and tolerancing (GD&T) is not met in real manufacturing conditions, misalignment introduces unintended contact forces, leading to intermittent micro-sliding and frictional energy release, which manifests as an
MICHAEL STEPHAN, NAVIN ESTAC RAJA, C M, MITHUN, Mohammed, Riyazuddin, R, Prasath
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
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
Effect of the Flow Forming Process on the Mechanical properties and Microstructure of GDC & LPDC cast aluminum alloy wheels.2026-26-0298To be published on 01/16/2026
Aluminum alloy wheels have become the preferred choice over steel wheels due to their lightweight nature, enhanced aesthetics, and contribution to improved fuel efficiency. Traditionally, these wheels are manufactured using methods such as Gravity Die Casting (GDC) [1] or Low Pressure Die Casting (LPDC) [2]. As vehicle dynamics engineers continue to increase tire sizes to optimize handling performance, the corresponding increase in wheel rim size and weight poses a challenge for maintaining low unsprung mass, which is critical for ride quality. To address this, weight reduction has become a priority. Flow forming [3,4], an advanced wheel production technique, offers a solution for reducing rim weight. This process employs high-pressure rollers to shape a metal disc into a wheel, specifically deforming the rim section while leaving the spoke and hub regions unaffected. By decreasing rim thickness, flow forming not only reduces overall wheel weight but also enhances strength and
Singh, Ram Krishnan, Medaboyina, HarshaVardhan, G K, Balaji, Gopalan, Vijaysankar, SUNDARAM, RAGHUPATHI, Paua, Ketan
Virtual Reality in Assembly Simulations : Outpacing Tecnomatix Process Simulate for Faster Time-to-Market2026-26-0398To be published on 01/16/2026
Virtual Reality (VR) technology is emerging as a transformative solution in manufacturing industry. It offers significant advantages over traditional tools like Tecnomatix Process Simulate (PS) in assembly and ergonomic simulations. Analysis using PS is time consuming and lacks real time human interaction as it relies on detailed modelling and sequential workflows, which will delay the identification of assembly no-build conditions and ergonomic issues. This paper evaluates the time and cost saving potential of VR in assembly processes and explores its role in minimizing the need for physical prototypes across various stages of vehicle development. VR provides interactive environments, enabling interaction with 3D models and real-time collaboration with various teams across the globe. This leads to faster identification of assembly process flaws, quicker iteration cycles, and a reduced need for physical prototypes in the station development process for the lines. VR allows individuals
Nagendran, Rakesh Kumar
Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application2026-26-0286To be published on 01/16/2026
Quality of the Shear Trimmed edge of HSLA 550 steels is significantly affected by process variations such as Shear Trimming Clearance, trim tolerance, burr height and clamping force. All these parameters largely influence the characteristics of the Shear Affected Zone, a region on sheet metal where it undergoes deformation during the trimming process. The Shear Affected Zone is predominantly vulnerable to failure due to work hardening and the effects of strain rate, induced by the tonnage during the trimming operation. To assess the edge ductility of these materials, Tensile, Fatigue Strength, Die Punch Clearance, Roughness and Hardness Tests are carried out. These tests are crucial for applications that demand high formability and resistance to edge failure. Virtual simulation of edge trimming operation using elastoplastic material models in LS-Dyna have been performed to gain insights into burr formation and damage evolution during shearing. These simulations act as a precursor to
Thota, Badri Vishal, Kashyap, Amit, Bhuvangiri, Jaydev
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
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
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
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
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
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
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
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
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
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
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
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