Browse Topic: Wear

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A Simple Method for Synthesizing Wear-Resistant Superhydrophobic Anti-Icing Coating2026-99-01297/31/2026
This research demonstrates a facile method for fabricating an anti-icing coating through spray deposition on a metallic substrate. A dual-layer structure was designed to enhance icephobic properties: a primer layer incorporating fluorocarbon resin, butyl acetate, and rod-shaped micrometer-sized metal oxides to establish a secondary roughness morphology, followed by a topcoat composed of butyl acetate and nano-scaled superhydrophobic particles. Evaluation of the coating performance revealed a maximum water contact angle of 171.9°, indicating exceptional hydrophobicity. Furthermore, the coating exhibited notable abrasion resistance and anti-icing capabilities against overlaying ice.
Li, Dongyang, Xu, Zelong, Wu, Jiang, Tong, Wei, Wang, Weiqing, Cong, Rimei, Qian, Jiawei, Qu, Shaohui
Development and Experiment of Rolling Friction and Wear Testing Machine Based on LabVIEW2026-99-02457/31/2026
To investigate the friction and wear characteristics of rolling bearings under various operating conditions, this paper develops a ring-block type rolling bearing friction and wear testing machine based on LabVIEW. The device achieves rotational friction by regulating the speed with a motor and applies the test load using a lever and weight loading method to simulate the actual working conditions of rolling bearings. The testing machine integrates a high-frequency response force sensor with a high-sampling rate data acquisition system, and combines with the LabVIEW platform to achieve real-time collection, processing, and display of friction force. Using a rolling bearing with a diameter of 50mm as the test object, continuous testing was conducted for 100 s under the conditions of a speed of 500r/min and a load of 50N. The experimental results show that the friction coefficient fluctuated significantly in the early stage of the test (the first 20s), and then stabilized. After stabilization, the average friction coefficient measured was approximately 0.005, which is highly consistent with the theoretical value, verifying the accuracy and reliability of this machine. The testing machine has a compact structure and is easy to operate. It is suitable for friction performance testing of various types of rolling bearings and provides an effective experimental means for the tribological research of rolling bearings.
Xiao, Supeng, Hu, Rui, Xu, Chunxia, Liu, Yang, Chen, Binhua
Research on the Erosion and Wear Characteristics of Gathering and Transportation Pipelines by Cyclone Abrasive Process Parameters2026-99-01847/31/2026
Cyclone abrasive pigging technology, with advantages like environmental friendliness, easy construction, and low destructiveness, has broad application prospects. Studying how the process parameters affect the erosion-wear characteristics of gathering pipelines is crucial for improving pigging efficiency and effectiveness. This study adopted numerical simulations based on gas-solid two-phase flow erosion theory to explore such effects and verified the simulations via a self-designed experimental platform. Results showed that within the given parameter range, erosion rate rose significantly with velocity, especially at 20-30 m/s, peaking at 60 m/s; 0.6 mm abrasives and 0.25 kg/s mass flow rate led to higher erosion rates. Experimental data matched simulations with <10% error, confirming accuracy. Thus, cyclone abrasive process parameters significantly influence pigging performance, and the findings can guide practical operations within the studied range.
Wang, Haoran, Zhou, Xianjun, Li, Long, Song, Huifang, Zhang, Jin, Jv, Xiaolong
Microstructure and Properties of 316L Stainless Steels Modified with C and Cr Elements2026-99-02177/31/2026
SiC-based power devices are favored for high-voltage and high-power applications due to their superior material properties. However, the demand for higher breakdown voltages and improved channel mobility presents significant challenges to the etching process, especially the micro-trenching effect. In this study, etching results from inductively coupled plasma (ICP) have been presents, which focused on using various SF6/O2/Ar gas ratios to eliminate micro-trenching effect. The profile analysis of micro-trench was taken by cross-sectional scanning electron microscopy (SEM). The results demonstrate that micro-trenches primarily originate from the coupling effect between ion multi-reflection from sidewalls and redeposition of etch byproducts. Based on this mechanism, we propose a quasi-Bosch process: a combined polymerization and etching step in oxygen-fluorine-rich plasma deposits polymer on exposed SiC and the mask, while removing it from the structure bottom via ion bombardment to enable etching and passivation; then alternates with a short fluorine-plasma step, which consumes sidewall polymer through ion incidence and prevents SiFxOy charge accumulation, cycle etching gradually deepens the structure without micro-trenches. Different gas ratios and etching time not only change the plasma energy distribution but also affect the temporal synchronization between etching and passivation steps. This approach reduces the special demands on ICP equipment capabilities while achieving superior trench profiles. The optimal etching conditions produced a micro-trench-free SiC structure with a vertical sidewall angle and a surface roughness of less than 1 nm. This methodology and resulting structures significantly advance the manufacturability of high-performance SiC power devices, enabling next-generation applications in electric vehicles and grid infrastructure where device yield and reliability are paramount.
Zhao, Yingfan, Dong, Shuang, Sun, Xiaoxu, Chang, Xiangpeng, Liang, Yiwei, Tong, Weiping
Casing Wear Degree Analysis Considering the Buckling and Whirling Effects of the Drill String2026-99-08417/30/2026
Drill string whirl and buckling cause impact-rub contact against the casing inner wall, which induces casing wear and threatens wellbore integrity. This study incorporates both whirl and buckling to analyze the wear mechanism. Finite-element dynamic models are established for three drill string states: stable unbuckled, sinusoidally buckled, and helically buckled. Transient dynamic simulations are performed in the ANSYS Workbench Transient Structural module to obtain whirl trajectories, contact pressures, and contact characteristics at multiple sections along the string. A casing-wear volume calculation based on the Kumar–Samuel formulation with time-varying contact pressure is then used to quantify wear at the lower drill collar, the upper stabilizer, the upper drill collar, the heavyweight drill string, and the buckled segment. Results show that once buckling occurs, whirl concentrates in the bottom-hole assembly and decays progressively from the bottom of the well toward the wellhead. Casing wear increases across all locations, with the largest increments at the lower drill-collar interval and within the buckled segment. Helical buckling produces greater casing wear than sinusoidal buckling. Neglecting drill string buckling, especially helical buckling, leads to underestimation of casing wear and thus underestimation of wellbore-integrity risk.
Liu, Junlin, Cao, Genpei, Wan, Zhiguo, Yang, Zheng, Li, Long, Dou, Yihua, Gu, Runpeng
Innovative Friction Modifier for Copper-Free Brake Pad Applications2026-36-03137/30/2026
The development of copper-free brake pads poses a significant challenge because copper plays a critical role in tribofilm formation and friction stability. This study proposes a novel approach using a recycled flake iron oxide material, characterized by high thermal stability and a unique plate-like morphology, as a sustainable alternative. The material acts as a friction modifier, promoting the formation of stable tribofilms and serving either as a copper substitute or a functional additive. Its iron-oxide composition ensures strong compatibility with the counterface tribofilm, enhancing adhesive friction, while its role as a primary plateau contributes to friction stability and reduced wear. Three application scenarios were investigated: (i) copper substitution in Low-Steel (LS) and Non-Asbestos Organic (NAO) formulations, (ii) partial replacement of steel fibers in copper-free LS formulations, and (iii) synergistic use with iron sulfide in copper-free NAO formulations. Tribological performance was evaluated using a tribometer, and worn surfaces were analyzed by SEM and EDS to characterize tribofilm formation. Results demonstrate that the proposed material provides friction stability and wear resistance comparable to copper in both LS and NAO formulations. Partial substitution of steel fibers improved wear resistance by up to 75%, while synergistic addition with iron sulfide further enhanced friction and wear performance in copper-free NAO pads. These findings highlight the potential of this recycled material as a sustainable and effective alternative for copper-free brake pads, offering both environmental benefits and high tribological performance while reducing reliance on critical raw materials.
Jara, Diego Chávez, Lorenzana, Carlos
Maximizing Autonomy, Minimizing Environmental Impact: The Cooperative Regenerative Braking2026-36-03167/30/2026
In conventional braking systems, the kinetic energy of a vehicle is predominantly converted into heat through friction, a thermodynamically inefficient process. This not only causes progressive wear of components but also leads to the release of various materials, including heavy metals and organic compounds. With increasing concern over non-exhaust emissions, the search for innovative solutions becomes imperative. In electrified vehicles (xEVs), regenerative braking emerges as a strategic technology, converting kinetic energy into electrical energy to recharge the battery and extend range. This process not only enhances the vehicle's energy efficiency but also results in reduced frequency and intensity of mechanical brake usage. Consequently, there is a direct reduction in the wear of friction braking components, which translates into a significant mitigation of particulate matter emissions associated with this wear. The optimization of these systems occurs through Cooperative Regenerative Braking (CRB), which intelligently integrates with hydraulic braking. The primary challenge lies in managing the transition between modes to recover maximum energy without compromising safety and driver comfort. This technical paper explores how CRB employs 'torque blending' via advanced ECUs and software to adjust in real-time the proportion of each braking type, aiming for maximum energy recovery in diverse driving scenarios. To verify the effectiveness of this system, practical tests were conducted on a vehicle. The results obtained from these tests were conclusive, demonstrating significant gains in energy efficiency, with an increased battery recharging capacity during decelerations, optimized by the braking system. This improvement in efficiency directly impacts the reduction in the use of the conventional friction brake system and, consequently, a sharp decrease in particulate matter emissions. In this context, the intelligent and cooperative management of regenerative braking is a strategic and fundamental component for building a more sustainable future in vehicular mobility.
Batagini, Emerson, Romão, Bruno
Influence of Modified Fly Ash Content on the Properties of Resin-Based Friction Materials2026-99-16577/24/2026
In this study, five resin-based brake pad samples with modified fly ash contents of 0%, 4%, 8%, 12%, and 16% were prepared to investigate the influence of fly ash content on the comprehensive performance of the friction materials. The tribological properties of all samples were evaluated under temperature conditions ranging from 100 °C to 350 °C, and their overall performance was assessed using five evaluation indices. Based on the AHP-MOORA algorithm, sample F12 exhibited the highest comprehensive weighted score of 0.11, followed by samples F0 and F8 with scores of 0.10 and 0.09, respectively, indicating a slight decline. In contrast, the comprehensive weighted scores of F4 and F16 were relatively low, at 0.05 and −0.01, respectively. Among the five composites, F12 demonstrated the best overall performance, with F0 and F8 ranking next, while F4 and F16 performed poorly. These results suggest that, within a certain range, increasing the fly ash content can enhance the comprehensive properties of the material. However, excessive addition of fly ash may lead to the detachment of harder particles during wear, thereby increasing wear thickness and wear rate.
Li, Xiaobiao, He, Kang, Zhao, Zhuanzhe, Wu, Bo, Sun, Fei
Lubrication Design and Experimental Verification of Long-Lifespan Ball Screw for Space Environment2026-99-16357/24/2026
Ball screws, as classic high-precision transmission structures, are widely used in various linear motion mechanisms. To meet the needs of space applications, it is necessary to address issues such as microgravity and long lifespan to enhance the in-orbit lifespan and reliability of ball screws. Traditional oil or grease lubrication methods are often unsuitable for space environments due to microgravity and vacuum evaporation problems. This paper conducts relevant research on lubrication design, friction pair design, and friction and wear verification to solve the lubrication and lifespan issues of long-lifespan ball screws for space applications.
Xie, Wen, Zhao, Jian, Gong, Kang, Hu, Xiaonan, Guo, Menglei, Jiao, Hanyu
Surface Engineering Approach to Enhance the Tribological Performance of Titanium Nitride–Coated Stainless Steel against Ti6Al4V under Wet Condition2026-01-50607/22/2026
The impact of a titanium nitride (TiN) coating by the cathodic arc deposition (CAD) technique on a 316L stainless steel (SS) 316L substrate is examined in this experimental work. The X-ray diffraction study showed that TiN made the osbornite phase grow in the coated specimen. The SS 316L sample had a hardness of 217.66 HV, and the samples with CAD coatings were five times harder than the uncoated disc. The wear test was conducted using a pin-on-disc tribometer under dry and wet conditions at loading conditions of 2 N, 4 N, and 6 N with the counterpart of grade 5 titanium alloy (Ti6Al4V). Wear resistance improved significantly, with the wear rate decreasing markedly after coating compared to the uncoated sample. The wear morphology of the wear on the contact surfaces was identified by SEM analysis of the images. The biocompatibility of the ceramic-coated SS 316L sample with the normal cell line was proved by a cell viability test. The demand for SS 316L and the use of CAD coatings to reduce friction and wear in bio-implant applications were the main topics of the current study.
Gopi, R., Devaraju, A., Sivasamy, P., Raju, M.
Plain Bearing Wear MeasurementARP5448/7A (Current)7/20/2026
This standard details two methods of inspecting PTFE lined spherical or journal bearing wear outside the test apparatus. The methods described herein are applicable only to bearings which were unidirectionally loaded and the area of sliding wear is known and held constant throughout the dynamic test. The two methods described are: a Destructive Inspection - Cut and measure (not applicable to molded liners) b Nondestructive Inspection - Radial play (gauge) measurement
ACBG Plain Bearing Committee
Electrical and Copper Compatibility Studies of Transmission Lubricants for Advanced Electric Vehicles2026-01-50366/3/2026
Improved energy efficiency and lower CO2 emissions are the two major drivers for the emergence of E-mobility. Growth of electric vehicles (EVs) has sustained ever since their introduction till 2020 and has substantially increased thereafter. EVs require specialized lubricants, which are different from conventional lubricants mainly due to the addition of new hardware technology including e-motor, inverter, battery, and new materials (copper windings, elastomers, plastic, and other materials). Lubricant when used in an advanced powertrain electric vehicle specifically in E-powertrains may encounter the e-motor and must deliver unique performance attributes such as optimal electrical properties, thermal management, and material compatibility apart from the traditional features including extreme pressure, friction performance, oxidation, and wear control. In the current study, we have investigated conventional GL5, manual transmission fluid (MTF), automatic transmission fluid (ATF), and dedicated e-fluids to understand additive and viscosity effects on aforesaid performance traits. Our study emphasized that additive chemistry plays a significant role on key properties such as electrical properties, corrosion resistance, oxidation resistance, and tribological performance.
Katta, Lakshmi, Seth, Sarita, Singh, Sandeep, Bhardwaj, Anil, Arora, Ajay Kumar
Wear Resilience Characteristics of Silicon Nitride Strengthened AZ31 Magnesium Composite2026-26-07406/1/2026
To develop magnesium matrix composites, ceramic silicon nitride (Si3N4) particles are added to the magnesium (AZ31) matrix at 2 wt.%. The composite is produced via disintegrated melt deposition vacuum-stir-casting procedure. Microstructural studies reveal the presence of Si3N4 particles and their uniform spreading. An L9 orthogonal array, planned using Taguchi’s experimental design, is selected for three wear parameters; axial load (AL), rotational speed (RS), and time duration (TD) with trials as per the G99 standard in the pin-on-disc apparatus to assess the wear resilient of the composite. Experimental results show an increase in axial stress, and wear loss (WL) increases dramatically. Because the area of contact shrinks as RS increases, WL diminishes dramatically. When the AL is low, the friction coefficient (CoF) increases, and when the AL is large, CoF drops. When the RS is increased, CoF decreases. To optimize multiple responses effectively, the TOPSIS (Technique for Order Preference by Similarity to Ideal Solution) approach was adopted. According to the analysis, the ideal combination turned out to be a 10 N A, an RS of 275 rpm, and a TD of 1000 seconds. ANOVA results show that AL (56.99%) and RS (27.2%) contribute more, with a regression coefficient of 92.99%. Abrasive and adhesive wear mechanisms are observed from the worn-out surface micrographs.
Senthilkumar, N., Dhinakar Raj, C K
Investigation of Aluminium Alloy Composites Reinforced with Zirconium oxide and Solid Lubricant Attributes for Brake and Clutch Components of Aircrafts2026-26-07526/1/2026
For brake and clutch components of aircraft vehicles which require higher mechanical strength and wear resilient, light-weight aluminium composites were developed infusing solid lubricant. In this study, hybrid composites were developed using powder metallurgy route with aluminum alloy AA356 and various amounts of zirconium oxide (ZrO2) (0, 5, 10, 15, and 20 wt.%) as reinforcements. A solid lubricant hexagonal boron nitride (hBN) at a fixed 5 wt.% is considered. Following the appropriate ASTM guidelines, the specimens were mechanically characterized by measuring their density, porosity, micro-hardness, compression strength, impact strength, and flexural strength, among other properties. The findings showed that the composites' mechanical and physical behaviour were greatly affected by the inclusion of ZrO2. Porosity increased as a result of particle clustering and interfacial voids, while density increased gradually as ceramic content increased. Consistently increasing ZrO2 addition led to micro-hardness improvements; at 20 wt.% reinforcement, values reached their maximum, indicating that the hard ceramic phase contributed to better surface resistance. The best balance between particle reinforcement and matrix continuity was suggested by the compression and flexural strengths peaking at 15 wt.% ZrO2. However, when the addition was raised to 20 wt.%, brittleness and porosity began to marginally deteriorate. Unreinforced and lower ZrO2 composites had superior toughness in impact, whereas materials with a higher content had a poorer energy absorption capacity. The 5 wt.% hBN improved fracture arresting capabilities and helped load transmission over the interface. Inclusion of hBN provides solid-lubricating tribofilm formation that enhances the tribological performance. This study reveals that AA356/ZrO2-hBN hybrid composites have good hardness and compressive strength improvements, with 15 wt.% ZrO2 being the best composition with good strength, toughness, and wear resistance.
Senthilkumar, N.
Lightweight Magnesium Nanocomposites with Enhanced Wear Resistance for Landing Gear Application2026-26-07516/1/2026
This study systematically evaluated the wear resilient performance of AZ61 magnesium alloy reinforced with 15 wt.% SiC and diverse amounts of multi-walled carbon nanotubes (MWCNTs) under dry sliding circumstances adopting pin-on-disc apparatus (ASTM G99). To identify the influence of factors like sliding speed (SS) (1-3 m/s), axial load (AL) (10-30 N), and MWCNT concentration (0-3 wt.%) that affect tribological performance, experiments were developed using a Central Composite Design (CCD) under Response Surface Methodology (RSM). SEM micrographs revealed a dispersion optimum near 2 wt.% MWCNT, where CNTs anchor to SiC and bridge the α-Mg matrix, while 3 wt.% shows agglomerates and micro-voids. Findings showed that wear loss (WL) and friction coefficient (CoF) was greatly amplified by increasing AL owing to localized heating and contact stresses. A compacted tribolayer was formed by increasing SS, which decreased WL but marginally raised the CoF. At low AL (10 N), SS (2.09 m/s), and 2.12 wt.% MWCNT, the wear resistance was significantly improved by improving load transfer and creating a lubricating carbon-rich coating, resulting in a decreased WL of 0.006 g. The CoF persisted within the range of 0.19 to 0.28. Agglomeration of MWCNTs caused increased WL and CoF when the MWCNT content is increased above 2 wt.%. Worn-surface microscopy at the optimum showed fine wear tracks and a continuous carbon/oxide glaze, evidencing a lubricious CNT-rich third-body film, whereas high AL/low MWCNT produced deep grooves and delamination.
Senthilkumar, N.
A High-Sensitivity and High-Throughput Inductive Sensor for Abrasive Particle Detection Using Rectangular Coils2026-99-07575/15/2026
The analysis of wear particles within machinery lubricants constitutes a critical methodology for assessing equipment health and enabling the early identification of potential failures. However, conventional inductive abrasive particle sensors typically exhibit lower detection sensitivity compared to other sensing technologies, limiting their practical application in precision condition monitoring. To address this limitation, this paper introduces an inductive abrasive particle sensor with enhanced sensitivity and throughput, employing rectangular coils, together with a custom-designed signal conditioning circuit. The sensor features two symmetrically arranged rectangular excitation coils and two symmetrically arranged rectangular sensing coils, with their respective axes mutually perpendicular. This unique spatial configuration not only ensures strong magnetic field intensity within the detection region but also significantly enhances magnetic field utilization efficiency. The sensing coils are connected in a differential output configuration to improve the common-mode rejection ratio, thereby enhancing the sensor's immunity to environmental interference. Furthermore, a specifically designed compensation circuit effectively counteracts the inherent unbalanced output of the probe, ensuring stable sensor operation. Subsequent the signal conditioning circuit successfully extracts weak particle signals from the sensor output while effectively suppressing noise interference and improving the signal-to-noise ratio. This paper also develops a comprehensive mathematical model for the proposed sensor, providing theoretical validation of the structural superiority. Experimental results reveal that the sensor can reliably detect ferromagnetic particles as small as 130 μm and non-ferromagnetic particles as small as 184 μm within a flow conduit of 7.2 mm equivalent diameter, maintaining high sensitivity while providing substantial flow throughput of 4.88 L/min.
Jiang, Ziyang, Qian, Min, Huang, Honglian, Lu, Yanlu, Zhang, Junjian, Pan, Chengliang
Research on the Friction Performance of EVA Insulating Mats for Live Working in Smart Grids2026-99-07145/15/2026
Live-line operation is a critical technique for maintaining the reliability and continuity of power supply in modern distribution networks. Insulating mats serve as essential protective equipment during such operations by providing both electrical insulation and mechanical shielding. In practical service conditions, insulating mats are subjected to repeated mechanical contact and friction against conductors, metallic fittings, and ground surfaces, which progressively deteriorates their surface integrity and compromises operational safety. Current performance standards for insulating mats emphasize dielectric and tensile properties, while tribological durability remains unaddressed. In this study, an EVA – PA6 composite film fabricated via the tape casting method was selected as the representative outer insulating layer of insulating mats. Reciprocating friction tests were conducted using an SDR339 abrasion tester to evaluate the effects of normal load and sliding speed on wear behavior. The results indicate that wear mass increased monotonically with friction cycles at a given speed, whereas the incremental wear rate gradually decreased due to contact area evolution. A pronounced transition from mild surface abrasion to severe material removal was observed when the applied load reached 5 N, accompanied by surface scratching and exposure of the internal fibrous layer. These findings demonstrate that the wear resistance of the EVA – PA6 composite film is insufficient for long-term service under realistic frictional conditions. The results provide experimental evidence supporting the necessity of incorporating standardized wear resistance evaluation into performance criteria for insulating mats used in live-line operations.
Sun, Xin, Wen, Libin, Kou, Hanpeng
Optimizing Coil Structural Parameters to Enhance the Sensitivity of Wear Particle Sensor2026-01-50335/14/2026
If wear particles generated during the operation of automobile engines are not monitored in time, they will contaminate the lubricating oil, leading to system failures or even accidents. Therefore, real-time wear particle monitoring is crucial for the stable operation of engines. Among mainstream wear particle monitoring sensors, the three-coil inductive sensor demonstrates significant application potential due to its ability to distinguish wear particle materials and strong resistance to environmental interference. However, its insufficient sensitivity to small-diameter wear particles limits further performance improvement. This paper takes the three-coil inductive wear particle monitoring sensor as the research object. First, a mathematical model of the sensor’s operation is established based on the law of electromagnetic induction, clarifying the relationship between structural parameters (such as channel radius, turns, coil spacing, and length) and the peak induced voltage. Subsequently, Multiphysics simulation software is employed to quantitatively analyze the influence of each structural parameter on the induced voltage, identifying directions for parameter optimization. Furthermore, orthogonal experiments are conducted to optimize discrete parameters, determining optimal levels for key parameters such as channel radius and coil spacing. Then, the simulated annealing algorithm is applied to achieve precise optimization of continuous parameters, ultimately obtaining the optimal combination of coil structural parameters. Experimental validation based on the optimized parameters shows that the peak-to-peak induced voltage for 1000 μm wear particles measured by the sensor optimized with the simulated annealing algorithm reaches 2.43 V, which is approximately 41 times higher than the 0.06 V observed before optimization. Additionally, the optimization effect of the simulated annealing algorithm further improves by 38.86% compared to the orthogonal experiment. In addition, experimental tests were also carried out on small-diameter abrasive particles of 100 μm, with the peak-to-peak value of the induced voltage reaching 0.38 V. The results confirm that this coil structural parameter optimization method effectively enhances the sensor’s sensitivity to small-diameter wear particles, providing a theoretical basis and technical support for the structural design and performance improvement of three-coil inductive wear particle monitoring sensors.
Yin, Hao, Zhao, Lijun, Shen, Yitao
Dynamic Testing and Component Inspection of a Pericyclic Drive SystemF-0082-2026-01945/5/2026
After four decades of research and 3.5 year prototype testing campaign, Penn State's pericyclic transmission technology demonstrator, dubbed the 'Pericycler', has achieved its operating speed of 5,000 RPM at 17 HP. The characterization of this system by experimental efficiency and vibration represents a major milestone in pericyclic gear technology. A post-test inspection procedure was performed to analyze component wear and validate hypotheses on mesh behavior. This work concludes with structural, tribological, and instrumentation modifications to the Pericycler for future testing.
McGovern, Jeremy, Eicholtz, Keith, DeSmidt, Hans, Darmstadt, Patrick, Mathur, Tanmay, Stevens, Mark, Smith, Edward, Schroen, Erik, Mitsingas, Constandinos
Fretting Wear of Boundary Lubricated M50 Steel and Si3N4 Cylindrical Rollers on M50 SteelF-0082-2026-02275/5/2026
Bench-level boundary-lubricated fretting experiments were conducted to compare the relative wear of all-steel and hybrid material pairs. Roller-on-raceway contacts were simulated using both AISI M50 steel and Si3N4 cylindrical rollers on flat AISI M50 steel disks. The rollers were 9 mm long with a 9 mm diameter. Tests were conducted with constant amplitude, oscillation frequency, and load. All tests were boundary-lubricated with 0.1 ml of DOD-PRF-85734, MIL-PRF-32538, MILPRF-23699, or unclassified ISO VG 68 aviation gear oil. Wear volume was calculated from 3D measurements on the roller and disk samples after each test. Wear tracks were inspected with light and scanning electron microscopy. It was concluded that hybrid pairs exhibited less wear than all-steel pairs when boundary-lubricated with three of the four aviation gear oils. Both hybrid and all-steel pairs exhibited similar wear when boundary-lubricated with MIL-PRF-23699 oil.
Hager, Carl, Carl, Matthew, Benak, Noah
Experimental Investigation Wear of the Power Cell Assembly of an Internal Combustion Engine Operated with Ethanol Through Vibration and Oil Analysis2026-01-03524/7/2026
The durability test is an experimental test widely used in the automotive industry to verify the ability of an engine to withstand all operating conditions throughout its useful life. The test is performed on a dynamometric bench that subjects the engine to specific operating cycles. The objective of this study was to monitoring the level of wear of the power cell assembly and the performance of the engine operated with ethanol during the durability test. Wear monitoring was performed through the application of vibration analysis and lubricating oil analysis techniques. The results showed that the level of wear and performance of the engine after the durability test were considered satisfactory. Compared to durability tests previously conducted without monitoring, the analysis of wear metals in the lubricating oil and oil properties, combined with vibration analysis throughout the durability test, allowed for safe testing with a shorter total test time, optimized technical downtime and reduced wear on engine components. The application of vibration analysis and lubricating oil analysis techniques was important in monitoring wear and allowed the complete completion of the test.
Santana, Claudio Marcio
Life of a Formula One Power Unit: Valvetrain Systems2026-01-02694/7/2026
The world of Formula One (F1) is changing with impending 2026 F1 regulations imposing even stricter limits on engine component usage while increasing races. The valvetrain system, specifically the intake valves, is a critical determinant in controlling gas exchange within the cylinders, directly impacting air-fuel charge and power output. The aim of this investigation is to study the mechanisms of intake valve and valve seat wear which will influence engine performance due to leakage path development. The wear mechanism of the intake valves considers wear from impact from valve seat interaction, sliding and foreign particle abrasion for quantifying valve seat recession. An FIA 2026-2030 regulations compliant valve train model was developed in GT-Suite to help estimate valve seat wear. The validated model could predict valve recession for a given engine operating speed trace from racetrack data. This report presents a systematic methodology for developing valve seat wear quantification, the effects of charge leakage past the valve on engine performance and hence, performance degradation per race through the decrease of air-fuel charge. It was found that the average wear of the valve and valve seat is within an envelope of 39.6 μm to 48.1μm resulting in power losses of up to 1.6 kW per eight race stint. The proposed schemes can thus be used by power unit manufacturers to evaluate valve seat materials as well as valvetrain kinematics for improving reliability and life of valve train systems for a given race.
Soh, Sean Kendrick, Samuel, Stephen
Plain Bearing High Speed Oscillation TestARP5448/2 (Current)3/6/2026
This test method outlines a standard procedure for performing cyclic reversing load testing on oscillating sliding bearings. The wear data from these tests is to be used for qualification requirements and to establish bearing design criteria.
ACBG Plain Bearing Committee
Effect of Sebastiana Rostrata Fiber Loading on the Tribological Behaviour of Polycaprolactone Biocomposite2026-28-00212/12/2026
This study investigates the tribological behaviour of Sesbania rostrata fiber (SRF) reinforced polycaprolactone (PCL) biocomposites using a pin-on-disc wear couple. The stationary SRF/PCL composite specimen interacted with a rotating EN31 steel disc (64 HRC), establishing the sliding wear interface in accordance with ASTM G99 standards. Composite laminates containing 10, 20, and 30 wt% SRF were evaluated at a sliding velocity of 1 m/s over a fixed distance of 1000 m under varying normal loads. The incorporation of SRF significantly enhanced the wear performance relative to neat PCL, with 20 wt% fiber loading achieving the lowest coefficient of friction and specific wear rate due to improved load transfer, stronger interfacial adhesion, and a more uniform laminate structure. In contrast, the 30 wt% composite exhibited fiber agglomeration, reduced homogeneity, and weakened fiber–matrix interactions, resulting in increased wear. SEM microstructural analysis confirmed the formation of a continuous polymer transfer film and uniform fiber distribution at 20 wt%, whereas 30 wt% showed non-uniform fiber orientation and clustering that negatively influenced tribological stability. These results demonstrate that optimized SRF loading significantly improves the load-bearing capacity and surface durability of PCL biocomposites, supporting their potential for wear-critical automotive, orthopaedic, and biodegradable engineering applications.
Raja, K., Senthil Kumar, M.S.
Development of a Fuel Injector Driver for Accelerated Testing2026-26-05641/16/2026
This paper presents the design of a cost-effective fuel injector driver designed for accelerated testing of injectors. The driver simulates injection patterns across a wide range of vehicle operating conditions and can be programmed with injection maps for different engines, test cycles based on drawing specifications, pre-defined engine running profiles, and manual control, where the user defines PWM frequency and duty cycle. It also enables remote operation through a Wi Fi access point. An injector driver-based test setup was developed to study wear and evaluate leakage tendency in an injector design. To simulate extended field usage in a short timeframe, an accelerated operating cycle was derived using telematics data. Injector samples were tested with periodic leak rate measurements. Conducting such tests at vehicle level or on engine test bench would involve significant time and cost. This setup is an effective tool for rapid comparative analysis across supplier design, enabling data driven product selection. It can also be used for quick evaluation of design improvement features introduced in injectors. The flexible architecture and remote operability make it a valuable tool for future injector development and validation.
Bhatt, Pancham, Agrawal, Adheesh, Kuchhal, Abhinav
Tractor Clutch Wear Simulation by Inhouse Development2026-26-05721/16/2026
To develop a Test Method & Procedure for validating the Tractor clutch system performance & Wear simulation endurance test. Tractor clutch wear simulation test conducted along with transmission by operating clutch in different modes as per RWUP operation. In this test we can validate clutch field failures in short time with improved test accuracy at lab. In one of M&M technology project, Transmission Wet clutch system for higher HP tractors where we don’t have any dedicated test rig/methodology for validating Clutch wear & related failure simulation at lab
D, Yashwanth, Raja, R, Udayakumar, S, M, Jeevaharan, Vijayakumar, Narayanan
Experimental Study to Investigate and Control Image Blurriness due to IRVM Vibration2026-26-03211/16/2026
Vibration is one of the prominent factors that determine the quality & comfort level of a vehicle. Moreover, if vibration occurs in areas that are almost entirely within customer touchpoints, it could become a critical factor behind vehicle comfort and affects the brand image within the market negatively. The interior rear-view mirror (IRVM) is one of the important components inside passenger cabin, providing drivers with a clear view of the rear traffic. However, vibrations induced by engine operation, road irregularities, and aerodynamic forces can cause the IRVM to oscillate, leading to image blurriness and compromised visibility and safety. This paper investigates the underlying causes of IRVM vibration and its impact on rear visibility. Through experimental analysis we identify key factors contributing to mirror instability. The findings indicate the specific frequencies of vibration, particularly those resonating with the mirror's natural frequency, significantly exacerbating image blurriness. This paper presents the design modifications and damping solutions to mitigate these vibrations, enhancing the overall safety and driving experience. The study results provide valuable insights for automotive engineers and designers aiming to reduce IRVM vibration and enhance the driver/ passenger safety.
Khan, Aamir Naved, Saraswat, Vivek, Jha, Kartik, Singh, Hemendra, Seenivasan, Gokulram, Khan, Nafees
Comprehensive Research Study Examining Tyre Wear and its Indian Perspective2026-26-06041/16/2026
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 provide a comparison of methods used for estimating tyre wear. This paper is an attempt to summarize effects of tyre wear and its Indian perspective. Specific market serves specific requirements. Bringing forward India specific perspective of tyre usage patterns, it is common observation that Indian tyre consumption pattern is different than the developed countries like other developed countries. Varied environmental conditions, road conditions and usage patterns also affect tyre wear. This paper will address various such aspects also.
Joshi, Amol, Khairatkar, Vyankatesh, Belavadi Venkataramaiah, Shamsundara
Solving the Exhaust Valve CNG Wear Problem: An Investigation into Hard-Facing Material Deposition for CNG Exhaust Valves2026-26-02781/16/2026
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 deposition, hardening processes, and Diamond-Like Carbon (DLC) coatings have been developed for valve face wear resistance improvement. Most common solution adapted by different OEM are using Hard facing material to resist wear and crack. Hard facing material is deposited by welding process which itself is overly critical and need precise control to achieve desired part quality. Our development focused on identifying key process-controlled parameters for preventing valve seat wear in Exhaust Valve by optimizing hard facing material deposition process parameters, hard facing material microstructure, residual stress, blowholes, and hardness.
Poonia, Sanjay, Kumar, Chandan, Kundu, Soumen, Kumar, Prabhakar, Vats, Rajesh, Khan, Prasenjit, Sharma, Shailender
Sensorless Tire Health Monitoring System based on Machine Learning for Passenger Vehicles2026-26-06701/16/2026
Tire wear progression is a nonlinear and multi-factor degradation phenomenon that directly influences vehicle safety, handling stability, braking performance, rolling resistance, and fleet operational cost. Global accident investigations indicate that accelerated or undetected tread depletion contributes to nearly 30% of highway tire blowouts, highlighting the limitations of conventional wear indicators such as physical tread wear bars, mileage-based service intervals, and periodic manual inspections. These manual and threshold-based approaches fail to capture dynamic driving loads, compound ageing, pressure imbalance effects, or platform-specific wear behaviours, thereby preventing timely intervention in real-world conditions. This work presents an Indirect Tire Wear Health Monitoring System that employs an advanced Machine Learning + Transfer learning architecture to infer tread wear level and Remaining Useful Life (RUL) without relying on any tire-mounted sensors. The system ingests CAN bus telemetry signals (e.g., wheel torque, longitudinal/lateral accelerations, brake pressure, speed distribution, steering dynamics, thermal exposure) and converts them into high-resolution wear state estimations through a multi-stage feature learning pipeline. A transfer-learning layer enables model domain adaptation across tire brands, rubber compounds, rim sizes, inflation pressure ranges, and axle-loading variations — reducing retraining cost and ensuring cross-platform. The pipeline supports both cloud analytics workloads (fleet health dashboards, risk scoring, and advisory scheduling) and real-time embedded inference on in-vehicle microcontrollers for predictive safety intervention. On-road validation experiments demonstrate that the proposed model maintains high correlation to ground truth tread depth measurements, delivering per-tire wear estimation, non-linear RUL curves (in km and %), progressive wear trend modelling, and dynamic replacement advisory logic. The proposed architecture therefore establishes a scalable, sensor-less predictive maintenance framework suitable for OEM, Tier-1, and fleet-operations deployment.
Imteyaz, Shahma, Iqbal, Shoaib
Curvature-Continuous Trajectory Refinement for Autonomous Vehicles Using a Pure Pursuit Based Path Smoothing Framework2026-26-01351/16/2026
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 provides a valuable approach to usual limitations of discrete path planning, on the contribution of control algorithms such as pure pursuit to bridging the gap between planning and execution towards more adaptable autonomous driving particularly automated parking systems.
S, Shriniyathi, A, Josana, Anto Edwin J, Joel, T, Akshayaa, M, Senthil Vel, Kumar, Vimal
Development of a Seamless Selectively Elevated Fabric Switch for Intuitive and Sustainable Automotive Interior Interfaces2026-26-05961/16/2026
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. Permanent magnets and electromagnets are used in combination in the system so that they repel the switch surface upward when necessary. The actuation sequence is triggered through proximity sensing or capacitive detection mechanisms, thus eliminating the necessity for responsive and user-friendly interfaces without sacrificing mechanical functionality. To ensure safe and deliberate interaction, the switch is designed not to be eligible for activation until the total thickness of the fabric and tactile layers reaches a predetermined threshold. The system is appropriate for smart appliances, next-generation user interface systems, and car interiors because it is not only conceptually elegant, which improves aesthetic integration, but it is also robust, dustproof, and easy to use. This invention sets a new standard for intelligent, adaptive user interfaces and supports upcoming advancements like haptic feedback and programmable elevation zones.
Mohunta, Sanjay, Panchal, Girish, Puthran, Shaunak
For CNG and FFV Fuel Application Exhaust Valve Redesign and Robustness Improvement to Combat Abnormal Valve Guide and Seat Wear2026-26-01251/16/2026
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 fuel lines, ECU, exhaust valves, and cylinder heads, vary depending on the fuel used. In CNG engine most challenging issue is leakage at Valve seat and Valve face interface causing unstable combustion and power drop. This study discusses the countermeasures adopted to address the high valve face, Valve guide and valve seat wear in cylinder heads and engine valves. The investigation focuses on material, design, and manufacturing process improvements specially for Exhaust valve, supported by part-level and vehicle-level validation and testing for CNG exhaust valves and cylinder heads.
Poonia, Sanjay, Kumar, Chandan, Sharma, Shailender, Khan, Prasenjit, Bhat, Anoop, P, Prasath, Neb, Ashish
Auto Braking System for Preventing Commercial Vehicle Overloading2026-26-00321/16/2026
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-voltage relationships, confirming linearity in load detection. System modelling in MATLAB demonstrated consistent linear responses in load-deflection-voltage interactions, proving theoretical efficacy. A Proteus-based simulation further validated the system’s operational logic. Key Contributions Preventive Safety Mechanism – Proactively restricts vehicle operation under unsafe loads. Regulatory Compliance – Ensures adherence to legal weight limits. Economic & Infrastructural Benefits – Reduces maintenance costs and road wear.
Raj, Amritesh, Pujari, Sachin, Londhe, Mahesh, Shirke, Sumeet, Shinde, Akshay
Electric Mobility and Materials Circularity - A Study of Recycled PET Textiles for Automotive Interiors2026-26-02371/16/2026
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 recycled fabrics can perform equal to the virgin materials in all aspects meeting all critical functional requirements. This development encourages the automotive industry to adopt environmentally responsible practices, fostering a more sustainable and eco-conscious future. The findings serve as a foundation for further exploration and innovation in the development of eco-friendly materials for automotive applications.
Palaniappan, Elavarasan, Varatharajan, Senthilkumaran, Balaji, K V, Dodiya, Rohanbhai
Research on Characterization Parameters of Main Bearing Wear Condition Based on Vibration Signals2026-01-50031/15/2026
This study aims to investigate the influence of torque, rotational speed, lubricating oil temperature, and main bearing clearance on the vibration signals of diesel engine block surfaces, thereby establishing a foundation for diagnosing abnormal main bearing wear conditions using engine block surface vibration signals. An experimental test bench was constructed for a six-cylinder diesel engine to collect vibration signals under varying rotational speeds, torques, lubricant temperatures, and main bearing clearances. Frequency domain analysis and wavelet packet decomposition were then performed. The frequency domain analysis results indicate that the vibration signal amplitudes associated with abnormal main bearing wear are primarily concentrated below 5 kHz. Specifically, the energy in frequency bands below 1 kHz and around 2.5 kHz tends to increase with higher rotational speed, torque, and main bearing clearance, while the overall frequency domain amplitudes decrease with rising lubricant temperature. The wavelet packet decomposition results reveal that the energy in most decomposed frequency bands exhibits a positive correlation with rotational speed, torque, and main bearing clearance, but a negative correlation with lubricant temperature. Notably, the energy in wavelet packet bands 1–5 is significantly affected by rotational speed, bands 1, 3, 4, and 5 are notably influenced by torque, and bands 1 and 2 are strongly affected by main bearing clearance. The findings of this study provide a theoretical foundation and data support for the identification of abnormal wear states in the crankshaft–main bearing system.
Dong, Yiming, Hu, Yuping, Ji, Shaobo, Pan, Chi, Yue, Yuanhang, Liao, Guoliang
Application of Vibration and Lubricating Oil Analysis Techniques to Monitor the Performance and Wear of an Internal Combustion Engine in a Durability Test2025-36-002512/18/2025
The durability test is an experimental test widely used in the automotive industry to verify the ability of an engine to withstand all operating conditions throughout its useful life. The test is performed on a dynamometric bench that subjects the engine to specific operating cycles. The objective of this study was to compare the level of wear of the power cell assembly and the performance of the engine operated with ethanol and gasoline during the durability test. Wear monitoring was performed through the application of vibration analysis and lubricating oil analysis techniques. The results showed that the level of wear and performance of the engine after the durability test were considered satisfactory. In general, the wear of the engine operated with ethanol was 5% higher than that of gasoline. The application of vibration analysis and lubricating oil analysis techniques was important in monitoring wear and allowed the complete completion of the test.
Marcio Santana, Claudio, Bruno Santana, Linicker Lopes, de Almeida, Helder Giostri Alves
Design and Construction of a Bench Test System for Elastomers Suspension2025-36-004112/18/2025
This study presents the design, construction, and experimental validation of a test bench for characterizing elastomer-based torsion suspensions in light vehicle applications. The system replaces conventional spring-damper assemblies with viscoelastic elements that simultaneously absorb and dissipate road-induced vibrations. We developed a scaled prototype instrumented with an Arduino-based data acquisition system and analyzed results using Octave®. The experimental protocol comprised: (1) tribological tests to identify optimal friction pairs through coefficient of friction (μ) and wear rate measurements, and (2) dynamometric evaluations of torque transmission capacity, power output, and efficiency across gear ratios (2.03-6.34). Results indicate that a steel-steel friction pair under a normal force of 250-300 N achieves optimal performance, delivering an output power of 1706 W (84.8% efficiency) and a torque of 30.25 Nm. Comparative analysis shows this configuration reduces wear rates by 42% compared to aluminum-polyurethane pairs while maintaining comparable μ values (0.32±0.03). The system provides a cost-effective platform (75% cheaper than commercial alternatives) for validating Continuous Torque Transmission (CTT) technologies, with direct applications in electric vehicle drivetrains and engineering education.
Silva, Diego Bruno, Grandinetti, Francisco José, Castro, Thais Santos, Dias, Érica Ximenes, Souza Soares, de Álvaro Manoel, Martins, Marcelo Sampaio, Reis de Faria Neto, dos Antônio
Study on the Wear Resistance of Aggregates Based on Surface Abrasion Characteristics2025-99-031112/17/2025
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Liu, Yong, Tian, Tao, Hou, Jianwei, Chen, Geng, Wang, Anping
Study on the Effect of Frequency-Modulated Rail Damper on Rail Vibration2025-99-032212/17/2025
To delay the formation and development of local periodic fluctuations on the surface of rail structures and improve the durability of rail facilities, the dynamic response and wheel-rail interaction of rail structures were studied in depth based on frequency-modulated rail dampers (TRDs). A fully-coupled 3-D FE framework of the wheel–rail assembly, integrating frequency-modulated rail dampers (TRDs), was developed to quantify vibration energy dissipation. Simulated decay curves revealed a marked rise (> 50 %) in lateral damping efficiency within 600–1 000 Hz, confirming TRD’s targeted suppression of rail transverse motion. Then, the suppression effect of rail corrugation after TRD installation was tested, and the data collection was carried out in the test section to calculate the frequency of rail corrugation. It was found that the possibility of corrugation deterioration of the rail structure was greatly reduced after the installation of the rail damper, and the suppression effect of the frequency modulation rail damper on the rail vibration was analyzed, which provided a reliable empirical reference for the evaluation of the effect of TRD damper.
Li, Chengshun, Lei, Zhenyu
Evaluating the Influence of Material Properties and Hardness on Tightening Torque2025-28-025511/6/2025
Earthmoving machines are equipped with a variety of ground-engaging tools that are joined by bolted connections to improve serviceability. These tools are made from heat-treated materials to enhance their wear resistance. Attachments on earthmoving machines, including buckets, blades, rippers, augers, and grapples, are specifically designed for tasks such as digging, grading, lifting, and breaking. These attachments feature ground-engaging tools (GET), such as cutting bits or teeth, to protect the shovel and other earthmoving implements 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, which will help to 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 influence of surface hardness on bolted joint torque is crucial for optimizing performance, reliability, and longevity of bolted connections in various engineering applications
Parameswaran, Sankaran Potti, Bhosale, Dhanaji, Kumar, Rajeev
Road Traffic State Classification Method Based on AutoEncoder and Clustering Algorithm2025-99-004810/17/2025
Urban road traffic state classification is essential for identifying early-stage deterioration and enabling proactive traffic management. This study presents a novel method to accurately assess the traffic state of urban roads while addressing the limitations of existing methods in spatial generalization performance. The approach consists of three key components. First, several indicators are designed to capture the spatial-temporal evolution mechanisms of traffic state, speed freedom, flow saturation, and their variations over time and space. Then, a feature learning module based on an AutoEncoder network is introduced to reduce the dimensionality of the constructed feature set. This enhances feature distinction while mitigating noise effects on classification results. Third, k-means clustering is applied to analyze significant features extracted from the AutoEncoder latent space, categorizing road traffic states into fluent, basic fluent, moderate congested and severe congested. Finally, a road network in Xuancheng, a city in Anhui Province, China, is selected as the test area. The results of road state categorization for both the entire network and single roads are visualized and analyzed, demonstrating the interpretability and practical utility of the approach. The proposed method is also compared with classical k-means clustering, the threshold-based classification, and FCM. To quantify performance, we introduce a traffic state fluctuation rate index, defined as the ratio of state transitions between adjacent time windows. The results show that during the daytime (06:00-20:00), the fluctuation index of the proposed method increases by 13.1%, 22.7%, and 29.4% compared to the classical k-means, threshold-based method, and FCM, respectively. Meanwhile, during the nighttime (20:00-24:00 and 00:00-06:00), the fluctuation index decreases by 12.7%, 22.5%, and 9.0%, aligning more closely with the real changing patterns of daytime and nighttime traffic conditions.
Wang, Xiaocong, Huang, Min, Guo, Xinling, Xie, Jiemin, Zhang, Xiaolan
Study on the Fracture Failure Problem of the Height Valve Regulating Rod2025-99-007510/17/2025
The height valve adjusting rod is an important part of the suspension system, used to adjust the height of the train to adapt to the train through the curve, slope or uneven track when the height valve adjusting rod fracture failure, the train’s suspension system can not be adjusted normally, may lead to the height of the train is too high or too low, affecting the stability of the train and the driving safety. In this paper, an underground vehicle height valve adjusting rod fracture failure of the problem was studied and analysed, the specific conclusions are as follows: height valve adjusting rod there are two main vibration frequency, 60Hz and 340Hz, 60Hz main frequency has always existed, and 340Hz vibration frequency are present in part of the interval, but also caused by the vehicle vibration of the main reason for the local larger; height valve adjusting rod stress there is also a significant vibration The main frequency of 340Hz, similar to the vibration characteristics of the vibration response, the main frequency of vibration only exists in part of the interval, and is the main reason for the stress is locally large; comprehensive consideration of the vehicle vibration state and stress level, 340Hz rail grinding frequency is the main reason for the height valve regulator vibration level and the stress level is obviously increased, but also led to the failure of the height valve regulator; can be achieved by grinding rail Or improve the structure of the crossbar so that the inherent modal frequency of the crossbar is far away from the wave abrasion frequency, which can provide a certain reference significance for other urban rail vehicle projects to solve such problems.
Wang, Chao, Yang, Chen, Pan, Minkai
Decay Analysis of Xinjiang G577 Asphalt Road Performance Based on Exponential Modeling2025-99-005410/17/2025
The accurate prediction of road performance decay is of great significance for road maintenance and management. This paper takes the Xinjiang G577 highway as the research object, collects the measured data of the typical indexes of asphalt pavement since the past years (Deterioration Condition Index (PCI), Technical Condition Index (PQI)), and studies its decay. The model is constructed on the basis of time series1, and the exponential decay model of asphalt road PQI and PCI is derived. The model’s accuracy is then tested by calculating the correlation coefficient, mean absolute error (MAE), and other accuracy tests. The results demonstrate that the model exhibits a high degree of fit.
Tian, Wei, Bai, Haotian, Wang, Taiwei, Wang, Jiayan, Dai, Xiaomin
Reinforcement Learning with Adaptive Discount Factor for Clutch Judder Suppression with Stable Learning in Two-Speed EV Transmission2025-01-037510/7/2025
Designing the gear shift control for an automotive transmission is a complex task because it involves handling nonlinear behaviors like changes in friction between clutch plates and fluctuations in oil temperature. While deep reinforcement learning (DRL) has recently been used to reduce shift shock, most existing methods don’t account for real-world changes such as transmission aging. One major issue that becomes worse with aging is clutch judder—a type of vibration caused by wear. Traditional reinforcement learning assumes that the environment stays the same, which can lead to unstable learning when conditions change, making it hard to consistently reduce shift shock. To address this, we propose a new algorithm that adapts to aging transmissions by adjusting the discount factor—a key parameter in reinforcement learning that balances short-term and long-term rewards. Instead of keeping this factor fixed, our method starts with a lower value to ensure stable learning and gradually increases it to improve long-term performance. We use the loss function, which reflects how well the model is learning, as a signal to control the discount factor using a PID controller. To make tuning easier, we apply a model matching approach to set the PID parameters. Simulation results show that this method not only reduces shift shock more effectively but also keeps the learning process more stable compared to traditional fixed-discount approaches.
Ogawa, Kazuki, Aihara, Tatsuhito, Goto, Takeru, Minorikawa, Gaku
From Temperature to Wear: A Quantitative Analysis of Tire Influence on Vehicle Cornering Using Handling Key Performance Indicators2025-01-50609/16/2025
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 that operating outside the tire’s optimal thermal and wear conditions significantly affects vehicle handling balance, responsiveness, and driver perception of agility. These effects scale with tire performance level: while standard passenger car tires exhibit limited sensitivity, slick formula tires show substantial variations in grip and cornering stiffness, reaching deviations of approximately 10% and 35% from their nominal values, respectively. Vehicle steady-state analyses indicate that front axle wear increases understeer, while rear axle wear reduces overall stability—resulting, for example, in a 25% increase in peak sideslip angle in the sports car configuration. Transient analyses further confirm that temperature has a more pronounced effect than wear, particularly on yaw rate and lateral acceleration response times, with variations reaching up to ±10% relative to optimal thermal conditions. This work highlights the need to include tire condition effects in handling target definition and validation processes, recommending careful monitoring of tire states during standardized ISO maneuvers. Fixed metrics should be replaced by performance ranges that reflect actual tire operating states, whether for custom-developed or off-the-shelf tires.
Aratri, Roberto, Romagnuolo, Fabio, De Pinto, Stefano, Farroni, Flavio, De Bellis, Sergio, Bottiglione, Francesco, Mantriota, Giacomo, Sakhnevych, Aleksandr
A Novel Simulation Method for Vehicle Brake Wear Emissions2025-01-03619/15/2025
The effective reduction of particulate emissions from modern vehicles has shifted the focus toward emissions from tire wear, brake wear, road surface wear, and re-suspended particulate emissions. To meet future EU air quality standards and even stricter WHO targets for PM2.5, a reduction in non-exhaust particulate (NEP) emissions seems to be essential. For this reason, the EURO 7 emissions regulation contains limits for PM and PN emissions from brakes and tire abrasion. Graz University of Technology develops test methods, simulation tools and evaluates technologies for the reduction of brake wear particles and is involved in and leads several international research projects on this topic. The results are applied in emission models such as HBEFA (Handbook on Emission Factors). In this paper, we present our brake emission simulation approach, which calculates the power at the wheels and mechanical brakes, as well as corresponding rotational speeds for vehicles using longitudinal dynamics equations integrated in the simulation tool PHEM (Passenger Car and Heavy duty Emission Model). This simulation model is applicable for both LDV and HDV in the case of NEP. The brake wear emissions, including PM10, PM2.5, PN23, and PN10, are interpolated from characteristic brake emission curves that depend on braking power and vehicle speed. These characteristic curves are generated from a database containing data from literature, partners, and measurement campaigns conducted by our team. The model also considers brake energy recuperation in hybrid and battery electric vehicles, as well as the use of retarders in heavy-duty vehicles The physical approach enables the simulation of all propulsion systems in various driving cycles for all vehicle categories. Furthermore, we will present the projected development of PM and PN emissions for European PC, LDV and HDV traffic through 2050, considering different propulsion technology scenarios including also exhaust particle emissions for comparison.
Landl, Lukas, Ketan, Enis, Hausberger, Stefan, Dippold, Martin
Brake System Homologation: A Holistic, Simulation-Based Approach2025-01-03519/15/2025
With the introduction of the Euro 7 regulation, non-exhaust emissions – particularly those arising from brake and tire abrasion – will be regulated and subject to emission limits for the first time. This presents significant challenges not only for OEMs striving to meet these targets within the given timeframe, but also for suppliers, who must develop innovative solutions for the precise measurement, analysis, and mitigation of these emissions. To address this, it is essential to establish and industrialize new testing methodologies as structured, scalable, and cost-efficient processes. Beyond pure measurement capability, service providers in this domain are increasingly expected to serve as feedback mechanisms – identifying process limitations, proposing targeted improvements, and thereby enabling continuous development in line with evolving technical and regulatory requirements. In this context, AVL is pursuing a holistic development strategy that integrates brake emission measurements with simulation and prediction tools. This combined approach facilitates early-stage assessment of brake emissions during the vehicle concept phase, minimizing development risk and effort. Central to this is the use of AI-based characteristic emission maps – based models, which allow for the prediction of emission levels based on material pairings and vehicle-specific parameters. These tools support informed decision-making without the need for extensive early-phase testing. Looking ahead, the integration of such emission prediction capabilities into AVL’s Vehicle Composer platform will enable customers to evaluate the impact of design changes on brake emissions in a highly time- and cost-efficient manner. This not only supports faster iteration cycles but also ensures that emission targets can be met without compromising vehicle performance or increasing simulation complexity.
Grojer, Bernd
Influence of Titanate Composition and Particle Size on Friction Stability and Wear in Brake Pads2025-01-03379/15/2025
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 findings demonstrate the importance of carefully controlling titanate composition and particle size to enhance brake pad performance. This research provides valuable insights for designing more durable and stable brake materials.
Jara, Diego Chavez, Lorenzana, Carlos, Sliepcevich, 1Lt Andrea, Conforti, Michael
Further Investigation of Variables Affecting Brake Squeal: Porosity Effect on Lowmet Pad Properties2025-01-03359/15/2025
As Lowmet pad porosity increases, pad hardness decreases; pad ISO compressibility increases; the nominal friction coefficient increases (SAE J2522); and the disc wear/pad wear decreases. Brake squeal occurrence is affected by the total wear of disc and pads; the wear differential between the inboard pad and outboard pad; pad tangential taper; and pad hardness/material damping. Also, pad chamfer shape has a strong influence on brake squeal occurrence.
Rhee, Seong Kwan, Rathee, Aman, Singh, Shiv Raj, Sharma, Devendra
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