Browse Topic: Polymers

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Design development and optimization of hybrid cross car beam for performance2026-01-0513To be published on 04/07/2026
The cross-car beam (CCB) within the instrument panel (IP) is a multifunctional structural element that supports safety, vibration control and modular integration in automotive design. The reduction of mass without compromising structural integrity plays a vital role in this endeavor. This study presents the design and optimization of design intent model of magnesium beam to meet the performance requirements Vs study model of hybrid cross car beam using magnesium steering column bracket, steel and plastic material to achieve reduced mass and enhanced stiffness while meeting performance targets. Advanced Computer Aided Engineering (CAE) techniques were employed, including topology optimization, lattice optimization, bracket sensitivity studies as well as shape & gauge optimization. Performed benchmarking against industry models such as Tesla Model Y observed hybrid material with structural simplification. The final hybrid beam design demonstrated overall cost reduction, while satisfying
Didgur, Gulzarahmed, McAdams, Ian, Viswaraj, Obuliraj
Dynamic Characterization and Viscoelastic Modeling of Polymer Foams for Automotive Applications2026-01-0236To be published on 04/07/2026
Viscoelastic behavior of polymeric materials serves as a critical indicator of their internal structure and chemical composition, offering valuable insights into energy absorption and dissipation mechanisms. This study focuses on the dynamic characterization of polymer foams through both experimental and numerical approaches, aiming to accurately capture their time and frequency dependent mechanical response. Experimental investigations include uniaxial tension and uniaxial compression, which characterize hyperelastic or instantaneous behavior of the material. Stress relaxation tests and Dynamic Mechanical Analysis (DMA) characterize the dependence on time, frequency and temperature. A combination of these tests is effectively utilized to create viscoelastic material models that can describe the material response as a function of time, frequency and temperature containing a viscous and an elastic part. This paper presents dynamic characterization of polymer foams in finite element
M, Gokula Krishnan, Lin, Chunfu, Savic, Vesna
Numerical Investigation of Low Velocity Impact Perforation in Natural–Synthetic Hybrid Composites for Automotive Applications2026-01-0246To be published on 04/07/2026
The increasing demand for sustainable and lightweight materials in the automotive industry has accelerated interest in natural fiber reinforced polymer composites. However, their limited impact resistance restricts application in structural and crash-relevant components. This work presents a numerical investigation of the low velocity impact (LVI) and perforation behavior of jute (J) and flax natural fiber reinforced epoxy composites (N) and their glass fiber (G) hybrid forms with synthetic fiber reinforced epoxy laminates (S), using LS-DYNA. A finite element model, developed with a discounted ply approach and MAT54 damage model, was first validated against published experimental data for glass/epoxy laminates, showing strong correlation in peak load and energy absorption. The validated model was then extended to simulate bidirectional natural fiber and hybrid laminates under 2–10 J impacts, replicating typical energy levels relevant to low-speed collisions and road debris impacts in
Mache, Ashok, Pingulkar, Harshad, Ambhore, Nitin, Hujare, Pravin, Salve, Aniket
High Strain-Rate Behaviors of Fiber Reinforced Composites in Principal and Off-Axis Directions2026-01-0175To be published on 04/07/2026
Materials can exhibit significantly different mechanical behaviors compared to quasi-static conditions at high strain rates (> 100 s-1). High strain rate tests using setups such as SHPB (Split-Hopkinson Pressure Bar) can provide, in a practicable manner, the stress-strain relations for a material at high strain rates. Such properties are vitally needed for activities such as simulation-driven impact safety design of composite structures deployed in the form of automotive body parts and assembly, and other sub-systems. Although the behaviors of isotropic and ductile materials such as various metallic alloys appear to have been extensively studied and reported in literature, dependence of mechanical properties of fiber-reinforced composites especially in different off-axis directions are extremely difficult to come across. To fill up this void, a detailed experimental study has been carried out on high strain rate mechanical characterization of orthotropic glass, carbon and a natural
Bawa, Prashant, Deb, Anindya, Zhu, Feng
Investigation into Dynamic Behavior of Jute-Glass-Aluminium Hybrid Polymer Composites for Automotive Applications2026-01-0245To be published on 04/07/2026
The research work in this paper investigates the development and dynamic characterization of lightweight hybrid polymer composites tailored for automotive applications. Fiber-reinforced polymer composites, owing to their high specific strength and stiffness, have emerged as promising candidates to replace conventional materials. Expanding on the current trend of hybridization that blends natural and synthetic fibers to optimize mechanical strength and vibration-damping behavior, this study incorporates aluminum perforated sheets (Al) as additional reinforcement to increase stiffness without significantly increasing weight. Jute (J) fibers, known for their inherent damping capability, were combined with glass fibers (G) and Al sheets. Six symmetric hybrid laminates G/J/Al/J/G, J/G/Al/G/J, J/J/Al/J/J, G/G/G/Al/G/G/G, and J/J/J/J/J were fabricated using hand lay-up followed by compression molding. The modal frequencies and damping properties were obtained through experimental testing
Salve, Aniket, Mache, Ashok, Nalawade, Dattatraya, Joshi, Shardul
Tensile and Fatigue Behavior of High Pressure Die Cast AE44 Magnesium Alloy at Elevated Temperatures2026-01-0234To be published on 04/07/2026
Tensile and cyclic behavior of high pressure die cast AE44 magnesium alloy have been studied at room temperature and elevated temperatures up to 350°C. Anelastic behavior has been found in both tensile and cyclic deformation at the temperature below 150°C. With increasing temperature, the anelasticity disappears, and tensile and cyclic behaviors become similar to other engineering materials, such as steels and aluminum alloys, i.e. the total strain contains only elastic strain and plastic strain. A method to determine the yield strength at 0.2% plastic strain (σ0.2) is proposed. By using the proposed method, the yield strength σ0.2 is higher than that determined using the traditional method, which is more suitable to the materials that do not exhibit anelasticity. It is believed that the anelasticity is closely related to twinning in Mg alloy, which disappears at elevated temperatures.
Liu, Yi, Yang, Wenying, Coryell, Jason
Machine Learning Modeling for Compressive Property Prediction of Foams2026-01-0512To be published on 04/07/2026
Foam material models for automotive structural analysis typically require tensile and compressive data at multiple strain rates. The testing is costly and may require a long time to complete. For many applications, foams of similar chemistry are used and the foam structural responses, such as stiffness and compression force deflection, are controlled by the foam density. In such cases, Machine Learning (ML) lends itself as an ideal tool to detect the trends in material response based on density and strain rate. In this paper, five microcellular polyurethane (PU) foams of different densities were tested at four strain rates ranging from 0.01/s to 100/s. A ML model capable of predicting compressive stress-strain response for a range of densities was developed. The model demonstrated good prediction capability for intermediate strain rates at all foam densities and in extrapolating stress-strain curves at higher densities at all strain rates. The strain rate trends for a density outside
M, Gokula Krishnan, Kavimani, Harish, Muppana, Sai Siddhartha, Savic, Vesna, Chavare, Sudeep, V S, Rajamanickam
Wear and Friction of PTFE and PEEK Coated Cast Iron for Piston Ring Application2026-01-0240To be published on 04/07/2026
In engine 30% of the total energy is lost due to the friction between piston ring and cylinder liner due to their constant rubbing motion. A piston that reciprocates at high speeds has piston rings that constantly scrape against the wall leading to high frictional losses within the engine. The engine has to work against this resistance to provide the required power, and hence it will consume more fuel. For this reason, material used for these components is more crucial. Reduction of surface friction between moving parts in order to increase overall efficiency can be achieved by suitable coating. The most commonly used piston rings are coated with chromium layers that are electroplated which is being replaced by chrome plating. Low coefficient of friction (COF) and high wear resistance can be achieved by self-lubricating coating of PTFE and PEEK polymer-based composite coatings. Experimental results showed that the PEEK and PTFE coating performed better in terms of friction and wear
Rajendran, R., Tamilarasan, T R, J, Chandradass
Design Optimization and Dimensional Tolerance Improvement of Expanded Polypropylene (EPP) for Enhanced Automotive System Integration2026-01-0248To be published on 04/07/2026
Historically, EPP has required larger dimensional tolerances and much thicker cross-sections than solid plastics produced by injection molding, vacuum forming, and blow molding. This has proved challenging when attempting to incorporate EPP into a wider variety of automotive applications. JSP has developed multiple grades of EPP that achieve tolerances at thinner cross-sections, once considered difficult to attain. These grades expand the potential for automotive applications by combining the established benefits of EPP with improved dimensional precision. This tighter control enables advances in part design and performance, including reduced wall thicknesses, improved surface appearance, reduced weight, lower cost, part consolidation, and more efficient molding with an improved processing window, resulting in faster cycle times and reduced utility consumption. At the vehicle level, these improvements contribute to lighter overall weight for reduced carbon footprint, as well as
Sopher, Steven, Parker, Joshua
Vibrational Analysis of Hybrid Composite Laminated Plates of E – Glass and Areca Fibers with Brake Pad Waste Powder2026-28-00732/12/2026
This study focuses on the vibration analysis of hybrid composite laminated plates fabricated from E-glass Fiber and areca Fiber reinforced with epoxy resin. The hybrid laminates were prepared using the Vacuum Assisted Resin Transfer Moulding (VARTM) process with different stacking sequences and Fiber ratios, where brake lining powder was also incorporated as a filler in selected configurations to enhance mechanical and damping properties. The fabricated plates (280 × 280 mm) were subjected to experimental modal analysis using an impact hammer and accelerometer setup, with data acquisition carried out through DEWESoft software. Natural frequencies and damping ratios were determined under three boundary conditions (C- C-C-C, C-F-C-F, and C-F-F-F). The results revealed that Plate 1, with E-glass outer layers, areca reinforcement, and filler addition, exhibited the best vibration performance, achieving a maximum natural frequency of 332.8 Hz under C-C-C-C condition, while Plate 2 showed a
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, R G, Ajay Krishna, Ng, Bhavan
Modelling and Analysis of Complex Shaped Cracks2026-28-00482/12/2026
This study provides an extensive analysis through finite element analysis (FEA) on the effects of fatigue crack growth in three different materials: Structural steel, Titanium alloy (Ti Grade 2), and printed circuit board (PCB) laminates based on epoxy/aramid. A simulation of the materials was created using ANSYS Workbench with static and cyclic loading to examine how the materials were expected to fail. The method was based on LEFM and made use of the Maximum Circumferential Stress Criterion to predict where cracks would happen and how they would progress. Normalizing SIFs while a crack was under mixed loading conditions was achieved using the EDI method [84]. We used Paris Law to model fatigue crack growth using constants (C and m) for the materials from previous studies and/or tests. For example, in the case of titanium Grade 2, we found Paris Law constants with C values from 1.8 × 10-10 to 7.9 × 10-12 m/cycle and m values from 2.4 to 4.3, which illustrate differing effects of their
T, Lokesh, Bhaskara Rao, Lokavarapu
Genetic Algorithm Based Optimization of Chaboche Kinematic Hardening Parameters along with the Validation of FE Model through Characterized Crack Initiation2026-28-00862/12/2026
In the context of electro-mobility for commercial vehicles, the failure analysis of a connector panel in a DCDC converter is crucial, particularly regarding crack initiation at the interface of busbar and plastic component. This analysis requires a thorough understanding of thermo-mechanical behavior under thermal cyclic loads, necessitating kinematic hardening material modeling to account for the Bauschinger effect. As low cycle fatigue (LCF) test data is not available for glass fiber reinforced polyamide based thermoplastic composite (PA66GF), we have adopted a novel approach of determining non-linear Chaboche Non-Linear Kinematic Hardening (NLK) model parameters from monotonic uniaxial temperature dependent tensile test data of PA66GF. In this proposed work a detailed discussion has been presented on manual calibration and Genetic Algorithm (GA) based optimization of Chaboche parameters. Due to lack of fiber orientation dependent test data for PA66GF, here von Mises yield criteria
Basu, Parichay, Srinivasappa, Naveen
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
Raja, K., Senthil Kumar, M.S.
A Study on the Thermal Degradation of Chlorinated Polyethylene Rubber2026-26-02761/16/2026
Elastomeric materials are essential in advanced automotive engineering for mobility, isolation, damping, fluid transfer (cooling, steering, fuel, and brake), and sealing because of their unique physio mechanical properties. Elastomers are commonly used in both static and dynamic components, such as hoses, mounts, bushes, and tires. Engine emission standards and weight optimization have caused higher temperature exposure conditions for automotive components. The steering system uses special purpose elastomers like Chlorinated Polyethylene that can deteriorate under abnormal conditions during vehicle operation or manufacturing process due to the high temperature exposure. Therefore, it is crucial to understand the causes and consequences of thermal degradation of elastomers. Thermal degradation is a significant phenomenon that changes the physiochemical properties of elastomers, which results in a product not meeting functional requirements. This study investigates the thermal
Thiruppathi, Anandhi, Mishra, Nitish, Krishnamoorthy, Kunju
Development of Sustainable Textile Solutions Using Recycled and Bio-Based Materials for Automotive Soft Trims2026-26-02361/16/2026
The rising importance of sustainability in the automotive sector has led to increased interest in circular and environmentally responsible materials, particularly for plastic trims parts, both interior and exterior. This study focuses on developing textile solutions using recycled polyethylene terephthalate (r-PET) sourced from post-consumer plastic waste, along with bio-based fibres such as bamboo. These materials made into woven and knitted fabrics are studied to suit different vehicle interior applications. r-PET textiles show promising strength, aesthetic appeal, and durability performance. Bamboo fabrics are known for their natural antimicrobial properties and enhanced breathability. Extensive testing is performed to validate explored sustainable materials performance against key automotive requirements. With this study, we gain an understanding of the performance of variedly sourced sustainable raw materials for automotive specific textile applications by different manufacturing
Deshpande, Sanjana, Borgaonkar, Subodh
Optimizer Sunshade Packaging with Half Aluminum Cassette and Metal Pull Bar2026-26-05971/16/2026
The automotive industry is advancing rapidly with the integration of cutting-edge technology, aesthetics, and performance. One area that has remained relatively underexplored in the pursuit of sleek, minimalistic interiors is the packaging of Sunshade in door trim system. Traditional sunshade design, often bulky and increasingly incompatible with the trend towards compact design and packaging. The car sunshade is a shield that is placed on a car side window and used for regulating the amount of light entering from the car window and helps improve the passenger comfort inside the cabin. Car Interior components, specifically plastic and seats are based on thermal stress properties. When we expose these parts to direct contact with sunlight, humidity and ambient temperature above threshold limit, the interior plastic parts can start to soften and melt. Due to this, they start emitting harmful chemicals which cause anemia and poor immune systems. So, the Sunshade, in addition to protecting
Palyal, Nikita, D, Gowtham, Bhaskararao, Pathivada, Bornare, Harshad, Ritesh, Kakade
Vehicle Interior Material Emissions and Contributions in Passenger Vehicle Cabin Air Quality2026-26-02871/16/2026
Polymer compounds used in the manufacturing of automotive interiors are traditionally consist of polymer virgin material, elastomers, additives, pigments, fillers. These compounded polymers are prone to the emission of low molecular weight chemicals over a period of usage and exposure to the environment called volatile organic compounds (VOCs) and carbonyl compounds. These released VOCs and carbonyl compounds consist of chemicals like benzene, toluene, xylene, styrene, acetaldehyde, formaldehyde, acrolein etc. Short term or long-term exposure of these chemicals have adverse health effects like nausea, headache, vomiting, cancer, even death of personnel if found beyond the permissible limits. It has been observed that the majority of passenger have the above symptoms whenever travelled using passenger cars within few minutes of boarding and exchange the car cabin air. The study was planned to understand the reasons for the concerns and further resolution. This paper is focused on the
Shukla, Sandeep Kumar, Balaji, K V, Varatharajan, Senthilkumaran
New Generation Natural Rubber-Based Bump Stopper with Improved NVH Characteristics2026-26-02921/16/2026
In automotive suspension systems, components like bump stoppers and jounce bumpers play critical roles in controlling suspension travel and enhancing ride comfort. Material selection for these components is driven by functional demands and performance criteria. Traditionally, Natural rubber (NR) has traditionally been favored for bump stopper applications due to its excellent vibration absorption, tear resistance, cost-effectiveness, and biodegradability. However, in more demanding environments, it has been largely replaced by microcellular polyurethane (PU) elastomers, which offer superior durability, environmental resistance, and enhanced noise, vibration, and harshness (NVH) performance. This study revisits NR with the goal of re-establishing its viability by enhancing its performance to match or surpass that of PU. Through compound optimization and advanced material processing techniques, significant improvements have been achieved in NR’s mechanical strength, compression set
Murugesan, Annarajan, Hingalaje, Abhijeet, Perumal, Mathavan, Pawar, Rohit
Development of Advanced Thermoplastic Elastomeric Mat and Its Study on Thermal Performance of Wireless Charger System2026-26-02831/16/2026
This study aimed to develop a thermally conductive TPE mat and assess its performance in comparison to an existing antiskid rubber mat, specifically evaluating its impact on wireless charger efficiency. Moreover, morphological and thermal analyses were conducted to establish a correlation between the material behaviours of the new and current thermally conductive antiskid mats. The process of developing the thermally conductive TPE involved utilizing a two-roll mill followed by compression moulding to achieve a 2D sheet shape. Notably, the thermally conductive mat demonstrated a consistent enhancement in charging efficiency over the conventional antiskid mat. To examine the thermal characteristics, thermal characterization techniques including DSC and TGA were employed for both the existing and newly developed mats. FTIR spectroscopy was also utilized to confirm the presence of organic functional groups within the mat. The morphological analysis of the fillers used to enhance thermal
Naikwadi, Amol Tarachand, Mali, Manoj, Patil, Bhushan, Tata, Srikanth
Failure Prevention of Permanent Deformation in HNBR Elastomeric Diaphragms Used in CNG Valve Applications2026-26-02941/16/2026
Hydrogenated nitrile butadiene rubbers (HNBR) and their derivatives have gained significant importance in automotive compressed natural gas (CNG) valve applications. In one of the four-wheelers, CNG valve application, HNBR elastomeric diaphragms are being used for their excellent sealing and pressure regulation properties. The HNBR elastomeric diaphragm was developed to sustain CNG higher pressure However, it was found permanently deformed under lower pressures. In this research work, number of experiments was carried out to find out the primary root cause of diaphragm permanent deformation and to prevent the failure for safe usage of the CNG gas. HNBR diaphragm deformation investigation was carried out using advanced qualitative and quantitative analysis methods such as Soxhlet Extraction Column, Fourier Transform Infrared Spectroscopy (FTIR), Differential Scanning Calorimetry (DSC), Optical Microscopy (OM), Scanning Electron Microscopy (SEM), and Thermogravimetric Analysis (TGA). For
Patil, Bhushan Gulab, NAIKWADI, AMOL, Mali, Manoj, Tata, Srikanth
Material-Optimization in Rib-Stiffened Polymer Structures: A Computational & Analytical Study2026-26-04981/16/2026
The demand for lightweight yet rigid polymer components continue to drive innovation in structural design, particularly for applications requiring optimal stiffness-to-weight ratios. The current literature focuses on single ribbed or homogeneous plate behavior. Understanding the behavior in parallel rib arrangement with inter connections – especially when the ribs are spaced close together is yet to be done. This study examines an alternative rib-stiffening approach for polypropylene plates, where conventional single-rib geometries are reconsidered in favor of parallel dual-rib configurations. While single ribs have been extensively studied, the potential benefits of distributed rib architecture remain less explored, particularly regarding their combined bending performance. The study attempts to understand the behavior of Polypropylene plates specifically, their bending stiffness, load transfer enhancement of the cross-rib structure through mathematical and computational methods. The
Sreejith, M P, Jain, Deepak, Ravi, Abhikrishna, Maheshwari, Pankaj, Kumar, Mandeep
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-02801/16/2026
This paper presents a comprehensive numerical methodology for simulating the coupled process-structure behavior of short glass fiber-reinforced, injection-molded thermoplastics. The approach integrates elastoplastic and anisotropic material characteristics using three engineering tools: Moldflow, Digimat, and ABAQUS. It accounts for fiber orientation and injection molding defects, linking to thermo-mechanical performance. This method enables accurate virtual modeling of real-time injection-molded components by transferring anisotropic data from Moldflow to ABAQUS. In this study, short fiber orientation and potential injection molding defects such as weld lines and residual stresses are discussed using Moldflow simulation. Besides, Digimat is employed as an interface tool to facilitate the transfer of Moldflow simulation results, namely fiber orientation and material behavior in the allied configurations directly into ABAQUS. This integration enables the evaluation of thermo-mechanical
T, Kalinga, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Incorporation of Strain Hardening and Sheet Thinning Effects during Forming Process for an Accurate Prediction of Buckling Loads on Sheet Metal Axle Parts2026-26-03911/16/2026
In the automotive industry, during the early phase of development, numerical prediction of strength and durability of chassis parts become crucial as these predictions help in design optimization, selecting the appropriate material and identifying potential issues before physical prototypes are built. One of the crucial simulation requirements is the prediction of accurate load carrying capacity or bucking load of axle links. When it comes to the sheet metal axle links there is a deviation in the hardware test and CAE results for load carrying capacity due to the non-integration of forming effects in the numerical simulation, resulting in overdesign of parts, increased costs and development time. This study aims to address these challenges by integrating forming effects experienced by the part during forming process into static strength simulations. These effects include plastic straining, which contributes to material strain hardening and local thickness changes that lead to thinning
R B, Govind, Selvaraj, Nirmal Velgin
Sustainable Tyre-A Journey to Meet Future Requirements of Tyre Industry2026-26-02911/16/2026
Sustainability and environmentally friendly business practices are becoming essential. Tyre industries are embracing the green initiatives to reduce its impact on the environment by exploring the eco-friendly strategies. Starting from the ethical raw material sourcing to a creative recycling technique, strategies are widely distributing in every step of tyre manufacturing to disposition. Each stage of a tyre’s life cycle viz. raw material procurement, manufacturing, transportation both upstream and downstream as well as during the end-of-life phases have an emission-saving potential. It is important to reduce emissions at every stage of tyre’s lifecycle. We have recently developed a Sustainable Tyre with 11% less GHG emission through sustainable raw material approach. Bio sourced or bio attributed raw materials like Styrene Butadiene Rubber (SBR), Polybutadiene Rubber (PBR), Rubber process oil (RPO) and Silica along with natural rubber (NR) had been used. Beside the raw materials from
Bhandary, Tirthankar, Singha Roy, Sumit, Paliwal, Mukesh, Dasgupta, Saikat, Chattopadhyay, Dipankar, Das, Mahuya, Mukhopadhyay, Rabindra
Value-Engineered Design Optimization of a Recycled Plastic Bracket to Meet Natural Frequency Targets in Passenger Vehicles2026-26-03551/16/2026
Engine mount brackets are a primary structural components of passenger vehicles that supports the powertrain to the chassis via engine mounts. These brackets are important to control vibrations and the transmission of noise into the cabin as well as vehicle stability. Since they support the engine mounts, these brackets play a role in determining ride comfort and load distribution on the mounts and the engine. While traditionally made from steel, cast iron and aluminum, we are trying to redesign engine mount brackets with recyclable engineering plastics to fit current demands of light-weighting, cost efficiency, and sustainability. The present work is concerned with the design of a plastic engine mount bracket, which aims to hit specified natural frequency targets in order to avoid resonance and fulfill strict NVH (Noise, Vibration, and Harshness) requirements. Because of the superior mechanical strength, thermal stability, and vibration-dampening properties, PPS, glass-fiber
Hazra, Sandip, Gupta, Deepak, Khan, Arkadip, Gite, Yogesh
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
Imteyaz, Shahma, Iqbal, Shoaib
High-Frequency Dynamic Stiffness Measurements of Automotive Elastomers for Electric Vehicles2026-26-03121/16/2026
The increasing adoption of electric vehicles (EVs) has intensified the demand for advanced elastomeric materials capable of meeting stringent noise, vibration and harshness (NVH) requirements. Unlike internal combustion engine (ICE) vehicles, EVs lack traditional masking noise generated by the powertrain. In the automotive industry, the dynamic stiffness of elastomers in internal combustion engines has traditionally been determined using hydraulic test rigs, with test frequencies limited to a maximum of 1,000 Hz. Measurements above this frequency range have not been possible and are conducted only through computerized FE or CAE calculation models. Electric drive systems, however, generate distinct tonal noise components in the high-frequency range up to 10,000 Hz, which are clearly perceptible even at low sound pressure levels. Consequently, the dynamic stiffness characteristics of elastomers up to 3,000 Hz are critical for optimizing NVH performance in EVs. This study focuses on high
Bohne, Christian, Gröne, Michael
Assessment of Emissions Behaviour of Volatile Compounds from Polymeric Materials used in Automobile Interiors2026-26-02221/16/2026
There is an increasing trend of using polymeric materials in the vehicle interior compartment. While the polymers provide benefits in terms of flexibility in profiling, lighter weight and aesthetics but one of the challenges with the polymers is emission of volatile organic compounds (VOCs) during their usage and particularly at a temperature prevailing in the vehicle cabin. VOCs adversely impact the vehicle interior air quality and can pose a risk to occupants’ health. However, there is a lack of information on volatile organic compound (VOC) emissions from automotive interior materials. There are two types of methods, a whole vehicle chamber method (ISO 12219-1) and a bag method (ISO 12219-2) for evaluation of VOCs emissions from materials used in vehicle interior parts. ISO 12219-2 method describes quantitative testing of VOCs and semi-VOCs. This test method is quick and cost effective for analysis of materials for quick emission checks and can prove to be very effective in
PAtil, Yamini Jitendra, Thipse, Sukrut, Bawase, Moqtik
Advancement in Analytical Characterization of NBR: Py-GC-MS as an Alternative to NMR for Acrylonitrile Quantification2026-26-05461/16/2026
Nitrile Butadiene Rubber (NBR), known for its superior resistance to hydrocarbon oil, low gas permeability, and excellent thermal stability, finds extensive use in seals, O-rings, conveyor belts etc. Importantly, these performance attributes are chiefly governed by acrylonitrile content in NBR. Analytical characterization of raw NBR is relatively straightforward using conventional techniques such as elemental analysis (CHNS) and liquid state 13C NMR. In contrast, the analysis of vulcanized NBR presents considerable challenges due to its crosslinked structure, which renders it insoluble in most organic and inorganic solvents, thereby restricting direct molecular-level analysis. While solid-state 13C NMR is an established technique for structural characterization in rubber vulcanizates, its high-cost curbs routine industrial analysis. In this study, Pyrolysis-Gas Chromatography-Mass Spectrometry (Py-GC-MS) technique has been explored as a robust, precise, cost-effective alternative
Samanta, Rajyasree, Ghosh, Debojit, Anjana, Kanhaiya, Sen, Amit, Guria, Biswanath, Chanda, Jagannath, Samui, Barun, Ghosh, Prasenjit, Mukhopadhyay, Rabindra
Methodology for Optimizing the Bench Testing of Steering I-Shaft Using Vehicle Level Data to Reduce Overall Product Development Time and Cost2026-26-05601/16/2026
Steering I-shaft with rubber coupling (or hardy disc) is an important part of complete steering system mainly in body on frame (BOF) vehicles. Hardy discs are used to dampen the vibrations that transmit to steering wheel through frame, steering gear and I-shaft. They also support to accommodate the variation between frame and BIW (Body in white) of body on frame vehicles. They are made up of rubber or other polymer composites, which have less torsional stiffness as compared to metals. The overall torsional stiffness of steering system reduces since the hardy disc is used in series in steering system, that impacts on the overall performance of steering system. So, during development of I shafts with different design, stiffness of hardy discs are used to optimize the steering and NVH performance of vehicle. Considering the development time and cost, each design of I-shaft cannot be validated at vehicle level. The torsional and axial force or displacement of hardy disc is measured at
Kabdal, Amit
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-05011/16/2026
Manufacturing tolerances play a critical role in the quality and functionality of components, particularly those made from rubber. Even slight deviations in dimensions can cause significant issues such as improper fit and reduced performance, leading to increased costs and project delays. This is especially true for rubber grommets, which are nonlinear elastic components commonly used as sealants, gaskets, and insulation covers in automotive and industrial applications. Typically manufactured from EPDM rubber with varying Shore hardness, grommets must maintain precise geometry to ensure sealing integrity and protect adjacent parts. Dimensional inaccuracies can result in failures such as buckling or misalignment, compromising both functionality and durability. This study proposes a digital simulation methodology for early-stage evaluation of grommet robustness, reducing reliance on physical prototypes. Using a stochastic design of experiments (DOE) approach, the influence of critical
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, Pathan, Eram
Optimizing Stick Slip Performance in Automotive Interiors by Material Selection, Additives and Design Strategies2026-26-03251/16/2026
The automotive industry is highly competitive, especially in terms of design and perceived quality. The use of hard plastics with a high gloss finish is driven by styling trends and the push towards zero gaps, making interfaces critical. In-cabin mood lighting is another feature being offered as a theme for interiors. Dashboard or cockpit designs often incorporate a significant amount of polycarbonate-acrylonitrile butadiene styrene (PC-ABS) and polycarbonate (PC). These materials provide strength and design flexibility but have the disadvantage of material incompatibility when used together, leading to stick-slip phenomena. Traditionally, felt tapes were used as interface isolation to solve this problem, but this increased manufacturing costs and assembly complications. The study focuses on the stick-slip phenomenon and material interface modifications. Specifically, it examines selecting the right surface finish on one side of the PC & PC-ABS interface to change adhesion and friction
Mohammed, Riyazuddin, R, Prasath, Rahman, Shafeeq
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
Palaniappan, Elavarasan, Varatharajan, Senthilkumaran, Balaji, K V, Dodiya, Rohanbhai
Conductive Hydrogel Holds Promise for ImplantsTBMG-544101/1/2026
Bioelectronics, such as implantable health monitors or devices that stimulate brain cells, are not as soft as the surrounding tissues due to their metal electronic circuits. A team of scientists has developed a soft polymer hydrogel that can conduct electricity as well as metal can. As the material is both flexible and soft, it is more compatible with sensitive tissues. This finding has the potential for a large number of applications, for example, in biocompatible sensors and in wound healing.
Multifunctional ANF/Mxene-Enhanced Hydrogels for Flexible EMI Shielding and Wearable Sensing ApplicationsTBMG-544161/1/2026
Researchers from Harbin Institute of Technology and their collaborators have developed a multifunctional polyelectrolyte hydrogel reinforced with aramid nanofibers (ANFs) and MXene nanosheets, achieving outstanding performance in absorption-dominated electromagnetic interference (EMI) shielding and wearable sensing. This innovative hydrogel addresses the long-standing challenge of balancing electrical conductivity and effective EMI absorption in flexible electronic materials. The research was published in the journal Nano-Micro Letters. 1
Predictive Analysis of Slip Distance of Highway Loess Slopes Based on Intense Rainfall Infiltration2025-99-024112/23/2025
Based on field investigations of loess slopes along highways in the Lüliang region, a numerical infiltration model of highway loess slopes was established using the ABAQUS finite element software. The study examined the time to plastic zone coalescence and variations in infiltration range under two intense rainfall scenarios for slopes of different heights. Furthermore, a landslide numerical model of the loess slope was constructed using the FEM-SPH method, and a predictive formula for landslide runout distance of highway loess slopes was derived through data fitting.The results indicate that under the same slope height, increased rainfall intensity leads to a certain degree of reduction in landslide runout distance. Conversely, under the same rainfall condition, greater slope height significantly increases the runout distance. This study provides a theoretical foundation and methodological support for stability evaluation and runout distance prediction of loess slopes under intense
Liu, Manfeng, Li, Hong
Study on the Influence of Liquid Composite Swivel Arm Positioning Nodes on the Dynamic Performance of High-Speed Trains2025-99-025512/23/2025
Rubber components are an important part of the suspension system of high-speed trains, and the complex nonlinear characteristics of rubber parts have a significant impact on the vehicle dynamic performance. This paper establishes a nonlinear dynamics model of the liquid composite swivel arm positioning node, which can reflect the dynamic stiffness and dynamic damping characteristics of the rubber components that change nonlinearly with the frequency and amplitude, and also has a fast calculation speed. The vehicle dynamics simulation model considering the longitudinal stiffness nonlinear characteristics of the arm node is established, and the influence of the stiffness nonlinearity of the liquid composite arm positioning node on the dynamic performance of the vehicle, such as straight-line stability and curve passing ability, is studied in depth through numerical simulation.
Cheng, Junqiang, Yang, Chen, Li, Longtao, Cong, Rilong, Hu, Tingzhou
Injection Molding Parameters Optimization to Enhance Mechanical Properties of Glass-Fiber Reinforced PA9T Polymer2025-36-012412/18/2025
The use of polymeric materials and polymer -based composites as alternatives to metals in conventional applications is a widely adopted strategy. These materials provide advantages in terms of processability, cost-effectiveness, and, most notably, weight reduction. This study aimed to develop and optimize the injection molding process for producing PA9T (Polyphthalamide 9T) components reinforced with varying amounts of glass fiber to achieve optimal mechanical and physical properties. To enhance mechanical performance, different glass fiber loadings were investigated. The study employed the Taguchi method with an L9 orthogonal array design. The selected variable parameters were material composition (PA9T reinforced with 30, 35, and 50 wt% glass fiber), injection pressure (1000, 1500, and 2000 bar), injection temperature (320, 330, and 340 °C), and injection speed (100, 125, and 150 mm/s). The Taguchi method was chosen because it allows for the identification of optimal process
Mendonça, Arthur S., Michelotti, Alvaro Canto, Berto, Lucas F., Salvaro, Diego B., Binder, Cristiano
Influence of the PTFE on the Tribological and Mechanical Properties of a Fiber-Reinforced Polyphthalamide2025-36-022112/18/2025
Materials science and engineering are essential for advancing energy-efficient mechanical systems through lightweight structures and friction reduction. Among engineering polymers, polyphthalamides (PPA) are widely used for their superior thermochemical and mechanical properties. This study investigates the influence of polytetrafluoroethylene (PTFE) on the mechanical and tribological performance of a commercial polymer matrix composite (PMC) reinforced with 30wt% glass fiber. Self-lubricating composites were manufactured by injection molding with PTFE contents ranging from 0-15 wt%. Density was measured using Archimedes’ method. Mechanical properties were measured through ISO 527 tensile testing, while tribological behavior was evaluated using ball-on-flat reciprocating tests under 189N (630 MPa), 2 H frequency, and 10 mm strokes for 60 minutes, employing a 10 mm diameter AISI 52100 steel sphere as counter-body. Friction coefficient (COF) was monitored throughout testing, and wear
Hromatka, Matheus, Salvaro, Diego B., Binder, Cristiano, Michelotti, Alvaro C., Berto, Lucas F.
Biocomposite of Euterpe oleracea Mart and Cocos nucifera l. : Sustainable Materials2025-36-016312/18/2025
Brazil is recognized for its vast biodiversity and abundance of natural resources, many of which are still underutilized. In an effort to promote sustainability and innovation, there is a growing movement to replace non-recyclable materials with ecological alternatives. Within this context, acai leaves (Euterpe oleracea Mart.) and coconut leaves (Cocos nucifera L.) appear as potential natural reinforcements in polymer composites. This study aims to evaluate the mechanical properties of composites formed by these sheets, using polyester resin as the matrix phase. Tensile strength tests were conducted on specimens, following the ASTM D 638M standard, to determine the mechanical properties of the composites. The results obtained were compared with data from the existing literature in order to validate the effectiveness of the composites produced. Additionally, fractures in the specimens were visually analyzed for a better understanding of the failure mechanisms.
Dias, Roberto Yuri Costa, Santos Borges, Larissa, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor, Silva de Mendonça, Alian Gomes, Fujiyama, Roberto Tetsuo
Mechanical Tensile Behavior of Polyester Composites with Addition of Banana and Sugarcane Fibers2025-36-015412/18/2025
Polymer composites with the addition of natural fibers have gained prominence as a sustainable and technically viable alternative to conventional synthetic materials, especially in applications that require a balance between mechanical performance and environmental responsibility. This study evaluated the mechanical behavior of composites produced with plant fibers from banana (Musa sapientum) and sugarcane (Saccharum officinarum L.), both sourced from the northern region of Brazil. The fibers, used in their natural state without chemical treatment, were cut to a uniform length of 5 mm for standardization. The polymer matrix used was unsaturated terephthalic polyester resin, pre-accelerated and catalyzed with methyl ethyl ketone peroxide (MEKP). The molding of test samples was performed manually in silicone molds, according to ASTM D638 specifications, to ensure repeatability and comparability of results. The mechanical tests revealed that the composites made with sugarcane fibers had
Santos Borges, Larissa, Dias, Roberto Yuri Costa, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor, Silva de Mendonça, Alian Gomes, Fujiyama, Roberto Tetsuo
Natural Fibers Applied in the Automotive Industry in Brazil: A Review2025-36-017012/18/2025
There is a growing demand for new materials that meet mechanical and structural performance requirements, with specific properties, especially in the automotive industry. From a context of innovation and global needs to be met, there is the appreciation of composite materials, specifically applied in the automotive sector, since these can be obtained from the combination of two or more different materials, obtaining certain properties from the individual characteristics of its phases, expanding the availability of materials to be used in this sector. In recent years the use of natural fibers in composite materials for automotive applications has gained relevance due to factors such as sustainability, low weight and good mechanical properties. The attempt to combine innovation and environmental preservation make such applications promising, aiming to obtain ecological solutions, considering that natural fibers of vegetable origin such as sisal, jute and flax are biodegradable and
Dias, Roberto Yuri Costa, Santos Borges, Larissa dos, Brandao, Leonardo William Macedo, Mendonca Maia, Pedro Victor de, Silva de Mendonça, Alian Gomes da, Fujiyama, Roberto Tetsuo
Review of Through-the-Thickness Reinforcement Technologies Applied to Aircraft CFRP Composites2025-99-035512/17/2025
Carbon fiber-reinforced polymer (CFRP) composites are widely used in aircraft structures for weight reduction due to their high specific strength and modulus. However, their weak interlaminar properties lead to high sensitivity to out-of-plane loads such as impact, making them prone to delamination damage, which threatens flight safety. To enhance interlaminar performance, through-thickness reinforcement technologies, particularly Z-pinning and stitching, have become key research focuses. This paper systematically reviews the manufacturing processes, structural mechanical characteristics, and application progress in aerospace structures of these two mainstream through-thickness reinforcement technologies. Research shows that Z-pintechnology, by implanting metal or CFRP pins, and stitching technology, by sewing multiple fabric layers with fiber threads, both effectively bridge interlaminar cracks, significantly improving the impact resistance of composites. However, the implantation
Cui, Bo, Zhang, Yongjie, Zhang, Chuzhe, Jin, Tao
Robotic Skin Allows Tiny Robots to Navigate Complex, Fragile EnvironmentsTBMG-5428512/1/2025
Researchers at the University of California San Diego have developed a soft robotic skin that enables vine robots that are just a few millimeters wide to navigate convoluted paths and fragile environments. To accomplish this, the researchers integrated a very thin layer of actuators made of liquid crystal elastomer at strategic locations in the soft skin. The robot is steered by controlling the pressure inside its body and temperature of the actuators.
Programming Robots with Rubber BandsTBMG-5428412/1/2025
From sorting objects in a warehouse to navigating furniture while vacuuming, robots today use sensors, software control systems, and moving parts to perform tasks. The harder the task or more complex the environment, the more cumbersome and expensive the electronic components.
Advances in Polyimide Tubing for Next-Generation Medical DevicesTBMG-5433512/1/2025
Minimally invasive and interventional platforms increasingly demand smaller profiles, tighter tolerances, and components that maintain performance under thermal, chemical, and mechanical stress. Polyimide (PI) has emerged as a workhorse within these parameters because it combines high strength, thermal stability, chemical inertness, dielectric performance, and biocompatibility in thin-wall formats suitable for catheters, electrophysiology tools, and neurovascular systems. 1- 3
SAE TOMORROW TODAY - Conquering the Australian Outback with Solar Power1354411/21/2025
What does it take to race 3,000 kilometers across the unforgiving Australian Outback powered only by the sun? Listen in as we sit down with Martijn Boonen, Electrical Engineer & Driver, Brunel Solar Team, and Tony Mathew, Global Market Manager, Teijin Aramid, to reveal the secrets behind their record-breaking solar car victory at the 2025 Bridgestone World Solar Challenge. Discover how cutting-edge engineering, relentless teamwork, and innovative sustainable materials came together to conquer extreme heat, torrential rain, and fierce competition. Hear firsthand how the Brunel Solar Team's winning mentality led to their eighth global win, and how circular fiber tire technology proved that sustainability and high performance can go hand-in-hand. We'd love to hear from you. Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in
Patterson, Lori
Static Seal Test Fixture and ProcedureAS7982 (Current)11/13/2025
This SAE Aerospace Standard (AS) provides dimensions and procedures for a standardized test fixture used to evaluate the static performance of O-rings and other seal types in glands per AS4716 and AS5857.
AMS CE Elastomers Committee
Hardness Testing of Elastomeric O-RingsAIR4738B (Current)11/13/2025
This SAE Aerospace Information Report (AIR) provides a general description of methods for hardness testing of O-rings including factors which affect precision and comparison of results with those obtained in standard tests.
AMS CE Elastomers Committee
Rubber, Fluorocarbon Elastomer (FKM) 70 to 80 Hardness, Low Temperature Sealing Tg -22 °F (-30 °C) For Elastomeric Shapes or Parts in Gas Turbine Engine Oil, Fuel and Hydraulic SystemsAMS3384A (Current)11/10/2025
This specification covers a high temperature, compression set and fluid resistant fluorocarbon (FKM) rubber in the form of sheet, strip, tubing, extrusions, and molded shapes for aeronautical and aerospace applications.
AMS CE Elastomers Committee
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