Browse Topic: Manufacturing processes

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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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
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
Innovative Friction Locking Mechanism for High Voltage Busbar Connections in EV Batteries2026-26-0155To be published on 01/16/2026
In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also reduces heat generation, addressing common issues associated with traditional screw-based connections. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency. This study presents the design methodology, performance
Venkatesh, Murali, Raghu, Arun, Bhramanna, Amol
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
Data analytics methodology for vehicle quality complaint analysis2026-26-0654To be published on 01/16/2026
Automobiles have become a part of people's everyday life. Customers base their trust on a brand's reputation while making a buying decision. With the evolving trends, feature advancements, automobiles have become a complex system. Ensuring product quality amidst system complexities is necessary to maintain the brand value & ensure customer satisfaction. Efficient addressal of customer quality complaints is pivotal in maintaining product quality. Until recent times, manual analysis using traditional data processing tools has been used for vehicle complaint analysis. However, considering the large quantum of data in new age vehicles with more number of control units, it becomes time-consuming, expertise dependent and susceptible to human errors. Given this & the advent of new age machine learning techniques & data analysis tools that can handle large amount of data, it is imperative to adopt them for vehicle complaint analysis. This research paper puts forth a method to analyze vehicle
Venkatesan, Prasanna, Raju, Vivek
Simulation driven design of robust Crank-train systems for elevated In-cylinder combustion pressure2026-26-0400To be published on 01/16/2026
The need for increased in-cylinder pressure to meet the higher engine rating and stringent emissions norms requires special attention on the Main moving components torsional behaviour and the bearing performance. The work presented in this paper utilizes the 1D and 3D simulation potential of AVL EXCITE for the assessment of design changes required in Crank-Train system for the increased in-cylinder pressure from 170bar to 220bar. The key feature of the executed work was that all the design changes were accommodated with minimal changes in packaging / layout interfaces. The given work was executed on 6-Cylinder Turbocharged In-cylinder with Type V valve-train configurations. Initial brain storming & 0d calculation helped in understanding the design optimization required in each and every crank-train parts. Considering the guidelines available in terms of L/d ratio for the bearing, connecting rod length, the overall linkage specification was set up for starting with design work for
Khandelwal, Meha
Balancing global and local formability properties through Nb microalloying2026-26-0303To be published on 01/16/2026
David Martin, CBMM Asia Bernardo Barile, CBMM Europe BV Caio Pisano, CBMM Europe BV Automotive high strength steels have specific microstructure-dependent forming characteristics. Global formability is generally associated with high uniform strain values which imply good drawability and stretch forming properties driven by pronounced work hardening. Local formability on the other hand is often measured by various fracture strain values—generally higher in single phase steels. In this respect, the so-called ‘local/global formability map’ concept has been established not only to provide a comprehensive methodology to characterize existing automotive steels but also to enable improvement strategies toward more balanced forming characteristics. Niobium (Nb) microalloying is a powerful tool to achieve both property improvement in general and property balance in particular. More than two decades of research has demonstrated that Nb-induced microstructural optimization is applicable to HSLA
Barile, Bernardo
Binder Jet Additive Manufacturing (BJAM) ProcessAMS7022 (Current)11/26/2025
This specification establishes process controls for the repeatable production of sintered parts by binder jet additive manufacturing (BJAM). It is primarily intended to be used to manufacture metallic or ceramic aerospace parts, but usage is not limited to such applications.
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Simulative Temperature Determination of an Electric Machine from Test Bench Tests2025-01-052011/25/2025
One of the most important components of an electric vehicle is the drive motor. Induction motors are often used for this purpose. During operation of these motors, power loss occurs, especially at high speeds. This power loss corresponds, among other things, to the sum of winding losses, iron core losses and mechanical losses. The power losses generate heat, which causes the temperature in the rotor and stator to rise. The increase in temperature of the components inside the motor can lead to premature wear and fatigue failure. To prevent overheating, the motors are air- or water-cooled. Water cooling can be achieved, for example, by means of jacket cooling. Here, the heat generated is dissipated directly by forced convection. However, the cooling jacket makes it difficult to determine the temperature inside the motor. Determining these temperatures is necessary to protect the motor from premature fatigue. The temperatures inside the motor during operation are of particular interest
Schamberger, Stephanie, Reuss, Hans-Christian
Electron Beam Directed Energy Deposition-Wire Additive Manufacturing Process (EB-DED-Wire)AMS7027 (Current)11/24/2025
This specification establishes process controls for the repeatable production of aerospace parts by EB-DED-Wire. It is intended to be used for metal aerospace parts produced by additive manufacturing (AM), but usage is not limited to such applications.
AMS AM Additive Manufacturing Metals
Additively Manufactured Aluminum-Lithium Alloys—Advances, Challenges, and Future Directions2025-01-507611/18/2025
Aluminum-lithium alloys are extensively used across various industries due to their exceptional strength-to-weight ratio, excellent fatigue/corrosion resistance and good thermal stability. These attributes, combined with improved weldability and ease of fabrication, make them ideal for lightweight engineering applications in sectors such as aerospace, automotive, and defense. Additive manufacturing (AM) offers unique opportunities to fully leverage the potential of aluminum-lithium alloys by enabling the fabrication of complex geometries, minimizing material waste, and supporting on-demand production. This paper explores the significance of lightweight materials, traces the evolution of aluminum-lithium alloys and provides a comprehensive overview of their AM. It discusses the properties and real-world applications of these alloys and examines various AM techniques employed in their processing. Key advancements in the AM of aluminum-lithium alloys are reviewed, including novel alloy
Santhana Babu, A.V., Antony Benson, B., Danusha, M.
3D Printed Injection Molding Tool: An Unique Approach for New Product Development2025-28-032111/06/2025
Automotive industry frequently uses 3D printed plastic proto parts during new product development phases as it bypasses the high tooling investment & development time at early part development stage. However, for some application, 3D printing technique & its limited material options are not fulfilling the required material properties in the part, resulting poor performance during product testing which may mislead the design engineer during validation process. To overcome this, we introduce a novel approach in constructing injection molding tool by 3D printing the core and cavity using Stereolithography (SLA). This enables production of parts with application-recommended material grades, facilitating traditional validation and increasing stakeholder confidence. This paper compares part quality from 3D printed molds against conventional metallic molds for a shifter gear housing cover, demonstrating a 45% reduction in tooling costs and a 75% decrease in tooling development time. Mold life
Gandhi, Sorna Rajendran, Gunduboina, Chaitanya
Evaluating the Influence of Material Properties and Hardness on Tightening Torque2025-28-025511/06/2025
Earthmoving machines are equipped with a variety of ground-engaging tools that are joined by bolted connections to improve serviceability. These tools are made from heat-treated materials to enhance their wear resistance. Attachments on earthmoving machines, including buckets, blades, rippers, augers, and grapples, are specifically designed for tasks such as digging, grading, lifting, and breaking. These attachments feature ground-engaging tools (GET), such as cutting bits or teeth, to protect the shovel and other earthmoving implements from wear. Torquing hardened plates of bolted joint components is essential to ensure uniform load distribution and prevent premature failure. Therefore, selecting the proper torque is an important parameter. This study focuses on analyzing various parameters that impact the final torque on the hardened surface, which will help to understand the torque required for specific joints. Several other parameters considered in this study include hardware
Parameswaran, Sankaran Potti, Bhosale, Dhanaji, Kumar, Rajeev
Impact of Biodiesel on Fuel Filtration System and Proposed Best Practices2025-28-022711/06/2025
Biodiesel acceptance and consumption increased rapidly from 2018 onwards because of government policies promoting and mandating (in few cases) the consumption of local made Biodiesel feedstock to replace/reduce the import crude oil to save fuel import costs. Currently biodiesel usage is unregulated and non-standardized in few countries and in cases it is mandated and well controlled by local government (e.g. Indonesia). This unregulated, non-standardized and rapidly increasing usage of Biodiesel started to show consequences such as reduced fuel filter life, degradation of engine and filter with material non-compatibility issues with biodiesel and this developed a need of in-depth study, research and creation of recommendations / best practices for the use of Biodiesel in various application. This paper will discuss the root causes of challenges related to usage of biodiesel (manufacturing process, storing and handling of biodiesel at application site), technical challenges and it’s
Bhalerao, Hariprasad, Shah, Avani, Khedkar, Prashant
E-Motor Thermal Management Using 2D-3D Coupling2025-28-022511/06/2025
In the electrical machines, detrimental effects resulted often due to the overheating, such as insulation material degradation, demagnetization of the magnet and increased Joule losses which result in decreased lifetime, and reduced efficiency of the motor. Hence, by effective cooling methods, it is vital to optimize the reliability and performance of the electric motors and to reduce the maintenance and operating costs. This study brings the analysis capability of CFD for the air-cooling of an Electric-Motor (E-Motor) powering on Deere Equipment's. With the aggressive focus on electrification in agriculture domain and based on industry needs of tackling rising global warming, there is an increasing need of CFD modeling to perform virtual simulations of the E-Motors to determine the viability of the designs and their performance capabilities. The thermal predictions are extremely vital as they have tremendous impact on the design, spacing and sizes of these motors.
Singh, Bhuvaneshwar, Tirumala, Bhaskar, Badgujar, Swapnil, HK, Shashikiran
Eyes of Robot Operating System for Future Hands2025-28-024611/06/2025
This paper presents a novel approach to automated robot programming and robot integration in manufacturing domain and minimizing the dependency on manual online/offline programming. Traditional industrial robots programming is typically done by online programing via teach pendants or by offline programming tools. This presents a major challenge as it requires skilled professionals and is a time-consuming process. In today’s competitive market, factories need to harness their full potential through smart and adaptive thinking to keep pace with evolving technology, customer demand, and manufacturing processes. This requires ability to manufacture multiple products on the same production line, minimum time for changeovers and implement robotic automation for efficiency enhancement. But each custom automation piece also demands significant human efforts for development and maintenance. By integrating the Robot Operating System (ROS) with vision-based 3D model generation systems, we address
Hepat, Abhijeet
Advanced Manufacturing Processes – Construction Equipment’s2025-28-024311/06/2025
With the global increase in demand for construction equipment, companies face immense pressure to produce more products in a competitive and sustainable way by utilizing advanced manufacturing technologies. Additionally, the need for data analytics and Industry 4.0 is increasing to take better decisions early in the development cycles and during the production phase. Advanced manufacturing processes & adopting Industry 4.0 is the only viable solution to address these challenges. However, the implementation of advanced manufacturing processes in heavy fabrication and construction equipment factories has been slow. A significant challenge is that the products being produced were originally designed for conventional manufacturing processes. When factories are becoming smart and connected through Industry 4.0 solutions, companies must reconsider many established assumptions about advanced manufacturing processes and their benefits. To maximize efficiency gains, improve safety standards
Bhorge, Pankaj, Saseendran, Unnikrishnan, Rodge, Someshwar
Novel Methodology for Assessment of Bolted Joints Under Vibration Fatigue2025-28-028711/06/2025
The smart industrial revolution in any organization brings faster product delivery to the market, which can meet customer expectations and full life requirements without failure. Failure per machine (FPM) is a very critical metric for any organization considering warranty cost and customer perception. One such area which needs a detailed evaluation is bolted joints. Bolts play a pivotal role when integrating a subassembly with the main structure. Often, it is challenging to address bolt failure issues due to vibration induced in structures. Current bolt virtual evaluation methods help to evaluate bolts in simple loading conditions such as axial and bending loads. But it is quite complicated to evaluate the bolts which are prone to vibration loading. Traditional methods of using gravity loads miss out on dynamic characteristics, hence it must be simulated using modal dynamic analysis. With the current vADV (virtual accelerated design verification) method it is not possible to capture
Desale, Amit Nanaji, Singh, Gurwinder, Vhatkar, Rushikesh, Patil, Akhil
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