Browse Topic: Materials

Items (64,334)
Find
Simulative temperature determination of an electric machine from test bench tests2025-01-0520To be published on 11/25/2025
One of the most important components of an electric vehicle is the drive motor. Induction motors are often used for this purpose. Power losses occur during the operation of these motors, particularly at high speeds. Among other things, this power loss corresponds to the sum of winding losses, iron core losses and mechanical losses. The power losses generate heat, causing the temperature in the rotor and stator to rise. The increase in temperature of the components inside the motor can lead to premature wear and fatigue failure. To prevent overheating, the motors are air or water cooled. Water cooling can be achieved by jacket cooling, for example. In this case, the heat generated is dissipated directly by forced convection. However, the cooling jacket makes it difficult to determine the temperature inside the motor. Determining these temperatures is necessary to prevent the motor from fatiguing prematurely. The temperatures that occur inside the motor during operation are of particular
Schamberger, Stephanie, Reuss, Hans-Christian
Thermal Model of a Traction Inverter for an Automotive Application including DC-link capacitor, power modules and electrical connections2025-01-0519To be published on 11/25/2025
In automotive applications a traction inverter is used for energy conversion between battery and electrical machine. For high performance drives lightweight design is demanded. Additionally, higher efficiency of the inverter results in lower cooling requirements but is often achieved by increasing component weight. Hence, thermal modelling of the components and their interactions is essential to determine the best compromise between weight, efficiency and cooling requirements. In traction inverters the DC-link capacitors, power modules, high voltage electrical connections and low voltage devices dissipate power. In this paper the focus is on the thermal modelling of the DC-link capacitor, power modules and high voltage electrical connections and their system, as the performance of the inverter is defined by these components. The thermal models are derived based on geometries and physical properties. First, the DC-link capacitor thermal model is presented and considers the anisotropic
Blaschke, Wolfgang Maximilian, Mengoni, Leonard, Pflüger, Robin, Kulzer, André Casal
Optimizing the Structural simulation process of Automobile Airvent knob design to evaluate the sustainability for human accidental sliding load2025-28-0289To be published on 11/06/2025
The research work elaborated the structural integrity of airvent by skipping the assembly level snap fit analysis of knob to reduce computational complexity of air vent knob sliding test post stopper. During assembly, the strain based mechanical breakage prediction of airvent sliding knob snaps is investigated in prestressed condition. The function of airvent knob is to rotate the vertical fins to divert the air flow as per comfort in intended direction identified by passenger. The airvent knob slides on central horizontal fin on a grove feature provided. Post sliding the knob to extreme end it gets stopped at end of grove feature of H fin. The sliding knob is assembled by compressing it against a silicon rubber elastomer inlay. The compression of inlay produces a constant tension on the knob snaps. The knob assembly has to sustain a passenger accidental and abrupt sliding loads while in stopped condition. The knob snaps in this press fit condition are the weak link in the accidental
Shah, Viren
Transformative Deep Learning for Image Colorization with Machine Learning-Based Classification2025-28-0317To be published on 11/06/2025
Imagine a user opening a technical manual, eager to troubleshoot an issue, only to find a mix of stark black-and-white illustrations alongside a few color images. This inconsistency not only detracts from the user experience but also complicates understanding. For technicians relying on these documents, grayscale graphics hinder quick interpretation of diagrams, extending diagnostics time and impacting overall productivity. Producing high-quality color graphics typically requires significant investment in time and resources, often necessitating a dedicated graphics team. Our innovative pipeline addresses this challenge by automating the colorization and classification of existing grayscale graphics. This approach delivers consistent, visually engaging content without the extensive investment in specialized teams, enhancing the visual appeal of materials and streamlining the diagnostic process for technicians. With clearer, more vibrant graphics, technicians can complete tasks more
Khalid, Maaz, Akarte, Anurag, Kale, Aniket, Rajmane, Gayatri, Nalawade, Komal
3D Printed Injection Molding Tool: An unique Approach for New product development2025-28-0321To be published on 11/06/2025
Automotive industry frequently uses 3D printed plastic proto parts during new product development phases as it bypasses the high tooling investment & development time at early part development stage. However for some application, 3D printing technique & its limited material options are not fulfilling the required material properties in the part, resulting poor performance during product testing which may mislead the design engineer during validation process. To overcome this, we introduce a novel approach in constructing injection molding tool by 3D printing the core and cavity using Stereolithography (SLA). This enables production of parts with application-recommended material grades, facilitating traditional validation and increasing stakeholder confidence. This paper compares part quality from 3D printed molds against conventional metallic molds for a gear housing cover, demonstrating a 45% reduction in tooling costs and a 75% decrease in tooling development time. Mold life analysis
Gandhi, Sorna Rajendran
Enhanced PTO motor operation modes in Electric tractor2025-28-0239To be published on 11/06/2025
This paper is about optimized way of operation of PTO motor (Auxiliary motor) in Electric tractor using 3 different modes - Low Idle mode, Loader mode and PTO mode. These modes will provide benefit to user by improved battery range, comfort/less fatigue while using loader operation and improved performance or productivity while using PTO operated implements.
sundaram, Pavithra, M, Rojer, Natarajan, Saravanan, Joshi, Priyanka
Method development for estimating deflection and fatigue life using flex body-based vibration fatigue2025-28-0266To be published on 11/06/2025
Author: Ajit Wandhare Co-Author: Prasad Kulkarni Abstract: The structural analysis of off-highway machine platforms has traditionally relied on inertial loads and single-point excitation-based vibration fatigue methods, derived from earlier testing. While these approaches provide qualitative insights, they often lead to either under- or over-designed components, resulting in the need for multiple physical builds to address issues related to platform deflection and lifespan. Furthermore, handrail deflection assessments have historically been subjective, allowing for potential inaccuracies in problem identification. This paper investigates the implementation of flex body-based estimation techniques for predicting deflections in both platforms and handrails, as demonstrated in a deflection estimation exercise for a current off-highway machine platform. This innovative methodology enhances the precision of deflection and life predictions during the mule or feasibility stages, enabling
Wandhare, Ajit, S Kulkarni, Prasad
Development of Door Impact Loads Using Frugal use of "Pedal Force Sensor"2025-28-0283To be published on 11/06/2025
The first step in designing or analyzing any structure is to understand “right” set of loads. Typically, off-road vehicles have many access doors for service/getting into cab etc. Design of these doors and their latches involve a knowledge of the closing loads when the door is shut mostly with an impact of varying magnitudes. In scenarios of these impact events, where there is sudden change of velocity within few milliseconds, produces high magnitude of loads on structures. One common way of estimating these loads using hand calculations involves evaluating the rate-of-change-of-momentum. However, this calculation needs “duration of impact”, and it is seldom known/difficult to estimate. Failing to capture duration of impact event will change load magnitudes drastically, e.g. load gets doubled if time-of-impact gets reduced from 0.2 to 0.1 seconds and subsequently fatigue life of the components in “Door-closing-event” gets reduce by ~7 times. For these problems, structures are usually
Valkunde, Sangram, Ghate, Amit, GAGARE, KIRAN
Novel Methodology for Assessment of Bolted Joints Under Vibration Fatigue2025-28-0287To be published on 11/06/2025
Bolts are one of the most standardized and preferred machine elements for connection and load transfer. On the other hand, since the mechanics of highly stressed bolted joints and the thread fatigue are complex issues, the design and validation of such joints is frequently carried out with major simplifications and assumptions, leading to either over-engineered solutions or to premature failures of the prototypes. Evaluating bolted joint for fatigue is itself complex phenomenon and with vibration loading it adds further challenges in terms modeling and simulation. Proven and most preferred method for vibration fatigue is modal superposition analysis. One major drawback of this method is its inability to include frictional contact. This leads to change in load path, causing incorrect fatigue life evaluation for these joints. In this paper, author presents two different methodologies to evaluate bolts under vibration fatigue capturing correct physics and load path. • Contact optimization
Desale, Amit Nanaji, Singh, Gurwinder, Vhatkar, Rushikesh, Patil, Akhil
Arcing simulation in automatic transfer switches2025-28-0284To be published on 11/06/2025
Automatic transfer switches (ATS) play an important role in the providing uninterrupted power to various applications like data centre, hospitals etc. They can be connected between two utility sources, two gensets or a combination of them. It operates when one of the sources to which load is connected to is not available or the preferred source is up. While they do their job smoothly, they internally see harsh conditions. When one of the sources is active and other ATS is disconnecting, an arc is generated. The arc exists when the air medium breaks into ions and electrons at very high temperatures, typically above 10000K. This arc needs to be quenched quickly to avoid damage to the contacts and current carrying conductors. This paper throws light on an inhouse methodology that is developed using commercial tool Ansys Fluent. The physics of arc consisting flow, thermal and electromagnetic fields are modelled. This paper includes the simulation of arc propagation along with the moving
Badhe, Vivek, Gaikwad, Nikhil Ravindra
Enhancing Tractor Operator Comfort and Safety Through Advanced Drive Assistance Features2025-28-0216To be published on 11/06/2025
This paper explains the role of Advanced drive assistance features that have been designed to increase comfort, operational efficiency, and safety in an electric tractor. Prime goal is to address the challenges faced by the operators currently in a variety of agricultural and utility applications. Hill hold and electric parking brake work in tandem to offer unparalleled safety by eliminating the fear of tractor roll back in uneven terrain and surfaces both in launch and normal operational scenarios. Cruise and Creep control in a combination have been designed to reduce operator fatigue and increase productivity.
M, Rojer, sundaram, Pavithra, Natarajan, Saravanan, devakumar, Kiran, Muniappan, Balakrishnan
Applicability of Machine Learning Techniques to Forecast Remaining Useful Life on Structural Components2025-28-0296To be published on 11/06/2025
Most of the major machines and structural components are designed for fatigue life and at same time it is important to design structural components for no premature fatigue failure. The performance of major machines and structural components are usually tested in controlled environment but in real life components are subjected to fluctuating loads known as fatigue loads which are common causes of failure. Fatigue cracks are common indicators of potential structural failure, and an early stage of crack initiation phase often goes undetected until noticeable performance degradation or failure to the component occurs resulting in a machine downtime. Early detection of Failure and understanding remaining useful life of a component is increasingly more important to customers as it helps in preventive maintenance by timely replacement of a component. This would also result in reducing costs by forecasting time to failure. With recent advancement in science, available data can be analyzed
Velayudhan, Vinod Kumar, ISSRANI, MANOJ, Pawar, Sanket, Goyal, Rakesh
Evaluating the Influence of Material Properties and Hardness on Tightening Torque2025-28-0255To be published on 11/06/2025
A Crawler Dozer is a tracked machine that uses a mounted blade at the front to move materials. Different blades (S-blade, U-Blade, Angle blade, PAT blade) are used for moving large amounts of soil, debris, and stones. Each blade is designed for a specific requirement/application. The blades are equipped with ground engaging (GET) tools, such as cutting bits or a set of cutting bits, to help protect the shovel and other earthmoving tools from wear. Torquing hardened plates of bolted joint components is essential to ensure uniform load distribution and prevent premature failure. Therefore, selecting the proper torque is an important parameter. This study focuses on analyzing various parameters that impact the final torque on the hardened surface. This will help understand the torque required for specific joints. Several other parameters considered in this study include hardware material, coefficient of friction, end bit and cutting-edge material, and their hardness. Understanding the
PARAMESWARAN, SANKARAN POTTI, Bhosale, Dhanaji, Kumar, Rajeev
Dynamic Stiffness Simulation Driven Design Changes for Tractor Cab to Mitigate Structure Borne Noise Levels2025-28-0291To be published on 11/06/2025
The dynamic stiffness of mount systems is a critical factor influencing the overall dynamic behavior and vibration isolation capabilities of mechanical assemblies. Effective cab isolation in product design can reduce structure borne noise and tactile vibrations experienced by operators. Detailed dynamic stiffness analysis of mounting brackets coupled with modal analysis using finite element method provide insights into the vibration response and resonant frequencies of components. By systematically varying parameters such as material properties, shape and geometry, the study elucidates the sensitivity of dynamic stiffness to design alternations. This study investigates on dynamic stiffness and their consequential impact on system dynamics on various design alternations by considering the space constraints at mount locations due to components, wiring harness and structural analysis driven solutions. In overall, this paper emphasizes the pivotal role of dynamic stiffness analysis in
Saveenkumar, Valakeerthi, Cone, Kerry, Mandke, Devendra Laxmikant, Fapal, Anand
E-Motor thermal management using 2D-3D coupling2025-28-0225To be published on 11/06/2025
In the electrical machines, detrimental effects are resulted often due to the overheating, such as insulation material degradation, demagnetization, decreased lifetime and efficiency of the motor and Joule losses. Hence, it is vital to optimize the reliability and performance of the electric motors (E-Motor) and to reduce the maintenance and operating costs. This study brings the analysis capability of CFD for the air-cooling of an E-Motor powering on E-Machines. With the aggressive focus on electrification across automotive industry, there is an increasing need of CFD modeling to perform virtual simulations of the E-Motors to determine the viability of the designs and their performance capabilities. The thermal predictions are extremely vital as they have tremendous impact on the design, spacing and sizes of motors. With this study using Ansys Fluent - Maxwell coupling, a complete 3D CFD with CHT modeling of an Electric Motor, including all the key components like the windings, rotor
Singh, Bhuvaneshwar, Tirumala, Bhaskar, Badgujar, Swapnil, HK, Shashikiran
Reduction in Product Development Time by Field-to-Lab Simulation2025-28-0282To be published on 11/06/2025
KEYWORDS: Flywheel Inertia, Clutch system, Gear Box, Tractor application, Instrumentation, data analysis, Design and develop new test methodology. ABSTRACT: Puddling is a crucial process in rice cultivation, involving the preparation of the soil in a flooded field to create a soft, muddy seedbed. There are two classifications for puddling: full cage and half cage. Full cage puddling involves replacing the rear wheels of the tractor with steel paddle wheels, which are used to till the rice paddies directly without any additional implement. In the half cage puddling, the rear wheels remain on the tractor, and a smaller cage or paddle wheel is attached to the outside. Considering the field size, the operator often releases the clutch very quickly after a speed or direction change. This generates torque spikes, which are harmful to Transmission Gears and Clutches. This can lead to gear teeth bending fatigue failure due to repeated higher bending stresses. In this paper, a study related to
Pathan, Irfan Hamidulla, Bardia, Prashant
Integrating Self Hydraulic Jacks Under the Chassis for off-Road vehicles, and Utility Task Vehicles2025-28-0264To be published on 11/06/2025
Imagine a futuristic vehicle chassis, sleek, low-slung, and aerodynamic, constructed from advanced materials like high-strength alloys or carbon fiber composites. Underneath this captivating structure, a sophisticated system of self-hydraulic jacks is seamlessly integrated. These jacks, situated adjacent to the four shock absorber mounts, are designed to lift the chassis at the tire areas, ensuring efficient underbody maintenance and quick, safe emergency lifts. The design incorporates an intuitive control system with strategically placed buttons for driver convenience. Whether positioned alongside the steering wheel, integrated near the infotainment display, or mounted within the driver-side door, these controls blend technology and practicality. Integrating Self Hydraulic Jacks Under the Chassis:- • Adjacent to each shock absorber mounting point, a self-hydraulic jack is integrated into the chassis design. Designed to be unobtrusive when not in use, these jacks are built into
Gogula, Venkateswarlu
Experimental and kinetic study of methane blending on the laminar combustion and emission characteristics of ammonia under various oxygen contents at high temperature and pressure2025-32-0060To be published on 11/03/2025
As a carbon-free fuel, ammonia is one of the alternatives to traditional fossil fuels, but its combustion characteristics are poor, and it is usually optimized by blending methane and increasing oxygen content. However, there are few relevant studies under different conditions under high temperature and high pressure conditions. In this study, the laminar burning velocities (LBV) and flame instability of NH3/CH4/O2/N2 mixtures at high initial temperature (T), high initial pressure (p), various oxygen contents (Ω) and methane energy ratios (α) are analyzed using a constant volume combustion chamber (CVCC). According to numerical simulation, how various oxygen contents and methane energy ratios affect the combustion characteristics of NH3/CH4/O2/N2 mixtures and NOx emission is analyzed. The results show that LBV is positively correlated with T、α、and Ω, and negatively correlated with p. Markstein length (Lb) does not change significantly with T, but increases with α and decreases with p
YU, Yuantao, Dai, Zhizhuo, Hou, Chunlei, Ye, Mingyuan, Zhang, Xiaolei, Cui, Zechuan, Yin, Shuo, Nishida, Keiya
Strategies for Improving Energy Consumption for Electric Vehicles.2025-32-0092To be published on 11/03/2025
The global transition toward sustainability and decarburization has positioned Electric Vehicles (EVs) at the forefront of future mobility. While EVs inherently offer lower emissions compared to internal combustion engine (ICE) vehicles, optimizing their energy efficiency remains a critical challenge to ensure their viability, affordability, and widespread adoption. With global EV sales surpassing 10 million units in 2022 representing over 14% of the global vehicle market. Energy efficiency has emerged as a cornerstone in addressing key concerns such as range anxiety, charging infrastructure, operational costs and overall environmental impact. This paper embarks on a comprehensive journey, beginning with the historical evolution of EVs and identifying the multifaceted energy losses that occur during vehicle operation. By mapping the energy distribution within a typical EV, the study lays a foundational understanding of where and how inefficiencies arise. It then explores current
Jain, Gaurav, Premlal, P, Pathak, Rahul, Gore, Pandurang
Development of high-efficiency, fully recyclable eMotors for light mobility applications produced in the EU2025-32-0098To be published on 11/03/2025
The growing awareness of the environmental impact of human activities, particularly in the field of transport, coupled with the European "Green Deal" strategy aiming for carbon neutrality, has triggered a revolution in mobility compared to the 20th century. Alongside the general focus for automotive sector, light mobility market is particularly rising in current years with tremendous creative solutions as well in terms of functionality as in the design, while the production volumes tend to increase by a fast rate. This domain is being developed using mainly existing permanent magnet rich motor technologies focusing on functionality and cost leaving aside efficiency, lifespan guarantee and end-of-life management which is one of the adjacent problems of the domain. Moreover, European Critical Raw Material act tends to develop a strong, resilient, and sustainable value chains requiring a different approach as well for light mobility powertrains. This article aims at presenting the
CISSE, Koua Malick, Milosavljevic, Misa, Mallard, Vincent, Valin, Thomas, De Paola, Gaetano
Development of Integrated Forming of New "NMAX" YECVT Parts Using the Plate Forging Method2025-32-0005To be published on 11/03/2025
Yamaha Motor Engineering Co., Ltd. provides plastic processing technology based on fuel tank press forming technology, and is developing various plastic processing methods, including forging, and developing mold equipment to realize them. This time, the core parts of the YECVT unit mounted on Yamaha Motor Co., Ltd.'s small premium scooter "NMAX" were not made by welding individual parts to each other, but by integrally forming them from a single thick plate using the cold forming method, resulting in lightweight, compact, high-strength, high-precision parts. By incorporating a composite plastic processing method that takes advantage of the characteristics of the material while making full use of analysis technology and mold technology, we were able to develop a composite plastic processing method (plate forging method) that creates new added value and mass produce it. In addition,this development has made it possible to achieve a thickness increase of 1.7 times the standard material
Hongo, Hironari, Tamaru, Shogo, Uda, Shinnosuke
Comprehensive Review on Strategies for Preventing and Managing Thermal Runaway in Lithium-Ion Batteries for Electric Vehicles2025-32-0099To be published on 11/03/2025
The rapid growth of electric vehicle adoption has elevated lithium-ion batteries as a cornerstone of modern transportation. However, this advancement is accompanied by increasing incidents of thermal runaway, a hazardous failure process involving uncontrolled temperature rise, combustion, or explosion. Particularly in space-constrained platforms such as electric two-wheelers, the risk is intensified due to limited thermal buffers and cost-driven design constraints. This study presents a comprehensive review and experimental investigation into strategies for preventing and managing thermal runaway in lithium-ion batteries. It begins by analyzing global incident trends and correlating them with the expanding electric vehicle market. The research examines the fundamental mechanisms of thermal runaway, emphasizing the roles of battery aging, material degradation, internal defects, and abuse conditions. A range of thermal safety enhancement approaches is critically reviewed, including
Jain, Gaurav, Premlal, P, Pathak, Rahul, Gore, Pandurang
Fatigue in Plastic Field of AISI 304L on an Engine Component: An Interesting Case on a Pulley for Automotive Application2025-32-0080To be published on 11/03/2025
This study investigates the failure mechanisms of a press-fitted AISI 304L pulley, which is used to drive an engine coolant variable water pump in automotive applications. The analysis focuses on the peculiar loading scheme of the pulley resulting from the innovative water pump design which combines high mean stress from press fitting with cyclic stress from rotating bending loads that exceed the material's yield point. This is coupled with the cyclic material behavior of AISI 304L which exhibit a strong cyclic hardening. This combination significantly influences the stress distribution and fatigue life of the component under cyclic loads combined with material plasticity, ultimately leading to fatigue failure at the pulley-shaft mating surface. Assembly endurance tests were conducted on a specialized test bench, allowing control of pulley bending load. A comprehensive failure analysis, including visual inspection, metallurgical examination, and finite element analysis (FEA) was
Franceschini, Alessandro, Squarcini, Raffaele, Rybicki, Gilles
A Simulation Approach for the Impact Assessment of an Axial Flux Traction Motor Applied on Road Electric Vehicle2025-32-0077To be published on 11/03/2025
In the transition towards sustainable mobility, Circular Design principles are crucial. Electric Motors are subject to continuous innovation to improve efficiency, performance density and reduce externalities associated with their production. Therefore, the choice of technological solutions during design phase must guarantee optimal performance and minimal environmental impact throughout the entire product life cycle: production, use, and end-of-life. In the automotive sector, the use phase is particularly critical since the efficiency of the traction system is directly related to total energy consumption during the life cycle and, consequently, to its environmental impact. This research introduces a simulation-based approach to evaluate the use phase of an Axial Flux Electric Motor equipped with Permanent Magnets (AFPM). While providing high performance for electric traction motors, these magnets are composed of Rare Earth Elements (REEs), e.g. Neodymium, classified as Critical Raw
Guadagno, Maurizio, Berzi, Lorenzo, Pugi, Luca, Delogu, Massimo
Temperature effect on the static and fatigue performance of thermoset and thermoplastic composites2025-32-0006To be published on 11/03/2025
The growing demand for lightweight, durable, and high-performance materials in industries such as aerospace, automotive, and energy has driven the development and evaluation of thermoset and thermoplastic composites. This study investigates the static and fatigue behavior of one thermoset material and two thermoplastic composites at varying temperatures (-30°C, 22°C, and 120°C) to simulate extreme environmental conditions. Experimental tests were conducted to evaluate mechanical performance and fatigue strength, focusing on the influence of temperature on strength and life cycles. The results highlight the significant impact of temperature on static properties and fatigue behavior, offering critical insights into their application in temperature-sensitive environments. A numerical modeling approach was applied to predict fatigue behavior by incorporating the effects of mean stress and temperature. Different fatigue damage models, including temperature-dependent formulations, were
Chiocca, Andrea, Sgamma, Michele, Franceschini, Alessandro, Vestri, Alessio, mancini, Simone, Bucchi, Francesco, Frendo, Francesco, Squarcini, Raffaele
Higher-strength, higher-toughness die cast wheel material using recycled aluminum2025-32-0007To be published on 11/03/2025
In an attempt to reduce CO2 release from the alloy wheel production, we have developed such an aluminum alloy for casting that satisfies necessary property requirements using recycled aluminum and without heat treatment. The wheel is a critical safety item of the vehicle requiring higher toughness and strength. In many wheels, virgin aluminum containing small amounts of impurities are used to maintain toughness, and the heat treatment (T6), in which quick heating and cooling are conducted after the casting, is applied to provide ensure strength. At the start of this project, we focused on two wheel-manufacturing processes; the production of virgin aluminum and the heat treatment, from which a large amount of CO2 is released. The change from the virgin to the recycled material allows reduction of CO2 release to 1/9. The issue in the use of recycled material is that impurities grow in the metal structures as an intermetallic compounds and lower toughness. To deal with the said issue, we
Suzuki, Noritaka
Impacts of enhanced physics-based estimation modeling for trapped air and EGR estimation in real-time control of hydrogen injection in a PFI internal combustion engine2025-32-0047To be published on 11/03/2025
Hydrogen PFI engines face abnormal combustion issues, especially during transient operation. The air-to-fuel ratio and trapped exhaust gas significantly affect combustion stability and NOx emissions, requiring continuous monitoring. Real-time estimation of the trapped gas composition and thermodynamic state is therefore crucial but challenging. This work introduces a real-time, physics-based Multi-Input-Multi-Output (MIMO) model for accurately estimating trapped air and exhaust gas mass at the intake valve closing (IVC) event. In detail, the estimation model makes use of dynamic in-cylinder and exhaust pressure measurements to accurately model mass flows and heat exchange equations with 0.5 CAD resolution. This allows an extremely high fidelity when modelling the physical properties of the various chemical species along the engine cycle. Moreover, the model calibration appears only in the form of two coefficients implemented on a lookup table for twelve different operating points
Galli, Claudio, Ferrara, Giovanni, Grilli, Niccolò, Balduzzi, Francesco, Romani, Luca, Vichi, Giovanni
Study on the Clarification of the Mechanism of Scooter Centrifugal Clutch Squeal2025-32-0022To be published on 11/03/2025
A centrifugal clutch is used in many machines such as scooters, lawn mowers, outboard motor of boats, brush cutters, and so on. It may produce a shrill sound, similar to a brake squeal, when the clutch engages for starting. In this study, we have proved that this shrill sound, in another word, clutch squeal, is caused by the self-excited vibrations of the centrifugal clutch. And we have also clarified that the clutch squeal can be restrained by employing an asymmetrical shape for the clutch housing. The clutch squeal tends to occur when the centrifugal clutch becomes hot due to repetitive starting and stopping, which causes the friction coefficient of the friction material on the clutch shoe to increase. It is presumable that vibration on the clutch housing generated by the self-excited vibrations is the cause of the clutch squeal. In an attempt to clarify the cause of clutch squeal, we first measured the sound pressure of the clutch squeal and the vibration shapes of the clutch
Yamamoto, Kohei, Iwamoto, Tatsuya, Otsuka, Takashi
The effect of differential humidification and membrane thickness on PEMFC operation2025-32-0039To be published on 11/03/2025
In the recent years, the urgency to decarbonize the mobility sector has highlighted the importance of the electrochemical hydrogen use in fuel cells to complement the battery-based electrification. Hydrogen is as an excellent energy carrier, and low-temperature Polymer Electrolyte Membrane Fuel Cells (PEMFCs) are part of an ever-evolving scenario, with particularly promising use in high energy demand mobility sectors. This paper presents a 3D-CFD study to analyse the behaviour of PEMFCs by examining the role of humidification conditions, covering fully humidified (anode and cathode), anode-only, cathode-only, and fully dry operations. This is simulated for several membrane thicknesses, reproducing a wide matrix of operating conditions and separator choices, and examining their respective effect on the cell’s resistance. In the first part of the paper, a part-specific mesh sensitivity analysis is conducted to establish general validity guidelines for the through-plane and in-plane grid
Scialpi, Leonardo, D'Adamo, Alessandro, Marra, Carmine
Establishing the method for simulation of electric potential in cooling water passages of outboard motors2025-32-0008To be published on 11/03/2025
Producing 3D models of cooling water passages of outboard motors, and calculating distribution of electric potential on the water passage surfaces using BEM, we have developed the new method for simulation of electric potential distribution. The outboard motor is a propulsion system attached to the transom of the boat with steering function. As the water around the boat is drawn in for cooling of the engine, the engine parts are susceptible to severe corrosion. As a means to help prevent corrosion, a part referred to as the anode metal, which has a lower natural potential, is provided. Such a method is called the sacrifice protection because the anode metal corrodes before the engine parts due to the difference of electric potential. Since anti-corrosion currents occur preferentially to areas close to the anode metal, the anode metal is required to be located at the most effective place for corrosion protection. However, there are certain restrictions in the layout of anode metal from
Shibuya, Ryota, Suzuki, Hiroki
Development of CAE Technology for the Design Support of Piston Pin Circlip2025-32-0015To be published on 11/03/2025
This study focuses on the technology for establishing design criteria for the piston pin circlip (hereinafter referred to as "circlip"), which is a component that holds the engine piston pin. The circlip is assembled into the piston by compressing it to the size of the piston circlip groove. However, in high-revving engines, the inertia forces caused by engine rotation can cause the circlip to disengage from the groove, potentially leading to the piston pin falling out and damaging the engine. To prevent this, it is possible to compress the circlip more and increase the reactive force acting on the groove to prevent falling out. However, this countermeasure raises concerns about the deterioration of the assemblability of the circlip. Therefore, it is necessary to establish evaluation criteria that prevent the circlip from disengaging and deteriorationg the assemblability of the circlip. To enable appropriate design of the circlip during the engine specifications review phase, we
Ishizuka, Atsushi, Watanabe, Naoto
Dome Profile Optimization and Stress Analysis of Type IV Composite Cylinders using a CLT-based MATLAB Program and FEA Validation2025-28-0374To be published on 10/30/2025
Type IV composite pressure (CP) vessels composed of a plastic liner and composite layers require special design attention to the dome region. The cylindrical portion of the composite cylinder is wrapped with composite layers consisting of the 900 hoop layers and low-angle helical layers, whereas the dome surface carries helical layers only. The winding angle of the helical layers being a constant over the cylindrical portion starts to vary from the cylinder-dome junction toward the boss at the top continuously. Along with the winding angle, the composite thickness also varies continuously resulting in a maximum thickness at the top crown region. The complete analysis and layer-wise stress prediction of Type IV composite cylinders for service pressures up to 70 MPa was analyzed by the Classical Lamination theory (CLT)-based MATLAB program. The MATLAB program developed in this work for the dome initially performs the dome profile generation through the numerical integration of the dome
R. S., Nakandhrakumar, Tandi, Ronak, M, Ramakrishnan, Raja, Selvakumar, Elumalai, Sangeethkumar, Velmurugan, Ramanathan
Cabin Thermal Management Analysis using Alternative refrigerants through 1D Simulation model2025-28-0390To be published on 10/30/2025
At present, all the major Automobile industries are working on sustainability to reduce environmental degradation, conserve resources, and promote the health of ecosystems. As a result, these industries are transitioning to refrigerants with lower Global Warming Potential (GWP) .With growing concerns over climate change, R134a's high Global Warming Potential (GWP of 1400) presents a major environmental challenge. R1234yf, with its substantially lower GWP, presents a more sustainable alternative that aligns with stricter global regulations. This shift not only helps mitigate climate impact but also demonstrates the automotive industry’s commitment to adopting greener technologies. Refrigerant properties like Latent heat, density, Thermal conductivity, e.t.c changes with respect to refrigerants hence cabin thermal management will be affected. In this paper, we will discuss the system level comparison of R134a and R1234yf by developing 1D simulation model. This paper will focus on 1D
Mudaliar, Devarajan, Wanjare, Amol, Rai, Amit, Ghate, Pravin
3D CFD Analysis on Flow and Thermal Dynamics of PEM Water Electrolyzer2025-28-0350To be published on 10/30/2025
The proton exchange membrane (PEM) water electrolyzer is an emerging technology to produce green hydrogen due to its compactness and producing high purity hydrogen. This study presents a numerical investigation of multiphase flow dynamics and heat transfer within the anode side of a PEM water electrolyzer, focusing on the anode plate and porous transport layer (PTL). Different channel configurations, i.e., rectangular, semicircular, and wavy channels are considered while varying the PTL thickness within the commercially available ranges. Simulations are conducted under varying oxygen generation rates (corresponding to different current densities) and different inlet water flow rates. The effects of channel configuration and PTL thickness on pressure drop, flow uniformity, and temperature distribution within the cell are illustrated pictorially and graphically. Additionally, impact of PTL thickness on crucial cell performance parameters are reported. The impact of varying water flow
Dash, Manoj Kumar, Bansode PhD, Annasaheb
Thermal Performance evaluation methodology for Wet Clutch: Simulation & Testing correlation2025-28-0372To be published on 10/30/2025
This paper describes a simulation methodology developed to predict the temperature distribution in separator plate & friction disc of the wet clutch corresponding to given slip power, oil flow rate & clutch geometry for off-highway applications. This study adopts a model-based design approach to understand thermal behavior of the wet clutch. This simulation methodology has been developed in a 1D environment with the right fidelity modeling approach to predict thermal performance of the clutch. This model includes heat flow through conduction & convection corresponding to heat generated due to friction between separator plate & friction material. Lab test includes multiple thermocouples installed on separator plate to capture temperature distribution in radial direction. This methodology has been correlated >90% with test data acquired in the lab. This dynamic simulation model aids to identify the potential root cause of clutch failures and risk mitigation. DOE has been performed to
Kumar, Suneel, Memane, Nilesh, Veerkar, Vikrant
DEVELOPMENT OF CAPACITIVE PRESSURE SENSOR FOR AUTOMOTIVES2025-28-0387To be published on 10/30/2025
The proposed electrostatic capacitive pressure sensor is intended for measuring pressure for automotives. It can measure pressure using this capacitive pressure sensor, which works by monitoring changes in capacitance and diaphragm movement. The diaphragm of the sensor moves lower in response to a boundary load, shortening the distance between it and the die's grounded portion and raising capacitance. By altering the dielectric material and geometry, the sensor is optimized. The sensor is made up of a silicon die, a steel base, and ceramic (Nextel 480 mullite fibers), as the dielectric material. To ensure uniform application of the boundary load around the circle, the geometry of the die changed from a cuboidal shape to a cylindrical one. Based on the broad range of pressure values the diaphragm, dielectric medium, and base thicknesses have been adjusted. The diaphragm is thickened to strengthen the sensor's resistance, to greater pressures. Compared to the prior model (cuboidal die
P, Geetha
A Smart Multi-disciplinary Approach to Evaluate Thermal Insulation Impact on Automotive Mobile Air Conditioning System Performance2025-28-0425To be published on 10/30/2025
Automotive mobile air conditioning (MAC) systems rely on effective thermal insulation to maintain cabin comfort and energy efficiency. However, insulation materials degrade over time due to thermal cycling and environmental exposure, impacting overall system performance. This study investigates the effects of reducing insulation material density (GSM) in critical areas such as the engine firewall, plenum, roof, and door panels on MAC system efficiency. A multi-disciplinary approach combining basic engineering calculations, frontloading CAE simulations, and targeted experimental testing was employed. Initial calculations provided directional input for cabin heat load analysis, guiding early-stage design decisions. Simulation models were used to predict the impact of insulation reduction on cooling performance, energy consumption, and component durability, reducing reliance on iterative physical testing. Experimental validation was then conducted selectively, focusing on critical areas
Kulkarni, Shridhar, Deshmukh, Ganesh, Joshi, Gaurav, Nayakawadi, Uttam, Shah, Geet, Jaybhay, Sambhaji
Numerical Investigation of Novel Hybrid Battery Thermal Management system Integrating angular cantor Fins for Lithium Ion batteries2025-28-0351To be published on 10/30/2025
To address the challenges of thermal management in lithium-ion batteries associated with safety scenarios, real-world driving conditions, and operating cycles, particularly at high discharge rates and extreme ambient conditions, it is necessary to maintain the battery temperature within its optimal operating range. This research introduces a novel hybrid Battery Thermal Management System (BTMS) integrating different cooling techniques, namely phase change material (PCM) and air cooling with fins in the air channel. Unlike conventional approaches that utilize standard rectangular fins, this study employs angular Cantor fins with varying angles and different numbers of fin segments to enhance heat dissipation. The hybrid system aims to exploit PCM's high latent heat storage capability while ensuring efficient convective heat removal via air cooling. The airflow through the cooling channel may accelerates heat dissipation from PCM, thereby increasing PCM's effectiveness. The angular
Kalvankar, Tejas, Lam, Prasanth Anand Kumar, ARURI, PRANUSHAA
DEVELOPMENT OF TEMPERATURE SENSOR FOR AUTOMOTIVES2025-28-0394To be published on 10/30/2025
The paper presents a micro-electromechanical system (MEMS) temperature sensor that has been designed using COMSOL Multiphysics 6.0 software for use in predicting the temperature of automotive parts. Due to its versatility, the shape of this design employs a meander, and this involves joule heating physics. It can measure temperatures ranging from -200°C to 600°C. It clearly shows the variation of resistance with temperature. For this design, copper material is used because of some advantages: high electrical conductivity, thermal conductivity, and mechanical strength, which help in withstanding harsh climate conditions in the stratosphere. This sensor works based on the principle of temperature dependence of resistance; that is, the resistance of the material increases or decreases based on temperature.
P, Geetha
Finite Element Analysis and Test Validation of New Cummins Agricultural Structural Engine2025-28-0376To be published on 10/30/2025
Cummins Inc. is an American multinational corporation that designs, manufactures, and distributes engines, filtration, and power generation products. This paper presents an overview of the design, analysis and testing carried out by Cummins to demonstrate the capability of a new structural engine for an agricultural tractor application. In general applications, the powertrain assembly is mounted onto a vehicle chassis via vibration isolators. Due to tight packaging constraints in agricultural tractors, leaving no room for the chassis rails. The engine in conjunction with the transmission and a front axle carrier becomes an integral member of the vehicle chassis. This leads to the engine being directly subjected to the wide range of agricultural tractor application specific loads. Multiple analysis lead design (ALD) iterations were carried out using cutting edge CAE software such as Ansys, Dassault Systems fe-safe, and PTC Creo to ensure all elements of the complex acceptance criteria
Pathak, Arun Jyoti
Graphene based solar photonic battery for Aircraft-A Finite Element based 2D Analysis2025-28-0389To be published on 10/30/2025
Over the past one decade, progresses in nanoscience and nano technology have unlocked up novel avenues for the formation of operative photo cells. Currently, metal, polymer and semiconductor nanostructure designs for photovolotaic cells can be built. Considering the optical and electrical mechanisms underlying photovoltaic conversion has also helped from hypothetical and modeling reviews. The great cost and low efficacy of contemporary solar photo voltaic cells avoid solar energy from being used extensively. nanomaterials of one-dimensional (1-D) in particular have made original project potentials for additional efficient solar cells possible because of nanostructured ingredients. These one-dimensional nano structures, which include nanowires, nanorods, and nanotubes, present fantastic opportunities to boost photon concentration, electron transport, and electron gathering in photovoltaic battery. Graphene is a 2D (two-dimension), atomically thin, hexagonal lattice of carbon. The
P, Geetha, Sudarmani, R, c, Venkataramanan, Satyam, Satyam, Nagarajan, Sudarson
Thermal Simulation and Experimental Validation of EV Off-Board Charger: A Correlation Study2025-28-0379To be published on 10/30/2025
In an electric vehicle, the Off-Board Charger (OFBC) is an essential component that converts AC power from the grid into DC power to charge the battery. During this process, the vehicle is getting charged, and a lot of heat is generated during the process. This present study is mainly focused on the modeling of OFBC in view of CFD simulations and validating the simulation results with experimental testing in the laboratory. For this purpose, we have carried out the CFD simulations and experimental tests. To perform the CFD simulation, we have used Ansys Icepak as a solver, which is a dedicated tool for electronics cooling. The simulation process includes the modeling of heat sources with appropriate material properties assigned to them, environmental conditions like ambient test temperature, and forced convection introduced because of the axial fan present in the assembly. With the help of the CFD model, we were able to analyze the thermal performance under given operating conditions
Deore, Uday, Patil, Nishikant, Naik, Shibabrata
Study on Oil Film Thickness of Piston Skirt Pattern Coating in A Commercial Vehicle Diesel Engine2025-01-0397To be published on 10/07/2025
In recent years, there has been a trend towards lower engine speeds and downsizing of diesel engines to improve fuel efficiency. This has the advantage of reducing frictional losses in the hydrodynamic lubrication condition but causes severe lubrication in the mixed lubrication condition. In order to reduce friction losses without the risk of abnormal wear or seizure, pattern coatings of the piston skirt area have been proposed. In this study, the oil film thickness between piston and cylinder was measured to investigate the effect of pattern coating on the oil film thickness. The oil film thickness between the piston and cylinder were measured by the laser-induced fluorescence method using the optical fibers embedded in the cylinder. The oil film thickness on the piston skirt was successfully measured under the engine operating conditions for the medium duty Direct Injection (DI) diesel engine. The oil film thickness for the pattern coatings was compared with that for the solid
Tanimoto, Keisuke, Ito, Akemi, Sumoto, Masayuki
Electromagnetic, Thermal, and Dynamic Performance Analysis of Permanent Magnet Linear Synchronous Motor and MR Damper Integrated Active Suspension2025-01-0409To be published on 10/07/2025
Active suspension systems are crucial for enhancing ride quality and passenger comfort in vehicles because they can dynamically adjust their stiffness and damping characteristics. Significant studies have recently been conducted on corporations' and academic institutions' structural design of active suspension systems. Currently, hydraulic and electromagnetic systems make up the majority of active suspension types. Notably, hydraulic active suspensions exhibit a comparatively slower response time, whereas electromagnetic actuator-based active suspensions typically lack the capability to actively modify the damping force's characteristics. Therefore, we proposed an active suspension system that consists of a permanent magnet linear synchronous motor (PMLSM) and a Magnetorheological (MR) fluid damper. In our system, linear motors could provide fast and accurate force response, and the MR fluid damper provides fast and widely adjustable damping force, improving the vehicle's ride comfort
Chowdhury, Nayan Kumar, Zhang, Jiajun, Yintao, Wei
Development of an SSP-180 Synchronizer Durability Test2025-01-0408To be published on 10/07/2025
Synchronizers are designed to provide smooth, efficient and safe transfer of torque between mechanical gears. Friction level, durability, and consistency of the fluid / friction lining system are crucial to ensuring crisp gear engagements without clashing and noise, vibration and/or harshness (NVH) for the life of the transmission. Excellent wear control of gears, synchronizer ring and cone surfaces is also critical to protecting the life of moving mechanical parts. The SSP-180 synchronizer rig measures friction durability and wear up to 100,000 engagements, using a variety of fluids and friction materials. Methodology for the development of a synchronizer durability procedure using the SSP-180 rig is presented for qualifying fluids for dry dual clutch (DCT) and manual transmission (MT) applications for General Motors. It will be shown that the new SSP-180 Synchronizer Durability Test in Appendix C of the dDCT fluid specification [1] satisfies four key conditions for new mechanical
Glasgow, Michael B., Zreik, Khaled, Ezanno, Philippe Nicolas, Shelton, Robert W.
From Temperature to Wear: A Quantitative Analysis of Tire Influence on Vehicle Cornering Using Handling Key Performance Indicators2025-01-5060To be published on 09/16/2025
Vehicle behavior is strongly influenced by tire performance, as tires serve as the primary interface between the vehicle and the road surface. Since identical vehicles equipped with different tire sets—or even the same tires operating under varying thermal and wear conditions—can exhibit significantly different handling characteristics, this study aims to quantify their impact on both steady-state and transient cornering responses through a dedicated evaluation methodology. To demonstrate the generalization of the proposed approach, three completely different validated vehicle digital twins—a passenger car, a sports car, and a formula car—are analyzed in a virtual environment, employing Vi-Car Real Time for vehicle and scenario representations, and RIDEsuite for tire modeling, considering thermal and wear effects. The simulations were designed using a structured design of experiments approach, resulting in 15 predefined combinations of tire temperature and wear states. Results show
Romagnuolo, Fabio, Aratri, Roberto, De Pinto, Stefano, Farroni, Flavio, Bellis, Sergio Andrea de, Bottiglione, Francesco, Mantriota, Giacomo, Sakhnevych, Aleksandr
Influence of Titanate Composition and Particle Size on Friction Stability and Wear in Brake Pads2025-01-0337To be published on 09/15/2025
The effects of particle size and composition of platelet titanates, including potassium titanate and potassium-magnesium titanate, were investigated to determine their friction stability, wear resistance, and transfer film formation. The composition and properties of titanates were characterized using X-ray diffraction (XRD), X-ray fluorescence (XRF), and particle size analysis. Tribological properties were evaluated using a tribometer (MFT-5000), while the worn surfaces were analyzed with scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS). Results indicate that the transfer film characteristics are significantly influenced by the particle size and composition of platelet titanates. Brake pads containing potassium-magnesium titanates formed a more uniform transfer film, leading to improved friction stability and reduced wear rates. In contrast, potassium titanates increased friction levels but also resulted in higher wear on the brake friction materials. These
Jara, Diego Chavez, Lorenzana, Carlos, Sliepcevich, 1Lt Andrea, Conforti, Michael
Further Investigation of Disc Pad Compression Deformation during ISO Compressibility and Dynamic Modulus Measurements under Relatively Low Pressures2025-01-0334To be published on 09/15/2025
In an earlier publication, it was reported that the pad compressibility measured under 160 bars on NAO formulas keeps decreasing with increasing number of repeated measurements due to unrecoverable residual deformation of the friction material combined with increasing moisture adsorption, which increases the hardness of the friction material. This current investigation was undertaken to find out if this same phenomenon occurs for NAOs under a low pressure of 100 bars during compressibility measurements and under 700N during dynamic modulus measurements. In all cases, it is found that the same phenomenon occurs, meaning that friction materials become permanently compressed without full recovery, making them harder to compress and raising up the modulus. The dynamic modulus of friction material attached to a backplate is found to be lower as compared with the friction material without the backplate, which is caused by more rapid moisture adsorption of friction material pads without a
Sriwiboon, Meechai, Rhee, Seong Kwan, Sukultanasorn, Jittrathep
Challenges in Quantifying Tire Wear Particle Emissions on an Outer Drum Test Bed2025-01-0352To be published on 09/15/2025
Tire wear is a significant source of microplastics and airborne particulate matter, contributing to environmental pollution and posing health risks. This study aims to develop a reliable method for quantifying tire wear and TWP on an outer drum test bed while achieving realistic wear rates. A degumming method using talcum powder was applied to prevent tire adhesion, which significantly increased wear rates but introduced complications in particle measurements. To address this, a flow-optimized enclosure was implemented to minimize background emissions. Particle emissions were quantified using APCs, PM samplers, and an ELPI+. The results underscore the challenge of distinguishing between TWP and talcum powder contributions. To estimate the percentage of airborne particle mass, a novel method was employed that calculates the RGB values of images of PM filters. This method estimates the blackening of the filter to determine the amount of TWP present. Size distribution analysis revealed
Schubert, Ludwig, Arias Torres, María Alejandra, Bigl, Stephan, Steiner, Gerald, Huber, Michael, Lex, Cornelia
Preliminary Multi-Physics Modelling and Characterization of a Magneto-Rheological Brake2025-01-0347To be published on 09/15/2025
Magneto-Rheological Fluid (MRF) is a smart material used in several applications for its ability to switch from fluid behaviour to solid-like conditions if a magnetic field is present. The dependency of viscosity on magnetic field makes this fluid suitable for braking system of electric vehicles, thanks to its high controllability and response time in the whole operative range. The main parameters that influence the behaviour of the fluid, and so the braking action of the system, are magnetic field and rotational velocity. In general, the variable physical properties make it complicated to simulate the system and its behaviour in different operating conditions. Therefore, it is usually necessary to build a physical prototype to experimentally verify the response of the braking system at different driving conditions. This paper presents the development of a virtual model of Magneto-Rheological Brakes (MRB) whose validity is extended to different driving conditions. This can be
De Luca, Elena, Imberti, Giovanni, de Carvalho Pinheiro, Henrique, Carello, Massimiliana
Items per page:
1 – 50 of 64334