Browse Topic: Materials

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Tuning structural and optical properties of Cu2ZnSnS4 thin films via annealing temperature2026-28-0015To be published on 02/01/2026
Cu2ZnSnS4 thin films, a promising material for solar cell absorber layers, have been effectively deposited onto soda-lime glass substrates using the chemical spray pyrolysis method. During this deposition method, the films have been deposited at a substrate temperature of 375 °C. The films are deposited with a spray rate of 10 ml/min to achieve uniform film formation. After the deposition of these films, to improve the crystallinity of the films and increase the sulfur content, the as-deposited films were annealed in a sulfur-rich atmosphere. Annealing was carried out at a two-zone vacuum tubular furnace at 500 - 550 °C. The as-deposited films are found to be rich in tin and deficient in sulfur. After annealing, there is a noticeable improvement in the Cu2ZnSnS4 phase formation and crystallinity. However, films annealed at the higher temperature of 550 °C showed signs of zinc loss in the deposited films. X-ray diffraction analysis confirmed the formation of the kesterite structure
M, Pavan Sai Reddy, Kumar, YB Kishore
Effect of Sebastiana rostrata Fiber Loading on the Tribological Behaviour of Polycaprolactone Biocomposite.2026-28-0021To be published on 02/01/2026
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.
Statistical Optimization of Wire Arc Additive Manufacturing Parameters Using Taguchi Methodology2026-28-0035To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) is an emerging metal additive manufacturing process known for its high deposition rates and cost-effectiveness in fabricating large-scale components. However, the quality of the final build is highly sensitive to process parameters such as wire feed rate, travel speed, voltage, and current. In this study, the Taguchi method is employed to statistically optimize key WAAM process parameters with the aim of improving surface finish and mechanical integrity of the deposited parts. An L9 orthogonal array was used to design experiments, and signal-to-noise (S/N) ratios were analyzed to identify optimal parameter settings. Analysis of variance (ANOVA) was performed to determine the significance of each factor on the selected output responses. The results demonstrated that specific combinations of process parameters can significantly reduce surface roughness and enhance bead geometry. The optimized settings obtained through the Taguchi approach provide a
PN, Vani
Optimization of Gear Design for Efficiency and Durability2026-28-0011To be published on 02/01/2026
Gears are the most common machine part used to transmit rotational motion and torque using a series of teeth that engage with compatible teeth of another gear or other part. Optimizing the working mechanism of the gear improves the efficiency of the machinery and improves the overall capability of the mechanism. Gear designs are directly influenced by constraints like strength, pitting resistance, tooth profile, bending stress, weight, and centre distance. Traditional optimization techniques often fail to yield optimal results so a genetic algorithm is employed to enhance the gear performance. Genetic algorithms are computational techniques derived from the principles of natural selection and evolution making them well-suited for optimization problems. Genetic algorithms are usually utilized to identify performance metrics and optimize them. Keywords: Genetic Algorithm, helix angle, crossover, Pareto solution, real-valued vectors, hyper parameters, hybridised algorithms
Kumar, Anush, A, Birla, Ramshree Dhashvanth, R, Bhaskara Rao, Lokavarapu
Influence of Copper oxide and Graphite additives on the lubrication performance of the engine oil2026-28-0017To be published on 02/01/2026
The parts of engine move at high speeds under heavy pressure. This leads to high temperatures and wear. To reduce the rate of wear, lubricants are used. But the lubricants are pollutants and increasing their useful life will result in the reduction of pollution. Additives may help in increasing the useful life of a lubricant. In the present study, the effect of the addition of cupric oxide and graphite nanoparticles to the engine oil on its performance of lubrication using pin on disc tribometer. AA2014 – 5 wt.% TiC composite material sliding against steel surface with lubricant was used to quantify the performance of additives. The base lubricant used in this study was 5W30 grade engine oil. Two types of lubricants, engine oil with 2 wt.% copper oxide (CuO) and engine oil with 2 wt.% Graphite (Gr) were tested and compared with the performance of the base oil in similar conditions. Adding Gr particles to the oil reduced the wear rate of sample by nearly 40% while CuO particles reduced
Ch, Sri Chaitanya, Mutyala, Venkata Ramarao, PONNAGANTI, Gopinadh Chowdary, Rajamalla PhD, Narasimha Rao, Bachugudem, Arun Kumar, Abdul Azeez, Mohammed, Kumar, Mohan
Evolution of a Novel Hybrid Stab-Link for a Born Electric Sports Utility Vehicle2026-28-0001To be published on 02/01/2026
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
Performance and Emission Analysis of Diesel Engine Fueled with Waste Polypropylene-Derived Biodiesel Blended with Diethyl Ether2026-28-0019To be published on 02/01/2026
To solve the dual environmental issues of plastic pollution and reliance on fossil fuels, this study investigates the pyrolysis of waste polypropylene (PP) plastic into alternative diesel fuel. To improve fuel performance, the refined pyrolytic oil from PP was combined with regular diesel and 5% diethyl ether (DEE). The following three blend ratios were developed and assessed for important fuel characteristics: viscosity, density, flash point, cetane number, and calorific value: B10-DEE5-D85, B20-DEE5-D75, and B30-DEE5-D65. In order to enhance cold-start performance and ignition quality, DEE was used as an oxygenated additive. A four-stroke, single-cylinder diesel engine was used to test these mixes in order to evaluate their emissions and brake thermal efficiency. According to the results, the B10-DEE5-D85 mix had the most balanced performance, reducing CO and CO₂ emissions significantly when compared to pure diesel, especially while operating at full load. However, as the amount of
K S, Karthi Vinith
Parameter Selection Strategies for High-Performance WAAM Structures in Automotive Engineering2026-28-0033To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) has gained traction as an advanced fabrication technique for producing large, structurally demanding components in the automotive industry. Achieving high-performance WAAM structures requires precise control and selection of key process parameters, which directly influence mechanical strength, dimensional accuracy, and surface quality. This study investigates the effect of critical process variables—including wire feed rate, travel speed, current, voltage, and inter-layer cooling time—on the structural integrity of WAAM-fabricated components designed for automotive use. A systematic experimental approach, supported by statistical modeling and optimization tools, was employed to identify parameter combinations that yield optimal results. The outcomes demonstrate improved microstructural uniformity, reduced residual stresses, and enhanced tensile properties in the fabricated parts. The findings serve as a foundation for developing robust parameter
V, Aravind
Topology Optimization of Steering Knuckle using Aluminium-Carbon Fiber Hybrid Material2026-28-0010To be published on 02/01/2026
The steering knuckle is the most vital element of a car; it is associated with the suspension system, front wheel, wheel hub, as well as chassis through the steering and braking systems. It travels along the driver's chosen paths with the help of the steering system. Under different conditions, it encounters a variety of loads. By implementing the steering knuckle's topology optimisation and moving from the present production material to a hybrid material, the major focus of this project is to lower the weight of a steering knuckle. In the automotive manufacturing and industrial sectors, the future car must be lightweight and fuel-efficient. This is due to a lighter steering knuckle generates higher power and less vibration because there is less inertia when driving. 5% carbon fibre and 95% aluminium (5XXX series) make up the hybrid material's makeup. Using the IGS format, the steering knuckle model's design was imported from SOLIDWORKS 2020 to ANSYS Workbench 18.1 for static analysis
M, Venkatesan, P, Nithyanand
Investigation of Wear and Friction Characteristics of 3D printed PLA and PLA–Carbon Fiber Composites against a Tribometer Counter Part Surface2026-28-0031To be published on 02/01/2026
PLA (poly Lactic Acid) carbon fiber composites is most widely used in industrial applications especially in automotive, consumer electronics sector due to low cost prototyping and durability. In this proposed work, investigation on PLA and PLA+CF 3D printed samples are taken for wear and friction testing with same material counterpart. This experiment helps to analyze wear and friction resistance by applying material interaction between part on pin, counterpart on disc with varying applied load of 5,10,15 to 20N and sliding velocity of 1m/s and 3m/s. At first designing the required prototype (Part sample, counterpart disc) with material as PLA, PLA+CF. The unique of the research, tested samples are 3D printed pin and counterpart disc, both are same material. Each sample subject to 4 different load and 2 different sliding velocity. In this work we use two materials namely PLA, PLA+CF composite material. In this work PLA and PLA Carbon Fiber materials are comparatively analysed where PLA
Ranganathan, Soundararajan, Karthickkumar, S, Alwin Jones, J
Experimental and Predictive Study on WEDM of Aluminium Alloys Using Taguchi and ANFIS2026-28-0040To be published on 02/01/2026
The attributes of aluminium alloys are acknowledged in the varied usage of these alloys because they have excellent mechanical properties and good ductility while being less vulnerable to fatigue. These alloys are widely applied in engineering disciplines. The aerospace and automotive industries are important industries using these alloys, and many other progressive engineering applications continue to embrace the use of these alloys. Their resistance to corrosion makes them even better suited for usage in some harsh environments. Unfortunately, producing parts with very complicated geometries through conventional machining techniques is still a challenge. To try to solve this limitation, there have been several advanced machining processes. Among them is Wire Electrical Discharge Machining (WEDM) - a specific form of Electrical Discharge Machining (EDM) for an effective solution for complex and hard-to-machine components. In this study, efforts have been made to study the WEDM process
Natarajan, Manikandan
Forced Vibration Analysis of Solid and Hollow Functionally Graded Shafts2026-28-0051To be published on 02/01/2026
This paper presents a comparative study on the forced vibration behavior of functionally graded material (FGM) shafts in solid and hollow configurations. FGMs exhibit a continuous variation in material composition from ceramic-rich surfaces to metal-rich cores, enhancing mechanical performance under dynamic loading. A finite element-based analysis is conducted using ANSYS Workbench under simply supported boundary conditions to evaluate the natural frequencies and mode shapes. The study investigates the influence of shaft geometry, material gradient, and structural configuration on vibrational characteristics. Results indicate that solid shafts generally exhibit higher natural frequencies due to increased stiffness, while hollow shafts offer reduced weight with moderate frequency shifts. Additionally, smoother material gradients improve dynamic stability. These findings offer valuable insights for optimizing FGM shaft design in automotive and aerospace applications where weight-to
R, Tharrun, Addanki, Karishma, D, Manish, Bhaskara Rao, Lokavarapu
Experimental Optimization of WEDM for Post Processing of Wire Arc Additive Manufactured Alloys2026-28-0041To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) is widely adopted for producing large-scale metal components due to its high deposition rates and material efficiency. However, WAAM-fabricated parts often exhibit poor surface finish and dimensional inaccuracies, necessitating precision post-processing. Wire Electrical Discharge Machining (WEDM) offers a suitable solution for finishing such components, especially those made from hard-to-machine alloys. This study presents an experimental investigation into the optimization of WEDM process parameters such as pulse-on time, pulse-off time, peak current, and wire feed for post-processing WAAM-fabricated alloys. Using a Taguchi design of experiments and statistical analysis, the influence of each parameter on surface roughness, material removal rate (MRR), and dimensional accuracy was evaluated. The optimized parameters yielded improved surface integrity and machining efficiency, making WEDM a reliable post-processing technique for enhancing the
Pasupuleti, Thejasree
EXPERIMENTAL ANALYSIS AND SIMULATION STUDY OF AN AUTOMOBILE RADIATOR WITH NANOFLUIDS2026-28-0020To be published on 02/01/2026
A nanofluid is the suspension of nanoparticles in a base fluid. Nanofluids are promising fluids for heat transfer enhancement due to their anomalously high thermal conductivity. The thermal conductivity enhancement mechanisms of nanofluids have not been fully understood yet. In the first part of this study, a detailed literature review about the thermal conductivity of nanofluids is performed. Experimental studies are discussed in terms of the effects of some parameters such as particle volume fraction, particle size, and temperature on the thermal conductivity of nanofluids. Enhancement mechanisms proposed to explain nanofluid thermal conductivity are also summarized. Research about the forced convection of nanofluids is important for the practical application of nanofluids in heat transfer devices. Recent experiments showed that heat transfer enhancement of nanofluids exceeds the thermal conductivity enhancement of nanofluids. This extra enhancement might be explained by thermal
R, GOWTHAM
Effect of Minimum Quantity Lubrication during Machining of Incoloy 800H Using Vegetable Oil Enriched With Nano Particles2026-28-0038To be published on 02/01/2026
In this experimental work an effort has made to investigate the machining of difficult to machine Incoloy 800H super alloy. Cryogenically treated textured cutting inserts and vegetable oil enriched with nano particles were used for this study. The turning experiments were performed with different parameters such as Cutting speed, feed rate and depth of cut. Surface Roughness, Cutting Force, Tool-Tip Temperature and Power were the output responses considered. Grey Relational Analysis (GRA) and Analysis of Variance (ANOVA) analysis were used to optimize the machining parameters and to find the most influencing machining parameter on the output responses. The results showed that the optimal machining conditions considered were cutting speed at 35 m/min, feed rate at 0.06 mm/rev and depth of cut at 0.5 mm for the multiple-characteristic performances and it was improved by 3.86 % with this approached method. Also, Tool-tip temperature and Power were reduced during machining with cryo
Natarajan, Manikandan
Experimental Investigation of Process Parameter Effects in WAAM of Nickel-Based Alloys2026-28-0027To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) is an evolving discipline in metal additive manufacturing characterized by rapid deposition, cost-effectiveness, and centrality to the near-net-shape fabrication of large-scale components. This study will concentrate on WAAM application to deposit nickel alloys, which find extensive use in aerospace, power generation, and marine industries, due to their good mechanical strength, corrosion resistance, and thermal stability. However, some drawbacks in WAAM processing of nickel alloys include thermal distortion, porosity, and residual stress. The research looks at how key WAAM process parameters, including wire feed rate, travel speed, current, and interpass temperature affect geometric accuracy, surface integrity, and mechanical performance of the fabricated components. Microstructural characterization was done using optical microscopy, and hardness distribution was measured as an indication of mechanical uniformity throughout the builds. It is
Natarajan, Manikandan
TOPSIS-Based Multi-Criteria Optimization of WAAM Parameters for Automotive Component Fabrication2026-28-0026To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) can make huge, complicated metal parts quickly and cheaply, making it popular in the automobile sector. This study uses TOPSIS, a multi-criteria decision-making method, to improve WAAM process parameters such wire feed rate, travel speed, and current. Automotive applications need surface roughness, deposition rate, and dimensional precision, which WAAM-fabricated components must meet. TOPSIS normalizes and ranks experimental findings to find parameter combinations that perform best across many quality metrics. The results show that integrated optimization improves component quality and consistency, making WAAM a feasible and economical sustainable vehicle manufacturing option.
Pasupuleti, Thejasree
Selection and Optimization of Process Parameters in Wire Arc Additive Manufacturing for Automotive Structural Applications2026-28-0039To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) has emerged as a promising technology for fabricating large, complex metal structures with reduced material wastage and improved design flexibility. In the automotive sector, WAAM offers significant potential for producing lightweight and high-strength components, particularly for structural applications. However, the quality and performance of WAAM-fabricated parts are highly dependent on the careful selection and optimization of process parameters such as wire feed rate, travel speed, arc voltage, current, and inter-pass temperature. This review focuses on the systematic evaluation of key process parameters influencing the mechanical properties, surface integrity, dimensional accuracy, and microstructural characteristics of WAAM-produced structures intended for automotive applications. The study also explores various optimization techniques—such as Taguchi, response surface methodology (RSM), and artificial intelligence (AI)-based approaches
V, Aravind
Design and Fabrication with Validation of a Smart Adaptive Anti-Roll Bar System for Enhanced Stability in Electric Vehicles2026-28-0029To be published on 02/01/2026
This project presents the design and characterisation of high-performance automobile anti-roll bars from the metal matrix composite of AA6082 aluminium alloy reinforced by 5 wt% Boron carbide (B4C), 10 wt% Fly ash, and 10 wt% Silicon carbide (SiC), prepared by stir casting for optimum particle dispersion. Mechanical characterisation revealed 22% greater ultimate tensile strength to 415 MPa, 31% greater hardness to 132 HB, and 27% greater fatigue life than the unreinforced AA6082, with only moderate lower density from fly ash addition. Finite Element Analysis in SolidWorks also confirmed the reinforced anti-roll bar to demonstrate 11% lower maximum Von Mises stress and 14% lower equivalent strain in simulated cornering loads, indicating greater durability and deformation resistance. Optical microscopy also confirmed homogeneous reinforcement particle dispersion and optimum grain refinement for greater grain refinement and wear resistance. These results demonstrate the technical promise
Deepan Kumar, Sadhasivam, S, Manikandan
Effect of Shot Peening on the Fatigue Life of Polylactic Acid Parts in Automobiles2026-28-0032To be published on 02/01/2026
Polylactic Acid (PLA), is a biodegradable thermoplastic and most widely used materials in automobiles also inherent fatigue performance limitations and its deployment in demanding load-bearing automobile applications. Shot peening, a well-established surface treatment known to significantly enhance the fatigue life of metallic materials, presents a potential post-processing strategy to improve the durability of polymers. The proposed work investigation into the effects of controlled shot peening pressure on the various behavior of injection molded PLA specimens. The outlined methodology encompasses the fabrication of PLA samples conforming to ASTM standards, the application of shot peening using precisely defined parameters, comprehensive characterization of the resulting surface modifications (including roughness, hardness, morphology, and systematic uniaxial fatigue testing according to ASTM D7791. Fatigue tests will generate fatigue behavior and fatigue life (by varying number of
Ranganathan, Soundararajan
Parameter Optimization for Improved Surface Finish in WAAM-Fabricated Steel Structures2026-28-0023To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) is a cost-effective and scalable metal additive manufacturing technique widely used for fabricating large metallic components. However, surface finish remains a critical challenge, especially for structural applications where post-processing needs to be minimized. This study focuses on optimizing key process parameters to improve the surface finish of ER70S-6 steel structures fabricated using the WAAM process. Experiments were designed using a statistical approach to systematically vary parameters such as wire feed rate, travel speed, voltage, and inter-pass cooling time. Surface roughness was measured using standard metrology tools, and the results were analyzed to identify the most influential parameters. An optimized parameter set was proposed based on the experimental outcomes, leading to a significant reduction in surface roughness without compromising the structural integrity of the deposited material. The findings contribute to enhancing
PN, Vani
AI-Driven Process Optimization in Wire Arc Additive Manufacturing of Nickel Alloys Using ANFIS2026-28-0025To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) is gaining significance in recent years as a process for additive manufacturing that produces large and complex components with high deposition rates at economically feasible rates. Nickel-based alloys, praised for their unique features, like mechanical strength, corrosion resistance, and thermal stability, find widespread application in the aerospace, marine, and energy sectors. However, achieving the desired surface finish, dimensional precision, and mechanical performance of WAAM nickel alloy structures is a continuing challenge because of the complex interactions occurring between the process parameters. The study presents an experimental analysis conducted to establish the effect of important process parameters of WAAM-wire feed rate, travel speed, welding current, interpass temperature-on the quality indicators such as surface roughness, dimensional accuracy, and hardness. For the purpose of prediction and process control, the Adaptive Neuro
Natarajan, Manikandan
Modelling and Analysis of Complex Shaped Cracks2026-28-0048To be published on 02/01/2026
This study offers a thorough analysis using finite element methods (FEA) to examine how fatigue cracks grow in three different materials: Structural steel , Titanium alloy (Ti Grade 2), and epoxy/aramid-based printed circuit board (PCB) laminates. Using ANSYS Workbench, we ran simulations under both static and repeated loading to understand how these materials fracture. The approach was based on Linear Elastic Fracture Mechanics (LEFM), employing the Maximum Circumferential Stress Criterion to predict where cracks might start and how they could spread. Also, the Equivalent Domain Integral (EDI) method helped us calculate the Stress Intensity Factors (SIFs) when cracks are under mixed loading modes. We modeled the growth of fatigue cracks using the Paris Law, relying on material-specific constants (C and m) drawn from previous studies and experimental tests. For example, titanium Grade 2 showed Paris Law constants with C values between 1.8 × 10⁻¹⁰ and 7.9 × 10⁻¹² m/cycle, and m values
T, LOKESH, Bhaskara Rao, Lokavarapu
Synthesis, characterization and electro active properties of poly (Meta Toudine-co-Fluro aniline) Ag dispersed nanocomposites: Shielding Composite as surface Coat or Enclose the ECU Housing for preventing signal distortion and ensuring reliable engine performance2026-28-0022To be published on 02/01/2026
A series of electroactive nanocomposites of silver dispersed poly (metatoludine-co-o-fluroaniline) copolymer has been prepared by in-situ polymerization method. The chemical molecular structures are identified by using UV–visible spectra, FTIR, X-ray diffraction instruments, SEM analysis. We propose that these composite materials possess a Electromagnetic Shielding interference coat or enclose the engine control unit (ECU) housing in the form of surface coating or moulded shell in order to prevent signal distortion and ensuring reliable engine performance in automobiles. This composite material possesses lightweight, corrosion-resistant EMI shielding solution for ECU housings. Implementation of these products significantly reduced signal interference from nearby high-power electronics, ensuring stable engine operation. The proposed system offers a cost-effective, lightweight alternative to metallic shielding in vehicular electronics in automobile industries.
Pachanoor, Vijayanand, Kumar, V
Sustainable Machining of Aluminium Alloys: Experimental Insights into WEDM Process Optimization2026-28-0034To be published on 02/01/2026
The most advanced mathematics transforms aluminum alloys into one of the most highly intricate materials into practically any engineering application based on the mechanical properties of ductility and low fatigue sensitivity. The use of aluminum alloys permeates critical industries like aerospace and automotive, besides being strong contenders in other high-performance applications. Their inherent corrosion resistance certainly gives an edge to aluminum alloys for applications in rigorous service environments. Conventional manufacturing processes would not successfully create components with some geometrical complexity; hence, advanced machining processes are being developed. Among them is Wire Electrical Discharge Machining (WEDM), which is increasingly being adopted within the EDM family, as it efficiently machines hard and complex shapes at high accuracy. The present investigation deals with WEDM of aluminum alloy using Taguchi's design of experiments approach, while focusing on
Natarajan, Manikandan
Machinability Evaluation of WAAM-Fabricated Alloys Using Wire EDM and Parameter Optimization Techniques2026-28-0036To be published on 02/01/2026
Wire Arc Additive Manufacturing (WAAM) is increasingly utilized for fabricating near-net shape metal components due to its high deposition rates and cost-effectiveness. However, post-processing of WAAM-fabricated parts, especially to achieve precise dimensions and surface finish, is essential. Wire Electrical Discharge Machining (WEDM) presents an effective solution for such requirements due to its ability to machine hard-to-cut materials with high precision. This study investigates the machinability of WAAM-fabricated alloy specimens using WEDM by analyzing key output responses such as material removal rate (MRR), surface roughness (Ra), and kerf width. Taguchi and other optimization techniques were employed to identify the optimal combination of WEDM parameters including pulse-on time, pulse-off time, peak current, and wire feed. Experimental results demonstrated that specific parameter settings significantly enhance machinability while maintaining structural integrity. The findings
Bangaru, Haritha
Galvanic Corrosion Susceptibility Analysis and Mitigation strategies in Automotive Battery Packs2026-28-0018To be published on 02/01/2026
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
The Impact of Color Correlated Temperature (CCT) on Automotive Headlights Performance and Driver Perception2026-26-0130To be published on 01/16/2026
Automotive lighting has been evolved from simple incandescent lamps to advanced LED based AFS and ADB functions. These lighting play crucial role in road traffic enhancing better visibility and safety to driver as well as other road users. Today’s Automotive Headlights use different light sources viz., Halogen, HID (Xenon), LED, and Laser each emitting light at different correlated color temperatures (CCT), measured in Kelvin (K). Color temperature not only influences visibility but also impacts the amount and perception of glare experienced by other drivers. The study was undertaken to evaluate the effect of correlated color temperature of automotive headlamps on driver visibility and comfort during night driving conditions. The experiment was conducted in a controlled laboratory environment using headlamps with different CCTs ranging from 3000K to 6500K. Participants from various age groups and genders were involved to capture diverse perceptions. Studies confirm that both CCT and
Patil, Mahendra G., Kirve, Jyoti, Parlikar, Padmakumar
Development of Advanced Thermoplastic Elastomeric Mat and Its Study on Thermal Performance of Wireless Charging System2026-26-0283To be published on 01/16/2026
This study aimed to develop a thermally conductive TPE mat and assess its performance in comparison to an existing antiskid rubber mat, specifically evaluating its impact on wireless charger efficiency. Moreover, morphological and thermal analyses were conducted to establish a correlation between the material behaviours of the new and current thermally conductive antiskid mats. The process of developing the thermally conductive TPE involved utilizing a two-roll mill followed by compression moulding to achieve a 2D sheet shape. Notably, the thermally conductive mat demonstrated a consistent enhancement in charging efficiency over the conventional antiskid mat. To examine the thermal characteristics, thermal characterization techniques including DSC and TGA were employed for both the existing and newly developed mats. FTIR spectroscopy was also utilized to confirm the presence of organic functional groups within the mat. The morphological analysis of the fillers used to enhance thermal
NAIKWADI, AMOL TARACHAND, Mali, Manoj, Patil, Bhushan, Tata, Srikanth
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
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
Manufacturing process advancement in CNG Exhaust Valve to prevent seat wear issue2026-26-0278To be published on 01/16/2026
Exhaust Valve CNG market share increased in India in recent years demanding for more durable and reliable CNG Engine. While in current scenario durability is one of the major concerns for CNG engine. Major issue faced in CNG powertrain is high wear at Exhaust valve CNG face due to excessive wear. In Current practice T400 Sintered material layer is deposited at Valve face which is very critical to achieve less wear at valve face. Due to manufacturing variability high level of variation is found mechanical properties of T400 deposit which is very critical for Exhaust Valve CNG performance. In this paper all important process parameters are discussed for achieving consistent Exhaust Valve CNG T400 deposit quality. Each process parameter detail impact on T400 material is studied and explained to achieve consistent quality of T400 deposit leading to robust design of Exhaust Valve CNG.
Poonia, Sanjay, KUMAR, CHANDAN, Kundu, Soumen, kumar, prabhakar, Vats, Rajesh, khan, Prasenjit, Sharma, Shailender
For CNG and FFV fuel application robustness improvement of Exhaust Valve2026-26-0125To be published on 01/16/2026
Today, globally, automotive manufacturers are striving to meet the increasing demand for fuel economy, high performance, and silent engines. The fundamental approach to achieving these requirements is through designing low friction mechanisms, resulting in less wear and higher durability. The demand for CNG vehicles has surged exponentially in recent years, prompting increased government focus on alternative fuels such as CNG and hydrogen. These dry fuels lack lubricating properties, unlike conventional fuels like petrol, diesel, and biofuels, which are wet and liquid. Consequently, the operations and failures associated with these fuels differ. The materials and designs of engine parts, such as fuel lines, ECU, exhaust valves, and cylinder heads, vary depending on the fuel used. This study discusses the countermeasures adopted to address the high seat and guide wear in cylinder heads and valves. The investigation focuses on material, design, and manufacturing process improvements
Poonia, Sanjay, KUMAR, CHANDAN, Sharma, Shailender, khan, Prasenjit, Bhat, Anoop, P, Prasath, Neb, Ashish
Failure Prevention of Permanent Deformation in HNBR Elastomeric Diaphragms Used in CNG Valve Applications2026-26-0294To be published on 01/16/2026
Hydrogenated nitrile butadiene rubbers (HNBR) and its derivatives have gained the significant importance in automotive compressed natural gas (CNG) valve applications. In one of the four-wheeler CNG valve application, HNBR elastomeric diaphragms are being used for their excellent sealing and pressure regulation properties. The HNBR elastomeric diaphragm was developed to sustain CNG pressure more than 10 bars. However, it was found permanently deformed under 4 bar pressures. In the present work, a set of experiments were carried out in order to find out the primary root cause of diaphragm permanent deformation and preventing the failure for safe usage of the CNG gas. HNBR diaphragm deformation investigation was carried out using advanced qualitative and quantitative analysis method such as Soxhlet Extraction Column, Fourier Transform Infrared Spectroscopy (FTIR), Differential Scanning Calorimetry (DSC), Optical Microscopy (OM), Scanning Electron Microscopy (SEM) and Thermogravimetric
Patil, Bhushan Gulab, NAIKWADI, AMOL, Mali, Manoj, Tata, Srikanth
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
Integrating Road Load Data Acquisition and Signal Processing Techniques to Generate Reliable Drive Files for Electrodynamic Shakers in Testing the Exhaust Systems of Off-Highway Applications2026-26-0552To be published on 01/16/2026
Generating a reliable drive file for an electrodynamic (ED) shaker from Road Load Data Acquisition (RLDA) and validating its correlation with real-world conditions through damage and fatigue analysis is crucial for accurate component testing, particularly in complex systems like off-highway exhaust systems. This paper presents a methodology for creating such a drive file and establishing its validity, highlighting the necessity of ED shakers for simulating the intricate dynamic loads experienced by these systems. The process begins with acquiring comprehensive RLDA under representative operational conditions of the off-highway vehicle. Drive files are generated using this data, which records accelerations at important exhaust system mounting locations. Advanced signal processing techniques are employed to condense the raw RLDA into a format suitable for shaker control. To establish proper correlation, the generated drive file is used to excite the exhaust system on an ED shaker
Khaire, Santosh Ramdas, Khaire, Rushikesh, Yadav, Dnyaneshwar
Integration of virtual testing methods in automotive safety: Methodology validation for rollover protection system (ROPS)2026-26-0375To be published on 01/16/2026
During recent years, the integration of virtual testing methodologies has gained significant importance in vehicle development for the passive safety evaluation. The accuracy of simulation results depends basically on the correct replication of physical test into the virtual model, for example to assign the realistic material properties from the structural components and following the boundary conditions replicated from real conditions. In this study the safety standards ISO 3471_2008 and ANSI ROHVA/OPEI-2016 have been considered as references of the safety validation process of hollow section roll-over protective structure (ROPS) integrated into a vehicle. A key objective is to stablish a virtual test methodology that could be applicable across different standards considering various industry markets, as for example European, American and Asian. A sensitivity analysis is necessary to evaluate what are the main aspects that gives significant deviations in results and in which we can
Laso Rodríguez, Manuel, Hanumantha, Chandrashekhar, Singh, Amit Kumar, Lal, Kundan
Design Robustness of Electronic Locking Differential for enhanced off-road performance2026-26-0502To be published on 01/16/2026
The Electronic Locking Differential (ELD) is a critical component for enhancing off-road vehicle performance by ensuring optimal traction in challenging terrains. This paper addresses intermittent engagement issues observed in the ELD system during off-road trials, which impacted its reliability and functionality. It presents a comprehensive study of design robustness improvements implemented to resolve these concerns and optimize the ELD’s performance, ensuring enhanced customer satisfaction in demanding off-road environments. The analysis begins with identifying factors contributing to the intermittent engagement and disengagement of the ELD system upon actuation. These factors include residual magnetism, material properties, temperature effects, and the stack-up characteristics of transfer path components under various boundary conditions. To address these challenges, three key design modifications were introduced: (1) reduction of residual magnetism through an increased air gap
S, Mohd Imtiaz, AP, Baaheedharan, Ghumare, Dheeraj, Kanagaraj, Pothiraj, Jain, Saurabh Kumar
A Comprehensive Analysis of Sealing Methods for EV Battery Packs: Trends and Insights.2026-26-0180To be published on 01/16/2026
The widespread adoption of electric vehicles (EVs) has brought about unique engineering challenges, particularly in the design of battery packs, which are central to vehicle performance, safety, and longevity. One critical requirement is maintaining ingress protection (IP) ratings of IP67 or higher to safeguard against water and dust exposure. These ratings are essential to ensure compliance with homologation standards and to meet the demands of diverse terrains and operating conditions. Achieving effective sealing of EV battery packs is thus a key aspect of their design and engineering. This study presents an in-depth analysis of sealing technologies employed in EV battery packs, focusing on four primary types: Adhesive-based sealants, Cure-In-Place Gaskets (CIPG), Foam Cut seals, and Rubber Gaskets. Benchmarking data gathered from more than 90 vehicle models across 20+ brands provide insights into adoption trends, historical shifts, evolution and interface requirements of different
Varambally, Vishakha, Sithick basha, Abubakker, Chalumuru, Madhu, Yaser, K U Syed, Sasikumar, K
Experimental Study on the Role of Hole Expansion Ratio in Enhancing Crashworthiness of Advanced High Strength Steel2026-26-0295To be published on 01/16/2026
To meet light weighting and safety target, the automotive industry is increasingly using advanced high strength steel (AHSS) materials and advanced manufacturing techniques for complex body parts. To improve energy absorption of automotive body parts, various steel grades are developed by steel manufactures with variety of properties ( YS, UTS, EL %, HER). Also, the formability of AHSS grades (TS > 980 MPa) is challenging due to its limited edge ductility. This study focuses on role of hole expansion ratio in energy absorption of AHSS material. In the study, different AHSS material with variety of microstructure and properties are experimented, with the aim to identify the optimum properties, that can help to enhance crash worthiness of formed part. From experimentation, it is evident that hole expansion ratio plays important role in determining edge ductility, as well as energy absorption. This study may not only help to improve crash performance but also help for light-weighting of
Jain, Vikas, Bandru, Shreenu, Nadarge, Harshad, Misal, Swapnali, Deshmukh, Mansi, Paliwal, Lokesh
Steel-based Laminates for Lithium-ion Pouch Cell of Electric Vehicles2026-26-0186To be published on 01/16/2026
Aluminium foils have gained traction with EV battery manufacturers for their pouch cell format. Over the years it has evolved as a material of choice, but it is still plagued by issues of stress concentration, swelling due to lower strength and stiffness of base aluminium layer. Preliminary investigation revealed that laminates using steel foil material (thickness <0.1mm) could be a potential candidate for EV pouch cell casing. Thus, steel-based laminate was developed meeting key functional requirements (e.g. barrier performance, insulation resistance, peel strength, electrolyte resistance, formable without cracking at edges, and heat sealing compliant). This innovative patented steel-based laminate was further used to manufacture pouch cell prototypes (maximum capacity 2.5Ah) for key performance tests (e.g. cell cycling, nail penetration and thermal runaway). The study paves the way for a low cost, sustainable and flexible yet strong steel-based laminate packaging material solution
Singh, Pundan Kumar, Raj, Abhishek, Kumar, Ankit, Chatterjee, Sourabh, Verma, Rahul Kumar, Samantaray, Bikash, Gautam, Vikas, Pandey, Ashwani
Assessing the impact of hole piercing edge quality on fatigue samples for S550MC steel sheet.2026-26-0306To be published on 01/16/2026
The exceptional strength, formability, and weldability of S550MC steel sheets make them a cornerstone material in the automotive industry. These properties translate into the creation of high-performance automotive components like chassis parts, structural reinforcements, and safety cages, ultimately contributing to enhanced vehicle safety and overall performance. Furthermore, S550MC steel boasts excellent fatigue resistance, a critical factor for ensuring long-term reliability in demanding automotive applications that experience repeated stress cycles. However, beyond its inherent properties, optimizing the performance of S550MC components hinges on a nuanced understanding of the critical relationship between hole edge quality and fatigue failure. This meticulous study delves into the impact of hole-piercing clearance on the quality of the hole edges in modified fatigue samples manufactured from S550MC steel, and its effect on the fatigue life. The surface morphology was assessed
Nahalde, Sujay, Hingalje, Abhijeet, Ughade, Vikas, Singh, Udita, More, Hemant
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
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
Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application2026-26-0286To be published on 01/16/2026
Quality of the Shear Trimmed edge of HSLA 550 steels is significantly affected by process variations such as Shear Trimming Clearance, trim tolerance, burr height and clamping force. All these parameters largely influence the characteristics of the Shear Affected Zone, a region on sheet metal where it undergoes deformation during the trimming process. The Shear Affected Zone is predominantly vulnerable to failure due to work hardening and the effects of strain rate, induced by the tonnage during the trimming operation. To assess the edge ductility of these materials, Tensile, Fatigue Strength, Die Punch Clearance, Roughness and Hardness Tests are carried out. These tests are crucial for applications that demand high formability and resistance to edge failure. Virtual simulation of edge trimming operation using elastoplastic material models in LS-Dyna have been performed to gain insights into burr formation and damage evolution during shearing. These simulations act as a precursor to
Thota, Badri Vishal, Kashyap, Amit, Bhuvangiri, Jaydev
Enhancing Factory Modelling: Integrating Drone Technology and Automated Post Processing Systems2026-26-0307To be published on 01/16/2026
The growing environmental, economic, and social challenges have spurred a demand for cleaner mobility solutions. In response to the transformative changes in the automotive sector, manufacturers must prioritize digital validation of products, manufacturing processes, and tools prior to mass production. This ensures efficiency, accuracy, and cost-effectiveness. By utilizing 3D modeling of factory layouts, factory planners can digitally validate production line changes, substantially reducing costs when introducing new products. One key innovation involves creating 3D models using point cloud data from factory scans. Traditional factory scanning processes face limitations like blind spots and periodic scanning intervals. This research proposes using drones equipped with LiDAR (Light Detection and Ranging) technology for 3D scanning, enabling real-time mapping, autonomous operation, and efficient data collection. Drones can navigate complex areas, access small spaces, and optimize factory
Narad, Akshay Maruti, C H, Ajheyasimha, Vijayasekaran, Vinothkumar, FASGE, ABHISHEK
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
Hypoid Gear Performance Redefined: Addressing Scoring and Whine Noise Concerns2026-26-0078To be published on 01/16/2026
Rear drive vehicles transfer power to the rear wheels through the Gear Carrier Assembly, which is fit at the central section of the Rear Axle. The Gear Carrier Assembly includes hypoid ring and pinion gears, set at the heart of the system. However, gear scoring and whine noise frequently emerge as critical challenges, leading to reduced durability and compromised performance of the vehicle. This study focuses on the design and process improvements aimed at addressing these concerns while enhancing the overall performance and reliability of hypoid gears. Design enhancements include macro geometry refinements, material upgrades, and modifications in the heat treatment process. These changes improved key mechanical properties such as contact stress, bending strength, impact strength, and motion transmission error (MTE). Process optimizations involved precise control over carburizing, hardening, and quenching temperatures, as well as adjustments in quenching pressure. These measures
Praveen, Abhinav, Deshpande, Praveen, Jain, Saurabh Kumar, Parmar, Mayur, Karle, Nilesh, Kanagaraj, Pothiraj, Pagar, Pawan
Next-Gen Driver Health and Wellness Platform for Fatigue Detection and Emotional Wellbeing Monitoring2026-26-0639To be published on 01/16/2026
Driver fatigue and emotional distress are major contributors to traffic accidents, especially among long-haul and professional drivers, making their detection a critical area in road safety and public health. While existing research has explored various sensor-based and wearable solutions to monitor driver states, these approaches often suffer from high cost, intrusiveness, or limited scalability. Camera-based systems have recently gained attention for being less invasive and more practical for real-world deployment; however, many still depend on multiple sensors or cloud-based processing, which raise concerns around energy consumption, privacy, and integration complexity. To address these gaps, we present a sustainable, camera-only Driver Health and Wellness Platform for real-time fatigue detection and emotional wellbeing monitoring. The system leverages a single in-cabin camera and applies lightweight, edge-optimized computer vision models to analyze facial features, eye dynamics
Iqbal, Shoaib, Imteyaz, Shahma
Enhanced Methodologies for predicting Automotive Wheel Bearing life and damage using RLDA2026-26-0482To be published on 01/16/2026
The durability of wheel bearings is assessed in terms of raceway life and flange life. Raceway life focuses on the performance and damage tolerance of rolling elements, while flange life evaluates the structural integrity of wheel flanges under operational stresses. Traditionally, durability predictions relied on conventional design methods and analytic formulas for raceway spalling, as well as static load assumptions for flange fatigue analysis. Recently, integrating design of experiments (DOE) with traditional approaches has enhanced these methods, enabling systematic evaluation of design variables and loading conditions. This paper introduces a methodology for analysing raceway life and damage in automotive wheel bearings using RLDA (Road Load Data Acquisition) data. The process involves acquiring raw deterministic load data, filtering it to preserve high-peaked signals, and transforming the filtered data into block cycles derived from load time histories. Each block cycle contains
Narendra, Vishwanath, Mane, Yogiraj, Paua, Ketan, Singh, Ram Krishnan, Vellandi, Vikraman
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