Browse Topic: Polymers

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Material Adapted Method for the Repair of Curved Thermoplastic Composite Structures by Induction Welding of Patches2025-01-0165To be published on 04/25/2025
Thermoplastic fiber-reinforced polymer composites (TPCs) are gaining importance in aviation due to their high strength, stiffness, and recyclability. To maximize their potential, efficient repair methods are needed to maintain aircraft safety and structural integrity. This article introduces a novel repair technique for damaged TPC structures, involving the insertion of a repair patch with a susceptor material. The susceptor consists of a material with high electrical conductivity and magnetic permeability and therefore reacts stronger to the electromagnetic field than the composite, even if it is carbon fiber based. This means that the thermal energy is specifically concentrated in the repair area. The susceptor can be placed on the patch surface or in the welding zone. The process begins by identifying and preparing the damaged area, followed by precise scarfing. Care is taken to ensure that the surrounding material remains intact and that an exact stepped structure is created, which
Geiger, Markus, Glaap, Anton, May, David, Schiebel, Patrick
Technical Paper
Proposed Solutions to Improve Green Hydrogen Production for Cars2025-01-8601To be published on 04/01/2025
Recently, global interest in hydrogen as a powerful, promising and clean source of energy has increased. Green hydrogen production is considered one of the most important modern projects worldwide, as it is the way to achieve a clean and sustainable environment. There are several methods for producing hydrogen, the most famous of which are: 1) Electrochemical separation of water; 2) Heating waste plastic at a high temperature using low-carbon emission technology. However, both methods still suffer from complexity and high cost, which calls for the search for scientific solutions to reduce economic costs and make hydrogen available to everyone at reasonable prices. While the first method is considered the best and easiest to produce high-purity hydrogen, but it faces challenges in collecting hydrogen on the surface of the positive electrode (cathode) in a way that is suitable for collecting it in a safe and less expensive way, so that it can be used in multiple applications, especially
Hamed, Maryam Salah, Ali, Salah H. R.
Technical Paper
Brittle or Ductile? Effects of Print Orientation and Raster Angle on Polylactic Acid (PLA) Fused Filament Fabrication (FFF) Tensile Samples2025-01-8335To be published on 04/01/2025
The automotive industry leverages Fused Filament Fabrication (FFF) -based Additive Manufacturing (AM) to reduce lead time and costs for prototypes, rapid tooling, and low-volume customized designs. This paper examines the impact of print orientation and raster angle on the tensile properties of Polylactic Acid (PLA), selected for its ease of use and accessibility. Dog bone samples were designed to the ASTM D638 tensile testing standard and printed solid with a 0.2 mm layer height, two outer walls, and varying raster-fill angles, with layers alternating by 90°. Testing was conducted on the MTS Criterion Model 43, 50 kN system. Varying print orientation along the X and Y axes (double angle builds) produced a Young's modulus (YM) range of 0.7519, reflecting a 34.42% increase between the witnessed minimum and maximum values. These builds exhibited more brittle behavior than most single angle builds, except for X10 Y10 Z0 at a 45° raster (the lowest recorded YM) and X0 Y15 Z0 at a 30
Strelkova, Dora, Urbanic, Ruth Jill
Technical Paper
Dynamic Performance Optimization of Double-isolation rubber mounts Based on Neural Network and Genetic Algorithm Collaboration2025-01-8266To be published on 04/01/2025
As a crucial connecting component between the powertrain and the chassis, the performance of rubber mounts is directly related to the NVH (Noise, Vibration, and Harshness) characteristics of electric vehicles. This paper proposes a double-isolation rubber mount, which, compared to traditional rubber mounts, incorporates an intermediate skeleton and features inner and outer layers of "cross-ribs". The design parameters can be simplified to: skeleton diameter, skeleton thickness, main rib width, and main rib thickness. To comprehensively evaluate its performance, a finite element analysis (FEA) model of the proposed double-isolation rubber mount was first established in Abaqus, with static stiffness and dynamic performance analyzed separately. The results indicate that, compared to traditional rubber mounts with similar static stiffness, this design effectively controls dynamic stiffness in the high-frequency range. To expand the effective vibration isolation frequency range of the
Xu, Che, Kang, Yingzi, Tu, Xiaofeng, Shen, Dongming
Technical Paper
A systematic review about heat shrink materials using nanomaterials for the automotive industry2025-01-8329To be published on 04/01/2025
Heat shrink polymer sleeves are a type of material used in various industries for their ability to contract and fit snugly around objects when heat is applied. These tubes are typically made from materials like polyolefin or fluoropolymers, which have the property of shrinking when heated. Nanomaterials present many applications and its usage is a remarkable tool aiming to improve many properties of materials. Then, many improvements including increase of performance and price reduction may be done due to its unique properties when nanomaterials are used into heat shrink polymer sleeves. This work presents a systematic review of the state of the art on heat-shrinkable materials for the automotive industry. As a methodology, articles from the last 10 years on the subject were selected. The keywords “heat shrink” AND “nanomaterial” AND “tubes OR sleeves” were used in three different databases. “Scopus”, “Web of Science” and “MDPI”. After using the keywords, articles only in English were
Kerche, Eduardo F., Polkowski, Rodrigo, Horiuchi, Lucas, Goncalves, Everaldo
Technical Paper
Mechanical Analysis of a Non-Pneumatic Tire’s Spokes2025-01-8327To be published on 04/01/2025
Mechanical analysis was performed of a non-pneumatic tire, specifically a Michelin Tweel size 18x8.5N10, that can be used up to a speed of 40 km/h. A Parylene-C coating was added to the rubber spoke specimens before performing both microscopic imaging and cyclic tensile testing. Initially, standard ASTM D412 specimens type C and A were cut from the wheel spokes, and then the specimens were subjected to deposition of a nanomaterial. The surfaces of the specimens were prepared in different ways to examine the influence on the material behavior including the stiffness and hysteresis. Microscopic imaging was performed to qualitatively compare the surfaces of the coated and uncoated specimens. Both coated and uncoated spoke specimens of each standard type were then subjected to low-rate cyclic tensile tests up to 500% strain. The results showed that the Parylene-C coating did not affect the maximum stress in the specimens, but did increase the residual strain. Type C specimens also had a
Collings, William, Li, Chengzhi, Schwarz, Jackson, Lakhtakia, Akhlesh, Bakis, Charles, El-Sayegh, Zeinab, El-Gindy, Moustafa
Technical Paper
Thermal Insulation Tiles and Sheets Based on Intergration of Recycled Plastic Waste Fibres and Epoxy Resin2025-01-8325To be published on 04/01/2025
Plastic waste has risen to be one of the most concerning and endangering pollutants to the environment and nature in the past few years, making its effective management and reduction a major domain of focus among researchers and industrialists. This comparative study is an attempt to utilize recycled Polyethylene Terephthalate (rPET) fibres combined with Epoxy Resin in various combinations, to provide effective and low-cost insulation in moderate to low requirements. The above-mentioned components serve as viable insulators with their thermal conductivities ranging from 0.2W/mK to 0.3W/mK and 0.15W/mK to 0.35W/mK respectively. Moisture resistance of both materials and temperature resistance of Epoxy resins ranging from 120°C to 150°C (depending upon the grade of Epoxy used) indicates good stability in harsh external operating environments. While epoxy resins are not inherently flame retardants, additives are introduced for this purpose to render the composite safer to use. Moreover
Purihella, Sri Sai Krishna, Pali, Harveer Singh, Kumar, Piyush, Sharma, Ved Prakash
Technical Paper
Sustainable automotive composites: A systematic review of dispersion methods for cotton fibers in poly(lactic acid) matrix2025-01-8326To be published on 04/01/2025
Composite materials are created by combining two or more different materials, such as a filler or fibrous reinforcement dispersed in a polymer matrix to improve the properties that surpass those of the individual components while reducing weight, making them ideal for the sustainable development of the automotive industry. Poly(lactic acid) (PLA) has emerged as a promising polymer matrix for composites due to its ecological and biodegradable nature and good mechanical properties (tensile strength and modulus of elasticity) but limited when compared to engineering polymers such as Acrylonitrile Butadiene Styrene (ABS) and Acrylonitrile Styrene Acrylate (ASA). Cotton fibers (CF) have gained visibility as filler or reinforcement in PLA/CF composites due to their low cost, renewable sources and relatively abundance. Although, to ensure mechanical enhancement, fiber dispersion in PLA matrix is of paramount importance, often being neglected. This article aims to study how to achieve a
De Andrade, Marina, Polkowski, Rodrigo, Horiuchi, Lucas Nao, Goncalves, Ana Paula, De Oliveira, Vinícius
Technical Paper
Evaluation of additively manufactured thermoplastic composite magnetic field shielding for stepper motors2025-01-8201To be published on 04/01/2025
As stepper motors become more and more widely used in engineering systems (vehicles, 3-D printers, manufacturing tools, and similar), the effects of their induced magnetic fields present a concern during the packing and orientation of components within the system. For applications requiring security, this is also a concern as the background electromagnetic radiation (EMF) can be captured at a distance and used to reproduce the motion of the motor during operation. One proposed alternative is to use customized non-magnetic plastic shields created using additive manufacturing. Some small studies have been completed which show some effectiveness of this approach but these studies have been small-scale and difficult to reproduce. To seek a more rigorous answer to this question and collect reproducible data, the present study used full factorial design of experiments with several replications. Three materials were used: Polylactide (PLA), PLA with 25% (weight) copper powder, and PLA with 15
Hu, Henry, Patterson, Albert E., Karim, Muhammad Faeyz, Porter, Logan, Kolluru, Pavan V.
Technical Paper
Modeling and Prediction of Truck Tire Temperature Using Advanced Computational Techniques2025-01-8758To be published on 04/01/2025
This paper explores the development of a Finite Element tire-road interaction thermal model for a Mixed Service Drive (MSD) truck tire sized 315/80R22.5. Physical experiments were performed at a high-speed track in Hällered, Sweden for a truck combination traveling at a constant speed of 80 km/h. For this investigation, the Gross Combination Weight is approximately 42 tons. In the Finite Element Analysis environment, ESI PAMCRASH, the truck tire is designed with hyperelastic Ogden solid rubber definitions. The Ogden material definition is used in this application as it is more suitable to perform thermal and wear analysis. The Finite Element truck tire model is designed to build up temperature through tire-road friction contact. The truck tire model simulates the thermal build-up over time for select tires on a High-Capacity transport truck combination, such as a tractor-semitrailer, particularly a free-rolling semi-trailer and dolly tire. Tire models over real-time in the FEA
Ly, Alfonse, Collings, William, El-Sayegh, Zeinab, El-Gindy, Moustafa, Johansson, Inge, Oijer, Fredrik
Technical Paper
Finite Element Simulation and Experimental Study of the In-Mold Graining Process2025-01-8330To be published on 04/01/2025
In-Mold Graining (IMG) is an innovative production technology applied to the skin wrapping of automotive interior components. In the design of automotive interior components of door panels and instrument clusters, to overcome process-related problems, such as the thinning of grain patterns and excessive reduction in thickness, simulation of the skin vacuum forming process is required. The Thermoplastic Olefin (TPO) skin material is investigated in this paper, and a viscoelastic mechanical model for this material is established. Dynamic Mechanical Analyzer (DMA) is utilized to perform scan for frequency and temperature, and the tested data is used to obtain key model parameters of the viscoelastic constitutive model. Based on the experimental data, the study explores how to calculate the relaxation time spectrum to describe the viscoelastic properties of TPO material during the vacuum adsorption process. Numerical simulation of the vacuum adsorption process of TPO material is conducted
Chai, Bingji, Guo, Yiming, Xie, Xinxing, Zhang, Qu
Technical Paper
Impact of Preload and Amplitude on the High-Frequency Behavior of Rubber Bushings in Electric Vehicles: An Experimental Study2025-01-8254To be published on 04/01/2025
Electric vehicles (EVs) are particularly susceptible to high-frequency noise, with rubber eigenmodes significantly influencing these noise characteristics. Unlike internal combustion engine (ICE) vehicles, EVs experience pronounced variations in dynamic preload during torque rise, which are substantially higher. This dynamic preload variation can markedly impact the high-frequency behaviour of preloaded rubber bushings in their installed state. This study investigates the effects of preload and amplitude on the high-frequency dynamic performance of rubber bushings specifically designed for EV applications. These bushings are crucial for vibration isolation and noise reduction, with their role in noise, vibration, and harshness (NVH) management being more critical in EVs due to the absence of traditional engine noise. The experimental investigation examines how preload and excitation amplitude variations influence the dynamic stiffness, damping properties, and overall performance of
Hazra, Sandip, Khan, Arkadip Amitava
Technical Paper
Advanced Methodology for Accelerated Durability Block Cycle Testing of Automotive Rubber Suspension Bushings and Powertrain Mounts2025-01-8236To be published on 04/01/2025
In the field of automotive engineering, the performance and longevity of suspension bushings and powertrain mounts are critical. These components must endure fatigue loads characterized by their variable amplitude, multi-axial nature, and out-of-phase oscillations. The challenge lies in comprehensively characterizing these service loads during the early stages of vehicle production to foresee potential issues that may arise during later stages. Additional complexity in this analysis is introduced by the nonlinear hyperelastic deformation exhibited by natural rubber, a common material used in these components. To address these challenges, original equipment manufacturers (OEMs) and suppliers employ Computer-Aided Engineering (CAE) techniques for fatigue life predictions. These predictions are complemented by physical testing involving what are known as block cycles. However, the results obtained from these approaches often fail to fully represent the real loading conditions that a
Zarrin-Ghalami, Touhid, Datta, Sandip
Technical Paper
WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSSLINKED MODIFIED ETFE, LOW FLUORIDE, NORMAL WEIGHT, SILVER-COATED COPPER, 200 °C, 600 VOLT, ROHSAS22759/54C (Current)02/25/2025
AE-8D Wire and Cable Committee
Technical Standard
WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSSLINKED MODIFIED ETFE, LOW FLUORIDE, LIGHTWEIGHT, SILVER-COATED COPPER, 200 °C, 600 VOLT, ROHSAS22759/52C (Current)02/24/2025
AE-8D Wire and Cable Committee
Technical Standard
WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSSLINKED MODIFIED ETFE, LOW FLUORIDE, LIGHTWEIGHT, SILVER-COATED HIGH STRENGTH COPPER ALLOY, 200 °C, 600 VOLT, ROHSAS22759/51C (Current)02/24/2025
AE-8D Wire and Cable Committee
Technical Standard
WIRE, ELECTRICAL, FLUOROPOLYMER-INSULATED, CROSSLINKED MODIFIED ETFE, LOW FLUORIDE, NORMAL WEIGHT, SILVER-COATED HIGH STRENGTH COPPER ALLOY, 200 °C, 600 VOLT, ROHSAS22759/53C (Current)02/24/2025
AE-8D Wire and Cable Committee
Technical Standard
Temperature-Dependent Analysis of the Tire–Road Interaction Characteristics for a Passenger Car Tire Using Finite Element Analysis15-18-02-001002/20/2025
In this article, a finite element analysis for the passenger car tire size 235/55R19 is performed to investigate the effect of temperature-dependent properties of the tire tread compound on the tire–road interaction characteristics for four seasons (all-season, winter, summer, and fall). The rubber-like parts of the tire were modeled using the hyperelastic Mooney–Rivlin material model and were meshed with the three-dimensional hybrid solid elements. The road is modeled using the rigid body dry hard surface and the contact between the tire and road is modeled using the non-symmetric node-to-segment contact with edge treatment. At first, the tire was verified based on the tire manufacturer’s data using numerical finite element analysis based on the static and dynamic domains. Then, the finite element analysis for the rolling resistance analysis was performed at three different longitudinal velocities (10 km/h, 40 km/h, and 80 km/h) under nominal loading conditions. Second, the steady
Fathi, Haniyeh, El-Sayegh, Zeinab, Ren, Jing
Journal Article
O-Ring Molded from AMS7267 Material, MetricMA3442A (Current)02/08/2025
This material type has resistance to hot air, but generally has poor resistance to fuels and lubricants, but usage is not limited to such applications. Each application should be considered separately. This material type has a typical service temperature range of -85 to 500 °F (-65 to 260 °C). The operating temperature range of the material is a general temperature range, but the presence of particular fluids and design parameters may modify this range. Recommendations on the material selection are based on available technical data and are offered as suggestions only. Each user should make his own tests to determine the suitability for his own particular use.
A-6C2 Seals Committee
Technical Standard
Development of AI Prediction Tool for Fused Deposition Modeling of ABS Material for Automobile Applications2025-28-012702/07/2025
Fused Deposition Modeling (FDM), a form of Additive Manufacturing (AM), has emerged as a groundbreaking technology for the production of complex shapes from a variety of materials. Acrylonitrile Butadiene Styrene (ABS) is an opaque thermoplastic that is frequently employed in additive manufacturing (AM) due to its affordability and user-friendliness. The purpose of this investigation is to enhance the FDM parameters for ABS material and develop predictive models that anticipate printing performance by employing the Adaptive Neuro-Fuzzy Inference System (ANFIS). Through experimental trials, an investigation was conducted to evaluate the influence of critical FDM parameters, including layer thickness, infill density, printing speed, and nozzle temperature, on critical outcomes, including mechanical properties, surface polish, and dimensional accuracy. The utilization of design of experiments (DOE) methodology facilitated a systematic examination of parameters. A predictive model was
Natarajan, Manikandan, Pasupuleti, Thejasree, Kumar, V, Kiruthika, Jothi, Katta, Lakshmi Narasimhamu, Silambarasan, R
Technical Paper
Fabrication and Analysis of Pneumatically Actuated Soft Robotic Gripper with Negative Pressure2025-28-014502/07/2025
Soft-bending actuators are gaining considerable attention in robotics for handling delicate objects and adapting to complex shapes, making them ideal for biomimetic robots. Soft pneumatic actuators (SPAs) are preferred in soft robotics because to their safety and compliance characteristics. Using negative pressure for actuation, it enhances stability by reducing the risk of sudden or unintended movements, crucial for delicate handling and consistent performance. Negative pressure actuation is more energy-efficient, safe and are less prone to leakage, increasing reliability and durability. This paper involves development of a new soft pneumatic actuator design by comparing various designs and to determine its performance parameters. This paper depicts on designing, and fabricating flexible soft pneumatic actuators working under negative pressure for soft robotic applications. The material used for fabrication was liquid silicone rubber and uniaxial tensile tests were conducted to
Warriar J S, Sreejith, Sadique, Anwar, George, Boby
Technical Paper
Computational Evaluations of Structural Integrity in Unmanned Aquatic Vehicles Utilizing Various Conventional and Hybrid Composites Using Hydro-Structural Analyses2025-28-005602/07/2025
This study focuses on developing and deploying an Unmanned Aquatic Vehicle (UAV) capable of underwater travel. The primary objectives of this project are to detect the presence of dimethyl sulfide and toluene, as well as to identify any potential oil leakage in underwater pipelines. The UAV has a maximum operating depth of 300 m below the water surface. The design of this UAV is derived from the natural design of Rhinaancylostoma, an underwater kind of fish. The maximum operational setting for this mission is fixed at a depth of approximately 300 m beneath the surface of the sea, and the choice of this species is suitable for fulfilling the objectives of this undertaking. This technology will mitigate the risk associated with human interaction in inspection processes and has the potential to encompass various other resources in the future. The initial design data of the UAV is determined using analytical processes and verified formulas. The selection of the airfoil is done by comparing
Veeraperumal Senthil Nathan, Janani Priyadharshini, Rajendran, Mahendran, Arumugam, Manikandan, Raji, Arul Prakash, Sakthivel, Pradesh, Madasamy, Senthil Kumar, Stanislaus Arputharaj, Beena, L, Natrayan, Raja, Vijayanandh
Technical Paper
Optimization of Fused Deposition Modeling Using Taguchi-Based Grey Relational Analysis for TPU Used in Auto Parts2025-28-015802/07/2025
Fused Deposition Modeling (FDM) is a highly adaptable additive manufacturing method that is extensively employed for creating intricate structures using a range of materials. Thermoplastic Polyurethane (TPU) is a highly versatile material known for its flexibility and durability, making it well-suited for use in industries such as footwear, automotive, and consumer goods. Hoses, gaskets, seals, external trim, and interior components are just a few of the many uses for thermoplastic polyurethanes (TPU) in the automobile industry. The objective of this study is to enhance the performance of Fused Deposition Modeling (FDM) by optimizing the parameters specifically for Thermoplastic Polyurethane (TPU) material. This will be achieved by employing a Taguchi-based Grey Relational Analysis (GRA) method. The researchers conducted experimental trials to examine the impact of key FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical responses
Pasupuleti, Thejasree, Natarajan, Manikandan, Ramesh Naik, Mude, Silambarasan, R, D, Palanisamy
Technical Paper
Optimization of Fusion Deposition Modeling Parameters for PLA Material for Automobile Interior Using Taguchi Based TOPSIS Approach2025-28-013102/07/2025
Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM), has transformed the manufacturing industry by allowing the creation of intricate shapes using different materials. Polylactic Acid (PLA) is a biodegradable thermoplastic that is commonly used in additive manufacturing (AM) because of its environmentally friendly nature, affordability, and ease of processing. This study aims to optimize the parameters of Fused Deposition Modeling (FDM) for PLA material using the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) approach. The researchers performed experimental trials to examine the impact of important FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical outcomes, including dimensional accuracy, surface finish, and mechanical properties. The methodology of design of experiments (DOE) enabled a systematic exploration of parameters. The TOPSIS approach, a technique for making decisions
Natarajan, Manikandan, Pasupuleti, Thejasree, D, Palanisamy, Katta, Lakshmi Narasimhamu, Silambarasan, R
Technical Paper
Investigating Mechanical Properties of Jute Fiber and Alumina-Reinforced Epoxy Composites: Application of Taguchi and Grey Analysis for Automotive Components2025-28-011302/07/2025
Natural fiber composites (NFC’s) have considerable promise for a wide range of technological applications due to their exceptional features, which include notable weight reduction, high strength, and affordability. The aforementioned materials are also biodegradable and sustainable, which makes them appealing for use in sustainable engineering methods. This research focuses on evaluating the mechanical features of jute fiber and Al₂O₃ particle fortified polymer composites, exploring their potential for advanced engineering uses. The Taguchi technique is used with a L9 orthogonal array, integrating three-level, three-parameter approach, to systematically examine potential combinations of process variables in the manufacturing of these polymer composites. The primary goal is to optimize the mechanical attributes of the composites, which include tensile modulus, tensile stress, and weight percentage increase. Detailed investigations are conducted to interpret the effects of these process
Somsole, Lakshmi Narayana, Natarajan, Manikandan, Pasupuleti, Thejasree, Katta, Lakshmi Narasimhamu, Vivekananda, Soma
Technical Paper
Synthesis and Characterization of Poly (Aniline –Co-Chloroaniline) Polymers and Applications in Automotive Industries as Paint Coatings2025-28-003702/07/2025
Polyaniline (PANI)-polymer based smart paints have emerged as a promising solution for enhancing the durability and performance of automobile surface coatings. These paint coatings offer a superior corrosion resistance, conductivity, and environmental stability, making it an ideal. Here novel copolymers of dodecylbenzene sulfonic acid(DBSA) aided poly (aniline-co-m-chloroaniline) nanocomposites of various compositions were prepared by oxidative method in micellar solution. These nanocomposites were analyzed by using UV-Vis and FT-IR spectroscopic methods. The crystalline nature of the polymer was evidenced through XRD patterns. SEM revealed the presence of particles with spherical morphology 100 nm in diameter. The electrical activity of the doped polymer was found to be content increasing from 3:1 to 3:3 x 10-2 S/cm to 5.64 x 10-7 S/cm with chloroaniline. These copolymers are added as additives in manufacturing of paint. These novel paints offer multiple protective mechanisms
Pachanoor, Vijayanand, Moorthi, Bharathiraja
Technical Paper
Vibrational, Thermal and Mechanical Performance Analysis of Hybrid Composite Plates Composed of Kenaf and Ridge Gourd Fibers with Waste Plastic Materials2025-28-003002/07/2025
Before starting your paper, please read, “How to Write an SAE this study investigates the performance and highlights the mechanical, thermal, and vibrational characteristics of hybrid fibre composite plate composed of Kenaf Fibre (KF), Ridge Gourd Fibre (RGF), Waste Plastic Materials (WPM), and matrix materials. The raw materials under goanalkaline treatment involving 2hoursofagitation with 5% NaOH. Following treatment, KF, RGF, and WPM are combined with epoxyres in using compression moulding to form four different hybrid composite plates in the %wt of 10:20:5, 20:10:5, 10:10:5, and 20:20:5. Various tests are conducted to evaluate their properties, including the Tensile Test, Shear Test, and Flexural Test, adhering to ASTM standards D638, D7078, and D790, respectively. The results indicate that 20:20:5 plate showed higher tensile strength (21.70 MPa), flexural strength (77.23 MPa), and shear strength (18.13MPa. Subsequently, Thermo gravimetric Analysis (TGA) was conducted on the 20:20
D R, Rajkumar, R, Baranitharan, Basha, Mohamed Humayun, S, Kamalesh
Technical Paper
Study of Mechanical, Barrier and Tribological Behaviour of Jute & Glass Fiber Epoxy Hybrid Polymer2025-28-003102/07/2025
The incorporation of natural available material into synthetic materials to form a fiber within a single polymer matrix has been ignited since environment concerns become crucial nowadays. Composite materials embedded with two or more types of fibers makes a composite as hybrid. The study of hybridization of natural and synthetic fibers brings out superior mechanical and tribological properties. In our present studies, fabrication of jute & glass fiber reinforced epoxy-based polymer hybrid composites were carried out using resin infusion technique. For comparing the various properties, the composite made of pure jute fiber i.e 100% jute, pure glass fiber i.e 100% glass, the hybrid composite containing 75% jute and 25% glass fiber, 50% jute and 50% glass fiber, and 25% jute and 75% glass fiber were made and its functional behaviors were studied. The results revealed the hybrid composite containing 25% jute and 75% glass fiber possessed maximum tensile strength of 292±5.8 MPa, flexural
J, Chandradass, T, Thirugnanasambandham, M, Amutha Surabi, P, Baskara Sethupathi, Rajendran, R, Murugadoss, Palanivendhan
Technical Paper
Characterization of Mechanical, Thermal, and Chemical Properties of Natural Fiber Composites: A Case Study of Bamboo Leaves and Coconut Leaves2025-28-011202/07/2025
The research project focused on investigating the mechanical, thermal, and chemical properties of composite plates made from bamboo leaves and coconut leaves reinforced with epoxy resin that has received limited attention in previous studies. The bamboo and coconut leaves underwent alkaline treatment, were thoroughly washed with distilled water, and dried in sunlight for 24 hours. For the fabrication of three composite plates, Hand lay up method was employed according to the American Society for Testing and Materials (ASTM) standards. The compositions of the composite plates were varied as first Composition has 25 wt% bamboo leaves, 25 wt% coconut leaves and 50 wt% resin, the Second Composition has 30 wt% bamboo leaves, 30 wt% coconut leaves, and 40 wt% resin and the third composition has 35 wt% bamboo leaves, 35 wt% coconut leaves, and 30 wt% resin. Tensile test, shear and flexural tests helped determine the tensile strength, shear strength, and flexural strength of the composite
D R, Rajkumar, O, Vivin Lenin, R, Saktheevel, S, Edwin Roshan
Technical Paper
Review of Mechanical Properties of Basalt Fibre-Reinforced Polymer Composites for Automotive Applications2024-01-524601/28/2025
The industrial world focuses on developing eco-friendly, natural fibres such as reinforcing lightweight, inexpensive compounds in modern days. Basalt, a rare phenomenon, derives its origins from molten volcanic rocks, which is essential for their cost-effectiveness and offers different glass fibre properties. High mechanical strength, outstanding wear resistance, and exceptional durability in a variety of environmental conditions are all displayed by basalt fibres. These fibres are ideal for reinforcing polymer composites because of their mechanical properties at high temperatures. Furthermore, basalt fibres are appropriate for long-term applications because they resist corrosion and degradation while maintaining structural integrity over time. This article provides a brief overview of basalt fibres as a substitute for glass fibres and as composite materials. Additionally, attempts are being made to draw attention to the expanding field of basalt fibre research. In the review, studies
Chidambaranathan, Bibin, Raghavan, Sheeja, Soundararajan, Gopinath, Arunkumar, S., Ashok Kumar, R., Rajesh, K.
Technical Paper
Optimizing Mechanical and Transport Properties of Carboxylated Nitrile Rubber Composites2024-01-526301/28/2025
The article describes a two-step technique that involves making a masterbatch that is 3:1 [by weight] carboxylated nitrile rubber (XNBR) and nanoclay (NC), compounding on a two-roll mill, and moulding at 150°C and 20 MPa pressure. Tensile strength (TS), elongation at break (EB), and modulus (M100, M200 and M300) all rises with the amount of nanofiller present, peaked at 5 phr, then fell off. The NC demonstrated a tendency to aggregate at greater concentrations. The amount of reinforcement provided by the NC filler can be determined by comparing the modulus of filled compounds (M100f) to that of unfilled XNBR (M100u). This ratio rises with the amount of NC present, peaked at 5-7.5 phr, and subsequently fell. Using sorption isotherms, the swelling behaviour of the solvent through the nanocomposites was studied. With increasing NC concentration, the solvent absorption fell, reaching a minimum at 5 phr NC. When toluene sorption for diffusion via XNBR-NC composites was measured, the amount
Vishvanathperumal, S., Manimaran, K., Murali, M., Meera, C., Gopika, P., Arun, M.
Technical Paper
Utilizing High-Performance Thermoplastics to Improve Durability and Efficiency in Automotive Instrument Panels2024-01-524501/28/2025
The present research explores the potential of high-performance thermoplastics, Polymethyl Methacrylate and Polyurethane, to enhance the passive safety of automotive instrument panels. The purpose is to evaluate and compare the passive safety of these two materials through the conduct of the Charpy Impact Test, Tensile Strength Test, and Crush Test —. For this, five samples were prepared in the case of each material via injection moulding, which enabled reliability, and consistency of the findings. As a result, it was found that in the case of the Charpy Impact Test, the average impact resistance varies with PMMA exhibiting a level of 15.08 kJ/m2 as opposed to the value of 12.16 kJ/m2 for PU. The Tensile Strength Test produced the average tensile strength of 50.16 for PMMA and 48.2 for PU, which implied superior structural integrity under tension for the first type of thermoplastic. Finally, the Crush Test showed that PMMA is more resistant to crushes on average than PU with the
Natrayan, L., Kaliappan, Seeniappan, Mothilal, T., Balaji, N., Maranan, Ramya, Ravi, D.
Technical Paper
Advancements in Lightweight Composite Materials for Enhancing the Structural Integrity of Automotive Component2025-01-500501/23/2025
This research was conducted with the aim of exploring the usage of advanced lightweight materials such as aluminum matrix composite and aramid fiber reinforcement polymer for increased structural integrity of the hood of an automotive vehicle. The automotive sector is moving toward lightweight materials because of the need to enhance fuel efficiency, the importance of reducing environmental impact, and the need to ensure safety of new-generation automobiles. While traditional materials such as steel and aluminum might be very rigid and durable, they also add huge weight to the overall vehicle design. Consequently, these vehicles become more fuel inefficient, which could lead to higher emissions and pollution. The two materials chosen for this research are very promising, considering that both are characterized by high specific strength and impact resistance capabilities. The low weight of the materials is also an added bonus. While AMC is manufactured by consolidating aluminum with
Arvinda Pandian, C.K., Balaji, N., Seeniappan, Kaliappan, Natrayan, L., Maranan, Ramya, Ravi, D.
Technical Paper
On the Potential of Upcycling Plastic Wastes to Carbon-Capturing Materials Using Supercritical Fluid-Assisted Injection Molding Process13-05-03-002101/09/2025
With the extensive production and widespread use of plastics, the issue of environmental pollution caused by plastic waste has become increasingly prominent. Consequently, researchers have been focusing on developing efficient methodologies for upcycling waste plastics and converting them into value-added materials. This hybrid review–conceptual article first provides an overview of strategies for upcycling waste plastic into carbon-capturing materials. It presents carbonization and activation as key steps in converting plastic waste into adsorbent materials and explores strategies for converting common waste plastics. Building upon this foundation, the article introduces and conceptualizes a novel upcycling approach with two manufacturing routes to convert plastic waste into carbon-capturing materials using supercritical fluid (ScF)-assisted injection molding process. It continues by investigating the potential of developing lightweight components made of such carbon-capturing
Pirani, Mahdi, Meiabadi, Mohammad Saleh, Moradi, Mahmoud, Enriquez, Lissette Garcia, Sreenivasan, Sreeprasad T., Farahani, Saeed
Journal Article
Presentation of Biocomposites for Proposal for Use in Car Bumpers2024-36-014812/20/2024
Car bumpers are protective structures for the occupants of a vehicle during a collision, absorbing impact energy, such a structure is located at the front and rear of the vehicle. Metals were used to manufacture the first bumpers, and it was subsequently assessed that using a different material would reduce their weight, for example plastic, resulting in increased fuel economy and impact absorption. Also, the use of polymers reinforced by glass fibers offer good mechanical strength. This work evaluates the replacement of conventional materials by an ecologically more viable alternative, natural fibers as plastic reinforcement, reducing costs, without considerable loss in the material mechanical properties. Specimens of reinforced composite material were produced with jute fiber. The fibers, obtained through fabrics, were standardized in length of 5.0 mm and 15.0 mm. The matrix phase applied was the unsaturated and pre-accelerated terephthalic polyester resin manufactured by Royal
Soares, Rafael Vilhena, Dias, Roberto Yuri Costa, de Mendonca Maia, Pedro Victor, Junior, Waldomiro Gomes Paschoal, Fujiyama, Roberto Tetsuo
Technical Paper
Preliminary Indication Approach of Jute Fiber Fabric with Polyester for Bumpers of Passenger Cars2024-36-014912/20/2024
Polypropylene has been the plastic traditionally used in the manufacture of bumpers. Composite materials have been presented as an alternative due to lightness and sustainability. This article presents a composite of polyester resin and jute fiber fabric as an innovative alternative to be studied for the manufacture of automotive bumpers. Composite material was manufactured for characterization. It was used as matrix the terephthalic polyester resin, unsaturated and pre-accelerated, and the catalyst MEK V388 for curing the composite. The chosen reinforcement was the jute fiber fabric. Silicone molds with dimensions according to ASTM 3039 were used to manufacture specimens, and subsequent tensile strength test to determine properties and compare with literature data. The composite with jute fiber reinforcement with alignment 0°/0°/0° was evaluated as viable for the application in car bumpers, having its value of tensile strength surpassed that of the composite reinforced by jute fiber
Dias, Roberto Yuri Costa, Soares, Rafael Vilhena, de Mendonca Maia, Pedro Victor, dos Santos, Jose Emilio Medeiros, Miranda, Igor Ramon Sinimbú, Junior, Waldomiro Gomes Paschoal, Fujiyama, Roberto Tetsuo
Technical Paper
Assessing the Engine Performance of Rubber Seed Oil Biodiesel Blends in Compression Ignition2024-01-522812/10/2024
This study investigates the efficiency of a compression ignition (CI) engine powered by biodiesel derived from rubber seed oil (RSO) and its various blends. This research aims to assess the feasibility of using RSO biodiesel as a substitute fuel in CI engines to reduce harmful emissions and the depletion of fossil fuels. Initially, the process of obtaining rubber seed oil was preceded by transesterification. After transesterification, the same was blended in different proportions with conventional diesel in B20, B40, B60, B80, and B100. Results show that brake thermal efficiency (BTE) decreased with rising concentration of biodiesel, particularly at higher blends. B100 had a 20-25% lower BTE in every load condition than conventional diesel. The brake specific fuel consumption (BSFC) generally decreased with increasing biodiesel content, particularly at lower loads applied to the engine. B100 portrayed a perceptible improvement of 25.6% in BSFC compared diesel at 1 kg load. This
Jayabal, Ravikumar, Lionus Leo, G. M., Madhu, S.
Technical Paper
Empirical Modelling of Machinability during Drilling of Aluminium Oxide/Glass Fiber Reinforced Resin/Epoxy Composites2024-01-521912/10/2024
This study describes the Taguchi optimization process applied to optimize drilling parameters for glass fiber reinforced composite (GFRC) material. The machining process is analyzed in relation to process parameters using analysis of variance (ANOVA). The characteristics assessed for both the drilling and the specimen include speed, feed rate, drill size, and specimen thickness. The commercial software program MINITAB14 was used to collect and analyze the measured results. Cutting force and torque during drilling are examined in relation to these parameters using an orthogonal array and a signal-to-noise ratio. The primary goal is to identify the critical elements and combinations of elements that impact the machining process to achieve minimal cutting thrust and torque, based on the evaluation of the Taguchi technique.
Raja, Rosari, Jannet, Sabitha, Kandavalli, Sumanth Ratna
Technical Paper
Effect of Silicon Carbide Addition and Jute Fiber Surface Treatment on Functional Qualities of Low-Density Polyethylene Composites2024-01-523812/10/2024
In the modern era, advanced hybrid polymer-based composites have the potential to replace conventional polymers and exhibit unique behaviour. This study focuses on low-density polyethylene (LDPE) hybrid composite made with jute fiber and enhanced with nano silicon carbide particles through the injection moulding process. The natural jute fiber undergoes chemical surface treatment to improve its adhesive behaviour. The study evaluates the effects of 10wt% chemically treated jute fiber and 1, 3, and 5wt% of SiC on the structural, impact, tensile, and flexural strength of the synthesized composites according to ASTM D7565, D3039, and D790 standards. The structural behaviour of LDPE composites is assessed through X-ray diffraction analysis, revealing improved crystalline structure and interaction. Among the five prepared composite samples, the composite containing 10wt% treated jute fiber and 5wt% SiC demonstrated enhanced impact, tensile, and flexural strength of 5.7 J/mm2, 43 MPa, and 56
Venkatesh, R., Kaliyaperumal, Gopal, Manivannan, S., Karthikeyan, S., Aravindan, N., Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad, Karthikeyan, N.
Technical Paper
Polyethylene Sheet Dispersion and Optical Constant Changes Due to Electron Beam Irradiation2024-01-523412/10/2024
Radiation has garnered the most attention in the research that has been conducted on polyethylene sheets. According to the calculations, there were 145892.35 kGy in total radiation doses administered. An ultraviolet visible spectrophotometer was used to examine the impact that electron beam irradiation had on the optical constants. Two of the most crucial variables taken into account when calculating the optical constants and the absorption coefficient are the reflectance and transmittance of polyurethane sheets. Reduced light transmission through the sheet achieves these characteristics, which are related to the transmittance and reflectance of the Fresnel interface. Cross linking makes it more challenging for the polyurethane molecular chains to become fixed. Both the refractive index and the dispersion properties have been altered as a direct result of this. Despite the fact that the doses of electron irradiation were getting lower, it eventually rose to 105 kGy. Contrary to the
Kaushik, Nitish, Sandeep, Ch, Srinivasan, V. P., Prakash, B. Vijaya, Kalaiarasan, S., Arunkumar, S.
Technical Paper
Study of Natural Fiber Incorporated Polypropylene Composite Laminate for Lightweight Applications2024-01-523612/10/2024
Biodegradable natural fiber-embedded polymer composites offer distinct mechanical properties and are utilized for lightweight applications. However, composites made with untreated natural fibers lack adhesive behaviour, and increased moisture absorption leads to reduced mechanical qualities. To address this, hemp fibers are treated with a 5% sodium hydroxide (NaOH) solution to enhance adhesive strength. The treated fibers are then used to fabricate polypropylene composites through a hand layup process involving compression force. The synthesized composite samples contain 0%, 10%, 20%, and 30% weight (wt%) of hemp fiber and undergo X-ray diffraction (XRD) analysis, as well as tensile, flexural, and impact strength studies. XRD analysis shows a short peak for the hemp fiber and a large peak for the polypropylene matrix. Experimental results indicate that the polypropylene composite with 30 wt% NaOH-treated hemp fiber exhibits increased tensile strength (53 MPa), improved flexural
Venkatesh, R., Aravindan, N., Manivannan, S., Karthikeyan, S., Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad, Karthikeyan, N.
Technical Paper
Rectangular Cross Section Polymeric Sealing RingsJ2310_202412 (Current)12/06/2024
The purpose of this SAE Recommended Practice is to establish guidelines for the automatic transmission and hydraulic systems engineer to design rectangular cross section seals for rotating and static grooved shaft applications. Also included are property comparisons of polymeric materials suitable for these applications. Historically, material covered in this document is not intended to include aluminum contact applications.
Automatic Transmission and Transaxle Committee
Recommended Practice
Fabrication and Functional Behavior Studies of Polypropylene Composite Containing Hybrid Reinforcements05-18-02-001512/06/2024
Hybrid reinforcement-made polypropylene (PP) composites are beneficial over monolithic PP and utilized for various engineering and non-engineering applications. The present investigation of PP hybrid composites is developed with 10 percentages of weight (wt%) of E-glass fiber embedded with 0–6 wt% of silicon carbide via compression technique associated with hot press. E-glass fiber and SiC influencing wear rate, tensile strength, and microhardness behavior of PP and its composites are experimentally investigated. The peak loading of SiC as 6 wt% into PP/10 wt% E-glass fiber is recorded as better wear resistance (0.021 mm3/m), maximum tensile strength value (54.9 MPa), and highest hardness (68 HV). Moreover, the investigation results of hybrid PP composite are better resistance to wear and hiked tensile and hardness behavior compared to monolithic PP. This PP/10 wt% E-glass fiber/6 wt% of SiC hybrid composite is adopted for high-strength to lightweight sports goods applications.
Venkatesh, R.
Journal Article
Characterization of Cut and Chip Damage in Ultra Low Rolling Resistance Tire for Electric Vehicles2024-28-017512/05/2024
Since the inception of battery driven electric vehicles in the automotive world, there has been a constant challenge in maximizing the range of an electric vehicles through various means including battery technology, vehicle weight optimization, low drag coefficients etc. The tires being a viscoelastic composite material have now become a vital to the range performance of an EV. The rolling resistance of a tire is now become a hotter topic than ever. The rolling resistance coefficient (RRC) is the measure of energy loss during rolling due to viscoelastic dissipation in the tire. The viscous dissipation in tire arises due to hysteresis in the various components of a tire including tread, sidewall, inner liner, apex etc rubber compounds. The internal friction between layers of body ply, steel belts and tread crown ply also contribute to the internal heat generation. Therefore, the development of ultra-low RRC tires is a serious challenge for tire engineers. Nevertheless, the recent
Mishra, Nitish, Singh, Ram Krishnan
Technical Paper
Development of New Generation Battery Cooling Hoses with TPV Material2024-28-016112/05/2024
The market for battery-fitted electric cars continues to experience robust growth globally as well as in Indian market. During the charging process heat generation happen because of internal resistance of the battery cells and electrical connectors. Making an efficient battery cooling system is vital for all electric vehicles. One common cause of battery overheating is due to low cooling efficiency. So this research highlights the importance of scientifically designing coolant circuits and selecting appropriate coolant hose materials. Currently, EPDM (ethylene propylene diene monomer) material is widely used for battery cooling hoses due to its design Flexibility, Compatibility with a 50:50 glycol-water mixture and Resistance to thermal and ozone cracking [1]. This study benchmarks EPDM hose technical properties with leading EV battery cooling plastic hose materials, such as mono layer polyamide, mono layer TPVs (thermoplastic vulcanizates) and PA PP two layer hose. Comparative
Murugesan, Annarajan
Technical Paper
A Facile Synthesis and Molecular Characterization of Electroactive Polyaniline Nanocomposites Materials Based on Sliver Embedded Poly Aniline Copolymers for Application in Automobile Industries2024-28-015812/05/2024
A lightning strike during raining season causes significant risks to automobiles, especially modern vehicles mostly dependent on electronic systems. Lightning can cause severe damage to electronic control unit that control the vehicle functions such as engine management, electrical circuits with sensors, braking systems, and safety features. Therefore, this research work focused for developing new electrical polymers with better conductive properties that would create a path for lightning to travel without damaging it. In-situ chemical oxidative polymerization was used to develop a new series of functional electroactive nanocomposites based on silver nanoparticles embedded poly (aniline-co-3-chloroaniline) matrix. Here we would suggest these electroactive polymers can be widely used as additive in paint manufacturing as special coatings in automobiles industry. Because of the internal chemical bonds and internal structure of these materials acts as a semiconducting nature, hence they
Pachanoor, Vijayanand, Moorthi, Bharathiraja
Technical Paper
Thermal Performance of Encapsulated LFP Battery Packs Encapsulants2024-28-022412/05/2024
Electric vehicles (EVs) represent a pivotal shift in the automotive industry, offering a sustainable alternative to traditional gasoline-powered vehicles. Central to their operation are lithium-ion batteries, which are favoured for their high energy density and long lifespan. Ensuring thermal stability during battery pack operation is crucial for both safety and efficiency. To enhance heat transfer within the battery pack, various encapsulants are employed. This study utilizes simulation to investigate the thermal performance of a 3.072kWh, 51.2V, 60Ah battery pack composed of 6Ah 32700 LFP cells, encapsulated with commercially available materials such as polyurethane (PU) foam, silicone, and silicone-modified epoxy under 1C and 2C discharge conditions. The findings show that, at 1C and 2C discharge rates, respectively, the battery pack potted with silicone attains a maximum temperature that is 2.57°C and 3.84°C lower than the pack simulated with air. Additionally, silicone-modified
Somarajupalli, Shanmukhadev, Vedantam, Srikanth, Gupta, Shubham, Jha, Kaushal Kumar
Technical Paper
Development of a Method to Model Flexible Hose in FE Linear Dynamics Simulations2024-28-025412/05/2024
Linear dynamics simulations are performed on engine components to ensure structural integrity under dynamic loading. The finite element model of the engine assembly must be prepared accurately to avoid under or over design of the engine components. Flexible hoses are present at pipe routings and modeling them in simulations is a challenge because the stiffness of the composite is not known. The hose under study in this paper is a rubber composite with a knitted reinforcement layer. A multiscale modelling approach is presented to characterize the hose stiffness. A representative volume element geometry i.e., unit cell representation of the composite, consisting of the knitted yarn and surrounding rubber is used to establish orthotropic elastic properties at microscale, by performing finite element homogenization using the ANSYS material designer module. The homogenized properties are assigned to the macroscale hose geometry to perform modal analysis simulation in free-free and fixed
Ashodiya, Jay Virendra, Jayachandran, Janarthanan, Santhosh, B
Technical Paper
Performance Specification Anti-Seize Thread Compound, High Temperature - PTFE OnlyAMS3050/5A (Current)12/04/2024
The foundation specification (AMS3050) and this category specification (AMS3050/5) cover anti-seize greases conforming to the requirements but using the anti-seize ingredient PTFE only. For use only below 600 °F / 315 °C.
AMS M Aerospace Greases Committee
Material Specification
MTA expands wireless communication, EV tech for trucks24TOFHP12_0912/01/2024
Automotive electrical and electronics manufacturer MTA attended IAA Transportation for the first time, demonstrating its new range of wireless communication technologies for the truck industry. Earlier this year, the company acquired Calearo Antenne S.p.A, a company with a long history of producing antennas, amplifiers and cables. MTA global sales director Davide Bonelli explained to Truck & Off-Highway Engineering how that acquisition complements its business. “From a more strategic point of view, we see the world of antennas as complementary to what MTA does,” he said. “Often MTA products have an antenna as an interface, so this is one reason why we have done the deal. There are also a lot of synergies from an engineering standpoint. Historically, MTA is a company that uses many mechanical parts - plastics, metals - which we are very strong with so we can share them. And there are also some competences from Calearo Antenne that can be transferred to us.”
Kendall, John
Magazine Article
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