Browse Topic: Forming

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Research on the Anti-Icing Characteristics of a Protective Coating Surface in Low-Temperature Environment2026-99-10038/7/2026
In order to improve the polar adaptability of the submarine, a protective coating was applied to a large surface injection-molded part. The anti-icing characteristics of the protective coating under a low-temperature environment were studied using the protective coating as the research object. The contact angle test, freezing time test, and hydrophobic face ice adhesion test between liquid droplets and coating surfaces at low temperatures were completed by controlling variables.The results showed that temperature had a significant impact on the contact angle, with a decrease of 8% to 11% from 25 °C to 0°C, while the droplet salinity only gave a small effect on the contact angle. The inherent properties of coatings and droplet salinity had a huge impact on the ice adhesion on droplets and freezing time.Under the same droplet salinity, there are significant differences in the time of freezing and ice adhesion of droplets on distinct coating surfaces. However, as the droplet salinity increases from 0‰ to 35‰, the droplets on the protective coating surface freeze more slowly, the time increases by 64.7 seconds, and the ice adhesion decreases by 43.9%.
Feng, Shengyao, Zou, Debo, Guo, Chao, Jiang, Yong, You, Chuang, Lu, Bingju
Control and Integration of Multi-Arc Additive Manufacturing System2026-99-09048/7/2026
This research develops a multi-arc cooperative additive fabrication to address the technical challenges of low forming efficiency and insufficient precision in the production of complex components using conventional single-arc additive manufacturing systems. With the core objective of achieving efficient and high-quality production of large high-performance metal parts, the equipment employs a modular architecture, incorporating four core modules: additive fabrication modular, 3D measurement module, subtractive machining module, and central control module. It creatively designs a multi-arc cooperative additive fabrication head assembly characterized by “two contours + one filling” arc layout, enabling synchronized operation of two contour single-wire arcs and an independently developed single-power three-wire oscillating filling arc. This system builds a multi-robot collaborative motion system based on the master-slave control strategy. It realizes time synchronization and trajectory synchronization of additive, measurement, and subtractive robots through the KUKA.RoboTeam software package. Meanwhile, it integrates a laser arc constraint device, a molten pool monitoring system, and a digital process parameter monitoring module. An integrated manufacturing capability of “additive - measurement - subtraction” is formed to enhance the forming efficiency and accuracy of components. Experimental verification shows that the forming efficiency of this equipment reaches 1800 cm^3/h, which is more than three times higher than that of traditional single-arc equipment. The surface roughness of the components is optimized to 41.50 μm, and the forming size error is controlled within ±0.5 μm. It can be adapted to the one-time forming of components with a width of 30 to 150 mm. It provides reliable technical support for the high-performance manufacturing of large metal components.
Zhang, Huadong, He, Tianying, Pan, Huiling, Zhang, Yi, Xuan, Liang
Conventional Friction Stir Extrusion MachineTBMG-555418/1/2026
NASA Marshall Space Flight Center has developed a new small-scale metal extrusion tool, called a conventional friction stir extrusion (C-FSE) machine that may be attached or added-on to a conventional friction stir welding (C-FSW) system. The C-FSE machine uses the heat generation and plastic deformation processes underpinning C-FSW to perform metal extrusion instead of metal joining.
Study on Formulation Design of Solvent-Free In-Situ Curing Liquid Rubber for Vacuum Sealing Materials2026-99-02037/31/2026
This study adopts a solvent-free in-situ molding process, using liquid ethylene-propylene-diene monomer (LEPDM) as the base rubber to prepare vacuum sealing materials. The effects of the blending ratio of EPDM/LEPDM on mechanical properties, processing characteristics, physical-mechanical properties, compression characteristics, and vacuum condensable volatiles were investigated. The influence of lamellar intercalated structural fillers on gas permeability was also examined. The results indicate that the addition of LEPDM significantly reduces the Mooney viscosity, improves filler dispersion, and achieves good processability. When the LEPDM blending amount exceeds 20 phr, significant changes occur in mechanical properties, compression modulus, and compression set, which are related to phase transformation. Vacuum pretreatment and vacuum condensable volatile test results show that the traditional plasticizer DOP exhibits high total mass loss (TML) and collected volatile condensable materials (CVCM). However, when LEPDM is partially used to replace EPDM at a blending ratio of 20 phr, TML ≤ 1% and CVCM ≤ 0.1% can be achieved. With the increase in organically modified montmorillonite (OMMT) content, the gas permeability coefficient first decreases and then increases. When the OMMT content is 15 phr, the material exhibits good gas barrier properties
Han, Xiao, Shi, Lei, Chen, Zongwen, Zhang, Zhaoyang, Cheng, Wei
Adaptability Analysis of The Depth and Curvature Radius of Automatic Fiber Placement2026-99-01127/31/2026
This study explored the relationship between the placement roller and the radius of curvature of the mold. In the production process, it is better to judge the feasibility of placement based on the actual placement profile. It is calculated that when the prepreg with a tow width of 6.35 mm is used for automatic fiber placement and forming, the 4-tow, 8-tow, and 16-tow laying rollers can be laid at a maximum depth of 2 mm. The formulas for the length of the automatic fiber placement roller and the axial radius of curvature of the die are obtained. At the same time, through geometric analysis, a formula for calculating the minimum radius of curvature of the pressure roller is obtained. The finite element software Abaqus was used to simulate the contact of the 4-tow, 8-tow, and 16-tow laying rollers with the minimum axial critical radius of curvature at a 2 mm depth, and output the force curve of the node where the mold surface contacts the pressure roller. It is found that the simulation results are consistent with the calculation results.
Ma, Cheng, Xiu, Zhifeng, Xue, Hongming, Yang, Maowei, Zhang, Pin
A Stress Relief Method Based on a Hybrid Process of Shot Peening and Laser Directed Energy Deposition with the Same Materials2026-99-02327/31/2026
Laser directed energy deposition (LDED) is widely used in various fields due to its fine forming structure and superior performance. However, the characteristics of the hot forming process result in significant residual tensile stress in the formed materials, which affects the capability and useful life of the mechanism accessory. The hybrid manufacturing technology of shot peening (SP) and LDED has a significant influence on the elimination of defects and the improvement in microstructure of formed materials and reducing residual stress, but it also has limitations. To solve the problems, such as the introduction of powders and the difficulty in recycling and classification when using heterogeneous materials for shot peening in hybrid processes, this paper proposes a method of strengthening with the same material, establishes a thermal shot peening simulation model for the hybrid process, and conducts experimental verification. The research finds that the average generated stress of SP in hybrid manufacturing technology is -215.6 MPa, and the thickness of the strengthening layer is about 40 μm. The subsequent hot forming process will eliminate part of the induced stress by SP on the previous deposition, but the deposited stress on the surface is reduced compared with that in the single process. The hybrid manufacturing technology of SP and LDED, based on the same material, effectively utilizes the residual heat from the forming process, providing feasibility for engineering applications.
Zhang, Xiaoyu, Zhang, Min, Li, Dichen, Jiang, Yunfeng, Chen, Xinjin, Fei, Ya, Hu, Ying, Liu, Yuyang
A Data-Driven Model for Predicting Casting Solidification Time and Mold Thermal Stress2026-01-50557/31/2026
This study proposes a data-driven surrogate modeling framework for predicting solidification time and mold thermal stress during low-pressure die casting (LPDC) of aluminum alloy wheels. The methodology employed an optimal Latin hypercube design (OLHD) to sample key parameters including cooling channel geometry and process conditions. A sequential simulation methodology combining ProCAST and Abaqus was implemented to generate a comprehensive dataset of solidification times and thermal stress distributions. Based on this dataset, surrogate models were developed using Support Vector Regression, Kriging, and Polynomial Response Surface Methodology, with their hyperparameters automatically tuned through Bayesian Optimization (BO). The optimized models were rigorously evaluated using four statistical metrics: Coefficient of Determination (R2), Mean Squared Error (MSE), Mean Absolute Error (MAE), and Root Mean Squared Error (RMSE). The evaluation results show that the BO–SVR model demonstrated superior prediction accuracy for both output responses and exhibited exceptional nonlinear fitting capability. This work establishes an effective modeling approach for simultaneous quality and efficiency optimization in wheel manufacturing.
Fuhao, Fan, Zhan, Yunlang, Zhan, Zhenfei, Yang, Yutong, Xiao, Yong, Huang, Shiyao
Numerical Investigation on Semisolid Closed-Die Forging of 6061 Aluminum Alloy Scroll Plate Based on the Arrhenius Constitutive Model2026-99-08367/30/2026
As a key structural component of scroll compressors, the forming quality of the scroll plate directly affects overall performance. To address the issues of high forming load and poor rib filling in conventional processes, this study investigates the semisolid closed-die forging of 6061 aluminum alloy through numerical simulation. Semisolid rheological data were obtained from high-temperature compression tests. We also formulated an Arrhenius-type constitutive model to predict material behavior. This model proved highly reliable, achieving a correlation coefficient of 0.99547 and keeping the average absolute relative error down to 3.67%. By employing both orthogonal experiments and simulations, we evaluated how different process parameters impacted the outcome. This analysis ultimately yielded an optimal parameter combination: a die temperature of 350°C, a billet temperature of 600°C, and a punch velocity of 10mm/s. Under these conditions, the forming load, flow behavior, stress–strain distribution, and temperature evolution were analyzed. The results show complete rib filling, uniform deformation, and absence of defects, providing theoretical guidance for industrial applications of semisolid closed-die forging of scroll plates.
Xiong, Linhua, Zhang, Mengjiao, Chang, Ming, Liu, Boyang, Wang, Yongfei, Zhao, Shengdun
Forming Characteristics of Wavy Fins Fabricated by Plowing Extrusion-Cutting2026-99-08357/30/2026
Metal fins with complex structural surfaces play a crucial role in cooling highly heat-intensive electronic products, and a facile method for fabricating such metal fins is urgently needed. Herein, a simple machining method was proposed for fabricating metal fins with novel waveform structures. The new machining method combined plowing extrusion and cutting (PE-C) processes, enabling one-step fabrication of wavy fins, exhibiting excellent flexibility and efficiency. The combined PE-C tool was first designed and manufactured. Subsequently, experiments for fabricating wavy fins were developed and conducted. Based on this, an in-depth analysis of forming procedures was performed using in-situ experimental insights. Moreover, forming characteristics of wavy fins under key parameters (e.g., the tool rake angle γ^c and the cutting velocity V^c) were discussed. Results show that the novel wavy fins were successfully manufactured by the proposed PE-C method. Wavy fins exhibited excellent, well-developed surfaces with a complete corrugation structure, and their geometric dimensions could be adjusted through processing parameters. The new PE-C method utilized two consecutive stages (i.e., the PE and cutting stages) to achieve the fabrication of wavy fins. The PE stage shaped the uncut metal surface into grooved structures, while the cutting stage transformed the groove structure into a waveform structure. Multiple folding principles, rather than conventional shear deformation, were utilized to achieve wavy fins. Reducing the γ^c and V^c would contribute to obtaining fins with the larger waveform structures. PE-C exhibited excellent potential in the field of heat exchange metal fin manufacturing.
Zhang, Baoyu, Liu, Shudeng, Ye, Zhitong
Analysis of the Hot Forming Behavior of AZ91 Magnesium Alloy2026-99-08387/30/2026
This study systematically discussed the high-temperature flow behavior of the Mg-Al-Zn based AZ91 alloy, which has significant application potential in modern aviation and automotive industries. The study was carried out in the temperature range of 250°C-450°C and the strain rate range of 0.001 s^−1 -0.1 s^−1, which met the typical industrial hot processing environment. The analysis of high-temperature flow behavior shows that the flow stress is inversely proportional to the deformation temperature and is proportional to the strain rate. An important finding is that the constitutive model parameters are significantly sensitive to strain, so the strain-compensated Arrhenius constitutive model is developed. The model shows high accuracy in predicting the thermal flow stress of AZ91, and provides a valuable calculation tool for the simulation and optimization of forming processes in aerospace parts manufacturing. The results show that the extruded original microstructure presents slender fine grains, while the deformed sample shows a temperature dependent transformation: the low-temperature bimodal structure evolves into uniform fine grains at intermediate temperature, and the grains begin to coarsen at high temperature. At constant high temperature, low strain rate promotes grain growth and twin formation, while high strain rate refines grains and inhibits twins, and dislocation slip is the dominant deformation mechanism. These findings provide vital guidance and support for optimizing hot working parameters of AZ91, and are particularly important for manufacturing lightweight components in aircraft structures and automotive systems. The established process performance relationship is helpful to develop energy-saving manufacturing strategies for transportation equipment, and supports the goal of reducing weight and improving performance in the industrial field.
Li, Jusen, Chang, Ming, Zhu, Wenyu, Sun, Haoran, Chen, Kaida, Yang, Xiaoyin, Zheng, Zhenhao, Zhao, Shengdun
Research on the Precision of 2A12 Aluminum Alloy Plate Incremental Forming Assisted by Electric Pulse2026-99-16067/24/2026
This paper introduces the electroplastic effect into the sheet metal incremental forming process, using 2A12 aluminum alloy as the research material. An orthogonal experiment was designed, and the results were analyzed using range analysis and matrix analysis methods. The influence of electric current, frequency, and traditional incremental forming parameters on the forming accuracy of 2A12 aluminum alloy sheets was investigated. The results show that the introduction of pulse current can improve the forming accuracy of 2A12 aluminum alloy sheet. And within a certain range, as the electric current increases, the geometry accuracy of the part is significantly improved. Based on two accuracy indicators—average springback amount and springback angle, a comprehensive analysis determined that the optimal forming parameters are electric current 375 A, feed rate 600 mm/min, step size 0.6 mm, tool diameter 12 mm, and current frequency 400 Hz.
Pan, Fei, Zhao, Quanguang, Huang, Xu, Fang, Jinxiu
Research on the Fabrication of Composite Lattice by the Expandable Mold Method2026-99-16497/24/2026
Advanced composite materials have garnered widespread attention in the aerospace and other fields with stringent weight requirements, owing to their superior properties, such as lightweight, high strength, high modulus, and corrosion resistance. Compared with traditional metal materials, advanced composite materials can reduce structural weight by 30%. Lattice structures possess unique characteristics, including high designability, low cost, and high damage tolerance. As a specialized reinforced structure, they have been identified as one of the key structural configurations for next-generation aircraft. Composite lattice structures, which integrate the advantages of composite materials and lattice architectures, provide an ideal structural material for achieving lightweight and multifunctional aerospace equipment. However, due to the intricate geometries and diverse functional design requirements of lattice structures, the fabrication of these structures presents significant challenges, and there is an increasing amount of research on improving the accuracy and performance of composite lattice structures. The expandable mold process represents an approach for manufacturing composite lattice structures, where pneumatic pressure from rubber expansion enables consolidation of the lattice assembly during elevated-temperature curing to achieve the finished composite part. This study reviews composite lattice structures, verifies the feasibility of using rubber as an expansion mold by investigating the thermal stability and expansion properties, and then prepares composite lattice structures via the expandable mold technique. Additionally, composite lattice structures are prepared using laminated machining, an interlocking process, and a 3D printing process. The advantages and disadvantages of different process methods for forming composite lattice structures are compared, and finally, the future trends in high-performance lattice development are discussed.
Han, Shuhao, Lv, Zhen, Ma, Cheng, Xiu, Zhifeng, Song, Yanhua
Methods for Determining Plastic Deformation in Sheet Metal StampingsJ863_202606 (Current)6/23/2026
This SAE Recommended Practice describes methods for determining plastic deformation encountered in the forming or drawing of sheet steel.
Metals Technical Committee
Metal Injection Molded Nickel Based Alloy 718 Parts Hot Isostatically Pressed, Solutioned and AgedAMS5917 (Current)6/19/2026
This specification covers a corrosion and heat-resistant nickel alloy in the form of metal injection molded (MIM) parts.
AMS F Corrosion and Heat Resistant Alloys Committee
Improvement of rCF Behaviour through the Introduction of NF2026-37-00396/9/2026
This study investigates the structural improvement of recycled carbon fibre composites through hybridisation with continuous flax fibres to address sustainability concerns and performance limitations. Recycled carbon fibres, while environmentally beneficial, suffer from short, randomized orientations and lower mechanical properties limiting their application beyond decorative uses. This research explores whether incorporating unidirectional flax fibres can enhance rCF behaviour for structural applications. Six hybrid composite layup variants and two plain composites were manufactured using cold compression moulding with Ampro Bio Resin. Each hybrid configuration comprised eight layers, divided into four layers of recycled carbon and four layers of flax fibres oriented at 0°. Complete mechanical characterization was performed following ISO standards for tensile (ISO 527), flexural (ISO 178), and impact (ISO 179) testing. Results demonstrated significant performance improvements in hybrid composites. Among hybrids, layup 2 achieved 212.5 MPa tensile strength whilst layup 3 managed to achieve 20.5 GPa in stiffness. Flexural testing revealed layup 6 achieved the highest flexural modulus of 19.6 GPa among hybrids. Impact resistance improved dramatically with layup 3 demonstrating 186% improvement in energy absorption over recycled carbon fibre. The study confirms that hybridisation creates a positive effect, producing more predictable and durable materials. The complementary behaviour between brittle and ductile materials enhances damage tolerance and structural integrity, establishing a foundation for sustainable engineering materials suitable for automotive applications without compromising reliability.
Hnatyk, Dawid, Chrysanthou, Andreas, De Vuyst, Tom, Ismail, Sikiru
Drilling Studies on Sustainable Lightweight Hybrid Polymer Matrix High-Performance Nanocomposites2026-26-07326/1/2026
Worldwide, engineers are exploring the possibility of using polymer composites in their quest for lightweight materials. In this study, injection moulding was used to develop a biodegradable polymer PLA composite containing 20 wt.% vetiver fibers (VFs) and 2 wt.% nano-silica (nSiO2) obtained from pearl millet, which is sustainable. Materials need machining as secondary operation that required joining. Desirability analysis was used to examine and optimize machining (drilling) studies that were designed with Taguchi's design (L9 orthogonal array). Surface roughness (SR) and delamination factor (Fd) were taken as outputs, while spindle speed (SS), feed rate (FR), and drill diameter (DD) were the inputs. Drilling studies were performed on a single vertical machining center (VMC). ANOVA identifies that the FR had the most decisive influence on SR (F=559.24, p=0.001785), followed by DD and SS. FR is the dominant contributor to Fd (F=379, p=0.00263), followed by SS and DD. At low SS and high FR, excessive thrust and heat cause fiber-matrix tearing and poor hole finish. Higher SS softens the PLA matrix, improving surface quality. Fd decreases with increasing SS, whereas it rises with extreme FR and DD due to elevated thrust and matrix cracking. The optimized parameters SS of 3000 rpm, FR of 15 mm/min, and DD of 6 mm achieved a maximum combined desirability of 1. A non-traditional meta-heuristic technique, the frog leaping algorithm (FLA), is adopted to optimize the inputs based on the developed regression model. FLA also provides the identical optimal condition as the desirability function, predicting the outputs SR=2.2195 μm and Fd=1.0383, which are very close.
Senthilkumar, N.
Evaluation of Thermal Behaviour of Ramie Fiber/Delrin Composites for Aircraft Cabin Components2026-26-07546/1/2026
This research investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5-20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via the injection moulding technique. Glass transition temperature (Tg), thermal conductivity, Vicat softening temperature (VST), heat deflection temperature (HDT), melt flow index (MFI), and coefficient of linear thermal expansion (CLTE) were the various thermal characteristics of the sustainable composites that were systematically evaluated as per the ASTM standards. The addition of RF drastically altered the Delrin matrix's performance. Among the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values, which provide greater dimensional stability at high temperatures; lower CLTE, resulting in less thermal expansion; comparatively better thermal conductivity; and improved heat dissipation. Eventually, there was a moderate drop in the MFI, indicating more rigid polymer chains that restrict the flowability of the composite, thereby increasing its heat-withstanding capabilities. DSC analysis revealed a slight upward shift in Tg and increased crystallinity, suggesting restricted polymer chain mobility and enhanced load transfer at 20 wt.% RF loadings, agglomeration effects, and weaker interfacial bonding with the matrix led to deterioration in properties. Aircraft cabin components like interior panels, ducting supports, and lightweight non-structural fittings requires dimensional stability, thermal resistance, and mechanical reliability under fluctuating flight conditions.
S, Thirumalvalavan, Senthilkumar, N., Selvarasu, S
Reducing Test Campaigns through Advanced Yield Surface Modeling for New Aircraft Metal Grades2026-26-07556/1/2026
Qualification of new aerospace alloys requires extensive mechanical testing to capture anisotropy and ensure reliable performance under complex loading conditions. This process is costly and time-consuming, particularly with emerging manufacturing routes such as additive manufacturing. Advanced yield surface prediction offers a route to reduce test campaigns by linking microstructural features to macroscopic constitutive models. In this work, Digimat is employed as a multi-scale material modeling platform to generate yield surfaces of polycrystalline metals using computational homogenization. Representative volume elements (RVEs) are constructed from experimental texture and grain morphology data, and their response under multiaxial loading is simulated using a crystal plasticity framework. The computed yield loci are then fitted with phenomenological functions (e.g. Yld2000-2D), enabling calibration of anisotropic yield models from virtual testing. As a case study, an AA6016-T4 sheet with strong cube texture is modeled and validated against experimental data, including yield stresses and Lankford coefficients in multiple directions. The predictive capability of the approach is further assessed through a cup drawing simulation in Simufact, where earing behavior is accurately reproduced. These results demonstrate that digital yield surface prediction can capture anisotropic plasticity and provide reliable input to forming simulations while significantly reducing experimental requirements. This capability lays the foundation for more efficient alloy qualification, with direct impact on fatigue and damage tolerance modeling in aerospace applications.
Padhan, Manas, Uppaluri, Rohith, Lemoine, Guerric, Soni, Ganesh
Design and Multi-Faceted Validation of UAV Arm Clamps, Landing Gear and Motor Mounts via Generative Design in Autodesk Fusion 3602026-26-07346/1/2026
This study presents a comprehensive methodology for optimizing critical UAV structural nodes—specifically Arm Clamps, Landing Gear, and Motor Mounts—using Generative Design (GD) tailored for Fused Filament Fabrication (FFF) with PLA+. Traditional “plate-and-standoff” UAV constructions often utilize orthogonal geometries that induce stress concentrations and fail to leverage the geometric freedom of additive manufacturing. Furthermore, reliance on expensive CNC machining or injection molding creates supply chain bottlenecks for custom or short-run UAV production. While FFF offers geometric freedom, applying it to structural airframe parts introduces challenges regarding anisotropy, layer adhesion, and material brittleness. This research optimizes these components for standard commercial 3D printers by strictly enforcing manufacturing constraints, including a 40-degree maximum overhang and a 0.4 mm nozzle size, to ensure printability without internal support structures. A significant challenge addressed in this work is the “stiffness hogging” artifact observed in hybrid assembly simulations; to resolve this, a rigorous “Isolated Component Analysis” workflow was developed and implemented using high-fidelity Finite Element Analysis (FEA) in Ansys. The results demonstrate that the optimized geometries significantly mitigate stress concentrations found in sharp-cornered baseline parts. Notably, the optimized Arm Clamp maintained a Factor of Safety (FoS) exceeding 3.0, and the optimized Motor Mount demonstrated a 19% increase in stiffness compared to the baseline design, despite using the same material mass. The study validates that with correct geometric optimization, rigorous process control, and conservative safety factors, low-cost PLA+ is a viable structural material for UAVs, offering a reliable, decentralized alternative to traditional manufacturing methods.
Krishna Bansal, Vaibhav
How Machina Labs is Reshaping Defense Manufacturing with AI-Driven 7-Axis Robotics26AERP05_015/1/2026
Machina Labs recently closed its latest round of financing with $124 million, enough to develop a facility featuring up to 50 of its RoboCraftsman cells capable of producing thousands of complex structural assemblies for aerospace and defense customers - a list that already includes Lockheed Martin and the U.S. Air Force, among others. Founded in 2019, Machina Labs is a California-based company that seeks to reinvent metal manufacturing with a robot that uses artificial intelligence (AI) to rapidly form and assemble complex military grade structures directly from digital design files. RoboCraftsman is the company's manufacturing robot that leverages its proprietary “RoboForming” process to integrate multiple manufacturing processes - including metal forming, trimming, scanning, and heat treating - into a single containerized machine.
Comparison of Formability Performance Between CR550LA and CR590DP2026-01-01784/7/2026
While rapid development of advanced high strength steels (AHSS) for a safer and lighter vehicle has been a primary focus in the automotive industry, the application of traditional high strength low alloy (HSLA) steel continues to be actively supported and developed. AHSS are often used to replace HSLA steels for downgauging while maintaining similar or better performance in crashworthiness and durability. However, recent developments have enabled the availability of higher strength, cold-rolled HSLA steels that could offer opportunities for a more balanced solution between material cost and material performance. Certain higher strength HSLA steels not only offer a cost-effective way to increase the strength-to-weight ratio but also provide comparable formability and better weldability to AHSS. In this study, cold rolled HSLA grades of CR420LA and CR550LA are evaluated in overall formability and in-use performance when compared to CR590 dual phase (DP) grade. The evaluations performed include both global and local formability tests such as forming limit curve (FLC) testing, true fracture strain, half specimen dome and hole expansion tests. Experimental results indicate that CR550LA tends to have a slightly better local formability but slightly lower global formability than CR590DP. The results demonstrate these higher strength, cold-rolled HSLA steels can potentially be used to replace CR590DP for certain components.
Shih, Hua-Chu, Brown, Lindsay, Pednekar, Vasant, Shi, Ming, Tedesco, Sarah
Artificial Intelligence in Automotive Stamping – The Latest Industrial Applications and Future Directions2026-01-01794/7/2026
A review of the applications of Artificial Intelligence (AI) in automotive stamping is presented. The focus is on recent AI implementations within the automotive industry. Through this review, the authors aim to capture the current momentum of AI in automotive stamping. The article begins with an overview of the importance and challenges of stamping in the automotive sector, followed by a discussion of key AI technologies applied in this domain. Several industrial applications are then introduced, categorized by their specific use cases. Finally, strategic challenges and future directions are discussed.
Sheng, ZiQiang, Huang, Lu, Asimba, Brian, McCarty, Eric, Whaley, Jason, Cabral, Kleber, Osegueda, Mario, Huang, Xiaosong, Erol, Baris
Wind-Tunnel Investigation of Snow/Ice Drag on a 30%-Scale DrivAer Model2026-01-06044/7/2026
Wind-tunnel tests were conducted using a 30%-scale DrivAer model, in estateback and notchback rear-geometry configurations, to investigate aerodynamic performance changes associated with snow and ice buildup on passenger vehicles. Around 20 snow/ice accumulation patterns were tested, at a Reynolds number of 2.8 × 106 based on model wheelbase, for each of the notchback and estateback variants. 5 additional patterns were tested on the estateback with roof-rack support bars. Snow accumulation was modelled with foam, while ice accumulation was simulated with aluminum tape hand-formed to the desired shape. A simulated full-scale snow thickness of 58 mm on the hood, roof and trunk increased the wind-averaged drag coefficient by 16% for both model variants. With 90 mm of snow, the drag of the estateback variant increased by 19%. Drag changes increased with, but were not proportional to, snow thickness. Chamfered front and rear edges, representing windblown shapes, reduced the drag penalty compared to square-edged snow models. The largest drag increases, of 18% and 20%, respectively, for the notchback and estateback configurations, were due to simulated patchy snow and ice on multiple surfaces. Localized ice/snow patches sometimes caused stronger increases in drag than a similar or larger volume of precipitation elsewhere. Critical surfaces include the A and aft-most (C/D) pillars, the lower-front corners, the leading-edge of the hood and the leading- and trailing-edges of the roof. Simulated snow and ice at more upstream positions often caused higher increases in drag than accumulations further downstream. Drag and base pressure were more likely to be correlated for changes closer to the rear of the model. Some snow/ice patterns were found to increase side force and rolling moment in crosswinds, or to increase lift and change the pitching moment, potentially affecting vehicle stability and traction. The results are intended to support additional studies that will examine the impacts of snow/ice accumulation on fuel/energy use and safety.
de Souza, Fenella, McAuliffe, Brian
Sideslip Angle Estimation for Mining Trucks Based on Real-Time Cornering Stiffness Identification2026-01-06184/7/2026
High-precision estimation of key vehicle–road state parameters is crucial for ensuring the accurate and safe control of mining trucks (MT), as well as for reliable trajectory tracking. Among these parameters, the vehicle sideslip angle is particularly critical for assessing and predicting lateral stability. However, its direct measurement is challenging, and its estimation typically depends on an accurate characterization of tire cornering stiffness. For MT, large variations in loading conditions (from empty to fully loaded) pose significant challenges to sideslip angle estimation due to the resulting nonlinearity and variability of tire cornering stiffness. To address this issue, a novel joint estimation framework integrating the Moving Horizon Estimation (MHE) and Square-Root Cubature Kalman Filter (SCKF) is proposed to simultaneously achieve high-precision estimation of both tire cornering stiffness for each tire and vehicle sideslip angle. In this framework, the cornering stiffness of the front, middle, and rear axles is identified and updated in real time using MHE through a forgetting-factor least squares method based on yaw rate and lateral acceleration data within a fixed-length time window. The updated stiffness is then incorporated into the SCKF for accurate estimation of the sideslip angle. This sequential process effectively establishes a coupling between the estimation of the two parameters, forming an integrated joint estimation mechanism. The proposed framework is validated on the TruckSim–Simulink co-simulation platform, and the results confirm its superior accuracy and robustness, demonstrating its potential to improve the safety and control performance of MT.
Xia, Xue, Shen, Peihong, Jiao, Leqi, Li, Tao, Chen, Huiyong, Zhao, Kun, Jiao, Leqi, Zhao, Zhiguo
Development of Automotive Hood Using Multi-Material Double Injection Molding – An Overview2026-01-04764/7/2026
This paper presents the multidisciplinary development of a hybrid automotive hood manufactured using double-shot injection molding with overmolded brackets. Conventional steel and aluminum hoods, while structurally reliable, pose challenges in terms of weight reduction, pedestrian head protection, and manufacturing cost. Composite and thermoplastic alternatives supported by computational analysis and advanced molding processes provide opportunities to address these challenges. Finite element analysis (FEA) was employed to evaluate torsional and bending stiffness, locking load, and crashworthiness, while pedestrian headform simulations following ECE R127 and EEVC WG17 guidelines were conducted to assess compliance with safety regulations. Adhesion and bonding strength of overmolded polymer–polymer interfaces were studied to validate manufacturing feasibility. Results confirm that hybrid hoods fabricated using multi-material double-shot molding can achieve weight reductions of up to 30% compared with steel, maintain structural stiffness equivalent to aluminum, meet head injury criterion (HIC) thresholds, and reduce assembly complexity by consolidating brackets and reinforcements into a single integrated structure.
Ganesan, Karthikeyan, Seok, Sang Ho, Jo, Hyoung Han
Development of an Advanced Tensile Testing Method for HDPE Composites in High Draw Molded Hollow Circular Regions: Effect of Sample Preparation, Asymmetry, Thermal Conditions, Pull Speeds and Fixture Parameters2026-01-02044/7/2026
High-Density Polyethylene (HDPE), Low-Density Polyethylene (LDPE) and Ethylene Vinyl Alcohol (EVOH) composite, particularly in high draw molded hollow circular configuration, present unique challenges in evaluating mechanical performance under tensile stress due to anisotropic deformation, geometric asymmetry, and localize thermal gradient. This study introduces an advanced tensile testing methodology designed specifically to assess such regions with greater precision and reproducibility. The method incorporates refines sample preparation protocols, tailored fixture geometry, and adjustable pull speed to accommodate varying thermal histories and draw ratios inherent to molded sections. Systematic variation of asymmetrical, temperature conditions, and clamping techniques revealed significant impact on tensile strength, elongation at break, and strain distribution. Findings emphasize the necessity of customized testing frameworks for molded composites geometries and demonstrate that fixture alignment and thermal conditioning are critical to mitigating error and enhancing material characterization. This approach offers a robust path forward for industrial applications requiring reliable evaluation in complex HDPE, LDPE, and EVOH composite structure.
Bhalerao, Saurabh Shankar
Design Optimization and Dimensional Tolerance Improvement of Expanded Polypropylene (EPP) for Enhanced Automotive System Integration2026-01-02484/7/2026
Historically, EPP has required larger dimensional tolerances and much thicker cross-sections than solid plastics produced by injection molding, vacuum forming, and blow molding. This has proved challenging when attempting to incorporate EPP into a wider variety of automotive applications. JSP has developed multiple grades of EPP that achieve tolerances at thinner cross-sections, once considered difficult to attain. These grades expand the potential for automotive applications by combining the established benefits of EPP with improved dimensional precision. This tighter control enables advances in part design and performance, including reduced wall thicknesses, improved surface appearance, reduced weight, lower cost, part consolidation, and more efficient molding with an improved processing window, resulting in faster cycle times and reduced utility consumption. At the vehicle level, these improvements contribute to lighter overall weight for reduced carbon footprint, as well as increased cargo space by taking advantage of EPP parts with thinner cross-sections. Using current production equipment, testing was conducted on physical parts through real-time molding trials with measurements and analysis to confirm the improvements in tolerance and performance described above. Incorporating these findings early in the design phase of a given application will allow automotive engineers to fully leverage these benefits, ensuring optimal part integration, system-level performance, and alignment with corporate sustainability goals.
Sopher, Steven, Parker, Joshua
Anisotropic Mechanical Property Simulation of Fiber Reinforced PEEK Using Composite Theory and Comparison to Experimental Results2026-01-02564/7/2026
The mechanical properties of 3D printed composites have been shown to vary due to the manufacturing infill direction due to artifacts from the printing process. PEEK (Polyether Ether Ketone) and PEEK reinforced with carbon fiber were studied for these experiments because they are widely used for their high strength properties. 3D printed composites that behave with anisotropic characteristics have been evaluated under Laminate Composite Theory (LCT), which can be used to determine the mechanical properties of these 3D printed composites. By changing the orientation of the extruded strands in a 3D printed part, the structure can be optimized in a specific orientation for specific loading conditions, and LCT can be applied for simulating mechanical responses. Three point bending tests were performed on rectangular 3D printed samples and compared to a 3D simulation using LCT for a similar bending load. This allows for the use of LCT in combination with a finite element software such as ANSYS to optimize the design of the 3D printed composite for specific loading conditions without the need of destructive testing. This approach can save time and materials if the simulation testing is proven to be consistent and has been verified using three point bending experimental results. The analysis of the experimental data found that the orientation of the stacking sequence caused a change in the flexural modulus with a maximum percentage difference of 177.63% for the carbon fiber reinforced PEEK and 5.85% for the regular PEEK. Tabular data and plots were created to compare the accuracy of the simulation data with the experimental results. The simulation used LCT to predict a modulus that was compared to the modulus of the recorded data. This was done to compare and confirm the accuracy of the simulation using LCT, the results showed that the largest percentage difference for PEEK CF is 7.774% in the 60 degree orientation and for PEEK the largest difference is 3.166% in the 30 degree orientation. The results show that a product can be printed in an orientation to improve mechanical properties of 3D printed parts with known loading conditions and allow for design and optimization using LCT.
Bradley, Coilin, Garcia, Jordan, Sibley, Brian
Modification of Composite Cathode for Sulfide-Based All-Solid-State Batteries2026-01-70372/27/2026
All-solid-state batteries (ASSBs) based on sulfide electrolytes hold great promise for next-generation energy storage, yet their performance is critically constrained by unstable cathode–electrolyte interfaces. Here, we report a dual-modification strategy utilizing ionic liquids (ILs) in combination with lithium salts to simultaneously improve interfacial wettability, ionic transport, and electrochemical stability in NCM811 composite cathodes. Three ILs (EMIMTFSI, Pyr₁₄FSI, and PP₁₃FSI) and three lithium salts (LiTFSI, LiDFOB, and LiBOB) were systematically evaluated and screened. While neat ILs improved initial capacities by reducing solid–solid contact resistance, they also triggered parasitic reactions with sulfides, resulting in capacity fading. Among the lithium salts, LiBOB was identified as the most chemically compatible additive, forming thin and uniform hybrid interphases enriched with B–O species. This interphase effectively suppressed high-voltage side reactions and reduced electrode polarization. Strikingly, the synergistic combination of PP₁₃FSI and 1 wt% LiBOB transformed discontinuous point contacts into continuous ionic pathways, yielding a discharge capacity of 165.9 mAh g-1 and maintaining excellent stability over 100 cycles at 0.1C. This work highlights a rational IL–Li salt pairing strategy that not only overcomes intrinsic limitations of sulfide-based composite cathodes but also provides a generalizable route to interfacial design in ASSBs. By integrating molecular-level ion transport regulation with interphase stabilization, our approach offers practical guidance toward realizing high-energy-density, long-cycle-life solid-state batteries.
Gu, Yu-Yang, Tian, Shi-Yu, Qi, Ji, Yang, Li-Peng, Zhan, Wen-Wei, Yang, Xiao-Guang, Yi, Yong
Vibrational Analysis of Hybrid Composite Laminated Plates of E – Glass and Areca Fibers with Brake Pad Waste Powder2026-28-00732/12/2026
This study focuses on the vibration analysis of hybrid composite laminated plates fabricated from E-glass Fiber and areca Fiber reinforced with epoxy resin. The hybrid laminates were prepared using the Vacuum Assisted Resin Transfer Moulding (VARTM) process with different stacking sequences and Fiber ratios, where brake lining powder was also incorporated as a filler in selected configurations to enhance mechanical and damping properties. The fabricated plates (280 × 280 mm) were subjected to experimental modal analysis using an impact hammer and accelerometer setup, with data acquisition carried out through DEWESoft software. Natural frequencies and damping ratios were determined under three boundary conditions (C- C-C-C, C-F-C-F, and C-F-F-F). The results revealed that Plate 1, with E-glass outer layers, areca reinforcement, and filler addition, exhibited the best vibration performance, achieving a maximum natural frequency of 332.8 Hz under C-C-C-C condition, while Plate 2 showed a balanced response and Plate 3 demonstrated higher stiffness but lower damping capability. These findings suggest that incorporating areca Fiber in combination with E-glass not only reduces weight but also improves damping without significantly compromising structural integrity. The developed hybrid composites hold strong potential for lightweight, vibration-sensitive applications such as automotive interiors, marine structures, construction panels, and sports equipment, where both sustainability and performance are critical.
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, R G, Ajay Krishna, Ng, Bhavan
Magnesium Alloy, Extrusions, 6.5Al - 0.95Zn (AZ61A-F), As ExtrudedAMS4350P (Current)2/6/2026
This specification covers a magnesium alloy in the form of extruded bars, rods, wire, tubing, and profiles.
AMS D Nonferrous Alloys Committee
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-02801/16/2026
This paper presents a comprehensive numerical methodology for simulating the coupled process-structure behavior of short glass fiber-reinforced, injection-molded thermoplastics. The approach integrates elastoplastic and anisotropic material characteristics using three engineering tools: Moldflow, Digimat, and ABAQUS. It accounts for fiber orientation and injection molding defects, linking to thermo-mechanical performance. This method enables accurate virtual modeling of real-time injection-molded components by transferring anisotropic data from Moldflow to ABAQUS. In this study, short fiber orientation and potential injection molding defects such as weld lines and residual stresses are discussed using Moldflow simulation. Besides, Digimat is employed as an interface tool to facilitate the transfer of Moldflow simulation results, namely fiber orientation and material behavior in the allied configurations directly into ABAQUS. This integration enables the evaluation of thermo-mechanical behavior in injection-molded thermoplastic components, incorporating material anisotropy. The simulation results demonstrate that anisotropic modeling effectively captures the influence of short fiber orientations, revealing localized stress distributions and macroscopic failure indicator results. Outcomes of the current approach are compared with isotropic simulations that exclude injection molding data, highlighting the advantages of incorporating process-induced anisotropy. These findings enhance understanding of the mechanical performance of short fiber-reinforced thermoplastics and provide a foundation for future integration of multi-scale finite element tools. The application of this methodology supports the development of cost-effective and efficient virtual product designs by accurately predicting deformation and failure under various loading conditions.
T, Kalinga, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Tailgate Stiffness Mitigation and Engineering Strategy for Full Width Tailgate-Mounted Tail Lamp Integration2026-26-04941/16/2026
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 Full width 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 lamp volume, thereby providing reduced design space, and intricate mounting schemes constrained by panel 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 presents a comprehensive design and engineering approach aimed at enhancing the modal performance of automotive tailgate systems, with a particular focus on configurations incorporating full width taillamps. The study addresses key structural challenges associated with maintaining stiffness and durability while accommodating complex styling and packaging constraints. By optimizing outer panel joinery, refining mounting strategies, and redefining inner structural reinforcements, the proposed methodology achieves significant improvements in dynamic stiffness characteristics. Experimental and simulation-based evaluations demonstrate a 12% increase in modal stiffness for conventional tailgate architectures and a 45% improvement in coupe-type liftgate configurations. The findings offer valuable insights into the co-development of structural and styling elements in modern tailgate systems, contributing to improved vehicle performance, NVH behavior, and customer satisfaction.
Beryl, Joshua, Mohanty, Abhinab, Unadkat, Siddharth, Selvan, Veera
Incorporation of Strain Hardening and Sheet Thinning Effects during Forming Process for an Accurate Prediction of Buckling Loads on Sheet Metal Axle Parts2026-26-03911/16/2026
In the automotive industry, during the early phase of development, numerical prediction of strength and durability of chassis parts become crucial as these predictions help in design optimization, selecting the appropriate material and identifying potential issues before physical prototypes are built. One of the crucial simulation requirements is the prediction of accurate load carrying capacity or bucking load of axle links. When it comes to the sheet metal axle links there is a deviation in the hardware test and CAE results for load carrying capacity due to the non-integration of forming effects in the numerical simulation, resulting in overdesign of parts, increased costs and development time. This study aims to address these challenges by integrating forming effects experienced by the part during forming process into static strength simulations. These effects include plastic straining, which contributes to material strain hardening and local thickness changes that lead to thinning. Both parameters are critical for accurately predicting the load carrying capacity of sheet metal axle parts. A multi-step forming simulation is carried out on a rear-axle sheet metal link, which involves simulating all the stages of the forming process to accurately predict the plastic strains and thickness changes. The forming simulations are 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, as well as anisotropy coefficients. The output of the forming simulation, Equivalent Plastic Strain (EPS) and thickness data, are then mapped on to the FEA model as initial conditions for static strength calculation.
R B, Govind, Selvaraj, Nirmal Velgin
Development of a GUI-Based Pitch Sequence Optimization Tool for Tire Noise Reduction2026-26-03301/16/2026
Tire noise reduction is important for improving ride comfort, especially in electric vehicle due to lack of engine noise and majority of the noise generated in-cabin is from tire-road interaction. Therefore, the tire tread pattern contribution is one of the important criteria for NVH performance apart from other structurally generated noise and vibration. In this work a GUI-based pitch sequence optimization tool is developed to support tire 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. The key point to be considered in this pitch sequence is that it should be reducing the tonal sound and equally spread i.e., the same pitch cannot be concentrated on one side which may lead to non-uniformity. So, the restriction is that the highest and lowest pitch types cannot occur adjacent to one another. This design rule helps in reducing undesirable pattern non-uniformity and improves both acoustic and structural performance. This tool helps in faster design iteration and integration with downstream development processes. This tool is also validated in current OE projects showing promising improvements in tire noise behavior while maintaining realistic design feasibility.
Sampathraghavan, Lakshmi, Ramarathnam, Krishna Kumar, Mantripragada PhD, Krishna Teja, Ramachandran, Neeraj
Effect of Flow Forming Process on the Mechanical Properties and Microstructure of GDC & LPDC Cast Aluminium Alloy Wheels2026-26-02981/16/2026
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 rim production technique, which 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 enhances strength and durability but also reduces overall wheel weight. This study investigates and compares the mechanical properties of conventional GDC and LPDC cast alloy wheels with flow-formed counterparts, focusing on the rim region. Results reveal that the flow-forming process facilitates a 30% thickness reduction in the rim section. Furthermore, it leads to a slight increase in yield and tensile strength while significantly improving elongation in parallel to the flow-forming direction. The study also examines microstructural changes, including the deformation behavior of silicon dendrites [5].
Singh, Ram Krishnan, Medaboyina, HarshaVardhan, G K, Balaji, Gopalan, Vijaysankar, Sundaram, Raghupathi, Paua, Ketan
Comparative Study of ADC12, A356, and AlSi10Mg Alloys in Sand Casting of EV Battery Housing2026-26-02961/16/2026
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. The objective was to evaluate the filling behavior, solidification characteristics, and final casting quality of ADC12 in sand molds, and to determine its potential for use in applications where die casting is not viable. A comprehensive evaluation was conducted covering key casting parameters: Fluidity and mold filling behavior (evaluated through flow pattern simulations and casting trials) Casting defects and internal integrity (analyzed using real-time X-ray radiography and defect quantification techniques). Density Index (DI) to assess gas entrapment and hydrogen porosity. Mechanical properties, including tensile strength, yield strength, elongation, and hardness (tested according to ASTM standards). Microstructural characterization via optical microscopy and SEM/EDS to examine grain structure, silicon morphology, and intermetallic phases. Fractography of failed tensile specimens to understand failure modes and defect influence. Preliminary results indicate that although ADC12 exhibits higher susceptibility to porosity and reduced ductility in sand cast form compared to A356 and AlSi10Mg, it is still capable of producing structurally acceptable components with optimized gating and venting designs. The study contributes new insights into the adaptability of ADC12 for sand casting, expands the material selection range for low-volume or prototype production scenarios, and provides a technical basis for further optimization of casting parameters to enhance the performance of ADC12 in sand mold applications.
Subramani, Rajesh, Singh, Gajendra, Doddamani, Mrityunjay
Development of a Lightweight Front-End Structure Using Injection Molding Technology2026-26-03041/16/2026
This paper focuses on the development of a lightweight, functionally integrated Front-End Structure (FES) using plastic-metal hybrid injection molding technology. The objective is to achieve modularization, part consolidation, weight and cost reduction. The proposed design integrates multiple components into a single module which makes assembly faster and easier. A mounting strategy with fixation features was added into the structure, which effectively supports various components and sub-assemblies. Component-level Finite Element Analysis (FEA) was carried out which includes static strength analysis, bending and torsional stiffness analysis, modal analysis as well as latch pull test to achieve required structural strength. Ribbing structures were designed and optimized based on FEA result to provide the necessary strength and stiffness to the structure within the minimum weight. Moldflow analysis was carried out to evaluate manufacturability with focusing on gate design, minimizing warpage, and flow balance. Based on Moldflow analysis, necessary design corrections were carried out before tool development for defect-free molding. After validating all performance criteria, the part was manufactured using injection molding process. Compared to conventional sheet metal structures, the thermoplastic FEM achieved an approximate 50% weight reduction while maintaining structural integrity.
Srivastava, Sanjay, Thakoor, Shruti Ghanshyam, Sonkusare, Shailesh
Optimization of Global and Local Formability Properties through Nb Microalloying2026-26-03031/16/2026
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 steels, AHSS (DP, CP, TRIP, TWIP) and PHS, and it has been realized in commercial production of such steels. This contribution details the underlying metallurgical and processing effects of Nb microalloying in automotive high-strength steels and highlights achieved global and local formability improvements. Respective optimization vectors are demonstrated through intrinsic formability mapping, where the possibilities and limitations are indicated.
Barile, Bernardo
Effect of Pipe Bending by Rotary Tube Bending Process on Durability of Frame Structure2026-26-03701/16/2026
Automobile frames, particularly trellis frame structures, are engineered for superior dynamic performance, with stiffness being a paramount consideration1. These frames frequently utilize welded tubes, a manufacturing process made more complex by the necessity of bending tubes to precise angles to meet packaging and assembly requirements2. This bending, however, induces residual stresses that can substantially compromise the frame's durability3. This investigation employs a detailed finite element simulation to analyse the structural deformation and residual stresses that arise during the bending of Cold Electric Welded (CEW) annealed round pipes4. A comprehensive 3D mechanical model, incorporating realistic tooling and contact interactions, was developed to accurately simulate shape change, ovality, and wall thickness redistribution during the bending process5. CEW pipes, unlike their Electric Resistance Welded (ERW) counterparts, possess minimal initial forming stresses, and the annealing process ensures they are stress-free prior to bending, facilitating a more controlled analysis of their deformation6. The simulation results reveal significant geometric alterations in the bent region, including changes in ovality and wall thickness, which are heavily influenced by the bend radius and angle7. The residual stress analysis indicates a combination of tensile and compressive stresses that could jeopardize the pipe's structural integrity8. Furthermore, deformation in the bend zone can lead to welding issues such as uneven fit-up, altered section modulus, and irregular weld profiles, all of which can diminish weld joint performance9. To address these challenges, a conservative approach was adopted in our fatigue analysis using FE-Safe, applying the lower bound of weld material properties to account for potential weld imperfections stemming from bending10. These simulation outcomes are critical for evaluating the fatigue life of weld joints and comprehending how bending affects the pipe's long-term performance11. Ultimately, this research aims to enhance the reliability and efficiency of piping systems, especially in trellis structures, by improving the accuracy of fatigue simulations12. The insights gleaned will aid in optimizing bending processes, refining weld joint designs, and supporting the development of robust tubular structures for demanding applications13.
Rajwani, Ishwar, Khare, Saharash
Electro Magnetic Radiation Analysis for the Vehicle Cable and Shielding Techniques and Performance Assessment2026-26-05631/16/2026
This study discusses the generalized workflow and design techniques for detecting radiated emissions from vehicle electronic systems to ensure an electromagnetic compatible (EMC) vehicle specified by radiated emission standards such as CISPR-12 and CISPR-25. In this work, CST studio suite software is used to examine the vertical polarization in an E vehicle. The results of the radiated emission are plotted as dBμV/m vs Hz to understand the radiation effects generated by different electronic devices across different frequencies. The discussed method serves as a guide for forming a virtual electromagnetic environment where a real vehicle is simulated to study the interference effects and design a suitable filter to reduce the effect of EMI.
Manuelraj, Masilamani, Prasad, Suryanarayana, Narayanan, Siva Suriya
Tire-Tooling Production and Maintenance Monitoring within a Fully Integrated Ecosystem2025-36-001912/18/2025
The work presented here was developed within the scope of the Tire-Tooling Benchmark Project – Mover – FUNDEP – Line IV – in response to demands from the tire manufacturing sector for solutions to monitor tire molds. This study presented the development and validation of an embedded device that integrates RFID technology, wireless communication (LoRa and Wi-Fi), and local processing via an ESP32 microcontroller. The system was capable of collecting and processing data related to mold lifecycle, such as usage cycles, inspections, and maintenance activities, enabling predictive maintenance strategies. A functional prototype was successfully built and tested, validating reliable cycle readings, stable communication with a remote database, and consistent embedded logic. Based on these results, a custom Printed Circuit Board (PCB) was designed, focusing on robustness, compactness, and industrial applicability. Although the PCB has not yet been fabricated or tested in the production environment, the project lays a solid foundation for the next steps, such as field validation and improvements to the digital ecosystem - including the interactive dashboard and future integration with industrial platforms.
Pivetta, Italo Meneguello, Cecone, Eduardo Christiano, Del Conte, Erik Gustavo
Synergistic Effects of Graphene Oxide and Nanoclay on the Structural and Electrical Properties of Automotive Nanocomposite Insulation2025-36-016112/18/2025
As vehicles become increasingly connected and electrified, the demand for high-performance cables and electrical connectors is growing quickly. Electrical insulation materials play an essential role in protecting and insulating those critical components, ensuring reliability, safety and durability. The development of a more robust composite material is essential to promote sustainability and energy efficiency, in both component application and its manufacturing processes. This research explores the development of advanced nanocomposite material for automotive electrical applications. The nanocomposite material comprises low-density polyethylene (LDPE), ethylene-vinyl acetate (EVA), nanoclay (NC) and graphene oxide (GO), processed via melt mixing in a twin-screw extruder. A design of experiments (DOE) was performed using 23, factorial design two levels and three variables (wt.% of EVA, NC and GO), to evaluate the effect of each variable on the material performance. Mechanical tests, (longitudinal stability, tensile strength and elongation at break), electrical insulation (dielectric strength and electrical resistivity) and flame-retardant properties were evaluated. The synergistic effect of GO and NC improved nanofiller dispersion and polymer-filler interactions, leading to enhanced structural integrity and efficiency for such applications. Experimental results confirm that the developed material offers improved resistance to deformation while maintaining excellent processability, that is critical for automotive wiring protection. An optimization of EVA, GO and NC was performed, and the nanocomposite material ensures enhanced insulation, mechanical strength and environmental resistance.
Horiuchi, Lucas Nao, Kerche, Eduardo Fischer, Gonçalves, Everaldo Carlos, Polkowski, Rodrigo
Mechanical Tensile Behavior of Polyester Composites with Addition of Banana and Sugarcane Fibers2025-36-015412/18/2025
Polymer composites with the addition of natural fibers have gained prominence as a sustainable and technically viable alternative to conventional synthetic materials, especially in applications that require a balance between mechanical performance and environmental responsibility. This study evaluated the mechanical behavior of composites produced with plant fibers from banana (Musa sapientum) and sugarcane (Saccharum officinarum L.), both sourced from the northern region of Brazil. The fibers, used in their natural state without chemical treatment, were cut to a uniform length of 5 mm for standardization. The polymer matrix used was unsaturated terephthalic polyester resin, pre-accelerated and catalyzed with methyl ethyl ketone peroxide (MEKP). The molding of test samples was performed manually in silicone molds, according to ASTM D638 specifications, to ensure repeatability and comparability of results. The mechanical tests revealed that the composites made with sugarcane fibers had an average tensile strength of 17.05 (±1.41) MPa, while those with banana fibers reached 28.85 (±0.94) MPa, compared to 26.94 (±4.60) MPa for the pure polymer matrix. These values indicate that the addition of sugarcane fibers resulted in an approximate 36.7% reduction in tensile strength, whereas the use of banana fibers led to an increase of about 7.1% in this property. The results demonstrate the potential of natural fibers added to polymer composites, especially banana fibers, which acted as reinforcement of the matrix, proving to be a technically efficient and environmentally promising alternative for applications in engineering materials.
Santos Borges, Larissa, Dias, Roberto Yuri Costa, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor, Silva de Mendonça, Alian Gomes, Fujiyama, Roberto Tetsuo
Development of a Localized Heat Treatment Route for Stamped Automotive Parts2025-36-008912/18/2025
The increasing demand for sustainable and space-efficient manufacturing solutions in the automotive industry has driven the search for alternative processes to conventional hot stamping. This study proposes a novel localized heat treatment technique based on Joule heating, aiming to reduce the physical footprint of production equipment, simplify the thermal processing of structural components, and minimize the carbon footprint of the process. The method consists of cold stamping followed by localized austenitization of 22MnB5 steel using electrically powered copper electrodes, eliminating the need for large-scale gas-fired furnaces. The process is particularly advantageous in the Brazilian context, where the electric energy matrix is predominantly hydroelectric, contributing to lower CO2 emissions. Experimental trials were conducted using a Gleeble® thermomechanical simulator to optimize thermal cycle parameters (heating rate, austenitization temperature, and soaking time) ensuring the formation of a martensitic microstructure in the treated region while preserving the original ferritic-pearlitic structure elsewhere. The resulting microstructural gradient enables localized mechanical properties, with potential application in crash-relevant automotive components. The proposed route demonstrates technical feasibility and industrial relevance, offering a compact and sustainable alternative to conventional hot stamping.
Santana, Jessica, Curti, Gustavo, Lima, Tiago, Sarmento, Matheus, Callegari, Bruna, Folle, Luis
A New Method to Protect Aircraft Against GPS OutagesTBMG-5429612/1/2025
Dangling from a weather balloon 80,000 feet above New Mexico, a pair of antennas sticks out from a Styrofoam cooler. From that height, the blackness of space presses against Earth’s blue skies. But the antennas are not captivated by the breathtaking view. Instead, they listen for signals that could make air travel safer.
3D Printed Injection Molding Tool: An Unique Approach for New Product Development2025-28-032111/6/2025
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 analysis using PP Glass Filled 30% (PPGF30) and Nylon 66 Glass Filled 30% (Nylon 66GF30) yielded approximately 100 and 25 parts, respectively. We also discussed the challenges encountered during the mold 3D printing and injection molding process. This innovative technique offers broad applicability across plastic part manufacturing industries.
Gandhi, Sorna Rajendran, Gunduboina, Chaitanya
Development of Integral Forming for New “NMAX” YECVT Parts Using the Plate Forging Method2025-32-000511/3/2025
Yamaha Motor Engineering Co., Ltd. provides plastic processing technology based on fuel tank press forming technology, and is developing various plastic processing methods, including forging, and developing mold equipment to realize them. This time, the core parts of the YECVT unit mounted on Yamaha Motor Co., Ltd.'s small premium scooter "NMAX" were not made by welding individual parts to each other, but by integrally forming them from a single thick plate using the cold forming method, resulting in lightweight, compact, high-strength, high-precision parts. By incorporating a composite plastic processing method that takes advantage of the characteristics of the material while making full use of analysis technology and mold technology, we were able to develop a composite plastic processing method (plate forging method) that creates new added value and mass produce it. In addition,this development has made it possible to achieve a thickness increase of 1.7 times the standard material thickness as a mass production method.
Hongo, Hironari, Tamaru, Shogo, Uda, Shinnosuke
Printable Heat Shield Formulations Advance Spacecraft ConstructionTBMG-5412011/1/2025
Innovators at NASA Johnson Space Center have developed additively manufactured thermal protection system (AMTPS) comprised of two printable heat shield material formulations. These formulations are directly applied by 3D printer or other robotic extrusion system and bonded to a spacecraft to devise a heat shield suitable for atmospheric entry. This technology could significantly decrease heat shield or thermal protection system (TPS) fabrication cost and time.
Electrochemical Machining Redefines Knee Implant ManufacturingTBMG-5416311/1/2025
Bruno Boutantin, Extrude Hone
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