Browse Topic: Wear

Items (3,095)

Bridging Human Expertise and Machine Intelligence in Chassis System Teardown Evaluation

2026-01-0805

9/14/2026

Teardown evaluation of chassis system components plays a critical role in benchmarking, failure analysis, and competitive product assessment. These inspections rely heavily on experienced engineers who interpret visual defect patterns, material conditions, wear signatures, and manufacturing variations. However, expert driven evaluation processes are often subjective, difficult to standardize, and challenging to scale across global engineering teams. This paper presents a structured AI-assisted expert evaluation framework developed to enhance consistency, preserve institutional knowledge, and enable continuous improvement in chassis component teardown analysis. The proposed system integrates convolutional neural network architectures, including ResNet18 and its variants, into a human in loop inspection workflow. AI models perform initial classification of component images (e.g., OK/not OK and defect subclasses) and provide associated confidence scores. These predictions are presented as decision support, while final authority remains with the evaluating expert. Experts can confirm or override AI outputs, annotate defect regions using bounding boxes, assign subclass categories, and provide structured technical comments. All expert interactions, including AI disagreements, are systematically recorded. Correction instances are analyzed to identify model limitations, ambiguous defect conditions, and data gaps. Expert validated evaluations are incorporated into the training dataset to enable iterative model refinement. This closed loop process supports progressive improvements in model robustness and classification accuracy across varying teardown conditions and component types. A centralized cloud-based repository maintains full traceability of inspections, including timestamps, AI confidence levels, expert modifications, and annotation metadata. This structured knowledge capture converts tacit engineering judgment into a persistent digital asset, supporting auditability, cross-site alignment, and accelerated onboarding of new engineers. The framework demonstrates how AI can be effectively deployed as an assistive technology in chassis teardown evaluation, improving repeatability, enhancing data driven benchmarking, and enabling scalable knowledge preservation without displacing expert authority.

Divakaruni, Saikiran, Vaibhav, Veer, Hansen, Scott, Hood, Trevor, Agrawal, Rahul

Finite Element-Based Wear Analysis of Brake Pads

2026-01-0817

9/14/2026

Brake pad wear progressively changes the pad–disc contact interface and can influence braking performance, wear uniformity, and component durability. This study presents a finite element-based procedure for predicting brake pad wear under braking conditions using generalized Archard’s wear law as the base framework. The method combines contact-pressure and slip-distance calculations with iterative geometry updating in Abaqus using the UMESHMOTION and USDFLD subroutines so that accumulated wear and evolving contact conditions can be continuously reflected during the analysis. To improve robustness in repeated-cycle wear simulation, a wear-direction algorithm, an extrapolation factor, and a contact stiffness scale factor are incorporated to reduce element distortion, enhance numerical stability, and control computational cost. Because temperature-dependent friction behavior, contact conditions, and material-property variations are strongly coupled in actual braking, their combined influence is represented through an effective wear coefficient calibrated from physical data using regression analysis, instead of independently modeling them. The proposed procedure was applied to burnish and subsequent evaluation modes, and the predicted wear results were compared with test measurements. Among the regression models considered, the log-linear model provided the best overall agreement with the experimental wear data. The results show that the proposed framework can reproduce both mean wear and location-dependent wear trends with good agreement over the evaluated operating range. The proposed procedure offers a practical numerical workflow for predicting brake pad wear under temperature-dependent operating conditions while maintaining acceptable numerical stability and computational cost.

Song, Seong Il, Joo, Sang Don, Kim, Min Sock, Kerszberg, Nicolas, Lee, Heewook

Correlation of Tribological Characteristics with Brake Emission Factors in Automotive Disc Brakes

2026-01-0829

9/14/2026

Following the recent introduction of the Euro 7 regulations, research on non-exhaust emissions, including brake wear particles, has increased. However, full-scale dynamometer tests are affected by complex variables such as vehicle class and brake system specifications, which makes it difficult to analyze the unique characteristics of friction materials independently. Previous studies have predominantly focused on comparing emission levels by friction material composition or on disc surface treatments, and quantitative correlations, resolved by friction material type, between the physical wear mass of friction materials and the Brake Emission Factor (BEF), remain scarce. In this study, the brake emissions from various friction materials were precisely measured using a scale dynamometer reflecting the UN-GTR No. 24 standards. By applying the WLTP cycle, a quantitative correlation was derived between the friction characteristics and the BEF for each braking section. The results show that BEF varies with friction material type depending on the friction- and wear-related factor, while disc wear and total wear were confirmed, regardless of friction material type, to be common key indicators that exhibit a statistically high correlation with BEF.

Jang, Pan Gyu, Kim, Duck Hyeon, Jeong, Yoon Oh, Kwon, Sung-Wook, Jung, Kwang Ki, Lee, Jungju

Advanced Brake Force Distribution and Pad Wear Life Integration in Supervisory Electronic Brake Control System for Combination Vehicles

2026-01-0797

9/14/2026

Commercial vehicle fleets frequently operate with tractors that connect to different trailers and dollies, resulting in combinations with varying brake pad wear across wheel ends. Traditional brake-force distribution strategies do not consider these pad-life differences, which can lead to uneven brake utilization, irregular maintenance intervals, and increased total cost of ownership (TCO) in mixed-trailer operations [7, 9]. While modern electronically controlled braking systems (EBS) already incorporate pad wear based braking for the tractor itself [5], these capabilities do not extend across the entire vehicle combination because trailer-side communication is typically limited to standardized CAN protocols such as ISO 11992 and J1939 [1, 2, 3]. As braking systems become more software defined and rely heavily on distributed electronic communication, ensuring the authenticity and integrity of trailer originated brake information becomes essential for both functional safety and cybersecurity [6]. In the proposed architecture, trailers and dollies communicate brake related data to the tractor over the ISO 11992 Tractor-Trailer CAN (TT-CAN) network [1, 2], allowing the tractor Brake Control ECU to securely validate the source of the information and register each towed unit for health aware braking. Once authenticated pad life data is available, the tractor constructs a combination level brake health map covering every wheel end in the configuration. During normal braking, a supervisory allocator computes wheel end specific brake pressure targets that bias braking toward wheel ends with greater remaining pad life while ensuring full compliance with stopping distance regulations and stability requirements [4, 7]. By integrating authenticated pad wear information with tractor hosted supervisory control, the system improves braking consistency across mixed combinations, harmonizes pad utilization, enhances maintenance predictability, and reduces TCO while meeting the safety and cybersecurity expectations of modern commercial vehicle fleets.

Ganesha, Vinodkumar

Real-Time Estimation of Brake Temperature using Physics-Informed Machine Learning Model

2026-01-0810

9/14/2026

The current work presents a novel approach to estimating brake surface temperature in real-time to aid in brake wear prognostics. Brake prognostics involve estimating brake pad wear in real-time, which enables its predictive maintenance. Brakes are a safety-critical system for vehicles; therefore, they require accurate and robust pad wear estimation to ensure vehicle safety. However, it involves several challenges. The estimation of pad wear is fundamentally a two-stage process: the first stage involves the accurate prediction of brake pad surface temperature, while the second stage utilizes this thermal history to calculate cumulative material wear. A significant challenge in estimating brake pad wear without an expensive sensor is that it is sensitive to the surface temperature prediction; any error in the thermal model propagates and compounds in the wear prediction stage. To identify surface temperature, traditional physical sensors are often cost-prohibitive or prone to failure in the harsh thermal and mechanical environments of the wheel end, necessitating a robust virtual sensing solution that can capture complex, non-linear heat transfer dynamics. The current work addresses the above challenge of identifying temperature dynamics using a Physics-informed Machine Learning approach. We employ Symbolic Regression (SR), a data-driven method that discovers the underlying mathematical expression of the system dynamics by searching for the optimal functional relationship between variables. SR provides an interpretable model that can be generalized across automotive platforms, offering a transparent, computationally efficient, and analytically tractable alternative to traditional ‘black box’ models. To generate the temperature dataset, a test vehicles were equipped with thermal sensors and underwent various braking scenarios. The SR-based virtual sensing model demonstrated strong and consistent predictive fidelity across all braking conditions tested. Under mild braking scenarios, the model achieved a Mean Absolute Percentage Error (MAPE) of approximately 6.0% in predicting brake surface temperature. This performance remained highly robust under mixed and harsh, high-speed braking, the most thermally demanding scenario, yielding MAPEs of only 11.6% and 11.9%, respectively.. Across all regimes, this level of temperature estimation fidelity directly limits error propagation into the downstream brake pad wear prediction stage, enabling reliable, sensor-less, cloud-based brake health monitoring at scale.

Gannavarapu, Shivadath, Pal, Anuj, Fan, Mengdi

Further Investigation of Brake Squeal: Effect of (Inboard/Outboard) Pads Property Differential

2026-01-0799

9/14/2026

It was reported earlier that the wear differential between the inboard pad and the outboard pad leads to brake squeal generation. The (inboard/outboard) pads wear differential can occur due to hardware issues such as brake pad drag and/or two different wear rates of the (I/O) pads, which is caused by two different material properties of the pads although the pad formula may be the same. It is found that (I/O) pads compressibility differential/hardness differential/friction differential are all interrelated and that they contribute to brake squeal generation in addition to the inboard pad tangential/radial taper wear. A method has been found to separate the inboard pad friction and the outboard pad friction and to estimate each friction coefficient.

Liu, Richard, Wu, Shane, Wu, Godot, Zou, Tianlang

Study on the Friction Characteristics of Disc Brakes with Ceramic Surfaces for High Performance Vehicle

2026-01-0827

9/14/2026

In this study, various methods were reviewed to simultaneously satisfy the high-temperature braking performance required for high-performance vehicles and the brake dust criteria by environmental regulations. Among them, the characteristics of two types of Brake disc with ceramic composite surfaces were evaluated to prevent disc wear even under the condition of using metallic friction materials with excellent fade performance. As a result of the evaluation, carbon ceramic disc without metal-to-metal contact during braking showed superior characteristics compared to hard metal cladding disc.

Kim, Yoon Cheol, Yeongwoo, Cho, Kim, Youngmin

Further Investigation of the Variables Affecting Brake Squeal: Dual-Piston and Single-Piston Calipers with NAO Pads

2026-01-0825

9/14/2026

An earlier publication reported that brake squeal occurrence increases with increasing (inboard/outboard) pads wear rate difference in the case of a front dual-piston (twin-piston) caliper for a GVW vehicle of 2,510 kg fitted with Lowmet pads of straight chamfers and diamond chamfers. The current investigation was undertaken to find out if a front dual-piston caliper for a heavier vehicle (GVW 3,200 kg) fitted with NAO pads of straight chamfers, and a lighter single-piston caliper (GVW 2,100 kg) fitted with NAO pads of straight chamfers behave the same or not, using the SAE J2521 and Los Angeles City Traffic simulation procedures. In all cases, brake squeal is found to increase with increasing (inboard/outboard) pads wear rate differences (wear differentials); increasing pad radial taper is associated with increasing (I/O) pads wear differential; pad tangential taper lowers the (I/O) pads wear differential. Increasing friction coefficients do not relate to increasing squeal occurrences. To minimize brake squeal occurrence, caliper should be designed to minimize (I/O) pads wear differential.

Sriwiboon, Meechai, Rhee, Seong Kwan, Sukultanasorn, Jittrathep, Khathinhorm, Nicha, Kunthong, Jitpanu

Predicting Wear of NAO Brake Pad Using Scaled-Down FMVSS 135 Testing and Machine Learning

2026-01-0808

9/14/2026

Brake pad wear is a major and growing source of non-exhaust particulate emissions, projected to reach 1.3 million tons annually by 2030 and contributing up to roughly 55% by mass of non-exhaust traffic-related PM10 in urban environments, underscoring the need for improved durability and material optimization. This study investigates a three-stage eXtreme Gradient Boosting (XGBoost) ensemble paired with a residual Fully Connected Neural Network (FCNN) corrector to predict brake pad wear rate and support formulation optimization. Experiments used a simplified FMVSS 135 protocol on a Universal Mechanical Tester (UMT) simulating realistic braking across eight friction regimes. Wear rate was the sole machine-learning prediction target, while coefficient of friction (CoF) was retained as an input feature rather than a target. Despite a limited but high-quality 280-cycle dataset, regime-aware stratified splitting, sample reweighting, and hyperparameter optimization enabled robust generalization. The three-stage XGBoost ensemble with residual FCNN correction achieved a global held-out test R2 of 0.976 for wear rate prediction. A Taguchi L8 design of experiments defined the brake pad compositions, reducing experimental time and material consumption compared to conventional approaches. The framework demonstrated strong agreement between measurements and predictions for the dominant low-severity regime, while per-regime analysis identified the high-severity minority regimes as the priority for additional data collection, since within-regime R2 remains negative for every regime given current sample sizes. A sequence-aware mean absolute scaled error (MASE) analysis further shows that, despite the high global R2, none of the four pipeline stages currently outperforms a naive one-cycle persistence forecast on absolute error, a distinction reported here for transparency. The scalable architecture enables straightforward integration of additional material and process parameters, supporting iterative brake formulation development in industrial settings and, by reducing empirical testing requirements, sustainable brake material development with reduced replacement frequency and associated emissions.

Katakam, Abhishek, Eslamiat, Hossein, Kancharla, Sai Krishna, Filip, Peter

Dynamic Characteristics Analysis of Needle Roller Bearings in Planetary Gear Trains with Consideration of Inner Bore Spalling Defects of Planet Gears

2026-99-1279

9/4/2026

Driven by the growing demand for higher efficiency and load-bearing capacity in fields such as new energy vehicles and heavy-duty engineering machinery, planetary gear sets are increasingly operating at elevated rotational speeds, coupled with a corresponding expansion of their revolution radii. This dual trend directly induces a substantial surge in centrifugal acceleration acting on the internal needle roller bearings. Under the cyclic stress inherent to transmission operations, such enhanced acceleration not only accelerates the initiation of spalling faults on the inner bores of planet gears but also exacerbates the propagation and deterioration of these faults throughout the service life. To elucidate the influence mechanism of inner bore spalling on the dynamic response of planetary gear bearings, this study develops a specialized dynamic model. This model explicitly incorporates the compound kinematic effects of simultaneous rotation and revolution, thereby ensuring a high-fidelity reconstruction of actual operating scenarios. The research systematically investigates how different spalling types and dimensional parameters affect the system’s dynamic behavior. Numerical results demonstrate a positive correlation between the severity of the spalling defect and the dynamic response intensity. Specifically, the expansion of defect dimensions under harsh operating regimes markedly exacerbates both the contact impulses at the needle-roller interface and the overall vibration acceleration amplitudes. Notably, the amplitude increment of the needle rollers is far more pronounced than that of other components. These findings enrich the theoretical understanding of fault-induced dynamic responses in planetary gear systems and provide a solid theoretical and model-based foundation for optimizing the fault diagnosis, condition monitoring, and maintenance strategies of the associated needle roller bearings.

Zou, Desheng, Lai, Junbin, Guo, Wei, Dong, Peng, Xu, Xiangyang, Sun, Qiang

Experimental and Mechanistic Study on Current Carrying Friction of Sliding Ring Slide in Shaft-Type Oil Distributor under Different Oil Environments

2026-99-1005

8/7/2026

The issue of current-carrying friction wear in the sliding ring slider of a controllable pitch propeller (CPP) oil distributor under shaft current conditions was addressed through the development of a specialized wear test device. Comparative tests were carried out with and without the application of electrical current in order to assess lubrication performance in bio-oil, mineral oil, and gear oil. Under conditions of low electrical current, the device exhibited significant signs of current-induced friction wear, in addition to substantial oil oxidation and the accumulation of deposits within the bio-oil. Conversely, the level of wear experienced was minimal in both mineral oil and gear oil conditions. These results imply that CPP systems utilising bio-oil encounter a considerable risk of wear under current-carrying circumstances. Quantitative analysis revealed that the wear depth of the friction pair in bio-oil under energized conditions reached 0.02 mm, accompanied by the formation of a phase-transformed layer up to 11.2 μm thick, which was approximately twice that observed in mineral or gear oils. Metallographic evidence confirmed severe arc erosion as the dominant wear mechanism, which was significantly exacerbated by the inferior oxidation stability and higher electrical conductivity of the bio-oil. In engineering practice, the utilisation of alternative lubricants is to be given precedence, and the shaft-type oil distributor is to be electrically insulated.

Xia, Miao, Li, Jiyue, Chang, Long, Wu, Rongjia

Research on the Erosion and Wear Characteristics of Gathering and Transportation Pipelines by Cyclone Abrasive Process Parameters

2026-99-0184

7/31/2026

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 Elements

2026-99-0217

7/31/2026

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

Development and Experiment of Rolling Friction and Wear Testing Machine Based on LabVIEW

2026-99-0245

7/31/2026

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

A Simple Method for Synthesizing Wear-Resistant Superhydrophobic Anti-Icing Coating

2026-99-0129

7/31/2026

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

Innovative Friction Modifier for Copper-Free Brake Pad Applications

2026-36-0313

7/30/2026

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 Braking

2026-36-0316

7/30/2026

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

Casing Wear Degree Analysis Considering the Buckling and Whirling Effects of the Drill String

2026-99-0841

7/30/2026

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

Influence of Modified Fly Ash Content on the Properties of Resin-Based Friction Materials

2026-99-1657

7/24/2026

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 Environment

2026-99-1635

7/24/2026

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 Condition

2026-01-5060

7/22/2026

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 Measurement

ARP5448/7A (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 Vehicles

2026-01-5036

6/3/2026

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 Composite

2026-26-0740

6/1/2026

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

Lightweight Magnesium Nanocomposites with Enhanced Wear Resistance for Landing Gear Application

2026-26-0751

6/1/2026

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.

Investigation of Aluminium Alloy Composites Reinforced with Zirconium oxide and Solid Lubricant Attributes for Brake and Clutch Components of Aircrafts

2026-26-0752

6/1/2026

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.

Research on the Friction Performance of EVA Insulating Mats for Live Working in Smart Grids

2026-99-0714

5/15/2026

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

A High-Sensitivity and High-Throughput Inductive Sensor for Abrasive Particle Detection Using Rectangular Coils

2026-99-0757

5/15/2026

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

Optimizing Coil Structural Parameters to Enhance the Sensitivity of Wear Particle Sensor

2026-01-5033

5/14/2026

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 System

F-0082-2026-0194

5/5/2026

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 Steel

F-0082-2026-0227

5/5/2026

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

Life of a Formula One Power Unit: Valvetrain Systems

2026-01-0269

4/7/2026

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

Experimental Investigation Wear of the Power Cell Assembly of an Internal Combustion Engine Operated with Ethanol Through Vibration and Oil Analysis

2026-01-0352

4/7/2026

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

Plain Bearing High Speed Oscillation Test

ARP5448/2 (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 Biocomposite

2026-28-0021

2/12/2026

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.

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

2026-26-0278

1/16/2026

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

Tractor Clutch Wear Simulation by Inhouse Development

2026-26-0572

1/16/2026

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

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

2026-26-0125

1/16/2026

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

Comprehensive Research Study Examining Tyre Wear and its Indian Perspective

2026-26-0604

1/16/2026

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

Experimental Study to Investigate and Control Image Blurriness due to IRVM Vibration

2026-26-0321

1/16/2026

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

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

2026-26-0596

1/16/2026

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

Auto Braking System for Preventing Commercial Vehicle Overloading

2026-26-0032

1/16/2026

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 Interiors

2026-26-0237

1/16/2026

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

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

2026-26-0135

1/16/2026

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

Sensorless Tire Health Monitoring System based on Machine Learning for Passenger Vehicles

2026-26-0670

1/16/2026

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

Development of a Fuel Injector Driver for Accelerated Testing

2026-26-0564

1/16/2026

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

Research on Characterization Parameters of Main Bearing Wear Condition Based on Vibration Signals

2026-01-5003

1/15/2026

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 Test

2025-36-0025

12/18/2025

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 Suspension

2025-36-0041

12/18/2025

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 Characteristics

2025-99-0311

12/17/2025

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Liu, Yong, Tian, Tao, Hou, Jianwei, Chen, Geng, Wang, Anping

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