This specification covers a corrosion-resistant steel in the form of investment castings homogenized and solution and precipitation heat treated to 180 ksi (1241 MPa) tensile strength.

AMS F Corrosion and Heat Resistant Alloys Committee

Material Compatibility Studies of Ethanol Blended Diesel

2026-26-0129

01/16/2026

The Government of India has mandated biofuel blending in automotive fuels to reduce crude oil imports and support the national economy. As part of this initiative, Oil Marketing Companies (OMCs) have begun nationwide blending of E20 fuel (20% ethanol in petrol). Ethanol supply is expected to exceed demand by the end of 2025 due to initiatives like the Pradhan Mantri JI-VAN Yojana. Alternative applications for ethanol are being explored; one promising approach is its use as a co-blend with diesel fuel (ED blends). However, ethanol’s low cetane number and poor lubricity pose challenges for direct use in diesel engines without modifications. ED blends demonstrated reduced emissions while maintaining performance comparable to conventional diesel. To further address concerns related to materials compatibility of ED blends with fuel system components, particularly plastomers that may impact engine durability, a detailed study was conducted using elastomers such as FVMQ, FKM, HNBR, and NBR in

Johnpeter, Justin P, Chakrahari, Kiran, Chakradhar, Maya, Arora, Ajay, Prakash, Shanti, Pokhriyal, Naveen Kumar

For CNG and FFV Fuel Application Exhaust Valve Redesign and Robustness Improvement to Combat Abnormal Valve Guide and Seat Wear

2026-26-0125

01/16/2026

Today, passenger car makers around the world are striving to meet the increasing demand for fuel economy, high performance, and silent engines. Corporate Average Fuel Economy (CAFE) regulations implemented in India to improve the fuel efficiency of a manufacturer's fleet of vehicles. CAFE goal is to reduce fuel consumption and, by extension, the emissions that contribute to climate change. CNG (Compressed Natural Gas) engines offer several advantages that help manufacturers meet and exceed these standards. The demand for CNG vehicles has surged exponentially in recent years, CNG engine better Fuel efficiency and advantage in CAFÉ norms make good case for OEM & Customer to use more CNG vehicle. CNG is dry fuel compared to gasoline. 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

Poonia, Sanjay, Kumar, Chandan, Sharma, Shailender, Khan, Prasenjit, Bhat, Anoop, P, Prasath, Neb, Ashish

Comprehensive Durability Assessment of Planet Carrier in Heavy-Duty Tipper Gearboxes Using RLDA Torque Data

2026-26-0443

01/16/2026

In heavy-duty tippers, where challenging conditions demand high torque, planet carriers play a crucial role by enabling efficient load distribution and torque transmission while supporting gear ratio and speed variation in space-constrained systems such as automatic transmissions, hybrid drivetrains, and electric vehicles. This paper focuses on the comprehensive durability performance assessment of planet carrier housing (PCH) using duty cycles derived from road load data acquisition (RLDA) measurements for a heavy-duty tipper gearbox development program. The existing Design Validation Plan (DVP) for the planet carrier considers first gear utilization of 10-15% at 40% vehicle overload, in line with historical data. However, recent trends in mining applications revealed vehicle overloads of 55-65%, leading to an increase in first gear utilization (25-35%). This shift presents challenges for original equipment manufacturer (OEM) to enhance design durability while incorporating additional

Bagane, Shivraj, Pendse, Ameya

Fatigue Life Prediction Methodology for Vehicle Suspension Systems and Correlation with Physical Test

2026-26-0459

01/16/2026

Fatigue analysis is a vital aspect of suspension design, especially for load bearing components such as the Rear Twist Beam, where durability under cyclic loading is essential for long-term vehicle performance. Among the various durability tests, the roll fatigue test is a key procedure for validating suspension strength and reliability. However, conducting physical roll fatigue tests can be both expensive and time consuming, particularly when multiple design iterations are required. This not only increases cost but also extends the development timeline. This study presents a virtual simulation methodology that replicates roll fatigue test conditions within a finite element analysis environment, enabling early fatigue assessment and design optimization. Developed to support the early design phase, the roll fatigue test simulation process ensures robust designs that meet targeted fatigue life requirements. The approach begins with a detailed understanding of the physical roll fatigue

Kokare, Sanjay, Nagapurkar, Tejas, Iqbal, Shoaib

Failure Prevention of Permanent Deformation in HNBR Elastomeric Diaphragms Used in CNG Valve Applications

2026-26-0294

01/16/2026

Hydrogenated nitrile butadiene rubbers (HNBR) and their derivatives have gained significant importance in automotive compressed natural gas (CNG) valve applications. In one of the four-wheelers, 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 higher pressure However, it was found permanently deformed under lower pressures. In this research work, number of experiments was carried out to find out the primary root cause of diaphragm permanent deformation and to prevent the failure for safe usage of the CNG gas. HNBR diaphragm deformation investigation was carried out using advanced qualitative and quantitative analysis methods such as Soxhlet Extraction Column, Fourier Transform Infrared Spectroscopy (FTIR), Differential Scanning Calorimetry (DSC), Optical Microscopy (OM), Scanning Electron Microscopy (SEM), and Thermogravimetric Analysis (TGA). For

Patil, Bhushan Gulab, NAIKWADI, AMOL, Mali, Manoj, Tata, Srikanth

Development of a Seamless Selectively Elevated Fabric Switch for Intuitive and Sustainable Automotive Interior Interfaces

2026-26-0596

01/16/2026

This technology solves a long-standing ergonomic and aesthetic problem in automotive and consumer interface design, as the use of mechanical switches disrupts the clean look of modern interiors and tends to attract dust and wear. Currently available technologies, such as capacitive touch buttons and mechanical push switches, do not provide the corresponding tactile feedback or clear indication of touch, and usually contain visible openings that interrupt the design flow. Moreover, traditional switches are made up of multiple built-in components, which results in complicated construction and difficult maintenance. To address these drawbacks, we propose a Seamlessly Integrated, Selectively Elevated Fabric Switch that remains flush with the surface when not in use and automatically rises to form a tactile interface when required. The system is a multi-layer construction consisting of an outer fabric upholstery layer, a tactile actuation membrane, and a smart electromagnetic actuator layer

Mohunta, Sanjay, Panchal, Girish, Puthran, Shaunak

Effects of Battery Integration in Modal Behaviour of Electric Two Wheeler Frame

2026-26-0310

01/16/2026

This research investigates the dynamic characteristics of an electric two-wheeler chassis through a combined experimental and numerical approach, and understands the contribution of battery towards overall behaviour of the frame in a structural manner. The study commences with the development of a detailed CAD model, which serves as the basis for Finite Element Analysis (FEA) to predict the chassis's natural frequencies and mode shapes. These numerical simulations offer initial insights into the structural vibration behavior crucial for ensuring vehicle stability and rider comfort. To validate the FEA predictions, experimental modal analysis is performed on a physical prototype of the electric two-wheeler chassis using impact hammer excitation. Multiple response measurements are acquired via accelerometers, and the resulting data is processed to extract experimental modal parameters. The correlation between the simulated and experimental mode shapes is quantitatively assessed using the

Das Sharma, Aritrya, Iyer, Siddharth, Prasad, Sathish, Anandh, Sudheep

Solving the Exhaust Valve CNG Wear Problem: An Investigation into Hard-Facing Material Deposition for CNG Exhaust Valves

2026-26-0278

01/16/2026

Compressed Natural Gas (CNG) offers a compelling alternative fuel solution due to its lower carbon emissions and cost-effectiveness compared to conventional gasoline. However, the dry combustion characteristics of CNG, coupled with higher combustion temperatures, often accelerate Exhaust valve face and Exhaust seat insert wear in internal combustion engines. Intake valve face and Intake seat insert are exposed to fresh air charge and temperature during engine operation remain with in limit and no issue reported in Intake valve side. This study addresses the critical challenge of premature exhaust valve wear in CNG applications by investigating the root cause and implementing improvements in the exhaust valve facing material, aiming to enhance durability and reliability for widespread CNG vehicle adoption. Exhaust valve face in CNG engine subjected to extreme condition leads to excessive valve face wear and cracking. To address these challenges, various technologies like hard material

Poonia, Sanjay, Kumar, Chandan, Kundu, Soumen, Kumar, Prabhakar, Vats, Rajesh, Khan, Prasenjit, Sharma, Shailender

Non-Metallic Inclusions in Carburizing Steels as a Contributory Factor for the Formation of Carbide Net

2026-26-0290

01/16/2026

The article deals with the issue of identifying structural defects that contribute to the formation of a carbide net during thermochemical treatment of steel parts, which negatively affects the mechanical properties complex of finished products. Based on the available data, a theory has been put forward regarding the influence of the present non-metallic inclusions in the carburizing steels structure on carbide formation process in the hardened layer. As an experimentally the samples have been produced from the varying chemical composition alloy structure carburized steel (0.17-0.23 % C, 0.17-0.37 % Si, 0.80-1.10 % Mn, 1.00-1.30 % Cr, 0.03-0.09 % Ti). During microstructure analysis of the samples it has been establish that non-metallic inclusions, in particular sulfides, contribute to the formation of carbides and carbide net in steel due to their high chemical activity with carbon. Thus, contamination of the metal of carburizing steels with non-metallic inclusions is not only a defect

Runova, Iuliia, Chatkina, Mariia, Musienko, Aleksandr

Comprehensive Research Study Examining Tyre Wear and its Indian Perspective

2026-26-0604

01/16/2026

Automobile emissions refer to the gases and particles released into the atmosphere by vehicles during their operation. These emissions contribute to environmental pollution and have an impact on human physiology and environment. This paper assimilates findings from a comprehensive research study examining tyre wear and its Indian perspective. Tyre wear understood as a factor affecting road safety, environmental health, and economic sustainability. The study identifies factors affecting tyre wear and provides overview regarding tyre wear generation in India, encompassing road infrastructure, vehicle characteristics, driving patterns, and environmental factors. Moreover, it examines the adverse effects of these particles on human health, such as respiratory ailments and cardiovascular diseases, as well as their impact on ecosystems. This paper delves measures to measure tyre wear and safeguard both environmental and public health. It also covers the tyre wear measurement methodologies to

Joshi, Amol, Khairatkar, Vyankatesh, Belavadi Venkataramaiah, Shamsundara

Durability Validation of Full Vehicle Structures Using Strain Correlation and RLDA-Based Simulations

2026-26-0523

01/16/2026

Durability validation of full vehicle structures is crucial to ensure long-term performance and structural integrity under real-world loading conditions. Physical test strain and finite element (FE) strain correlation is vital for accurate fatigue damage predictions. During torture track testing of the prototype vehicle, wheel center loads were measured using wheel force transducers (WFTs). In same prototype strain time histories were recorded at critical structural locations using strain gauges. Preliminary FE analysis was carried out to find out critical stress locations, which provided the basis for placement of strain gauges. Measured loads at wheel centers were then used in Multi Body Dynamics (MBD) simulations to calculate the loads at all suspension mount points on BIW. Using the loads at hard points transient analyses were performed to find out structural stress response. Strain outputs from the FE model were compared with physical measurements. Insights gained from these

Jaju, Mayur, Dokhale, Sandeep, Gadre, Nilesh, Patil, Sanjay

Experimental Study on the Role of Hole Expansion Ratio in Enhancing Crashworthiness of Advanced High Strength Steel

2026-26-0295

01/16/2026

To meet light weighting and safety targets, 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 (HER) 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 an 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

Jain, Vikas, Bandru, Shreenu, Nadarge, Harshad, Misal, Swapnali, Deshmukh, Mansi, Paliwal, Lokesh

Thermo-Mechanical Fatigue Assessment of Cylinder Heads Using Advanced Simulation Techniques

2026-26-0465

01/16/2026

Thermo-mechanical fatigue (TMF) is a critical durability concern for cylinder heads in internal combustion engines, particularly under severe cyclic thermal and mechanical loads. TMF-induced damage often initiates in geometrically constrained regions with high thermal gradients and can significantly reduce component life. As performance demands increase, understanding and mitigating TMF becomes essential to ensure the structural integrity and long-term reliability of engine components. This study presents a simulation methodology for evaluating thermo-mechanical fatigue (TMF), a temperature-dependent low-cycle fatigue (LCF) mechanism that arises from repeated thermal expansion and contraction under mechanical constraints, leading to cyclic plastic deformation and damage. The methodology consists of two key phases. Phase I involves global finite element (FE) simulations both thermal and structural to obtain temperature and displacement fields under rated and idle engine conditions

Ghotekar, Sunil, Kumbhar, Dipak Madhukar, Pendse, Ameya

Development of Advanced Thermoplastic Elastomeric Mat and Its Study on Thermal Performance of Wireless Charger System

2026-26-0283

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

A Comprehensive Analysis of Sealing Methods for EV Battery Packs - Trends and Insights

2026-26-0180

01/16/2026

The widespread adoption of electric vehicles (EVs) has introduced distinct engineering challenges, particularly in the design of battery packs, which are crucial for vehicle performance, safety, and longevity. A critical requirement is maintaining ingress protection (IP) ratings of IP67 or higher to protect the high voltage battery packs against water and dust exposure. These ratings are crucial for ensuring compliance with homologation standards and meeting the demands of diverse terrains and operating conditions. Consequently, achieving effective sealing of EV battery packs is a fundamental aspect of their design and engineering. This study presents a comprehensive analysis of sealing technologies employed in EV battery packs, focusing on four primary types: adhesive-based sealants, Formed-In-Place Gaskets, foam cut seals, and rubber gaskets. Benchmarking data collected from over 100 vehicle models across more than 50 brands provides insights into adoption trends, historical shifts

Varambally, Vishakha, Sithick basha, Abubakker, Chalumuru, Madhu, Yaser, K U Syed, Sasikumar, K

A Review on ‘Sensor Technologies’, its Application, Regulatory Standards & Emerging Trend Towards Safe Hydrogen Economy

2026-26-0111

01/16/2026

In a developing country like India, the growing energy demand across all sectors underscores the urgent need for clean, sustainable, and efficient energy alternatives. Hydrogen stands out as a promising fuel, offering virtually zero emissions and helping to reduce greenhouse gas (GHG) emissions, which directly contributes to mitigating global warming, ensuring a cleaner environment, and lowering dependency on fossil fuels. In line with Sustainable Development Goal 7 (SDG 7), which seeks to guarantee that everyone has access to modern, cheap, and sustainable energy, hydrogen is well-positioned to be a major player in India's energy transformation. However, hydrogen has unique properties such as its wide flammability range, high reactivity, and high energy content present significant challenges in terms of safety, particularly in its storage, transportation, and usage. Improper handling or inadequate safety measures can lead to hazardous incidents, making robust testing, certification

Pawar, Yuvraj, Dekate, Ajay Dinkar, Thipse, S, Belavadi Venkataramaiah, Shamsundara

Development of Busbar with New Locking Mechanism for High Voltage EV Battery Applications

2026-26-0155

01/16/2026

In the development of high-voltage (HV) batteries, ensuring secure connections between HV conductors and maintaining the safety and performance of the battery pack is paramount. Therefore, In the pursuit of enhancing efficiency and reliability in electrical connections, this paper explores the innovative alternate for a traditional screwing method with a friction locking mechanism for connecting busbars. The novel design reimagines the busbar as a Friction clamp (Female part) that securely holds the male part of the Busbar, significantly increasing the contact surface area up to 50%. This enhanced surface area not only improves electrical conductivity but also addresses heat generation issues associated with traditional screw-based connection. By eliminating the need for screws, the new design streamlines the assembly process, resulting in reduced cycle times and improved overall assembly line efficiency. This study presents the design methodology, performance analysis, and potential

Venkatesh, Murali, Raghu, Arun, Bhramanna, Amol

Curvature-Continuous Trajectory Refinement for Autonomous Vehicles Using a Pure Pursuit Based Path Smoothing Framework

2026-26-0135

01/16/2026

Path planning is a key element of autonomous vehicle navigation, allowing vehicles to calculate feasible paths in challenging environments for applications like automated parking and low speed autonomous driving. Algorithms such as Hybrid A*, Reeds-Shepp, and Dubins paths are widely used and can generate collision-free paths but tend to create curvature discontinuities. These discontinuities result in sudden steering transitions, which create control instabilities, higher mechanical stress, and lower passenger comfort. To overcome these issues, this paper suggests a path-smoothing technique based on the pure-pursuit algorithm to produce smoothed curve paths appropriate for real-world driving. This method utilizes the practical approach of the original path, but removes sudden transitions that destabilize control. By ensuring smooth curvature, the vehicle undergoes fewer jerky steering actions, improved energy efficiency, less actuator wear, and improved high-speed tracking. This paper

S, Shriniyathi, A, Josana, Edwin J, Joel, T, Akshayaa, M, Senthil Vel, Kumar, Vimal

Assessing the Impact of Hole Piercing Edge Quality on Fatigue Samples for S550MC Steel Sheet

2026-26-0306

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, 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, optimizing the performance of S550MC components depends on a fine understanding of the critical relationship between hole edge quality and fatigue failure. This study highlights the impact of hole-piercing clearance on the edge quality of the hole in modified fatigue samples manufactured from S550MC steel, and its effect on fatigue life. The surface morphology was characterized by using stereoscope for edge quality of hole piercing operation

Nahalde, Sujay, Hingalje, Abhijeet, Ughade, Vikas, Singh, Udita, More, Hemant

Simulation Based Approach to Optimize Electric Vehicle Battery Thermal System

2026-26-0376

01/16/2026

The performance and longevity of Li-ion batteries in electric vehicles are significantly influenced by the cell temperature. Hence, efficient thermal management techniques are essential for battery packs. Simulation based optimization approaches improves the efficiency of the battery pack thermal management during the early stage of product development. In this paper, a simulation-based methodology has been introduced to increase the heat transfer from/to coolant via cooling plate as well as to reduce the heat transfer from/to the external environment. The heat transfer coefficient between cooling plate and coolant needs to be enhanced to achieve efficient heat transfer through cooling plate, without exceeding the coolant pressure drop the target limit. A one-dimensional simulation methodology described in this work analyzed numerous design of experiments for coolant layout without performing CAD iteration loops and optimized the cooling channel width, height and number of channels to

U, Reghunath, P S, Shebin

Johnson-Cook Model Calibration for Brittle Materials under Impact Loads

2026-26-0367

01/16/2026

In the assessment of parts subjected to impact loading, the current process relies on static analysis, which overlooks the significant influence of high strain rate on material hardening and damage. The omission of these effects hinders accurate impact simulations, limiting the analysis to comparative studies of two components and potentially misidentifying critical hot spot locations. To address these limitations, this study emphasizes the importance of incorporating the effects of high strain rate in impact simulations. By utilizing the Johnson-Cook material calibration model, which includes both material hardening and damage models, a more comprehensive understanding of material behavior under dynamic loading conditions can be achieved. The Johnson-Cook material hardening model accounts for the strain rate sensitivity of the material, providing an accurate representation of its behavior under high strain rate conditions. This allows for improved prediction of material response

Pratap, Rajat, Apte, Sr., Amol, Babar, Ranjit, Dudhane, Karan, Poosarla, Shirdi Partha Sai, Tikhe, Omkar

Optimizing Busbar Design by Investigating Critical Parameters and their Influence on Electrical and Thermal Behaviors for Reliable Electric Vehicle Battery Packs

2026-26-0474

01/16/2026

With the rise of EVs, researchers are focusing on optimizing busbar design to meet the demands of high energy density, fast charging, and compact battery packs. The busbar design starts by selecting the material and the cross-sectional area required based on the rated current requirement. The width matches or may exceed the battery cell terminal size, whereas the length is optimized such that it is packaged within the given space constraints. The research also highlights the risk of busbars to oxidation and corrosion, which increases resistance and decreases conductivity for which plating/coating techniques are applied to improve the surface finish, overall durability, conductivity and in some cases the surface hardness, while minimizing the heat loss. Using simulations and experimental validation, the study examines three key design parameters: the weld diameter for busbar welded joints, electrical resistance, and contact resistance. A detailed analysis investigates how the weld

Nogdhe, Yogesh, Singh, Shobit Kumar, Paul, Jibin, Mishra, Mukesh, Menon, Praveen

Effect of Pipe Bending by Rotary Tube Bending Process on Durability of Frame Structure

2026-26-0370

01/16/2026

Automobile frames, particularly trellis frame structures, are engineered for superior dynamic performance, with stiffness being a paramount consideration1. These frames frequently utilize welded tubes, a manufacturing process made more complex by the necessity of bending tubes to precise angles to meet packaging and assembly requirements2. This bending, however, induces residual stresses that can substantially compromise the frame's durability3. This investigation employs a detailed finite element simulation to analyse the structural deformation and residual stresses that arise during the bending of Cold Electric Welded (CEW) annealed round pipes4. A comprehensive 3D mechanical model, incorporating realistic tooling and contact interactions, was developed to accurately simulate shape change, ovality, and wall thickness redistribution during the bending process5. CEW pipes, unlike their Electric Resistance Welded (ERW) counterparts, possess minimal initial forming stresses, and the

Rajwani, Ishwar, Khare, Saharash

Auto Braking System for Preventing Commercial Vehicle Overloading

2026-26-0032

01/16/2026

Overloading in vehicles, particularly trucks and city buses, poses a critical challenge in India, contributing to increased traffic accidents, economic losses, and infrastructural damage. This issue stems from excessive loads that compromise vehicle stability, reduce braking efficiency, accelerate tire wear, and heighten the risk of catastrophic failures. To address this, we propose an intelligent overloading control and warning system that integrates load-sensing technology with real-time corrective measures. The system employs precision load sensors (e.g., air below deflection monitoring via pressure sensors) to measure vehicle weight dynamically. When the load exceeds predefined thresholds, the system triggers a multi-stage response: 1 Visual/Audio Warning – Alerts the driver to take corrective action. 2 Braking Intervention – If ignored, the braking applied, immobilizing the vehicle until the load is reduced. Experimental validation involved ten iterative tests to map deflection-to

Raj, Amritesh, Pujari, Sachin, Londhe, Mahesh, Shirke, Sumeet, Shinde, Akshay

Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application

2026-26-0286

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

Accurate Component Load Prediction with Hybrid Test-FEA Approach

2026-26-0366

01/16/2026

Accurately determining the loads acting on a structure is critical for simulation tasks, especially in fatigue analysis. However, current methods for determining component loads using load cascade techniques and multi-body dynamics (MBD) simulation models have intrinsic accuracy constraints because of approximations and measurement uncertainties. Moreover, constructing precise MBD models is a time-consuming process, resulting in long turnaround times. Consequently, there is a pressing need for a more direct and precise approach to component load estimation that reduces efforts and time while enhancing accuracy. A novel solution has emerged to tackle these requirements by leveraging the structure itself as a load transducer [1]. Previous efforts in this direction faced challenges associated with cross-talk issues, but those obstacles have been overcome with the introduction of the "pseudo-inverse" concept. By combining the pseudo-inverse technique with the D-optimal algorithm

Pratap, Rajat, Apte, Sr., Amol, Babar, Ranjit

Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly

2026-26-0302

01/16/2026

This research paper investigates the failure of an isolator clip used in the seat slider assembly, which guides and restricts the sliding motion of the tooth bracket within the seat. The component is made of C80 high-carbon spring steel, known for its high strength. According to the manufacturing process details, zinc plating was applied to the component for corrosion protection, as confirmed by EDS analysis. A fractographic examination of the failed part revealed a brittle, intergranular fracture morphology with visible cracks. Certain areas also exhibited micro-void coalescence, indicating a dimpled fracture surface. The primary failure mode was intergranular (IG) fracture. The delayed fracture was attributed to intergranular fracture mechanisms, micro-void coalescence, and the high strength of the steel, which made the component susceptible to hydrogen embrittlement. Hydrogen embrittlement occurs when hydrogen atoms become trapped along the grain boundaries, where they form hydrogen

Saindane, Mehul Kishor, Bali, Shirish

Design Optimization of the Propeller Shaft and Transfer Case for High-Speed 4WD Vehicles

2026-26-0343

01/16/2026

Nowadays, vehicle enthusiasts often vary the driving patterns, from high-speed driving to off-roading. This leads to a continuous increase in demand for four-wheel drive (4WD) vehicles. A 4WD vehicle have better traction control with enhanced stability. The performance and reliability of 4WD vehicles at high speeds are significantly influenced by driveline stiffness and natural frequency, which are largely affected by the propeller shaft and transfer case. This study focuses on the design optimization of the transfer case and the propeller shafts to enhance the vehicle performance at high speeds. The analysis begins with a comprehensive study of factors affecting the power transfer path, transfer case stiffness, and critical frequency, including material properties, propeller shaft geometry, and different boundary conditions. Advanced computational methods are employed to model the dynamic behavior of the powertrain, identifying the natural frequency of the transfer case and propeller

Kumar, Sarvesh, Yadav, Sahdev, S, Manickaraja, Sanjay, L, Kanagaraj, Pothiraj, Jain, Saurabh Kumar, Deole, Subodh M

Thermal Management of High-Voltage Connectors Using Double-Layered Phase-Change Materials (PCM)

2026-26-0279

01/16/2026

High Voltage cables and terminals are prone to high temperatures and rapid heat generation due to high current ratings, especially in electric vehicles (EVs). If the temperature exceeds a critical limit, danger may be posed to the components which are connected and the overall safety of the passengers. Traditionally, cooling methods are often energy-intensive and rely on active systems, which may not always be practical for high-power applications. Thus, a localized, fast, and reliable passive thermal management methodology that can be retrofitted into existing connector designs through modifications (e.g., enlargement and PCM integration) would provide significant safety enhancement. The material property of phase change materials, which possess high latent heat, has been used to maintain a steady temperature for a period of time. A dual PCM-layer has been incorporated into the design of the high-voltage connector to serve two purposes:1. The first PCM layer (PCM-1), with good

Neogi, Angshuman, Shinde, Shardul

Accelerating Product Development Life Cycle through Digitalization of Fatigue Life for Structural Components

2026-26-0496

01/16/2026

In today’s market, faster product development without compromising durability is essential. Durability assessment ensures a vehicle maintains structural integrity under normal and extreme conditions. Achieving this requires effective Road Load Data Acquisition, integrated with robust design practices and efficient validation processes. However, physical RLDA is time-consuming and costly, as it depends on prototype vehicles that are often available only in the later development stages. Failures identified during these late-stage tests can delay the product launch significantly. This study presents a full digital methodology of fatigue life estimation for suspension aggregates. A study has been demonstrated on Rear Twist Beam component of rear suspension. The approach integrates the digital RLDA methodology presented in literature and finite element analysis simulation process, enabling durability assessments entirely within the virtual domain. This approach demonstrates how digital RLDA

Kokare, Sanjay, Dwivedi, Sushil, Siddiqui, Arshad, Iqbal, Shoaib

State-of-the-Art Battery Thermal Management Technologies for SCV EV: An Integrated Approach to Enhance Energy Utilization and Reduce Expenses

2026-26-0076

01/16/2026

The performance, lifespan, safety, and overall cost of high-voltage batteries—central elements in electric vehicles (EVs)—are fundamental to the success of the entire EV industry. These batteries, primarily used as energy storage systems, are especially critical in small commercial vehicles (SCVs), where efficient thermal management directly impacts reliability and durability. This paper presents innovative methods to improve energy efficiency, driving range, charging speed, and cost-effectiveness by combining advanced insulation techniques with thermoelectric cooling systems (TECs). The automotive industry is growing in EV domain and mostly in commercial vehicle application. The major challenge in EV’s is maintaining battery temperature to get optimal performance and best battery warranty. The key strategy of this research is providing insulating materials to stabilize battery temperatures. The thermal insulation minimizes thermal losses and buffers against external environmental

Chormule, Suhas Rangrao, Warule, Prasad, Nagpure, Rahul, Jadhav, Vaibhav

Electric Mobility and Materials Circularity - A Study of Recycled PET Textiles for Automotive Interiors

2026-26-0237

01/16/2026

The adoption of sustainability in electric mobility has made it crucial to investigate environmentally friendly materials. Polymer materials used in automotive application plays very important role in material circularity contributing significant value addition to the overall carbon footprint index. This study discloses the development of recycled polyester textiles derived from PET bottle waste and use for automotive interior parts. The use of recycled textiles is directly helping the organization in scope 3 emissions to get the lower carbon footprint value as it is eliminating the use of fossil fuel resources in making the PET textiles. In this study, the development of 50% recycled PET textile and its feasibility for automotive interior is disclosed in detail. The 50 % recycled PET was tested against automotive critical requirements such as sun load UV resistance, abrasion durability, color migrations, soiling resistance, mechanical and thermal properties. The findings showed that

Palaniappan, Elavarasan, Varatharajan, Senthilkumaran, Balaji, K V, Dodiya, Rohanbhai

Realistic LiDAR Data Simulation for Autonomous Systems using Physics-Informed Learning

2026-26-0138

01/16/2026

Accurate and realistic simulation of LiDAR data is critical for the development and validation of autonomous driving systems. However, existing simulation approaches often suffer from a significant sim-to-real gap due to oversimplified modelling of physical interactions and environmental factors. In this work, we present a physics-informed deep learning framework that bridges this gap by enhancing the realism of simulated LiDAR data using generative adversarial networks guided by domain-specific physical constraints for LiDAR intensity. Our method incorporates key physical factors such as range, surface material properties, angle of incidence, and environmental conditions along with their underlying physical relationships as constraints into the Cycle-Consistent GAN architecture, enabling it to learn realistic transformations from synthetic to real-world LiDAR intensity data without requiring paired samples. We demonstrate the effectiveness of our approach across multiple datasets

Anand, Vivek, Yadav, Sourav, Limba, Mohit, Pandey, Gaurav, Lohani, Bharat

Cabin Heat-Up Thermal Assessment for Human Comfort in Passenger Car

2026-26-0408

01/16/2026

The HVAC (Heating, Ventilation, and Air conditioning) system is designed to fulfil the thermal comfort requirement inside a vehicle cabin. Human thermal comfort primarily depends upon an occupant’s physiological and environmental condition. Vehicle AC performance is evaluated by mapping air velocity and local air temperature at various places inside the cabin. There is a need to have simulation methodology for cabin heating applications for cold climate to assess ventilation system effectiveness considering thermal comfort. Thermal comfort modelling involves human manikin modeling, cabin thermal model considering material details and environmental conditions using transient CAE simulation. Present study employed with LBM (Lattice-Boltzmann Method) based PowerFLOW solver coupled with finite element based PowerTHERM solver to simulate the cabin heat up. Human thermal comfort needs physiological modelling; thus, the in-built Berkeley human comfort library is used in simulation. Human

Baghel, Devesh Kumar, Kandekar, Ambadas, Kumar, Ravi, Dimble, Nilesh