Browse Topic: Materials

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Computational fluid dynamic and fatigue analysis of turbocharger turbine wheel2026-28-0070To be published on 02/12/2026
Turbochargers are essential for improving engine efficiency by compressing air and delivering it to the engine at higher pressure, thereby increasing power output. The turbine wheel in a turbocharger operates under severe mechanical and thermal stresses, making it highly susceptible to fatigue failure, which can occur even under conditions below the rated operating load. To ensure long-term reliability, detailed analysis of the turbine’s fatigue life is essential. This study combines computational fluid dynamics with fatigue analysis to predict the performance and lifespan of a turbocharger's turbine wheel, with a focus on Inconel alloys known for their durability in extreme conditions. A numerical mesh analysis, employing 1,165,610 nodes, was conducted to achieve convergence for both temperature and stress evaluations, leading to the selection of a 2 mm mesh size. Pressure contours at the turbine-fluid interface revealed a pressure range between 1.09 and 1.05 bar, with most of the
Chelladorai, Prabhu, Balakrishnan, Navaneetha Krishnan, G, Naresh, T J, Sreejaun
Genetic algorithm based optimization of Chaboche kinematic hardening parameters along with the validation of FE model through characterized crack initiation2026-28-0086To be published on 02/12/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a low voltage (LV) connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for thermo-plastic composite material Ultramid A3U44G6, we have adopted a novel approach of determining non-linear Chaboche Kinematic Hardening (CKH) model parameters from monotonic uniaxial temperature dependent tensile test data of Ultramid A3U44G6. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for Ultramid A3U44G6, here von Mises yield
Basu, Parichay, Srinivasappa, Naveen
Modelling and Analysis of Complex Shaped Cracks2026-28-0048To be published on 02/12/2026
This study offers a thorough analysis using finite element methods (FEA) to examine how fatigue cracks grow in three different materials: Structural steel , Titanium alloy (Ti Grade 2), and epoxy/aramid-based printed circuit board (PCB) laminates. Using ANSYS Workbench, we ran simulations under both static and repeated loading to understand how these materials fracture. The approach was based on Linear Elastic Fracture Mechanics (LEFM), employing the Maximum Circumferential Stress Criterion to predict where cracks might start and how they could spread. Also, the Equivalent Domain Integral (EDI) method helped us calculate the Stress Intensity Factors (SIFs) when cracks are under mixed loading modes. We modeled the growth of fatigue cracks using the Paris Law, relying on material-specific constants (C and m) drawn from previous studies and experimental tests. For example, titanium Grade 2 showed Paris Law constants with C values between 1.8 × 10⁻¹⁰ and 7.9 × 10⁻¹² m/cycle, and m values
T, Lokesh, Bhaskara Rao, Lokavarapu
Mechanical Performance & Vibration Analysis of Hybrid Composite Plates Composed of E - Glass and Areca Fibers2026-28-0073To be published on 02/12/2026
This study investigates the vibration characteristics of hybrid composite laminated plates made from E-glass and areca fibers, targeting applications that demand both mechanical performance and environmental sustainability. The motivation stems from the growing interest in replacing synthetic fibers with natural alternatives in structural applications, particularly for lightweight and vibration-sensitive components. Areca fiber, an abundant and biodegradable natural material, was combined with high-strength E-glass fiber to form hybrid laminates using the Vacuum Assisted Resin Transfer Moulding (VARTM) process. Three distinct composite plates were fabricated with different stacking sequences and filler variations using epoxy resin and brake lining powder. The mechanical integrity and vibrational behavior of these plates were then studied using experimental modal analysis. The tests were conducted under three boundary conditions: fully clamped (C-C-C-C), two-edge clamped (C-F-C-F), and
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, R G, Ajay Krishna, Ng, Bhavan
Galvanic Corrosion Susceptibility Analysis and Mitigation strategies in Automotive Battery Packs2026-28-0018To be published on 02/12/2026
As electric vehicles continue to revolutionize transportation, ensuring the reliability of their powertrain systems and battery packs has become a critical focus. One key challenge is galvanic corrosion, which occurs when dissimilar metals in contact are exposed to an electrolyte, such as seashore moisture or road salt used in snow or ice zones. This corrosion can weaken structural components, compromise electrical conductivity, and reduce the lifespan of critical systems. Common areas at risk include metallic joints within battery enclosures, busbars, cooling systems, and electrical connectors. Environmental factors such as high humidity and temperature fluctuations further amplify the issue, making it a pressing concern for manufacturers. This paper aims to systematically identify critical galvanic joints within electric powertrain systems and battery packs and provide effective strategies to mitigate corrosion risks. Preventative measures include choosing compatible materials with
NARAIN, ADITYA, Venugopal, Sivakumar, Gopalan, Vijaysankar, Varatharajan, Senthilkumaran
TOPSIS-Based Multi-Criteria Optimization of WAAM Parameters for Automotive Component Fabrication2026-28-0026To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) can make huge, complicated metal parts quickly and cheaply, making it popular in the automobile sector. This study uses TOPSIS, a multi-criteria decision-making method, to improve WAAM process parameters such wire feed rate, travel speed, and current. Automotive applications need surface roughness, deposition rate, and dimensional precision, which WAAM-fabricated components must meet. TOPSIS normalizes and ranks experimental findings to find parameter combinations that perform best across many quality metrics. The results show that integrated optimization improves component quality and consistency, making WAAM a feasible and economical sustainable vehicle manufacturing option.
Pasupuleti, Thejasree
Parameter Optimization for Improved Surface Finish in WAAM-Fabricated Steel Structures2026-28-0023To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is a cost-effective and scalable metal additive manufacturing technique widely used for fabricating large metallic components. However, surface finish remains a critical challenge, especially for structural applications where post-processing needs to be minimized. This study focuses on optimizing key process parameters to improve the surface finish of ER70S-6 steel structures fabricated using the WAAM process. Experiments were designed using a statistical approach to systematically vary parameters such as wire feed rate, travel speed, voltage, and inter-pass cooling time. Surface roughness was measured using standard metrology tools, and the results were analyzed to identify the most influential parameters. An optimized parameter set was proposed based on the experimental outcomes, leading to a significant reduction in surface roughness without compromising the structural integrity of the deposited material. The findings contribute to enhancing
PN, Vani
Experimental Investigation of Process Parameter Effects in WAAM of Nickel-Based Alloys2026-28-0027To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is an evolving discipline in metal additive manufacturing characterized by rapid deposition, cost-effectiveness, and centrality to the near-net-shape fabrication of large-scale components. This study will concentrate on WAAM application to deposit nickel alloys, which find extensive use in aerospace, power generation, and marine industries, due to their good mechanical strength, corrosion resistance, and thermal stability. However, some drawbacks in WAAM processing of nickel alloys include thermal distortion, porosity, and residual stress. The research looks at how key WAAM process parameters, including wire feed rate, travel speed, current, and interpass temperature affect geometric accuracy, surface integrity, and mechanical performance of the fabricated components. Microstructural characterization was done using optical microscopy, and hardness distribution was measured as an indication of mechanical uniformity throughout the builds. It is
Natarajan, Manikandan
Selection and Optimization of Process Parameters in Wire Arc Additive Manufacturing for Automotive Structural Applications2026-28-0039To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) has emerged as a promising technology for fabricating large, complex metal structures with reduced material wastage and improved design flexibility. In the automotive sector, WAAM offers significant potential for producing lightweight and high-strength components, particularly for structural applications. However, the quality and performance of WAAM-fabricated parts are highly dependent on the careful selection and optimization of process parameters such as wire feed rate, travel speed, arc voltage, current, and inter-pass temperature. This review focuses on the systematic evaluation of key process parameters influencing the mechanical properties, surface integrity, dimensional accuracy, and microstructural characteristics of WAAM-produced structures intended for automotive applications. The study also explores various optimization techniques—such as Taguchi, response surface methodology (RSM), and artificial intelligence (AI)-based approaches
V, Aravind
Sustainable Machining of Aluminium Alloys: Experimental Insights into WEDM Process Optimization2026-28-0034To be published on 02/12/2026
The most advanced mathematics transforms aluminum alloys into one of the most highly intricate materials into practically any engineering application based on the mechanical properties of ductility and low fatigue sensitivity. The use of aluminum alloys permeates critical industries like aerospace and automotive, besides being strong contenders in other high-performance applications. Their inherent corrosion resistance certainly gives an edge to aluminum alloys for applications in rigorous service environments. Conventional manufacturing processes would not successfully create components with some geometrical complexity; hence, advanced machining processes are being developed. Among them is Wire Electrical Discharge Machining (WEDM), which is increasingly being adopted within the EDM family, as it efficiently machines hard and complex shapes at high accuracy. The present investigation deals with WEDM of aluminum alloy using Taguchi's design of experiments approach, while focusing on
Natarajan, Manikandan
Effect of Minimum Quantity Lubrication during Machining of Incoloy 800H Using Vegetable Oil Enriched With Nano Particles2026-28-0038To be published on 02/12/2026
In this experimental work an effort has made to investigate the machining of difficult to machine Incoloy 800H super alloy. Cryogenically treated textured cutting inserts and vegetable oil enriched with nano particles were used for this study. The turning experiments were performed with different parameters such as Cutting speed, feed rate and depth of cut. Surface Roughness, Cutting Force, Tool-Tip Temperature and Power were the output responses considered. Grey Relational Analysis (GRA) and Analysis of Variance (ANOVA) analysis were used to optimize the machining parameters and to find the most influencing machining parameter on the output responses. The results showed that the optimal machining conditions considered were cutting speed at 35 m/min, feed rate at 0.06 mm/rev and depth of cut at 0.5 mm for the multiple-characteristic performances and it was improved by 3.86 % with this approached method. Also, Tool-tip temperature and Power were reduced during machining with cryo
Natarajan, Manikandan
Enhanced Solar Desalination Using Natural Dolomite-Integrated PCM and MWCN Thermal Storage: An Experimental Study2026-28-0082To be published on 02/12/2026
Systems for solar desalination provide a practical and environmentally friendly way to turn salty or polluted water into drinkable water. Three configurations are experimentally investigated in this study: a traditional solar desalination system, a system integrated with a thermal energy storage unit (TESU) based on phase change material (PCM), Multi wall Carbon nano particle were mixed with PCM at 1% of total volume of the PCM and a system that incorporates powdered natural dolomite into the PCM-based TESU. Each of the four configurations was created, tested simultaneously, and thoroughly examined. In comparison to the traditional system, the experimental findings showed that the adoption of PCM-based TESUs increased daily cumulative water output by 11.41%, 14.8% with addition of MWCNT and the addition of dolomite powder further increased productivity by 18.60%. Furthermore, the energy efficiency increased by16.1% with PCM, PCM with MWCNT is increased by 17.43% and 18.18% with the
R L, Krupakaran, Petla, Ratnakamala, Anchupogu, Praveen, P, Umamaheswarrao, SATYA MEHER, R, Dunna PhD, Vijay
Effect of Sebastiana rostrata Fiber Loading on the Tribological Behaviour of Polycaprolactone Biocomposite.2026-28-0021To be published on 02/12/2026
This study investigates the tribological performance of Sesbania rostrata fibers (SRFs) reinforced polycaprolactone (PCL) composites, focusing on the effects of fiber loading under varying normal loads. Composite samples with fiber contents of 10%, 20%, and 30% were tested at sliding velocities of 0.5 m/s and a fixed sliding distance of 500 m. Results show that the inclusion of SRFs significantly reduces the coefficient of friction (COF) and specific wear rate (SWR) compared to neat PCL, particularly at fiber loadings up to 20%. Beyond this threshold, fiber agglomeration leads to increased wear. The results highlight the potential of SRF/PCL composites for use in wear-critical automotive and orthopedic applications due to improved load-bearing capability and surface resistance.
Raja, K., Senthil Kumar, M.S.
Evolution of a Novel Hybrid Stab-Link for a Born Electric Sports Utility Vehicle2026-28-0001To be published on 02/12/2026
The present study details the design evolution and failure analysis of a novel hybrid stabilizer bar link (stab link) developed for the front suspension of a born electric sports utility vehicle (SUV) platform characterized by higher gross vehicle weight (GVW), increased wheel travel, and constrained packaging space. To address these challenges, a unique hybrid stab link was designed featuring dual plastic housings at both the metal ball joint ends, connected by a steel tube, and achieving a 30% weight reduction while offering enhanced articulation angles for extremely lower turning circle diameter (TCD) of the vehicle, compared to the conventional stab link. The unique hybrid stab failed under complex loading conditions during accelerated durability testing (ADT), prompting a comprehensive investigation. The failure analysis included road load data acquisition across various stab bar diameter configurations evolved during suspension tuning, different stabilizer link designs evolved
SELVENDIRAN, P, J, Ramkumar, NAYAK, Bhargav, M, Sudhan, Patnala, Avinash
Statistical Optimization of Wire Arc Additive Manufacturing Parameters Using Taguchi Methodology2026-28-0035To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) is an emerging metal additive manufacturing process known for its high deposition rates and cost-effectiveness in fabricating large-scale components. However, the quality of the final build is highly sensitive to process parameters such as wire feed rate, travel speed, voltage, and current. In this study, the Taguchi method is employed to statistically optimize key WAAM process parameters with the aim of improving surface finish and mechanical integrity of the deposited parts. An L9 orthogonal array was used to design experiments, and signal-to-noise (S/N) ratios were analyzed to identify optimal parameter settings. Analysis of variance (ANOVA) was performed to determine the significance of each factor on the selected output responses. The results demonstrated that specific combinations of process parameters can significantly reduce surface roughness and enhance bead geometry. The optimized settings obtained through the Taguchi approach provide a
PN, Vani
Parameter Selection Strategies for High-Performance WAAM Structures in Automotive Engineering2026-28-0033To be published on 02/12/2026
Wire Arc Additive Manufacturing (WAAM) has gained traction as an advanced fabrication technique for producing large, structurally demanding components in the automotive industry. Achieving high-performance WAAM structures requires precise control and selection of key process parameters, which directly influence mechanical strength, dimensional accuracy, and surface quality. This study investigates the effect of critical process variables—including wire feed rate, travel speed, current, voltage, and inter-layer cooling time—on the structural integrity of WAAM-fabricated components designed for automotive use. A systematic experimental approach, supported by statistical modeling and optimization tools, was employed to identify parameter combinations that yield optimal results. The outcomes demonstrate improved microstructural uniformity, reduced residual stresses, and enhanced tensile properties in the fabricated parts. The findings serve as a foundation for developing robust parameter
V, Aravind
Niobium Alloyed Brake Disc for reduced NVH and emission control2026-26-0285To be published on 01/16/2026
Recent regulations limiting brake dust emissions have presented many challenges to the brake engineering community. The objective of this paper is to provide a low cost, mass production solution utilizing well known existing technology to meet brake emissions requirements. The proposed process is to alloy the Gray Cast Iron with Niobium. The Niobium addition will reduce wear debris and improve NVH (Noise Vibration Harshness). The test methodology included: Manufacture of disc samples alloyed with Niobium, and Evaluation of airborne wear debris utilizing a pin-on-disc tribometer equipped with emission collection capability. The airborne emission and wear surfaces were further analyzed by Scanning Electron Microscopy, Energy Dispersive techniques (SEM-EDS), X-Ray Diffraction and Optical Microscopy. The cast iron test matrix included four groups; Unalloyed eutectic 4.3% Carbon Equivalent (CE), Unalloyed hypereutectic >4.3% CE, Niobium alloyed Eutectic and Niobium alloyed hypereutectic
Barile, Bernardo, Holly, Mike
Decision-fatigue mitigation in Automotive HMI System2026-26-0652To be published on 01/16/2026
Abstract - With advent of digital displays in driver cabins in commercial vehicles, the drivers are getting offered with many features. Due to availability of vast number of features, drivers face decision fatigue in choosing the appropriate features. Many are unaware of all available functionalities displayed in the HMI System, leading to a bare minimum usage or complete neglect of helpful features. This not only affects the driving efficiency but also increases cognitive load, especially in complex driving scenarios. Instead of manually choosing between multiple settings, the driver can simply activate a recommendation mode, allowing the system to optimize selections dynamically. Novelty of this proposal focuses on introducing Intelligence in HMI Systems in such a way that it will maximize the usage index and reduce decision fatigue in drivers. To achieve this, an AI-driven recommendation system is introduced, based on User Customization and Adaptive Learning Model along with ML
K, Sunil, Dhoot, Disha
Risk assessment of cold side components using quick modal analysis correlation technique.2026-26-0441To be published on 01/16/2026
Abstract: Modal analysis is performed to determine the natural frequencies and mode shapes of a structure or system. It helps engineers understand how a system vibrates and how external forces, such as mechanical loads, might excite unwanted resonances. To check the stresses due to vibration inputs, certain G levels are assumed, and stresses are scaled to those vibration levels. This gives an understanding of the stresses of component with respect to its EFR limit and design margins are calculated. But, assumed acceleration levels in pre-prototype stage level can over predict or under predict the design margins. A quick modal analysis corelation technique can be used by using test measured accelerations conducted at prototype stage of the program. In this work, a modal analysis corelation technique is used to perform risk assessment of intake manifold. The intake manifold failed due to high vibration levels which were not captured from high cycle fatigue analysis with assumed G-level
Bale, Shrikant Bhaskar, Bawache, Krushna
Cabin Heat-up Thermal Assessment for Human Comfort in Passenger Car2026-26-0408To be published on 01/16/2026
The HVAC (Heating, Ventilation and Air conditioning) system is designed to fulfil the thermal comfort requirement inside vehicle cabin. Thermal comfort is significantly subjective which predominantly dependent on occupant’s physiological condition. Vehicle AC performance is evaluated by air flow and local temperature thus, thermal comfort assessment is carried out by mapping of velocity and temperature at various places inside cabin. There is need to have Simulation methodology for heating cabin during cold climate to assess ventilation system effectiveness. Thermal comfort modelling involves human manikin, complex cabin material along with environmental condition in expensive transient simulation. Present study employed with LBM (Lattice-Boltzmann Method) based PowerFLOW solver coupled with finite element based PowerTHERM solver to simulate the cold soaking and heating up of cabin. Thermal comfort is subjective to human physiological modelling thus in-built Berkeley human comfort
Baghel, Devesh Kumar, Kandekar, Ambadas, Kumar, Ravi, Dimble, Nilesh
Lightweight Cascade Design Using Type IV Cylinders for Efficient Hydrogen Gas Logistics in India2026-26-0485To be published on 01/16/2026
Hydrogen mobility in India faces a key challenge in the form of high transportation and logistics costs, particularly in tier-II and tier-III cities where dedicated pipelines are not yet feasible. Current methods using traditional steel based cascades are heavy, inefficient, and limit payload capacity. This paper presents a novel lightweight cascade system designed to enhance the efficiency of hydrogen gas logistics using Type IV composite cylinders and an aluminium structural frame. The design adheres to PESO (Petroleum and Explosives Safety Organisation) standards and achieves a structural weight reduction of 52%, owing to the use of carbon fibre composite cylinders and aluminium framework. Field level analysis demonstrates that the gas transport efficiency is improved by a factor of 2.5 compared to conventional steel based systems when used in heavy duty trucks. This innovation offers a significant step forward in enabling economically viable hydrogen distribution for mobility
Parasumanna, Ajeet Babu, Muthusamy, Hariprasad, Ammu, Vnsu Viswanath, Kola, Immanuel Raju
FATIGUE FAILURE ANALYSIS FOR AUTOMOTIVE TRASNMISSION2026-26-0577To be published on 01/16/2026
A fatigue failure in the transmission input shaft was identified during a bench-level endurance test under 2nd gear loading conditions. The test transmission’s input shaft comprises fixed 1st, reverse, and 2nd gears, with the remaining gears mounted as floating. The shaft was subjected to cyclic torsional loads, and failure occurred after a defined number of cycles. Metallurgical analysis revealed a brittle fracture surface with crack initiation at the outer surface, propagating to core in a helical pattern, ultimately resulting in complete shaft fracture. To monitor and replicate the failure, the test setup was instrumented with a Reilhofer Delta Analyzer for early fault detection. TTL signals from accelerometers mounted on the transmission and a bench speed sensor were fed into the system, which generated FFT spectra and trend indices. A warning alarm triggered upon deviation in the trend index, indicating premature damage initiation. The test was subsequently halted for component
Kushwaha, Rakesh, Patel, Hiral, Navale, Pradeep
Accelerating Product Development Life Cycle through Digitalization of Fatigue Life for Structural Components2026-26-0496To be published on 01/16/2026
In today’s competitive market, accelerating product development without compromising durability is critical. Durability is a key benchmark for assessing the quality and reliability of automotive products. To meet rising customer expectations and regulatory demands, the industry must develop vehicles that offer high performance and reduced weight while ensuring safety. A well-engineered vehicle must retain structural integrity and functionality under normal operating conditions and withstand extreme load events without critical failure. Achieving this requires effective Road Load Data Acquisition (RLDA), integrated with robust design practices and efficient validation processes. However, physical RLDA is time-consuming and costly, as it depends on prototype vehicles that are often available only in the later development stages. Failures identified during these late-stage tests can delay the product launch significantly. To address these challenges, this paper introduces a digital
Kokare, Sanjay, Dwivedi, Sushil, Siddiqui, Arshad, Iqbal, Shoaib
Investigation of Fatigue Durability Failure Mechanisms in High-Pressure Hydraulic Pipes of Power Steering Systems2026-26-0542To be published on 01/16/2026
Abstract—The high-pressure hydraulic pipeline in the power steering system is a vital component for ensuring optimal performance. During warranty analysis, leakage incidents were observed at the customer end within the warranty period. The primary factors contributing to these failures include pipe material thickness, material composition, mechanical properties, and engine-induced vibrations. This study investigates fatigue-related failures through detailed material characterization and Computer-Aided Engineering (CAE) based on real world usage road load data collected. The objective is to identify the root causes by examining the influence of varying pipe thickness on fatigue life. The investigation discovered that crack initiation predominantly occurred on the concave side of bent pipe sections, specifically on the engine-side high-pressure steering line, which is connected to the power steering pump mounted on the engine. Fracture surfaces exhibited characteristics consistent with
Survade, Lalit, Koulage, Dasharath Baliram, Biswas, Kaushik
Study of Style wheel rim failure Due to Rim and disc assembly interference2026-26-0541To be published on 01/16/2026
This study focuses on the investigation of wheel rim failures near weld zone during repeated cornering induced by interference between the rim and disc during the wheel manufacturing assembly process. Strain gauges were employed to capture real-time stress and strain distributions at critical zones during interference fitting. The experimental results revealed that improper interference levels lead to significant stress concentrations, often surpassing the material's elastic limit, initiating micro-crack formation and promoting fatigue failure. Detailed strain analysis indicated that both radial and axial stresses contribute to long-term structural degradation. The study highlights the critical role of dimensional tolerances, surface finishes, and assembly forces in minimizing stress-induced failures. Recommendations are provided for optimizing design and assembly practices to enhance the durability and reliability of automotive wheels.
P, Praveen, DEsigan, Lakshmipathy, K, Chandramohan, C, Santhosh
Improvement study of Style steel wheel durability in Multiple pothole impacts2026-26-0539To be published on 01/16/2026
This study focuses on improving the durability of steel wheel rims subjected to Multiple Pothole which is commonly found in Indian village roads - a critical scenario affecting vehicle safety and wheel lifespan. Initial steel wheel designs often face significant deformation or failure under repeated strikes and resulting in tyre air loss due to wheel bend, prompting the need for enhanced performance standards. In this research, a combination of finite element modelling, experimental impact testing, and material optimization strategies were employed to assess and improve the structural integrity of steel rims. Key parameters such as rim profile geometry & material composition were systematically varied to evaluate their influence on impact resistance. Results demonstrate that strategic design modifications and material enhancements can significantly increase the rim's ability to absorb energy and resist bending without substantial weight penalties. The findings offer practical
DEsigan, Lakshmipathy, P, Praveen, K, Chandramohan, C, Santhosh
Development of Door Impact Loads Using Pedal Force Sensor and First Principles2026-26-0538To be published on 01/16/2026
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
Structural analysis and Design optimization of Cylinder Head of Cummins Light duty Engine for Medium Wheelbase (MWB) pick-up truck2026-26-0495To be published on 01/16/2026
This paper presents the design, structural analysis, and risk assessment done by Cummins to evaluate the structural integrity of Light Duty engine cylinder head for a Medium Wheelbase (MWB) pick-up truck. Initially, Cummins used F2.5L (4-cylinder) engine that has 154hp, but rising market demands for more power, fuel efficiency, lower cost and weight, and future emission compliance led to customer requirements for 177hp (Drive New F2.5L, 15% uprate) and 197hp+ (Drive New F3.0L, 22% uprate) from the same base engine. The increase in power requirement possesses challenges on critical components, especially cylinder heads in terms of thermal and structural limits. This paper addresses the challenges and risks in current cylinder head design driven by new power demands, specifically reduced fatigue margins in the water jacket area and increased temperatures on the combustion face under high thermomechanical loads. It explores the design modifications made to the cylinder head design to
Pathak, Arun Jyoti, Adiverekar, Vaidehi, Singh, Rahul, Biyani, Mayur
Optimization of the Rodip CED Process Suitability through Strategic Fixture System for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-0486To be published on 01/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is latest technology used by Automotive Manufacturers for higher quality corrosion protection in new generation Automobiles. This process involves multiple 360-degree rotation of automotive body in white (BIW) which exert higher hydrostatic forces on large surface panels like Hood. For maintaining consistent gaps & flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel Hood panel while undergoing through this CED process. This study investigates the enhancement of hood panel alignment through strategic optimization of support rod placement and quantity within the Ro-dip CED system. By conducting experimental trials and computational simulations, the research identifies critical deformation points and evaluates the impact of varying support rod configurations on dimensional stability. The outcome results demonstrate that positioning support rods at
Tile, Vikrant, Unadkat, Siddharth, Askari, Hasan, Jadhav, Devidas
Failure Analysis of Dissimilar Metal Weld Joint of an Air Spring Bracket within an Automotive Active Seat Suspension System2026-26-0487To be published on 01/16/2026
In modern four-wheelers, seat suspension systems play a crucial role in enhancing occupant comfort by mitigating the effects of road unevenness and vibrations. Among these systems, active suspension mechanisms offer advanced performance through complex assemblies involving welded, riveted, and bolted joints. This study investigates the failure of an air spring bracket - a critical component of a pneumatic active suspension system - manufactured by Gas Metal Arc Welding (GMAW) of two dissimilar ferrous materials which are likely to be SAPH440 and S355J2. These different materials were used based on mechanical properties required to perform by their particular part. System level validation tests were conducted to ensure the reliability of the seat suspension system. The one of the validation tests is continuous cyclic fatigue test which is carried out on the complete seat assembly. However, during vibration / cyclic endurance testing, premature failures were observed near the weld joints
Patale Jr, Reshma, Pinjari, Jayant Namdev, Bali, Shirish
AI-Driven Stress and Fatigue Life Prediction of Engine Connecting Rods using Geometric Deep Learning2026-26-0633To be published on 01/16/2026
The connecting rod is one of the critical components of the engine which is subjected to complex cyclic loading, demanding precise evaluation of stress distribution and fatigue life. Conventional Finite Element Method (FEM)-based simulations, while accurate, are computationally expensive and time-intensive—especially when iterating through multiple design variations. To address this, we present an AI/ML-based predictive framework using Graph Neural Networks (GNNs) and Geometric Deep Learning (GDL) techniques to efficiently predict stress and fatigue life of the connecting rod. The methodology involves representing FEM mesh data as graph structures, where nodes and edges capture geometric and physical relationships. GNN architectures, including MeshCNN and PointNet++, are trained on historical simulation data to learn spatial dependencies and nonlinear mappings between geometry, load conditions, and resulting stress/life outputs. The framework significantly reduces computation time
Pathan, Mohammed Shakil, K, Karthikeyan, Pilla, Sashanka, S Kangde, Suhas
Early Prediction of CNG Filling Time using Artificial Intelligence for Design Optimization2026-26-0662To be published on 01/16/2026
The CNG fuel system is a critical component in vehicle development and typically includes large-volume gas cylinders (up to 800 liters). As these vehicles often operate over long distances daily, frequent refueling is necessary, making a short gas filling time highly desirable. Currently, CNG filling time is evaluated after prototype development to determine the refueling duration. If the filling time is excessive, design changes to the fuel system are required, leading to significant cost and time penalties and causing delays in the vehicle product development cycle. By integrating AI/ML technology, a mathematical model has been developed based on various influencing parameters. This model will predict CNG gas filling time across all commercial vehicle platforms at the initial Zero design release gateway. This early prediction will enable further optimization to improve gas filling time. The goal of this research work to optimising the filling time for various platform before physical
Choudhary, Aditya Kant, Petale, Mahendra, Dutta, Surabhi, Bagul, Mithilesh
Sensorless Tire Health Monitoring System Based on Machine Learning for Passenger Vehicles2026-26-0670To be published on 01/16/2026
Tire wear is a critical factor in vehicle safety and operational reliability, with worn-out tires contributing to nearly 30% of highway blowouts and a significant portion of tire-related accidents. Traditional tire wear indicators—such as tread wear bars or mileage-based replacement schedules—lack precision, do not offer real-time feedback, and often fail to prevent hazardous situations caused by uneven or rapid tire degradation. These shortcomings underscore the urgent need for intelligent, data-driven solutions in predictive tire maintenance. While earlier efforts have focused on physical models or basic machine learning algorithms, their limited adaptability and poor generalization across platforms reduce effectiveness in real-world deployments. This paper presents a Machine Learning-based Tire Wear Prediction System, designed for both cloud-based analytics and on-vehicle edge deployment. The system predicts individual tire wear using CAN-based inputs, supported by a transfer
Imteyaz, Shahma, Iqbal, Shoaib
Effect of pipe bending by rotary tube bending process on durability of frame structure2026-26-0370To be published on 01/16/2026
For Original Equipment Manufacturers (OEMs), ensuring the overall quality of two-wheeler frames hinges on robust process capability and meticulous design considerations. A comprehensive Computer-Aided Engineering (CAE) simulation approach, integrating manufacturing processes and design elements, is vital for achieving optimal durability. This study focuses on developing such an approach through detailed finite element analysis of Cold Electric Welded (CEW) annealed round pipes used in frame construction. We simulate the bending process, capturing structural deformation and residual stresses. A 3D mechanical model with realistic tooling geometries and contact interactions accurately represents shape changes, ovality, and wall thickness redistribution. Unlike Electric Resistance Welded (ERW) pipes, CEW pipes, due to annealing, offer a stress-free initial state, allowing precise deformation analysis. Simulation results demonstrate significant geometric alterations in the bend zone
Rajwani, Ishwar, Khare, Saharash
A study on the thermal degradation of chlorinated Polyethylene rubber2026-26-0276To be published on 01/16/2026
Elastomeric materials are essential in advanced automotive engineering for mobility, isolation, damping, fluid transfer (cooling, steering, fuel, and brake), and sealing because of their unique physio mechanical properties. Elastomers are commonly used in both static and dynamic components, such as hoses, mounts, bushes, and tires. Engine emission standards and weight optimization have caused higher temperature exposure conditions for automotive components. The steering system uses special purpose elastomers like Chlorinated Polyethylene that can deteriorate under abnormal conditions during vehicle operation or manufacturing process due to the high temperature exposure. Therefore, it is crucial to comprehend the causes and consequences of thermal degradation of elastomers. Thermal degradation is a significant phenomenon that changes the physical and chemical properties of elastomers, which results in a product not meeting functional requirements. This study investigates the thermal
Thiruppathi, Anandhi, Mishra, Nitish, Krishnamoorthy, Kunju
Experimental Study to Investigate and Control Image Blurriness due to IRVM Vibration2026-26-0321To be published on 01/16/2026
Vibration is one of the prominent factors that determine the quality & comfort level of a vehicle. Moreover, if vibration occurs in areas that are almost entirely within customer touchpoints (during either city or highway driving conditions), it could become a critical factor behind the deterioration of brand image within the market. The interior rear-view mirror (IRVM) is one of the important components inside passenger cabin, providing drivers with a clear view of the rear traffic. However, vibrations induced by engine operation, road irregularities, and aerodynamic forces can cause the IRVM to oscillate, leading to image blurriness and compromised visibility and safety. This paper investigates the underlying causes of IRVM vibrations and their impact on image clarity. Through a combination of experimental analysis and computational modelling, we identify key factors contributing to mirror instability. The findings indicate the specific frequencies of vibration, particularly those
Khan, Aamir Naved, Saraswat, Vivek, Jha, Kartik, Singh, Hemendra, Seenivasan, Gokulram, Khan, Nafees
Development of Sustainable Textile Solutions Using Recycled and Bio-Based Materials for Automotive Soft Trims2026-26-0236To be published on 01/16/2026
The shift towards sustainable and circular practices in the automotive industry is driving the development of eco-friendly materials for soft trims. This research explores the development and integration of sustainable textile solutions using recycled polyethylene terephthalate (rPET) from post-consumer waste and bio-based fibers such as banana and bamboo in various fabric forms—woven, knitted, and non-woven. Applications studied include seat fabrics, headliners, parcel shelves, and wheel arch liners. rPET textiles demonstrated promising strength, aesthetic appeal, and durability performance, while significantly reducing carbon footprint. Blends of rPET and virgin PET were optimized to balance properties with sustainability targets. Banana fibre, an agricultural by-product abundantly available in India, was explored for headliner substrates and parcel shelves, offering biodegradability and regional sourcing advantages. Bamboo fabrics, known for their natural antimicrobial properties
Deshpande, Sanjana, Borgaonkar, Subodh
Evaluating the Suitability of ADC12 for Sand Casting: Filling, Solidification, and Mechanical Properties2026-26-0296To be published on 01/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Singh, Gajendra, Doddamani, Mrityunjay
Vehicle interior material emissions and contributions in passenger vehicle cabin air quality2026-26-0287To be published on 01/16/2026
Polymer compounds used in the manufacturing of automotive interiors are formulated with various kind of additives, pigments, fillers, and resins. These compounded polymers are prone to the emission of chemicals called volatile organic compound (VOC) over a period of usage, temperature exposure etc. VOCs include a variety of chemicals, some of which may have short term adverse health effects like nausea, headache, vomiting, and long-term adverse health effects like cancer, even death if beyond the permissible limits. Studies indicates the concentrations of many VOCs are consistently higher in indoors (up to ten times higher) than outdoors and hence these chemical emissions are required to be controlled within the defined limits. This paper is focused on the identification part and material, evaluation against the recommended test (Odor/Fogging/VOC/Carbonyl compound emissions) and development of materials used inside the car cabin. This study further provides the guidelines for the
Shukla, Sandeep Kumar, Balaji, K V, Varatharajan, Senthilkumaran
Developing Advanced CAE Model for Door Glass Regulator Operating Noise Reduction through TEST/CAE Correlation2026-26-0311To be published on 01/16/2026
The importance of performance improvement and weight optimization using CAE in the early design stages of vehicle development has been continuously increasing over the past two decades. And, the accuracy of CAE models plays key role, more efforts are required to improve it. Representation of exact physical model in CAE is still a big challenge for achieving an accurate TEST vs CAE correlation. In this research, the procedure and application of door system model correlation were described to reduce the glass regulator operating noise. The function of a regulator in door system is to open and close the glass. The regulator under improper design creates unwanted noise and discomfort to the passenger. In current door CAE Model, we are unable to identify this real time problem. Therefore, this paper discusses how to correlate door system model according to the assembly stage based on modal correlation and it helped in calculating accurate glass regulator operating noise. As a result, the
Panuganti, Naresh Kumar, Choi, Seungchan
Design optimization of the propeller shaft and transfer case for high-speed 4WD vehicles2026-26-0343To be published on 01/16/2026
Nowadays, vehicle enthusiasts often vary their driving patterns, ranging from driving at very high speeds to off-roading. Due to these driving patterns, 4WD vehicle demand is continuously growing day by day. A 4WD vehicle used to have better traction control with enhanced stability. The 4WD vehicle performance and reliability at high speed are critically influenced by driveline stiffness and natural frequency. Driveline stiffness and natural frequency are very critical parameter for high-speed vehicles, that significantly influenced by the propeller shaft and transfer case. This study focuses on the design optimization of the transfer case and critical frequency of propeller shafts to enhance vehicle performance at high speeds. The analysis begins with a comprehensive study of the factors affecting power transfer path, transfer case stiffness, critical frequency, including material properties, propeller shaft geometry and the boundary conditions. Advanced computational methods are
Kumar, Sarvesh, Yadav, Sahdev, S, Manickaraja, Sanjay, L, Kanagaraj, Pothiraj, Jain, Saurabh Kumar, Deole, Subodh M
Electric mobility and materials circularity - a study of recycled PET textiles for automotive interiors2026-26-0237To be published on 01/16/2026
The adoption of sustainability in electric mobility has made it crucial to investigate environmentally friendly materials. Polymer materials used in automotive application plays very important role in material circularity contributing significant value addition to the overall carbon footprint index. This study discloses the development of recycled polyester textiles from PET bottle waste, use for automotive interior parts and carbon footprint impact. The use of recycled textiles is directly helping the organization in scope 3 emissions to get the lower carbon footprint value by eliminating the use of fossil fuel resources in making the PET textiles. In this study, the development road map methodology adopted, and validation cycle of recycled polyester textiles (PET) were explained broadly with results of different constructions, color and finishes against automotive critical requirements such as sun load UV resistance, abrasion durability, color migrations, soiling resistance
Palaniappan, Elavarasan, Varatharajan, Senthilkumaran, Balaji, K V, Dodiya, Rohanbhai
Predictive Analysis and Risk Management of Nickel-Plated Aluminum Automotive Parts Exposed to Harsh Environmental Conditions2026-26-0305To be published on 01/16/2026
Aluminium is widely used across various industries due to its lightweight properties, high strength-to-weight ratio, and cost-effectiveness. However, its susceptibility to corrosion, particularly in harsh environmental conditions, presents challenges to its long-term durability and performance. To mitigate these issues, nickel plating was applied as a protective measure, creating a barrier to minimize aluminums' direct exposure to corrosive environments and enhance its resistance to degradation. In this study, nickel-plated aluminum was subjected to controlled corrosion testing under simulated real-world conditions, including high humidity, saline atmospheres, and industrial pollutants. The primary objective was to evaluate the effectiveness and longevity of nickel plating as a corrosion prevention method. Periodic observations and measurements were conducted to monitor material changes, such as surface degradation and corrosion product formation. The findings highlight the critical
Narain, Aditya, Venugopal, Sivakumar, Gopalan, Vijaysankar, Varatharajan, Senthilkumaran
Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly2026-26-0302To be published on 01/16/2026
This research paper investigates the failure of an isolator clip used in the seat slider assembly, which guides and restricts the sliding motion of the tooth bracket within the seat. The component is made of C80 high-carbon spring steel, known for its high strength. According to the manufacturing process details, zinc plating was applied to the component for corrosion protection, as confirmed by EDS analysis. A fractographic examination of the failed part revealed a brittle, intergranular fracture morphology with visible cracks. Certain areas also exhibited micro-void coalescence, indicating a dimpled fracture surface. The primary failure mode was intergranular (IG) fracture. The delayed fracture was attributed to intergranular fracture mechanisms, micro-void coalescence, and the high strength of the steel, which made the component susceptible to hydrogen embrittlement. Hydrogen embrittlement occurs when hydrogen atoms become trapped along the grain boundaries, where they form hydrogen
Saindane, Mehul Kishor, Bali, Shirish
Enhancing Factory Modelling: Integrating Drone Technology and Automated Post Processing Systems2026-26-0307To be published on 01/16/2026
The growing environmental, economic, and social challenges have spurred a demand for cleaner mobility solutions. In response to the transformative changes in the automotive sector, manufacturers must prioritize digital validation of products, manufacturing processes, and tools prior to mass production. This ensures efficiency, accuracy, and cost-effectiveness. By utilizing 3D modeling of factory layouts, factory planners can digitally validate production line changes, substantially reducing costs when introducing new products. One key innovation involves creating 3D models using point cloud data from factory scans. Traditional factory scanning processes face limitations like blind spots and periodic scanning intervals. This research proposes using drones equipped with LiDAR (Light Detection and Ranging) technology for 3D scanning, enabling real-time mapping, autonomous operation, and efficient data collection. Drones can navigate complex areas, access small spaces, and optimize factory
Narad, Akshay Maruti, C H, Ajheyasimha, Vijayasekaran, Vinothkumar, Fasge, Abhishek
New generation Natural Rubber-Based Bump Stopper with Improved NVH Characteristics2026-26-0292To be published on 01/16/2026
In automotive suspension systems, components like bump stoppers and jounce bumpers play critical roles in controlling suspension travel and enhancing ride comfort. Material selection for these components is driven by functional demands and performance criteria. Traditionally, Natural rubber (NR) has traditionally been favoured for bump stopper applications due to its excellent vibration absorption, tear resistance, cost-effectiveness, and biodegradability. However, in more demanding environments, it has been largely replaced by microcellular polyurethane (PU) elastomers, which offer superior durability, environmental resistance, and enhanced noise, vibration, and harshness (NVH) performance. PU's high compressibility, low lateral expansion, and low compression set make it the material of choice across automotive, aerospace, and industrial sectors. Other materials like thermoplastic elastomers (TPE/TPU) and EPDM rubber are also used, offering advantages such as recyclability, ease of
Murugesan, Annarajan, Hingalaje, Abhijeet, Perumal, Mathavan, Pawar, Rohit
Thermal Management of High-Voltage Connectors using double-layered Phase-Change Materials (PCM)2026-26-0279To be published on 01/16/2026
Abstract: High Voltage cables and terminals are prone to high temperatures and rapid heat generation due to high current ratings, especially in electric vehicles (EVs). If the temperature exceeds a critical limit, danger may be posed to the components which are connected and the overall safety of the passengers. Traditionally, cooling methods are often energy-intensive and rely on active systems, which may not always be practical for high-power applications. Thus, a localized, fast, and reliable passive thermal management methodology that can be retrofitted into existing connector designs through modifications (e.g., enlargement and PCM integration) would provide significant safety enhancement. The material property of phase change materials, which possess high latent heat, has been used to maintain a steady temperature for a period of time. A dual PCM-layer has been incorporated into the design of the high-voltage connector to serve two purposes:1. The first PCM layer (PCM-1), with
Neogi, Angshuman, Shinde, Shardul
Accurate Component Load Prediction with Hybrid Test – FEA Approach.2026-26-0366To be published on 01/16/2026
Knowing accurate loads acting on the structure is still a main pain area for analyst. Accurate fatigue analysis through FEA is still a difficult task because of uncertainties associated with component load profile. Even for known duty cycle, approximation involved in measurements and load cascading techniques (MBD simulation models) put limits on accuracy of component load prediction. Small error in loads can lead to very large error in fatigue life calculations. Various researches proposed various innovative alternate means for accurate component load prediction and published in literature over past few decades. Author has explored and developed hybrid Test-FEA approach to estimate component loads based on robust strain-load transformation and pseudo inverse technique. This approach is based on effective use of strain transformations along with accurately measured strain data to calculate accurate load histories. The accuracy of load estimates depends upon number of factors such as
Pratap, Rajat, Apte, Sr., Amol, Babar, Ranjit
Value-Engineered Design Optimization of a Reinforced Plastic Bracket to Meet Natural Frequency Targets in Passenger Vehicles.2026-26-0355To be published on 01/16/2026
The transition from metal to plastic in the design of engine mount brackets marks a pivotal step toward sustainable and value-driven automotive engineering. This study investigates the optimization of plastic engine mount brackets, focusing on material selection, structural performance, and alignment with NVH (Noise, Vibration, and Harshness) targets. Recycled polymer composites were chosen for their favorable mechanical properties, environmental resilience, and contribution to circular economy goals. The primary objectives were weight reduction, cost-effectiveness, and manufacturability, without compromising structural integrity or long-term durability. A combination of Finite Element Analysis (FEA), CAE-based durability simulations, modal analysis, and comprehensive vehicle-level validation was conducted to assess dynamic performance. Results demonstrated that the optimized plastic brackets not only satisfy critical natural frequency and durability requirements but also offer a
Hazra, Sandip, Gupta, Deepak, Khan, Arkadip, Gite, Yogesh
Virtual Paint Shop: Automotive E-coating Process2026-26-0365To be published on 01/16/2026
The automotive paint shop is one of the most energy-intensive processes in vehicle manufacturing. This drives automotive OEMs to continuously improve production efficiency and reduce operational costs through digital twin technologies. Additionally, the push for shorter time-to-market emphasizes the need for simulation-based manufacturing processes—such as virtual testing and CAE simulations—to enable faster, data-driven decision-making early in the product development cycle, ultimately reducing cost and development time. Among the various stages in the paint shop, two of the most critical are: 1. Electro-dip coating (E-coating), also known as Electro-Deposition coating, which applies a corrosion-resistant primer to the Body-in-White (BIW). 2. Oven curing, which ensures the primer is properly bonded and cured for long-term protection and finish quality. To optimize these processes, a Dip-Drain-E-Coating simulation was developed using Siemens Simcenter STAR-CCM+. This simulation
Gundavarapu, V S Kumar, P, Vivekaanandan, Garg, Manish, Navelkar, Tanay, BS, Balachandran
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