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Thermal Model of a Traction Inverter for an Automotive Application including DC-link capacitor, power modules and electrical connections2025-01-0519To be published on 11/25/2025
In automotive applications a traction inverter is used for energy conversion between battery and electrical machine. For high performance drives lightweight design is demanded. Additionally, higher efficiency of the inverter results in lower cooling requirements but is often achieved by increasing component weight. Hence, thermal modelling of the components and their interactions is essential to determine the best compromise between weight, efficiency and cooling requirements. In traction inverters the DC-link capacitors, power modules, high voltage electrical connections and low voltage devices dissipate power. In this paper the focus is on the thermal modelling of the DC-link capacitor, power modules and high voltage electrical connections and their system, as the performance of the inverter is defined by these components. The thermal models are derived based on geometries and physical properties. First, the DC-link capacitor thermal model is presented and considers the anisotropic
Blaschke, Wolfgang Maximilian, Mengoni, Leonard, Pflüger, Robin, Kulzer, André Casal
Simulative temperature determination of an electric machine from test bench tests2025-01-0520To be published on 11/25/2025
One of the most important components of an electric vehicle is the drive motor. Induction motors are often used for this purpose. Power losses occur during the operation of these motors, particularly at high speeds. Among other things, this power loss corresponds to the sum of winding losses, iron core losses and mechanical losses. The power losses generate heat, causing 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 by jacket cooling, for example. In this case, 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 prevent the motor from fatiguing prematurely. The temperatures that occur inside the motor during operation are of particular
Schamberger, Stephanie, Reuss, Hans-Christian
Paint Dip-in and Drain-out Analysis for Off-road Applications Using Low Fidelity Versatile Multi-Phase Simulation Practices2025-28-0244To be published on 11/06/2025
In complex manufacturing processes, reliable simulation tools are essential to supplement expensive prototyping and physical testing, optimizing the design stage efficiently. The manufacturing industry seeks solutions for e-coating, which involves optimizing design parameters like tank dimensions, part trajectory, line speed, and geometrical details. New generation CFD tools, such as Creo Flow Analysis (CFA), offer high accuracy, efficient workflows, and short computational times. The goal is to gain insights into how design parameters affect the process and optimize them. CFA provides powerful Volume of Fraction (VOF) multiphase simulation techniques along with body motions in a user-friendly process, enabling quick verification of painting processes or part designs. Surface coating protects industrial products from corrosion and other environmental influences. Electrophoretic coating (e-coating) is a surface engineering process used to coat metallic components. The paint deposition
Rao, Pooja Dhaval, Tirumala, Bhaskar, Soni, Tanushree
Optimizing the structural finite element method based process to evaluate the sustainable human accidental sliding load of automobile airvent knob design made with thermoplastic PC - ABS2025-28-0289To be published on 11/06/2025
The research work elaborated the structural integrity of airvent by skipping the assembly level snap fit analysis of knob to reduce computational complexity of air vent knob sliding test post stopper. During assembly, the strain based mechanical breakage prediction of airvent sliding knob snaps is investigated in prestressed condition. The function of airvent knob is to rotate the vertical fins to divert the air flow as per comfort in intended direction identified by passenger. The airvent knob slides on central horizontal fin on a grove feature provided. Post sliding the knob to extreme end it gets stopped at end of grove feature of H fin. The sliding knob is assembled by compressing it against a silicon rubber elastomer inlay. The compression of inlay produces a constant tension on the knob snaps. The knob assembly has to sustain a passenger accidental and abrupt sliding loads while in stopped condition. The knob snaps in this press fit condition are the weak link in the accidental
Shah, Viren, Wani, Dishant, Miraje, Jitendra
Development of Door Impact Loads Using Frugal use of "Pedal Force Sensor"2025-28-0283To be published on 11/06/2025
The first step in designing or analyzing any structure is to understand “right” set of loads. Typically, off-road vehicles have many access doors for service/getting into cab etc. Design of these doors and their latches involve a knowledge of the closing loads when the door is shut mostly with an impact of varying magnitudes. In scenarios of these impact events, where there is sudden change of velocity within few milliseconds, produces high magnitude of loads on structures. One common way of estimating these loads using hand calculations involves evaluating the rate-of-change-of-momentum. However, this calculation needs “duration of impact”, and it is seldom known/difficult to estimate. Failing to capture duration of impact event will change load magnitudes drastically, e.g. load gets doubled if time-of-impact gets reduced from 0.2 to 0.1 seconds and subsequently fatigue life of the components in “Door-closing-event” gets reduce by ~7 times. For these problems, structures are usually
Valkunde, Sangram, Ghate, Amit, Gagare, Kiran
Enhancing Tractor Operator Comfort and Safety Through Advanced Drive Assistance Features2025-28-0216To be published on 11/06/2025
This paper explains the role of Advanced drive assistance features that have been designed to increase comfort, operational efficiency, and safety in an electric tractor. Prime goal is to address the challenges faced by the operators currently in a variety of agricultural and utility applications. Hill hold and electric parking brake work in tandem to offer unparalleled safety by eliminating the fear of tractor roll back in uneven terrain and surfaces both in launch and normal operational scenarios. Cruise and Creep control in a combination have been designed to reduce operator fatigue and increase productivity.
M, Rojer, Sundaram, Pavithra, Natarajan, Saravanan, Devakumar, Kiran, Muniappan, Balakrishnan
E-Motor thermal management using 2D-3D coupling2025-28-0225To be published on 11/06/2025
In the electrical machines, detrimental effects are resulted often due to the overheating, such as insulation material degradation, demagnetization, decreased lifetime and efficiency of the motor and Joule losses. Hence, it is vital to optimize the reliability and performance of the electric motors (E-Motor) and to reduce the maintenance and operating costs. This study brings the analysis capability of CFD for the air-cooling of an E-Motor powering on E-Machines. With the aggressive focus on electrification across automotive industry, 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 motors. With this study using Ansys Fluent - Maxwell coupling, a complete 3D CFD with CHT modeling of an Electric Motor, including all the key components like the windings, rotor
Singh, Bhuvaneshwar, Tirumala, Bhaskar, Badgujar, Swapnil, HK, Shashikiran
3D Printed Injection Molding Tool: An unique Approach for New product development2025-28-0321To be published on 11/06/2025
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 gear housing cover, demonstrating a 45% reduction in tooling costs and a 75% decrease in tooling development time. Mold life analysis
Gandhi, Sorna Rajendran
Transformative Deep Learning for Image Colorization with Machine Learning-Based Classification2025-28-0317To be published on 11/06/2025
Imagine a user opening a technical manual, eager to troubleshoot an issue, only to find a mix of stark black-and-white illustrations alongside a few color images. This inconsistency not only detracts from the user experience but also complicates understanding. For technicians relying on these documents, grayscale graphics hinder quick interpretation of diagrams, extending diagnostics time and impacting overall productivity. Producing high-quality color graphics typically requires significant investment in time and resources, often necessitating a dedicated graphics team. Our innovative pipeline addresses this challenge by automating the colorization and classification of existing grayscale graphics. This approach delivers consistent, visually engaging content without the extensive investment in specialized teams, enhancing the visual appeal of materials and streamlining the diagnostic process for technicians. With clearer, more vibrant graphics, technicians can complete tasks more
Khalid, Maaz, Akarte, Anurag, Kale, Aniket, Rajmane, Gayatri, Nalawade, Komal
Reduction in Product Development Time by Field-to-Lab Simulation2025-28-0282To be published on 11/06/2025
KEYWORDS: Flywheel Inertia, Clutch system, Gear Box, Tractor application, Instrumentation, data analysis, Design and develop new test methodology. ABSTRACT: Puddling is a crucial process in rice cultivation, involving the preparation of the soil in a flooded field to create a soft, muddy seedbed. There are two classifications for puddling: full cage and half cage. Full cage puddling involves replacing the rear wheels of the tractor with steel paddle wheels, which are used to till the rice paddies directly without any additional implement. In the half cage puddling, the rear wheels remain on the tractor, and a smaller cage or paddle wheel is attached to the outside. Considering the field size, the operator often releases the clutch very quickly after a speed or direction change. This generates torque spikes, which are harmful to Transmission Gears and Clutches. This can lead to gear teeth bending fatigue failure due to repeated higher bending stresses. In this paper, a study related to
Pathan, Irfan Hamidulla, Bardia, Prashant
Arcing simulation in automatic transfer switches2025-28-0284To be published on 11/06/2025
Automatic transfer switches (ATS) play an important role in the providing uninterrupted power to various applications like data centre, hospitals etc. They can be connected between two utility sources, two gensets or a combination of them. It operates when one of the sources to which load is connected to is not available or the preferred source is up. While they do their job smoothly, they internally see harsh conditions. When one of the sources is active and other ATS is disconnecting, an arc is generated. The arc exists when the air medium breaks into ions and electrons at very high temperatures, typically above 10000K. This arc needs to be quenched quickly to avoid damage to the contacts and current carrying conductors. This paper throws light on an inhouse methodology that is developed using commercial tool Ansys Fluent. The physics of arc consisting flow, thermal and electromagnetic fields are modelled. This paper includes the simulation of arc propagation along with the moving
Gaikwad, Nikhil Ravindra, Badhe, Vivek
Applicability of Machine Learning Techniques to Forecast Remaining Useful Life on Excavator Structural Component2025-28-0296To be published on 11/06/2025
Most of the major machines and structural components are designed for fatigue life and at same time it is important to design structural components for no premature fatigue failure. The performance of major machines and structural components are usually tested in controlled environment but in real life components are subjected to fluctuating loads known as fatigue loads which are common causes of failure. Fatigue cracks are common indicators of potential structural failure, and an early stage of crack initiation phase often goes undetected until noticeable performance degradation or failure to the component occurs resulting in a machine downtime. Early detection of Failure and understanding remaining useful life of a component is increasingly more important to customers as it helps in preventive maintenance by timely replacement of a component. This would also result in reducing costs by forecasting time to failure. With recent advancement in science, available data can be analyzed
Velayudhan, Vinod Kumar, ISSRANI, MANOJ, Pawar, Sanket, Goyal, Rakesh
Evaluating the Influence of Material Properties and Hardness on Tightening Torque2025-28-0255To be published on 11/06/2025
A Crawler Dozer is a tracked machine that uses a mounted blade at the front to move materials. Different blades (S-blade, U-Blade, Angle blade, PAT blade) are used for moving large amounts of soil, debris, and stones. Each blade is designed for a specific requirement/application. The blades are equipped with ground engaging (GET) tools, such as cutting bits or a set of cutting bits, to help protect the shovel and other earthmoving tools 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. This will help understand the torque required for specific joints. Several other parameters considered in this study include hardware material, coefficient of friction, end bit and cutting-edge material, and their hardness. Understanding the
Parameswaran, Sankaran Poyyi, Bhosale, Dhanaji, Kumar, Rajeev
Novel Methodology for Assessment of Bolted Joints Under Vibration Fatigue2025-28-0287To be published on 11/06/2025
Bolts are one of the most standardized and preferred machine elements for connection and load transfer. On the other hand, since the mechanics of highly stressed bolted joints and the thread fatigue are complex issues, the design and validation of such joints is frequently carried out with major simplifications and assumptions, leading to either over-engineered solutions or to premature failures of the prototypes. Evaluating bolted joint for fatigue is itself complex phenomenon and with vibration loading it adds further challenges in terms modeling and simulation. Proven and most preferred method for vibration fatigue is modal superposition analysis. One major drawback of this method is its inability to include frictional contact. This leads to change in load path, causing incorrect fatigue life evaluation for these joints. In this paper, author presents two different methodologies to evaluate bolts under vibration fatigue capturing correct physics and load path. • Contact optimization
Desale, Amit Nanaji, Singh, Gurwinder, Vhatkar, Rushikesh, Patil, Akhil
Integrating Self Hydraulic Jacks Under the Chassis for off-Road vehicles, and Utility Task Vehicles2025-28-0264To be published on 11/06/2025
Imagine a futuristic vehicle chassis, sleek, low-slung, and aerodynamic, constructed from advanced materials like high-strength alloys or carbon fiber composites. Underneath this captivating structure, a sophisticated system of self-hydraulic jacks is seamlessly integrated. These jacks, situated adjacent to the four shock absorber mounts, are designed to lift the chassis at the tire areas, ensuring efficient underbody maintenance and quick, safe emergency lifts. The design incorporates an intuitive control system with strategically placed buttons for driver convenience. Whether positioned alongside the steering wheel, integrated near the infotainment display, or mounted within the driver-side door, these controls blend technology and practicality. Integrating Self Hydraulic Jacks Under the Chassis:- • Adjacent to each shock absorber mounting point, a self-hydraulic jack is integrated into the chassis design. Designed to be unobtrusive when not in use, these jacks are built into
Gogula, Venkateswarlu
Influence of Laser Sintered Process Parameters on Crystalline Characteristics and Mechanical Properties of AlSi10Mg Alloy05-19-03-001911/03/2025
The present study examines the influence of process parameters on the effect of strength and crystalline properties of AlSi10Mg alloy with laser sintered process. A detailed work was carried out with the effects of varying the laser power, scan speed, and hatch distance on crystalline structure, hardness, and surface roughness. From the analysis, the improved surface quality and mechanical performance were achieved with a scan speed of 1200 mm/s, a laser power of 370 W, and a hatch distance of 0.1 mm. An increase in hardness, improved surface finish, and reduced porosity was observed with decreased hatch distance. However, the balanced results were obtained for scanning speed of 1200 mm/s and laser power of 370 W. The ideal processing conditions decreased the crystalline size, increasing the overall material strength, when crystalline analysis was carried out. The higher scanning speeds supported improved grain refinement and heat diffusion, with the poor hardness value. With the lower
Shailesh Rao, A.
Development of High-Efficiency, Fully Recyclable eMotors for Light Mobility Applications Produced in the EU2025-32-009811/03/2025
This article presents a new generation of electric motors developed for light mobility and industrial applications. The motor range is based on synchronous reluctance technology using non-rare-earth permanent magnets. Three continuous power levels have been developed: 2, 4 and 6 kW. The challenges related to that motor range is their high continuous performances (cooled by natural convection) under nominal 48V, and reparability easiness without adding complexity. These motors stand out thanks to their competitive manufacturing cost and peak efficiency above 94%, which is a remarkable performance for this power and torque class. A prototype of a 6 kW continuous power has been produced and benchmarked. The experimental test showed a high level of correlation with the simulation calculation.
CISSE, Koua Malick, Milosavljevic, Misa, Mallard, Vincent, Valin, Thomas, De Paola, Gaetano
A Simulation Approach for the Impact Assessment of an Axial Flux Traction Motor Applied on Road Electric Vehicle2025-32-007711/03/2025
In the transition towards sustainable mobility, Circular Design principles are crucial. Electric Motors are subject to continuous innovation to improve efficiency, performance density and reduce externalities associated with their production. Therefore, the choice of technological solutions during design phase must guarantee optimal performance and minimal environmental impact throughout the entire product life cycle: production, use, and end-of-life. In the automotive sector, the use phase is particularly critical since the efficiency of the traction system is directly related to total energy consumption during the life cycle and, consequently, to its environmental impact. This research introduces a simulation-based approach to evaluate the use phase of an Axial Flux Electric Motor equipped with Permanent Magnets (AFPM). While providing high performance for electric traction motors, these magnets are composed of Rare Earth Elements (REEs), e.g. Neodymium, classified as Critical Raw
Guadagno, Maurizio, Berzi, Lorenzo, Pugi, Luca, Delogu, Massimo
Experimental and kinetic study of methane blending on the laminar combustion and emission characteristics of ammonia under various oxygen contents at high temperature and pressure2025-32-006011/03/2025
As a carbon-free fuel, ammonia is one of the alternatives to traditional fossil fuels, but its combustion characteristics are poor, and it is usually optimized by blending methane and increasing oxygen content. However, there are few relevant studies under different conditions under high temperature and high pressure conditions. In this study, the laminar burning velocities (LBV) and flame instability of NH3/CH4/O2/N2 mixtures at high initial temperature (T), high initial pressure (p), various oxygen contents (Ω) and methane energy ratios (α) are analyzed using a constant volume combustion chamber (CVCC). According to numerical simulation, how various oxygen contents and methane energy ratios affect the combustion characteristics of NH3/CH4/O2/N2 mixtures and NOx emission is analyzed. The results show that LBV is positively correlated with T、α、and Ω, and negatively correlated with p. Markstein length (Lb) does not change significantly with T, but increases with α and decreases with p
YU, Yuantao, Dai, Zhizhuo, Hou, Chunlei, Ye, Mingyuan, Zhang, Xiaolei, Cui, Zechuan, Yin, Shuo, Nishida, Keiya
Development of Integrated Forming of New "NMAX" YECVT Parts Using the Plate Forging Method2025-32-000511/03/2025
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
Hongo, Hironari, Tamaru, Shogo, Uda, Shinnosuke
Temperature effect on the static and fatigue performance of thermoset and thermoplastic composites2025-32-000611/03/2025
The growing demand for lightweight, durable, and high-performance materials in industries such as aerospace, automotive, and energy has driven the development and evaluation of thermoset and thermoplastic composites. This study investigates the static and fatigue behavior of one thermoset material and two thermoplastic composites at varying temperatures (-30°C, 22°C, and 120°C) to simulate extreme environmental conditions. Experimental tests were conducted to evaluate mechanical performance and fatigue strength, focusing on the influence of temperature on strength and life cycles. The results highlight the significant impact of temperature on static properties and fatigue behavior, offering critical insights into their application in temperature-sensitive environments. A numerical modeling approach was applied to predict fatigue behavior by incorporating the effects of mean stress and temperature. Different fatigue damage models, including temperature-dependent formulations, were
Chiocca, Andrea, Sgamma, Michele, Franceschini, Alessandro, Vestri, Alessio, mancini, Simone, Bucchi, Francesco, Frendo, Francesco, Squarcini, Raffaele
Higher-strength, higher-toughness die cast wheel material using recycled aluminum2025-32-000711/03/2025
In an attempt to reduce CO2 release from the alloy wheel production, we have developed such an aluminum alloy for casting that satisfies necessary property requirements using recycled aluminum and without heat treatment. The wheel is a critical safety item of the vehicle requiring higher toughness and strength. In many wheels, virgin aluminum containing small amounts of impurities are used to maintain toughness, and the heat treatment (T6), in which quick heating and cooling are conducted after the casting, is applied to provide ensure strength. At the start of this project, we focused on two wheel-manufacturing processes; the production of virgin aluminum and the heat treatment, from which a large amount of CO2 is released. The change from the virgin to the recycled material allows reduction of CO2 release to 1/9. The issue in the use of recycled material is that impurities grow in the metal structures as an intermetallic compounds and lower toughness. To deal with the said issue, we
Suzuki, Noritaka
Impacts of enhanced physics-based estimation modeling for trapped air and EGR estimation in real-time control of hydrogen injection in a PFI internal combustion engine2025-32-004711/03/2025
Hydrogen PFI engines face abnormal combustion issues, especially during transient operation. The air-to-fuel ratio and trapped exhaust gas significantly affect combustion stability and NOx emissions, requiring continuous monitoring. Real-time estimation of the trapped gas composition and thermodynamic state is therefore crucial but challenging. This work introduces a real-time, physics-based Multi-Input-Multi-Output (MIMO) model for accurately estimating trapped air and exhaust gas mass at the intake valve closing (IVC) event. In detail, the estimation model makes use of dynamic in-cylinder and exhaust pressure measurements to accurately model mass flows and heat exchange equations with 0.5 CAD resolution. This allows an extremely high fidelity when modelling the physical properties of the various chemical species along the engine cycle. Moreover, the model calibration appears only in the form of two coefficients implemented on a lookup table for twelve different operating points
Galli, Claudio, Ferrara, Giovanni, Grilli, Niccolò, Balduzzi, Francesco, Romani, Luca, Vichi, Giovanni
Study on the Clarification of the Mechanism of Scooter Centrifugal Clutch Squeal2025-32-002211/03/2025
A centrifugal clutch is used in many machines such as scooters, lawn mowers, outboard motor of boats, brush cutters, and so on. It may produce a shrill sound, similar to a brake squeal, when the clutch engages for starting. In this study, we have proved that this shrill sound, in another word, clutch squeal, is caused by the self-excited vibrations of the centrifugal clutch. And we have also clarified that the clutch squeal can be restrained by employing an asymmetrical shape for the clutch housing. The clutch squeal tends to occur when the centrifugal clutch becomes hot due to repetitive starting and stopping, which causes the friction coefficient of the friction material on the clutch shoe to increase. It is presumable that vibration on the clutch housing generated by the self-excited vibrations is the cause of the clutch squeal. In an attempt to clarify the cause of clutch squeal, we first measured the sound pressure of the clutch squeal and the vibration shapes of the clutch
Yamamoto, Kohei, Iwamoto, Tatsuya, Otsuka, Takashi
The effect of differential humidification and membrane thickness on PEMFC operation2025-32-003911/03/2025
In the recent years, the urgency to decarbonize the mobility sector has highlighted the importance of the electrochemical hydrogen use in fuel cells to complement the battery-based electrification. Hydrogen is as an excellent energy carrier, and low-temperature Polymer Electrolyte Membrane Fuel Cells (PEMFCs) are part of an ever-evolving scenario, with particularly promising use in high energy demand mobility sectors. This paper presents a 3D-CFD study to analyse the behaviour of PEMFCs by examining the role of humidification conditions, covering fully humidified (anode and cathode), anode-only, cathode-only, and fully dry operations. This is simulated for several membrane thicknesses, reproducing a wide matrix of operating conditions and separator choices, and examining their respective effect on the cell’s resistance. In the first part of the paper, a part-specific mesh sensitivity analysis is conducted to establish general validity guidelines for the through-plane and in-plane grid
Scialpi, Leonardo, D'Adamo, Alessandro, Marra, Carmine
Establishing the method for simulation of electric potential in cooling water passages of outboard motors2025-32-000811/03/2025
Producing 3D models of cooling water passages of outboard motors, and calculating distribution of electric potential on the water passage surfaces using BEM, we have developed the new method for simulation of electric potential distribution. The outboard motor is a propulsion system attached to the transom of the boat with steering function. As the water around the boat is drawn in for cooling of the engine, the engine parts are susceptible to severe corrosion. As a means to help prevent corrosion, a part referred to as the anode metal, which has a lower natural potential, is provided. Such a method is called the sacrifice protection because the anode metal corrodes before the engine parts due to the difference of electric potential. Since anti-corrosion currents occur preferentially to areas close to the anode metal, the anode metal is required to be located at the most effective place for corrosion protection. However, there are certain restrictions in the layout of anode metal from
Shibuya, Ryota, Suzuki, Hiroki
Development of CAE Technology for the Design Support of Piston Pin Circlip2025-32-001511/03/2025
This study focuses on the technology for establishing design criteria for the piston pin circlip (hereinafter referred to as "circlip"), which is a component that holds the engine piston pin. The circlip is assembled into the piston by compressing it to the size of the piston circlip groove. However, in high-revving engines, the inertia forces caused by engine rotation can cause the circlip to disengage from the groove, potentially leading to the piston pin falling out and damaging the engine. To prevent this, it is possible to compress the circlip more and increase the reactive force acting on the groove to prevent falling out. However, this countermeasure raises concerns about the deterioration of the assemblability of the circlip. Therefore, it is necessary to establish evaluation criteria that prevent the circlip from disengaging and deteriorationg the assemblability of the circlip. To enable appropriate design of the circlip during the engine specifications review phase, we
Ishizuka, Atsushi, Watanabe, Naoto
Optimization of Arc Welding Parameters for FB590 Hot-Rolled Ferritic-Bainitic Steel with 2.5 mm Thickness05-19-03-001810/31/2025
In this study, the optimization of robotic gas metal arc welding (GMAW) parameters for joining hot-rolled ferritic-bainitic FB590 steel sheets with a thickness of 2.5 mm was investigated. The main objective was to evaluate the effect of wire feed speed and welding speed on the penetration depth, throat thickness, and mechanical performance of the welded joint. A series of welding experiments were carried out with wire feed speeds ranging from 50 cm/min to 100 cm/min and welding speeds ranging from 5 cm/min to 15 cm/min. Tensile and microhardness tests were carried out to evaluate the structural integrity of the welded joints. The results show that increasing the wire feed speed significantly improves the weld penetration and throat thickness, especially at constant welding speeds. The most suitable combination was found to be 70 cm/min wire feed at 8 cm/min travel speed and 100 cm/min wire feed at 12 cm/min and 15 cm/min travel speeds. The microhardness in the heat-affected zone
Babir, Naime, Üzel, Uğur
Dome Profile Optimization and Stress Analysis of Type IV Composite Cylinders Using a CLT-Based MATLAB Program and FEA Validation2025-28-037410/30/2025
Type IV composite pressure (CP) vessels composed of a plastic liner and composite layers require special design attention to the dome region. The cylindrical portion of the composite cylinder is wrapped with composite layers consisting of the 900 hoop layers and low-angle helical layers, whereas the dome surface carries helical layers only. The winding angle of the helical layers being a constant over the cylindrical portion starts to vary from the cylinder-dome junction toward the boss at the top continuously. Along with the winding angle, the composite thickness also varies continuously resulting in a maximum thickness at the top crown region. The complete analysis and layer-wise stress prediction of Type IV composite cylinders for service pressures up to 70 MPa was analyzed by the Classical Lamination theory (CLT)-based MATLAB program. The MATLAB program developed in this work for the dome initially performs the dome profile generation through the numerical integration of the dome
R. S., Nakandhrakumar, Tandi, Ronak, M, Ramakrishnan, Raja, Selvakumar, Elumalai, Sangeethkumar, Velmurugan, Ramanathan
Numerical Investigation of Novel Hybrid Battery Thermal Management System Integrating Angular Fins for Lithium-Ion Batteries2025-28-035110/30/2025
To address the thermal management challenges in lithium-ion batteries-which are associated with safety, real-world driving, and operating cycles, particularly at high discharge rates and in extreme ambient conditions-it is essential to maintain the battery temperature within its optimal range. This work introduces a novel hybrid Battery Thermal Management System (BTMS) that integrating a Phase Change Material (PCM) and air cooling with fins attached to air-channel in PCM side. Unlike conventional approaches that use standard rectangular fins, this study employs angular fins with varying dimensions to enhance heat dissipation. The hybrid system is designed to leverage the high latent heat storage capability of the PCM while ensuring efficient convective heat removal through air cooling. The airflow through the cooling channel accelerates heat dissipation from the PCM, thereby increasing its effectiveness. The angular fins are strategically positioned within the PCM section to enhance
Kalvankar, Tejas, Lam, Prasanth Anand Kumar, Aruri, Pranushaa
Graphene Based Solar Photonic Battery for Aircraft-A Finite Element Based 2D Analysis2025-28-038910/30/2025
Over the past decade, significant progress in nano science and nanotechnology has opened new avenues for the development of high-performance photovoltaic cells. At present, a variety of nanostructure-based designs—comprising metals, polymers, and semiconductors—are being explored for photovoltaic applications. Advancements in the understanding of optical and electrical mechanisms governing photovoltaic conversion have been supported by theoretical analyses and modeling studies. Nevertheless, the high fabrication cost and relatively low efficiency of conventional solar photovoltaic cells remain major barriers to their large-scale deployment. One-dimensional (1D) nano materials, in particular, have introduced promising prospects for enhancing photovoltaic performance owing to their unique structural and electronic characteristics. Nanowires, nano rods, and nanotubes exemplify such 1D nanostructures, offering substantial potential to improve photon absorption, electron transport, and
P, Geetha, Sudarmani, R, c, Venkataramanan, Satyam, Satyam, Nagarajan, Sudarson
Development of Temperature Sensor for Automotive2025-28-039410/30/2025
The work presents a micro-electromechanical system (MEMS) temperature sensor that has been designed using COMSOL Multiphysics 6.0 software for use in predicting the temperature of automotive parts. Due to its versatility, the shape of this design employs a meander, and this involves joule heating physics. It clearly shows the variation of resistance with temperature. For this design, Nitinol nano material is used because of the following advantages: Enhanced Shape Memory Effect, Superior Super elasticity, Increased Surface Area, Increased Surface Area, Improved Biocompatibility, Tunable Properties, Enhanced Mechanical Properties. Nitinol having high strength to weight ratio find its application in aerospace industry. This sensor works based on the principle of temperature dependence of resistance; that is, the resistance of the material increases or decreases based on temperature. It is observed that Nitinol has low von Mises stress, proving the safety nature of the material in
P, Geetha
A Smart Multi-Disciplinary Approach to Evaluate Thermal Insulation Impact on Automobile Mobile Air Conditioning System Performance2025-28-042510/30/2025
Automotive mobile air conditioning (MAC) systems rely on effective thermal insulation to maintain cabin comfort and energy efficiency. However, insulation materials degrade over time due to thermal cycling and environmental exposure, impacting overall system performance. This study investigates the effects of reducing insulation material density (GSM) in critical areas such as the engine firewall, plenum, roof and door panels on MAC system efficiency. A multi-disciplinary approach combining basic engineering calculations, frontloading CAE simulations and targeted experimental testing was employed. Initial calculations provided directional input for cabin heat load analysis, guiding early-stage design decisions. Simulation models were used to predict the impact of insulation reduction on cooling performance, energy consumption and component durability, reducing reliance on iterative physical testing. Experimental validation was then conducted selectively, focusing on critical areas to
Kulkarni, Shridhar, Deshmukh, Ganesh, Joshi, Gaurav, Nayakawadi, Uttam, Shah, Geet, Jaybhay, Sambhaji
Thermal Performance Evaluation Methodology for Wet Clutch: Simulation and Testing Correlation2025-28-037210/30/2025
This paper describes a simulation methodology developed to predict the temperature distribution in separator plate and friction disc of the wet clutch corresponding to given slip power, oil flow rate and clutch geometry for off-highway applications. This study adopts a model-based design approach to understand thermal behavior of the wet clutch. This simulation methodology has been developed in a 1D environment with the right fidelity modeling approach to predict thermal performance of the clutch. This model includes heat flow through conduction and convection corresponding to heat generated due to friction between separator plate and friction material. Lab test includes multiple thermocouples installed on separator plate to capture temperature distribution in radial direction. This methodology has been correlated >90% with test data acquired in the lab. This dynamic simulation model aids to identify the potential root cause of clutch failures and risk mitigation. DOE has been
Kumar, Suneel, Memane, Nilesh, Veerkar, Vikrant
3D CFD Analysis of Flow and Thermal Dynamics of PEM Water Electrolyzer2025-28-035010/30/2025
The proton exchange membrane (PEM) water electrolyzer is an emerging technology to produce green hydrogen due to its compactness and producing high purity hydrogen. This study presents a numerical investigation on multiphase flow dynamics and heat transfer within the anode flow field of a PEM water electrolyzer. Two different channel configurations, i.e., rectangular, semi-circular are considered having same cross-sectional area while keeping the porous transport layer (PTL) thickness constant (which is within the commercially available ranges). Simulations are conducted for various oxygen generation rates and heat fluxes (corresponding to different current densities) and different inlet water flow rates. The effects of channel configurations on pressure drop, flow uniformity, and temperature distribution are illustrated pictorially and graphically. The impact of water flow rates and oxygen generation rates on phase distribution, pressure drop, and temperature profiles, particularly
Dash, Manoj Kumar, Bansode PhD, Annasaheb
Development of Capacitive Pressure Sensor for Automotives2025-28-038710/30/2025
Measurement plays a crucial role in the precise and accurate management of automotive subsystems to enhance efficiency and performance. Sensors are essential for achieving high levels of accuracy and precision in control applications. Rapid technical advancements have transformed the automobile industry in recent years, and a wide range of novel sensor devices are being released to the market to speed up the development of autonomous vehicle technology. Nonetheless, stricter regulations for reliable pressure sensors in automobiles have resulted from growing legal pressures from regulatory bodies. This work proposes and investigates a tribo electric nano sensor that is affected by a changing parameter of the separation distance between the device's primary electrode and dielectric layers. The system is being modeled using the COMSOL multiphysics of electrostatics and the tribo-electric effect. Open circuit electric potential and short circuit surface charge density are two of the
P, Geetha, K, Neelima, Sudarmani, R, C, Venkataramanan, Satyam, Satyam, Nagarajan, Sudarson
Rubber: Fluorosilicone (FVMQ) High Temperature Fuel and Oil Resistant For Seals In Fuel Systems and Specific Engine Oil SystemsAMS7273D (Current)10/24/2025
This specification covers a fluorosilicone (FVMQ) rubber in the form of molded rings.
AMS CE Elastomers Committee
Steel Bars, Forgings, Mechanical Tubing and Forging Stock, 0.92Cr - 0.75Ni - 0.52Mo - 0.003B - 0.04V (98BV40), Aircraft QualityAMS6423K (Current)10/23/2025
This specification covers an aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock.
AMS E Carbon and Low Alloy Steels Committee
TOC99-07-05-0TOC10/23/2025
TOC
Tobolski, Sue
Steel, Welding Wire 2.0Cr - 10Ni - 14Co - 1.0Mo - (0.13 - 0.17C) Vacuum Melted, Environment Controlled PackagingAMS6533D (Current)10/23/2025
This specification covers a premium aircraft-quality alloy steel in the form of welding wire.
AMS E Carbon and Low Alloy Steels Committee
Rubber: Acrylonitrile-Butadiene Rubber (NBR) Fuel and Low Temperature Resistant 60 - 70 Type “A” Hardness For Seals in Fuel SystemsAMS7271K (Historical)10/22/2025
This specification covers an acrylonitrile-butadiene rubber in the form of molded rings, compression seals, O-ring cord, and molded-in-place gaskets for aeronautical and aerospace applications.
AMS CE Elastomers Committee
COUPLING, SHEET METAL, 40° V-BAND, WIDE, STANDARD LATCHAS4751/1A (Current)10/21/2025
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Research on Reflective Characteristics of Road Tunnel Pavement and Low Carbon Energy Saving Technology2025-99-001010/17/2025
Highway tunnel lighting has a key impact on traffic safety and lowcarbon energy saving. Under the same lighting conditions, the brightness and uniformity of the road surface are closely related to the reflection characteristics of the road surface. In this paper, firstly, the brightness of asphalt concrete specimens made of different materials was tested by indoor experiments, and the reflective parameters of asphalt concrete of different colors were compared, and then the images of colored pavement of different colors were collected at the tunnel site, and the brightness and uniformity indexes of the colored pavement and the conventional asphalt pavement were analyzed and compared by using graphic image analysis technology. The results show that when the lighting conditions are the same, the luminance of yellow asphalt concrete is about 2.3 times that of black asphalt concrete, and the luminance of red asphalt concrete is about 1.5 times that of black asphalt concrete, and the use of
Si, Jialai, Wang, Zijian, Wang, Luhai, Ma, Fei, Han, Lulu, Zhang, Zhongbin
Hydrodynamic and Flow Distribution Responses to Integrated River Regulation Measures in the Yangtze River’s Chizhou Reach2025-99-004010/17/2025
River regulation engineering is pivotal for harmonizing flood resilience, ecological integrity, and navigation efficiency in large alluvial systems, particularly under intensified hydrological stressors. The Yangtze River, Asia’s largest fluvial network, has experienced altered hydro-sedimentary regimes and exacerbated channel instability due to cascade reservoir operations, demanding adaptive strategies to stabilize dynamic reaches. This study investigates hydrodynamic and flow distribution responses to integrated regulation measures in the Chizhou Reach—a vulnerable alluvial segment characterized by severe bank erosion, sedimentation-induced flow imbalances, and constrained floodplains. Using a 1:500/1:100 scaled hydraulic model validated under flood and low-flow conditions, we assess synergistic effects of dredging, submerged dams, and flow-regulating groynes. Here we show that dredging the Wanchuanzhou right branch increases its flow diversion ratio by 1.71% (annual average flow
Gao, Jin, Feng, Lilei, Ruan, Junsheng, Lu, Lixin, Yan, Jun
Analysis on the Effect of Assembling Prefabricated Components of Assembled Subway Stations under Different Block Types2025-99-007610/17/2025
With the rise of prefabricated metro stations in metro construction, the selection of its block type has become a key issue under specific stratigraphic conditions. In this paper, three types of prefabricated metro stations (Type 1, Type 2 and Type 3) are studied in the stratum of a metro station in Shenzhen as an example. Through MIDAS GTS NX, a single-ring stratum-structure model is established and the same calculation step is set to analyse the mechanical response of precast component assembly to the concrete at the bottom of the pit and the bottom slab. In terms of the concrete at the base of the footing, the stress of Type 3 has an advantage but the overall fluctuation is complicated, the stress of Type 2 fluctuates greatly and the stress of some nodes is high, and the change of Type 1 is relatively smooth; in terms of deformation, Type 2 and Type 3 settle symmetrically, and the influence of Type 2 is small. For precast structural base plate, stress on type 3 part of the stage of
Xie, Jun, Jiang, Wei, Fan, Xiaomin, Zheng, Pengpeng, Huang, Zhuming, Yang, Zhao
Study on the Fracture Failure Problem of the Height Valve Regulating Rod2025-99-007510/17/2025
The height valve adjusting rod is an important part of the suspension system, used to adjust the height of the train to adapt to the train through the curve, slope or uneven track when the height valve adjusting rod fracture failure, the train’s suspension system can not be adjusted normally, may lead to the height of the train is too high or too low, affecting the stability of the train and the driving safety. In this paper, an underground vehicle height valve adjusting rod fracture failure of the problem was studied and analysed, the specific conclusions are as follows: height valve adjusting rod there are two main vibration frequency, 60Hz and 340Hz, 60Hz main frequency has always existed, and 340Hz vibration frequency are present in part of the interval, but also caused by the vehicle vibration of the main reason for the local larger; height valve adjusting rod stress there is also a significant vibration The main frequency of 340Hz, similar to the vibration characteristics of the
Wang, Chao, Yang, Chen, Pan, Minkai
Road Traffic State Classification Method Based on AutoEncoder and Clustering Algorithm2025-99-004810/17/2025
Urban road traffic state classification is essential for identifying early-stage deterioration and enabling proactive traffic management. This study presents a novel method to accurately assess the traffic state of urban roads while addressing the limitations of existing methods in spatial generalization performance. The approach consists of three key components. First, several indicators are designed to capture the spatial-temporal evolution mechanisms of traffic state, speed freedom, flow saturation, and their variations over time and space. Then, a feature learning module based on an AutoEncoder network is introduced to reduce the dimensionality of the constructed feature set. This enhances feature distinction while mitigating noise effects on classification results. Third, k-means clustering is applied to analyze significant features extracted from the AutoEncoder latent space, categorizing road traffic states into fluent, basic fluent, moderate congested and severe congested
Wang, Xiaocong, Huang, Min, Guo, Xinling, Xie, Jiemin, Zhang, Xiaolan
Decay Analysis of Xinjiang G577 Asphalt Road Performance Based on Exponential Modeling2025-99-005410/17/2025
The accurate prediction of road performance decay is of great significance for road maintenance and management. This paper takes the Xinjiang G577 highway as the research object, collects the measured data of the typical indexes of asphalt pavement since the past years (Deterioration Condition Index (PCI), Technical Condition Index (PQI)), and studies its decay. The model is constructed on the basis of time series1, and the exponential decay model of asphalt road PQI and PCI is derived. The model’s accuracy is then tested by calculating the correlation coefficient, mean absolute error (MAE), and other accuracy tests. The results demonstrate that the model exhibits a high degree of fit.
Tian, Wei, Bai, Haotian, Wang, Taiwei, Wang, Jiayan, Dai, Xiaomin
Composite Materials Handbook Volume 3 - Revision HR-64010/16/2025
The third volume of this six-volume compendium provides methodologies and lessons learned for the design, analysis, manufacture, and field support of fiber-reinforced, polymeric-matrix composite structures. It also provides guidance on material and process specifications and procedures for using the data that is presented in Volume 2. The information provided is consistent with the guidance provided in Volume 1, and is an extensive compilation of the current knowledge and experiences of engineers and scientists from industry, government, and academia who are active in composites. The Composite Materials Handbook, referred to by industry groups as CMH-17, is a six-volume engineering reference tool that contains over 1,000 records of the latest test data for polymer matrix, metal matrix, ceramic matrix, and structural sandwich composites. CMH-17 provides information and guidance necessary to design and fabricate end items from composite materials. It includes properties of composite
Aluminum Alloy, Sheet and Plate, 2.95Cu - 0.75Li - 0.50Mg - 0.30Mn - 0.18Ag (2074-T8), Solution Heat Treated, Stress Relieved, and Artificially AgedAMS4449 (Current)10/16/2025
This specification covers an aluminum-lithium alloy in the form of sheet and plate 0.032 to 0.500 inch (0.81 to 12.70 mm), inclusive, in thickness (see 8.6).
AMS D Nonferrous Alloys Committee
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