Browse Topic: Body structures

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An Outer Waist Seal with Integrated Glass Wiping Mechanism for a Window Frame of a Vehicle2026-26-00111/16/2026
This innovation addresses a major safety concern where drivers experience poor visibility of the Outside Rear View Mirror due to rain, fog, dust, or ice accumulation on the side door window glass. Existing solutions like hydrophobic coatings and heated door window glasses offer limited effectiveness, leading to the need for a more reliable and efficient system. To solve this issue, we have modified Outer Waist Seal by integrating Glass Wiping Mechanism in it. The Outer Waist Seal is a weatherproof strip located at the bottom edge of a vehicle’s side window, attached to the door panel. It prevents heavy water flow, dust, and debris from entering the door cavity while also supporting the window glass during its movement. This system features a stationary fixed arm and a rotating arm with an attached wiper blade, driven by a low-speed, high-torque motor and connected with the vehicle's Body Control Module. Upon activation, the rotating arm with blade wipes the Outside Rear View Mirror
Neelam, Rajat, Chowdhury, Ashok, Panchal, Girish, Kumar, Saurav
Developing Advanced CAE Model for Door Glass Regulator Operating Noise Reduction through TEST/CAE Correlation2026-26-03111/16/2026
The importance of performance improvement and weight optimization using CAE in the early design stages of vehicle development has been continuously increasing over the past two decades. And, the accuracy of CAE models plays key role, more efforts are required to improve it. Representation of exact physical model in CAE is still a big challenge for achieving an accurate TEST vs CAE correlation. In this research, the procedure and application of door system model correlation were described to reduce the glass regulator operating noise. The function of a regulator in door system is to open and close the glass. The regulator under improper design creates unwanted noise and discomfort to the passenger. In current door CAE Model, we are unable to identify this real time problem. Therefore, this paper discusses how to correlate door system model according to the assembly stage based on modal correlation and it helped in calculating accurate glass regulator operating noise. As a result, the
PANUGANTI, NARESH KUMAR, Choi, Seungchan
A Comprehensive Study of vehicle side door structure and window glass displacement during slam for refinement2026-26-05491/16/2026
In the vehicle closures validation process, the displacements in its structure and window glass have significant impact on its service life. The objective of this paper is to develop a test case using instrumentation and data acquisition for measuring the vehicle door structure and its window glass displacement along the lateral direction. This measurement support for understanding the door and window glass displacement impact on its primary and secondary rubber seals, striker, check arm, hinges, and its structural rigidity. The door mechanisms also get affects by door displacement which results to significant deterioration in its performance. The test setup comprises of sensors with required range and accuracy connected with data acquisition system by selecting appropriate sampling rate. The sensors placed on window glass and on door structure top corner during the measurement. Different window glass positions like full close, half close and fully opened considered for the study
Arthanathan, Sankaranarayanan, SHASHIDHAR, S, B, VENKATASUBRAMANIAN
Optimisation of frontal impact force scheme to accelerate the target setting process for development of front-end structures in vehicles.2026-26-00011/16/2026
A passenger vehicle's front-end structure's structural integrity and crashworthiness are crucial to ensure compliance with various frontal impact safety standards (such as those set by Euro NCAP & IIHS). For a new front-end architecture, design targets must be defined at a component level for crush cans, longitudinal, bumper beam, subframe, suspension tower and backup structure. The traditional process of defining these targets involves multiple sensitivity studies in CAE. This paper explores the implementation of Physics-Informed Neural Networks (PINNs) in component-level target setting. PINNs integrate the governing equations into neural network training, enabling data-driven models to adhere to fundamental mechanical principles. The underlying physics in our model is based upon a force scheme of a full frontal impact. A force scheme is a one-dimensional representation of the front-end structure components that simplifies a crash event's complex physics. It uses the dimensional and
Gupta, Ishan, Bhatnagar, Abhinav, Kumar, Ayush
Development of Door Impact Loads Using Frugal use of Pedal Force Sensor2026-26-05381/16/2026
The first step in designing or analyzing any structure is to understand “right” set of loads. Typically, off-road vehicles have many access doors for service/getting into cab etc. Design of these doors and their latches involve a knowledge of the closing loads when the door is shut mostly with an impact of varying magnitudes. In scenarios of these impact events, where there is sudden change of velocity within few milliseconds, produces high magnitude of loads on structures. One common way of estimating these loads using hand calculations involves evaluating the rate-of-change-of-momentum. However, this calculation needs “duration of impact”, and it is seldom known/difficult to estimate. Failing to capture duration of impact event will change load magnitudes drastically, e.g. load gets doubled if time-of-impact gets reduced from 0.2 to 0.1 seconds and subsequently fatigue life of the components in “Door-closing-event” gets reduce by ~7 times. For these problems, structures are usually
Valkunde, Sangram, Ghate, Amit, GAGARE, KIRAN
OPTIMIZER SUNSHADE PACKAGING WITH HALF ALUMINIUM CASSET 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 Sunshade packaging in door trim system. Traditional sunshade design, often bulky and are increasingly incompatible with the trend towards compact. Car sunshade is a shield that is placed on a car side window, and it is used for regulating the amount of light entering from the car window and improves the passenger comfort inside the cabin. Car Interior components specifically plastic and seats based on thermal stress properties. When we exposed these parts direct contact with sunlight, humidity and ambient temperature above threshold limit then interior plastic parts can start softening and melt after that they emit harmful chemical which is caused to anemia and poor immune systems. So, Sunshade protection not only serve to protect passenger comfort inside car
palyal, Nikita, D, GOWTHAM, BHASKARARAO, PATHIVADA, bornare, harshad, RITESH, KAKADE
UNIQUE HYBRID PANORAMIC HEADLINER CLIP WITH HIGH TOLERANCE TO REPLACE DUAL LOCK FASTENERS2026-26-02991/16/2026
Mounting strategies for vehicles with panoramic sunroofs remains a challenge owing to its high complexity to balance cost, performance and assembly efficiency. Achieving efficient and reliable headliner mounting solutions is one of the conundrums where cost optimization must go together with uncompromised performance. Traditional methods like Dual Lock Fasteners (DLFs), have set high benchmarks for robustness but at the cost of increased manufacturing complexity and expense. In pursuit of a more economical and production-friendly alternative, various plastic clip designs were explored. However, these solutions posed significant challenges during validation due to the stringent requirements for mounting feasibility, tolerance management, and long-term durability This paper introduces a novel hybrid plastic-metal clip solution that addresses those challenges comprehensively. The new design achieves precise tolerance control, ensuring reliable headliner installation under varying Body-in
D, GOWTHAM, Kumarasamy, Raj Ganesh, Shoeb, Mohd, Chauhan, Aarti
Optimization of the Rodip CED Process Suitability through Strategic Fixture System for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing2026-26-04861/16/2026
The Ro-dip Cathodic Electrodeposition (CED) process is latest technology used by Automotive Manufacturers for higher quality corrosion protection in new generation Automobiles. This process involves multiple 360-degree rotation of automotive body in white (BIW) which exert higher hydrostatic forces on large surface panels like Hood. For maintaining consistent gaps & flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel Hood panel while undergoing through this CED process. This study investigates the enhancement of hood panel alignment through strategic optimization of support rod placement and quantity within the Ro-dip CED system. By conducting experimental trials and computational simulations, the research identifies critical deformation points and evaluates the impact of varying support rod configurations on dimensional stability. The outcome results demonstrate that positioning support rods at
Tile, Vikrant, Unadkat, Siddharth, ASKARI, HASAN, Jadhav, Devidas
Analysis of door seal compression and its influence on NVH performance in heavy-duty vehicle2026-26-03391/16/2026
Seals in a truck cabin is one of the major contributors for cabin noise in terms of structure borne as well as air borne noise transfer path. This study emphasizes on the effect of door seal compression prediction and its impact on structure borne NVH in trucks. Vibrations are regarded as quality criteria in the perception of customers. It is necessary to ascertain the contribution of seal stiffness on compression of the seal under closed condition of the door rather than uncompressed conditions. The dynamic stiffness of door seal is calculated by non-linear analysis. The simulations models are constructed using the Mooney - Rivlin theory for both 2D and 3D seals. This encompasses contemplating the relevant seal mounted boundary condition on the body and the door of the vehicle. The stiffness after compression of seal is extracted from this non-linear analysis which is further used to obtain the vibration modes for the doors in the truck cabin. Subsequently, the compressed seal
L, Kavya, Ramanathan, Vijay
Crash Pulse Characterization for the Passenger Vehicle Fleet in India.2026-26-00291/16/2026
A crash pulse is the signature of the deceleration experienced by a vehicle and its occupants during a crash. The deceleration-time plot or crash pulse provides key insights into occupant kinematics, occupant restraints, occupant loading and efficiency of the structure in crash energy dissipation. Analysing crash pulse characteristics like shape, slope, maximum deceleration, and duration helps in understanding the impact of the crash on occupant safety and vehicle crashworthiness. This paper represents the crash pulse characterization study done for the vehicles tested at ARAI as per the ODB64 test protocol. Firstly, the classification and characterization of the crash pulses is done on the basis of the unladen masses of the vehicles. The same are further analysed for suitability of mathematical waveform models such as Equivalent Square Wave (ESW), Equivalent Triangular Wave (ETW), Equivalent Sine Wave (ESW), Equivalent Haversine Wave (EHSW) as well as EDTW (Equivalent dual trapezia
Jaju, Divyan, Mishra, Satish, Kulkarni, Dileep, Borse, Tanmay, Mahindrakar, Rahula Ashok, Mahajan, Rahul
Packaging the HPTS Airbag in a Second-row bench seat2026-26-00331/16/2026
Seats of modern cars should necessarily meet the regulatory safety norms along with aesthetics and comfort. In the existing passenger cars prevailing across the Indian subcontinent, the measure of safety has been a challenging one. The stringent regulatory norms thereby make the Airbag very promising. In the domain of automotive safety, certain features hold exceptional importance, with airbags taking a forefront position. Their fundamental objective is to provide an advanced level of safety for both the driver and passengers in the unfortunate event of a collision. This is accomplished through the automatic deployment of an inflatable airbag, engineered to swiftly respond during a crash and furnish the necessary sophisticated cushioning to enhance overall passenger safety. The technology has been practiced widely upon a many vehicles seat. However, the present work highlights a novel approach of packaging the HPTS air bag in second row seat. This Air bag unit is fitted in the seat
Buradkar, Rajat Ramkrishna, BOSE, KARTHIK, JADHAV, DEEPIKA, Balakrishnan, Gangadharan
Infotainment-Free Sunroof Control Testing Using National Instruments Framework2026-26-05191/16/2026
Verification of sunroof operation via voice commands conventionally necessitates a fully assembled vehicle platform integrated with an updated Body Control Module (BCM) and infotainment software. This hardware-software dependency presents significant limitations, particularly during the early stages of development, where rapid validation and iteration are critical. Additionally, vehicle availability and software readiness often act as bottlenecks in the validation process. To address this, a novel approach has been developed to simulate sunroof operations—including both physical switch and voice command inputs—using a National Instruments (NI) system. This setup eliminates the reliance on the vehicle’s BCM and infotainment system by simulating LIN commands directly through the NI interface. The integration of the sunroof module with the NI system facilitates comprehensive bench-level testing, including functional validation, endurance evaluation, and abuse case simulation. This
GHANWAT, HEMANT, Lad, Aniket Suryakant, Joshi, Vivek, More, Shweta
Wireless Mobile charger Packaging in Pecuilar Rear Door Trim Profile.2026-26-02701/16/2026
Abstract A mobile wireless charger is a device that charge a smartphone or other compatible gadgets without the need for physical cables. Principle of wireless mobile charger system based on inductive coupling phenomena. The main objective of this paper aims to address the challenge of packaging wireless mobile charger in peculiar door trim profile keeping overall functionality and aesthetic appearance of door trim intact. This paper deals with integration of a wireless charging system within the door trim of a vehicle to provide convenience and advanced functionality. The objective is to pack a wireless charger in door trim meeting the ergonomic target and equilibrium state stability while maintaining sleek and minimalist design of the door trim. The study focuses on innovative packaging solutions related to space optimization in door despite multiple challenges involved. Major challenge lies in packing the unit amidst complex mechanisms such as window regulators, speakers, structural
palyal, Nikita, D, GOWTHAM, BHASKARARAO, PATHIVADA, Kumarasamy, Raj Ganesh, bornare, harshad
A Scientific approach to identify the source of intermittent steering rattle noise and implementing the design solutions2026-26-03461/16/2026
Body-on-frame vehicles are well-regarded for their durability and off-road capabilities, but their structural design often makes them more vulnerable to noise, vibration, and harshness (NVH) issues. Vibrations originating from uneven roads are transmitted through the suspension and steering assemblies, sometimes resulting in rattles or other disturbances. These vibrations can be amplified by the inherent flexibility in the body-to-frame mounting system. In such vehicles, the steering system plays a critical role in driver comfort and is highly sensitive to vibrational inputs from the road surface, especially on coarse or uneven terrain. Occasionally, these inputs result in subtle rattle noises that are perceptible only to the driver and may not be detected under controlled testing environments. This poses a challenge for engineers trying to isolate and resolve such intermittent NVH phenomena. Identifying the source requires a combination of real-world driving evaluations, structural
Ramesh Chand, Karan Kumar, Gopinathan, Haridoss, Kabdal, Amit
Optimization of Air extractor for improved Door closing effort and perceived premium Feel2026-26-05921/16/2026
This research analyses the significance of air extractor on car door closing effort, especially within the context of highly sealed cabins. The goal is to measure their effectiveness in lowering pressure-induced resistance, study how cut-out cross section and location affect performance, and its contribution to vehicle premium feel. Current vehicle design trends prioritize airtight cabin sealing for improving aerodynamic efficiency, NVH performance. This causes a problem in door closing operation. Air trapped while closing door creates transient pressure pulses. This pressure surge creates immediate discomfort to user i.e., Popping in Ears and requires high door closing force, and long-term durability problems in hinges and seals. In properly sealed cabins, air pressure resistance can contribute to 25% to 40% of total door closing force. Air extractors, which are usually installed in the rear quarter panels or behind rear bumpers, serve as pressure relief valves, allowing for smoother
P, Sivasankar, Sankineni, Vikhyath Rao, Shah, Sahil, Marimuthu, Anbarasan
A Novel Approach to Deep Drawing Using Hybrid System and Pneumatic-Assisted Forming2026-26-03011/16/2026
ABSTRACT: This paper presents a novel Plunger-Integrated Hybrid System aimed at enhancing the efficiency and performance of deep drawing operations in metal forming processes. The proposed hybrid system strategically combines the mechanical strength of metals with the elastic flexibility of polymers, specifically polyurethane rubber, to improve formability and reduce spring-back, two critical challenges in conventional sheet metal forming. A novel two-stage forming technique is employed, an initial drawing operation using a larger radius with polyurethane rubber, followed by final radius formation using the same rubber in conjunction with a pneumatic cylinder. This integrated approach ensures uniform force distribution via the embedded plunger, significantly minimizing forming defects and enhancing the dimensional accuracy of the final components. The solution has been validated using Finite Element (FE) simulation methods, confirming its capability to produce high-quality parts
Chava, Seshadri Reddy, Singh, Prakhar, DHANAJKAR, NARENDRA, Roy, Amlan, Raju, Gokul
Side Crash Pressure Sensor response Prediction: CPM approach2026-26-04131/16/2026
Side Impact crashes are generally hazardous because there is no room for large deformation to protect an occupant from the crash forces. A crucial point in side impacts is the rapid intrusion of the side structure into the passenger compartment which need sufficient space between occupants and door trim to enable a proper unfolding of the side airbag. This problem can be alleviated by using the rising air pressure inside the door as an additional input for crash sensing. With improvements in the crash sensor technology, pressure sensors that detect pressure changes in door cavities have been developed recently for vehicle crash safety applications. The crash pulses recorded by the acceleration-based crash sensors usually exhibit high frequency and noisy responses. The data obtained from the pressure sensors exhibit lower frequency and less noisy responses. Due to its ability to discriminate crash severities and allow the restraint devices to deploy earlier, the pressure sensor
Bhagat, Milind, Narale, Naganath, MAHAJAN, Ashutosh, wayal, Virendra, Jadhav, Swapnil
Methodology for optimizing the bench testing of Steering I shaft using vehicle level data to reduce overall product development time and cost.2026-26-05601/16/2026
Steering I-shaft with rubber coupling (or hardy disc) is an important part of complete steering system mainly in body on frame 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 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 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 vehicle level on different
Kabdal, Amit
Do Not Let the Door Hit2026-26-00261/16/2026
Modern vehicles are equipped with numerous safety systems focused primarily on active and passive crash protection, but less attention is given to low-speed or stationary scenarios: particularly when occupants exits the vehicle. One common and often underestimated risk occurs when the vehicle door is opened without awareness of nearby obstacles such as walls, poles, or other vehicles. This paper introduces a novel, intelligent solution aimed at enhancing safety during driver egress. The proposed system leverages the existing ORVM (Outside Rear View Mirror) cameras to monitor and measure the surface area adjacent to the vehicle. When the vehicle is parked and the engine is turned off, the system becomes active. As the driver initiates the exit, the system scans for obstructions near the door. If an obstacle is detected within a predefined danger zone, it projects a warning symbol on the Instrument cluster via the puddle lamp and triggers an audible chime to alert the occupant. This dual
Bhuyan, Anurag, Khandekar, Dhiraj, Jahagirdar, Shweta
Experimental Evaluation of Metro Rail Bogie Frame through Bench Testing2026-26-05611/16/2026
Bogie frame is a main skeleton and structural member in railway system which is carrying all the loads such as Suspensions,Axles,wheels, car body, Motor, Gear box etc. The frame is subjected the exceptional and service stresses in Vertical, Longitudinal, Lateral and twist directions throughout the service life which should be withstand for a life span of 30 years without failure. The purpose of this project is to determine the Structural integrity of the Metro rail bogie frame in consideration with EN13749 standard .This paper is the outcome of bench testing of metro rail bogie frame with the application of multiaxial loading in static and dynamic campaign through which stress data is collected with strain gauge sensors and correlated with the FEA results at design stage. This helps to verify and evaluate the design and validate the quality of metro rail frame as per the requirement specified in EN13749 European standard in early design stages.
Tormal, Uday Bapurao
Virtual Strain correlation with measured strain test data over Frame using nCode Design Life2026-26-05451/16/2026
Physical tests serve as a benchmark to validate and improve the accuracy of CAE models. If the CAE results correlate well with physical test data, it confirms that the simulation is reliable and can be used for predictive analysis. Earlier for correlation, we use stress output from generic load-cases and single max value of measured strain data which was inappropriate to get exact correlation. Since output of virtual strain gauge is strain history, so entire characteristics can be compared i.e. magnitude and phase. In this paper, we have used nCode Design Life’s virtual strain gauge approach to correlate an FE Model’s (Frame) result with measured strain gauge data of RLDA test. If the model has been properly meshed, loaded, and constrained, the predicted virtual strain from Design Life will correlate with the measured strain. In this problem, model (Frame) is loaded with unit force and moment in all three directions at 31 locations (Hardpoints). Virtual Strain gauge calculates the
Kumar, Mohit, Dhole, Avinash, Trigune, Vinayak, Kangde, Suhas
Optimized Panel Design for Reducing Seal Squeak and Chucking in Door & Body Seals2026-26-03411/16/2026
Quieter cabins in an automobile are the new era, they provide customers with pleasurable driving experience. Squeak and Rattle are spoil sport for any OEM that aim to improvise customer driving experience. Their nonlinear nature makes it difficult to formulate design frontloading methods. The issue of seals rubbing against the body & door interface is a clear sign of seal squeak & seal chucking. Seals are applied with anti-friction coatings to avoid stick slip phenomena between EPDM and painted panel. Primary root cause for seal squeak is coating erosion. The challenge lies in determining whether the body or the closure side contributes to the seal issue. This paper presents a distinctive approach for identifying the seal squeaking noise and enriches on the new modelling methods for seal interaction with door and body interfaces using FE software. The proposed method was able to highlight the locations along the door-body interface for squeak noise. The approach for reducing the
H, RAVISHANKAR, C M, MITHUN, MICHAEL STEPHAN, NAVIN ESTAC RAJA, Mohammed, Riyazuddin
Design of the BIW structure for battery pack protection in case of side pole impact.2026-26-00251/16/2026
Electric vehicles (EVs) are becoming more popular than Internal Combustion Engine (ICE) powered vehicles, but their battery and motor components elevate their Gross Vehicle Weight (GVW), posing unique collision risks. Manufacturers strategically mount the high voltage (HV) battery packs under the passenger compartment to lower the Centre of Gravity and shield them from the front impacts. However, side impacts remain a concern, as the battery deformation in such instances could trigger fires or explosions, endangering occupants. To address this, crashworthiness designs adhere to New Car Assessment Program (NCAP) standards, particularly against side pole impact and side mobile barrier impact. Unlike the frontal section of BIW, which typically has larger crush space to absorb the crash energy, extensive design attention is required to the vehicle's side structure to absorb pole impacts without transmitting excessive force to the battery pack. Utilizing aluminium extrusions and sheet
Nivesh, Dharun, NAMANI, Prasad, Ramaraj, Rajasekar
Analysis of the Effect of Combination Frame Flexibility on Weave Modes2024-32-00494/18/2025
The weave mode of a motorcycle is known to be affected by the flexibility of the vehicle frame. The weave mode has been shown to be more unstable in the 10-DOF model than in the 4-DOF model. However, it is not clear why the weave mode would be unstable, given the six different frame flexibilities. In this study, the authors analyzed the stability of the weave mode in a 4-DOF model when the same was integrated with two types of frame flexibilities. In the vehicle specifications used in the analysis, the combination of the bending flexibility of the front forks and the torsional flexibility of the main frame destabilizes the weave mode. The analysis results show that the phase delay of the front tire lateral force is caused by the phase delay of the steering angle. The combined bending flexibility of the front forks and the torsional flexibility of the main frame results in a large phase lag in the steering angle.
Haraoka, Reiya, Katayama, Tsuyoshi, Yoshino, Takahiko
Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions2024-32-00384/18/2025
The arc welding process is essential for motorcycle frames, which are difficult to form in one piece because of their complex shapes, because a single frame has dozens of joints. Many of the damaged parts of the frames under development are from welds. Predicting the strength of welds with high reliability is important to ensure that development proceeds without any rework. In developing frames, CAE is utilized to build up strength before prototyping. Detailed weld shapes are not applicable to FE models of frames because weld shapes vary widely depending on welding conditions. Even if CAE is performed on such an FE model and the evaluation criteria are satisfied, the model may fail in the actual vehicle, possibly due to the difference between CAE and actual weld bead geometry. Therefore, we decided to study the extent to which the stresses in the joint vary with the variation of the weld bead geometry. Morphing, a FE modeling method and design of experiment method, was utilized to
Hada, Yusuke, Sugita, Hisayuki
Necessity of Body Torsional Rigidity of Personal Mobility Vehicles (PMVs) with an Inward Tilting Mechanism2024-32-00134/18/2025
In traditional four-wheeled automobiles, the imbalance between the roll moment, which is the product of the centrifugal force during a turn acting on the center of gravity and the height of the center of gravity, and roll stiffness, which is the product of the left-right difference in tire vertical load and the tread width and commonly used among automotive suspension engineers, of the front and rear sections necessitates body torsional rigidity. However, there is a lack of specific cases and guidelines for constructing the body structure of three-wheeled PMVs (Personal Mobility Vehicles) with a tilting mechanism from the perspective of vehicle dynamics characteristics. In this paper, the basic considerations related to the dynamics of such three-wheeled PMVs are investigated. We use the term “torsional rigidity” to refer to the stiffness as the torsional deformation of the body itself, and the term “roll stiffness” to refer to the moment that counteracts the roll moment during a turn
Haraguchi, Tetsunori, Kaneko, Tetsuya
Fatigue Analysis of Motorcycle Rear Swing Arm on Different Road Surfaces2024-32-00464/18/2025
The rear swing arm, a crucial motorcycle component, connects the frame and wheel, absorbing the vehicle’s load and various road impacts. Over time, these forces can damage the swing arm, highlighting the need for robust design to ensure safety. Identifying potential vulnerabilities through simulation reduces the risk of failure during the design phase. This study performs a detailed fatigue analysis of the swing arm across different road conditions. Data for this research were collected from real-vehicle experiments and simulation analyses, ensuring accuracy by comparing against actual performance. Following CNS 15819-5 standards, road surfaces such as poorly maintained, bumpy, and uneven roads were tested. Using Motion View, a comprehensive multi-body dynamic model was created for thorough fatigue analysis. The results identified the most stress-prone areas on the swing arm, with maximum stress recorded at 109.6N on poorly maintained roads, 218.3N on bumpy surfaces, and 104.8N on
Chiou, Yi-Hau, Hwang, Hsiu-Ying, Huang, Liang-Yu
Test GV 162025JTEST162025 (Current)1/6/2025
test
Ground Vehicle European Prospect Committee
3D-Printed Reactor Core Makes Solar Fuel Production More EfficientTBMG-5219312/1/2024
In recent years, engineers at ETH Zurich have developed the technology to produce liquid fuels from sunlight and air. In 2019, they demonstrated the entire thermochemical process chain under real conditions for the first time, in the middle of Zurich, on the roof of ETH Machine Laboratory. These synthetic solar fuels are carbon neutral because they release only as much CO2 during their combustion as was drawn from the air for their production. Two ETH spin-offs, Climeworks and Synhelion, are further developing and commercializing the technologies.
Developing Customer Loss Function for Door Opening Angle in Passenger Cars: Balancing the Ergonomic Performance between “Entry/Exit (Ingress/Egress) Accommodation” and Door Reachability15-17-03-00147/27/2024
Abstract Occupant packaging is one of the key tasks involved in the early architectural phase of a vehicle. Accommodation, as a convention, is generally considered related to a car’s interior. Typical roominess metrics of the occupant like hip room, shoulder room, and elbow room are defined with the door in its closed condition. Several other roominess metrics like knee room, leg room, head room, and the like are also specified. While all the guidelines are defined with doors in their closed condition, it is also important to consider the dynamics that exist while the occupant is entering the vehicle. This article expands the traditional understanding of occupant accommodation beyond conventionally considering the vehicle interior’s ability to accommodate anthropometry. It broadens the scope to include dynamic conditions, such as when doors are opened, providing a more realistic and practical perspective. As a luxury car manufacturer, it is important to ensure the best overall customer
Rajakumaran, Sriram, Sreenivas, Kalyan
INTEGRATION AND OPTIMIZATION OF GENEVA MECHANISM IN THE CAR DOOR HANDLE2024-26-02851/16/2024
The car door handle is an essential component of any vehicle, as it plays a crucial role in providing access to the cabin and ensuring safety of the passenger. The primary function of the car door handle is to allow entry and exit from the vehicle while preventing unauthorized access. In addition to this, car door handles also play a critical role in ensuring passenger safety by keeping the door closed during accidents or when there is a significant amount of G-force acting on the vehicle. A typical car door handle comprises several components including the structure, cover, Bowden lever, bracket, pins and other child parts. The structure provides the ergonomics and rigidity for grabbing the handle, while the cover gives the handle an aesthetic appearance. The Bowden lever facilitates the unlatching of the door and the intermediate parts ensure that the handle operates smoothly. The position of the Bowden lever is crucial for the unlatching process and for keeping the door closed
Kumar, Vinayak
Effect of environmental factors on the function of an Automotive Luggage Cover of a passenger vehicle – A case study2024-26-02281/16/2024
Abstract: - Automobile OEMs, universally, have always given high priority to the Luggage Area of the vehicle. Luggage Area primarily includes a Load Floor (the load bearing part), Side & Rear garnishes & the Luggage Shelf (or the Parcel Tray) for covering the luggage. The Parcel Tray makes the Luggage Area look neat and aesthetically appealing & is occasionally also used for carrying small items like files, papers, cushion, tissue box etc. The article under consideration in this paper is a Luggage Cover made from thermoplastic composite such as PP-Compounds (with Glass-fiber or Wood-powder), with rotating hinges towards the cabin side. Such types of Covers are predominantly in use in many markets including India. In the vehicle, the Luggage shelf is suspended on the Side Trims or Garnishes & has an elastomer interface with the back Door. The back door tends to be opened and closed in frequent intervals and the elastomer tends to harden with time. This leads to increased load on
Sreejith, M P, Khandelwal, Lokesh, Sandilya, Arnab, Natu, Mandar R, Ray, Amulya Kali, Handa, Rajat
An experimental approach to investigate the FEAD cover failure & its design optimization.2024-26-03711/16/2024
In automotive Front End Accessory Drives (FEAD), the crankshaft supplies power to accessories like alternators, pumps, etc. FEAD undergoes forced vibration due to crankshaft excitation, dynamic tension fluctuations can cause the belt to slip on the accessory pulleys. By considering the criticality of the system, when engine mounting is longitudinally to the vehicle which makes it directly exposed to the air flow containing foreign particles which may cause the damage to the FEAD system and deteriorate the intended functionality. FEAD cover is introduced in the system to enhance belt-pully system functionality by restricting the entry of foreign particles during engine operation. This paper contains study of FEAD cover failure and provide the stepwise approach to capture such issue during novel model development for 4 cylinder naturally aspirated engine during engine bench testing. Failure mechanism was studied using various methodology such as CAE and G-Load measurement to identify the
PATEL, HARDIK MANUBHAI, KUMAR, NITISH, Chand, Subhash, Gupta, Vineet
Experimental Evaluation of Metro Rail Bogie Frame through Bench Testing2024-26-03251/16/2024
Bogie frame is a main skeleton and structural member in railway system which is carrying all the loads such as Suspensions, Axles, wheels, car body, Motor, Gear box etc. The frame is subjected the exceptional and service stresses in Vertical, Longitudinal, Lateral and twist directions throughout the service life which should be withstand for a life span of 30 years without failure. The objective of this work is to estimate the structural integrity of the Metro rail bogie frame .This paper is the outcome of bench testing of metro rail bogie frame with the application of multiaxial loading in static and dynamic campaign through which stress data is collected with strain gauge sensors and correlated with the FEA results at design stage. This helps to verify and evaluate the design and validate the quality of metro rail frame as per the requirement specified in EN13749 European standard in early design stages.
Tormal, Uday Bapurao
Finite Element Analysis and Correlation with Physical Test of Tractor Hood Bang Endurance Test2024-26-00711/16/2024
Tractors are machines primarily used for agricultural operations. However, tractors are used for various other application like loader, construction, haulage etc. There are many aggregates available in tractor like Engine, Transmission, Front hood assembly, Skid etc. and Hood is one such critical system in tractor, which encloses Engine and its associated parts. It is made of sheet metal with class 'A' surface finish for aesthetic purpose. Hood is locked using latch mechanism which is mounted on the tractor chassis. The main purpose of hood latch is to open and close the hood assembly during servicing. In some events, hood is closed by slamming which leads to structural failure and there is a need to validate hood assembly. This RWUP is replicated in lab as Hood bang test. To front load hood bang test, CAE methodology is developed and discussed in this paper. This paper focuses on FE methodology, process establishment of Hood bang simulation and correlation between CAE and test. FE
PANDEY, MANOJ, Kumar, Arun, Redkar, Dinesh, Perumal, Solairaj, Thankaraj, Pratheesh, Udayakumar, S
Cab RLDA using VI & MI approach: A Co-Simulation of ADAMS & FEMFAT Lab VI/MI2024-26-00511/16/2024
The current approach of hybrid RLDA is typically incapable of providing accurate dynamic loads coming on cab at chassis-to-cab load transfer locations, primarily due to following two reasons. Firstly, all of the model parameters of the vehicle, which is put on the four post, are not known. Secondly, MBS (Multi-body System) Cab model is multi degree of freedom with rigid bodies, flex bodies, contacts and non-linear force elements. Therefore, if the system identification is to be performed manually it becomes an arduous and humanly impossible task. Towards generating an accurate dynamic loads on cab, an approach using FEMFAT LAB - VI & MI has been developed which involves a two-step process: a) Generating MBS excitation by back calculating from measured frame response - VI (Virtual iterations). b) Fine tuning modelling parameters to match measured cab response - MI (Model Improvement). To execute the VI & MI approach for calculating dynamic loads on cab through 4-poster & 7-poster
Singh, Prempal, PRASAD, TEJ
Analytical tool for Design and Optimization of Double Isolation Mounting System for Electric Powertrain2024-26-01251/16/2024
As the world rapidly moves from IC engine powered vehicles to the 'more sustainable' Electrified Vehicles, the Powertrain Mounting System needs to be re-engineered to meet refinement requirements of customer. Electric vehicles are quieter but due to lack of "masking effect", are sensitive to minor disturbances that are perceived to be objectionable by passengers. Also, E-powertrains are lighter, produce higher torque at low rpms & operate at higher rpms which calls for different countermeasures for mounting systems compared to conventional single isolation 3-point mounting system as used in IC engines. Double Isolation Mounting System, where powertrain is connected to an auxiliary mass (sub frame/cradle) via mounts, which is suspended to the vehicle body via cradle bushes results in 12 rigid body modes, 6 for each mass, is highly effective in lowering the transmission of vibration at high frequencies. This paper discusses 12 DOF analytical tool developed to rapidly analyze Powertrain
Verma, Shemon, Jayachandran, Suresh kumar, Mane, Yogiraj, Paua, Ketan, Vellandi, Vikraman
Countermeasures for Low Frequency Boom noise Reduction in Electric Vehicle2024-26-02141/16/2024
Electric vehicles are much quieter than IC engine powered vehicles due to less mechanical components and absence of combustion. The lower cabin noise in electric vehicles make customers sensitive to even small disturbance in vehicle. Road boom noise is one of the major concerns to which the customers are sensitive in electric vehicles. The test vehicle is a front wheel driven compact SUV powered by electric motor. In normal plain road, noise levels are acceptable but when the vehicle has been driven on coarse road, the boom noise is perceived, and the levels are objectionable. Multi reference Transfer path Analysis (MTPA) is conducted to identify the path through which maximum forces are entering the body. Based on MTPA, modifications are proposed on the suspension bushes and the noise levels were assessed. Operational deflection shape (ODS) analysis is conducted on entire vehicle components like suspension links, sub frame, floor, roof, and doors to identify the deflection pattern of
S, Nataraja moorthy, Rao, Manchi, Raghavendran, Prasath, Selvam, Ebinezer
Methodology for jury evaluation and target setting for passenger vehicle operational sound quality2024-26-02271/16/2024
In automotive market, with competitive car prices, build quality of a car will be a major distinguishing factor. Consumer's need for acoustic comfort has evolved from the removal of annoying noises to perceived sound quality. Operational sounds from electromechanical systems like sunroof system, window regulator, door lock system, HVAC etc. directly interact with users' senses. The perceived acoustics comfort of these sounds are direct indicators of vehicle character and can influence customer's buying decision. With the reduction in product development time and stringent cost constraints, a proper structured target setting methodology to benchmark & evaluate these operational sounds is crucial. In this paper, such a target setting methodology is proposed and discussed for operational sound quality evaluation. Electromechanical noises from various vehicles are measured using binaural head measurement system. Using Simultaneous Categorical Scaling method, jury evaluation is performed
Somasundharam, Sundaralingam, Manoj K, Mridul, RAJ, GAURAV, Mohammed, Riyazuddin, R, Prasath
Active-Learning method : An effective way to generate ground truth data to test & validate ADAS functions2024-26-03641/16/2024
In today’s autonomous industry, Machine learning plays an important role in development of various functions for self-driving vehicles. The learning models are trained using data, and their performance is determined by the quality of data they get trained on. For autonomous driving, sometimes, we don't have valid data and our model doesn't know what to do. As a result, the models must be trained on as much as diverse data as possible to make them efficient to deal with unusual situations in the actual world. Huge amount of unlabeled data is collected by cars moving around, equipped with multiple sensors to capture the surrounding environment in a frame. It becomes difficult to annotate each data manually and find data frame with more information. Therefore, automated methods are needed to identify and extract the most informative data from collected ones. Active learning is a powerful data selection technique which improves data efficiency for learning models. In Active Learning, the
Katariya, Rashmi, Kumari, Anita
SUV Multi-Link Rigid Axle Control Links Optimization for Ride and Handling Improvement2024-26-00481/16/2024
In automotive world, role of suspension system is to absorb vibrations from the road, and to provide stability while vehicle is going over bumps or uneven roads, cornering, acceleration and braking etc. For body on frame SUVs which are typically characterized by high center of gravity, it is quite critical to find best balance in ensuring stability of the vehicle and having comfortable ride performance. Rigid axle rear suspension is quite typical choice in such vehicles, wherein lower and upper control links are two important components subjected to lateral, longitudinal, and vertical loads. These links allow the vehicle to move smoothly throughout the entire range of suspension travel. Kinematics and compliance optimization of these links is major factor in definition of ride-handling performance of the vehicle. The present study describes key challenges and methodology to define position as well as orientation of control links, where-in multiple inter-related handling and comfort
Hussain, Inzamam, Jani, Harshil, Rasal, Shraddhesh, Asthana, Shivam, ahire, Manoj, Jadhav, Prashant, Lenka, Visweswara, Vellandi, Vikraman
Coupled FEM-DEM for determination of payload distribution on Tipper load body2024-26-02551/16/2024
Tippers used for transporting blue metal, construction and mining material is designed with different types of load body to suit the material being carried, capacity and its application. Structural strength verification of load body of tipper is conducted using FEM, by modelling forces due to payload as a pressure function on the panels of the load body. Determining the pressure function on panels is a challenge owing to the complexity of modelling large volume of granular payload using conventional FE methods. Hence, typically the spatial variation of pressure is assumed. The Discrete Element Method (DEM) allows the modelling of granular materials such as gravel, wet or dry sand, coal, etc., taking into account its flow and interaction with the structure holding them. DEM has the ability to numerically calculate displacements and rotations of finite particles. Also, automatically perform contact detection for particle assembly. DEM uses a discrete approach that is very well suited for
Sadasivam, Sivasankaran, Loganathan, Ekambaram, Mahalingam, Manikandan
Simulation methodology development for vibration test of Bus Body Structure code AIS 153:20182024-26-02491/16/2024
A bus is integral part of public transportation in both rural and urban areas. It is also used for scheduled transport, tourism, and school transport. Buses are common mode of transport all over the world. The growth in economy, the electrification of public transport, demand in shared transport, etc., is leading to a surge in the demand for buses and accelerating the overall growth of the bus industry. With increased number of buses, the issue of safety of passengers and the crew assumes special importance. The comfort of driver and passenger in the vehicle involves the vibration performance and therefore, the structural integrity of buses is critically important. The bus safety act depicts the safety and comfort of bus operations, management of safety risks, continuous improvement in bus safety management, and public confidence in the safety of bus transport, appropriate stakeholder involvement and the existence of a safety culture among bus service providers. In order to provide
Bijwe, Vilas B., Mahajan, Rahul, Vaidya, Rohit, Patel, Kaustubh, Hiwale, Diwakar, Walke, Abhijit Ashok
Method Of Improving Slam Durability Fatigue Of Vehicle Liftgate Subsystem For Fast-Track Vehicle Development Cycle2024-26-03021/16/2024
ABSTRACT With reference to existing literature, most OEMs are working on reducing product development time by around ~20%, to achieve seamless integration to digital ecosystem and focusing on new features catering to dynamic customer needs. The Systems Engineering approach focuses on functions & systems rather than components. In this approach, designers (Computer Aided Design) / analysts (Computer Aided Engineering) need to understand program requirements early to enable seamless integration. This approach also reduces the number of iterative loops between cross functions thereby reducing the development cycle. In this paper, we have taken a common challenge faced by Closures (Liftgate) engineering to meet slam durability fatigue life, replicating customer normal and abusive closing behavior. For modern vehicles, with faster vehicle development process, major challenges are balancing mass with improved structural and durability performance while also considering design changes with
Subramanian, Vijayasarathy, Evans, Jon, Schoenow, James, Arikatti, Karegowda
Lightweighting of Two-Wheeler Frame with CAE - Multi Domain Optimization (MDO)2024-26-02611/16/2024
Lightweighting in the automotive industry without the use of finite element methodologies is now inconceivable. With the development and enhancement of various CAE tools available in the market, CAE-driven optimization has become part of the product development cycle. Using a variety of CAE techniques in a lightweight optimization process can significantly reduce product development lead time with good results. Traditional light weighting can be done through different iterative approaches with different manual inputs from cross-domain teams, which is usually time consuming and leads to repeated analyses, etc. The current method describes the case of a multi-domain optimization (MDO) approach involving E-Motorcycle frame weight reduction while taking into account various important cross-domain load cases using CAE methodologies. For frame optimization, the most important loads - stiffness, durability/strength (Normal & Abusive), and NVH (Modes & Vibration) - were taken into account, as
S, Vishnu, kakanur, Ashok, U PE, Manjunatha, Bhat, Sachin, POOJARY, KIRAN, V N, Kishor
Vehicle Dynamics Simulation Correlation : Impact of Flexible Tyre and Flexible Frame in Comfort Prediction of Two Wheelers Motorcycles and Scooters2024-26-00531/16/2024
For any two wheeler vehicle development, rider and pillion comfort while driving the vehicles over different kinds of road perturbations holds high importance. Designing a vehicle for comfort starts at the very beginning of its layout definition through vehicle geometric parameters, key hardpoints, mass-inertia distribution of subsystems and suspension characteristics. There is a need for highly reliable simulation models for comfort predictions as any change in layout during subsequent design stages is a very costly affair. Accurately predicting comfort using a full vehicle model is a challenging task though as it depends on how realistic the Simulation Model is to that of actual vehicle. While suspension stiffness and damping characteristics remain critical parameters for the comfort, selection of tyres are known to hold equal importance in vehicle comfort. The details to which the tyres are captured in the simulation model and the formulation of tyre interaction with roads in a
Govindula, Srikanth, Pandey, Pradyumn, Saraswat, Udit, Mishra, Ashish
INTEGRATION OF SEAT-BELT WEB-GUIDE FUNCTIONALITY IN TRIM PART2024-26-00181/16/2024
Restraint systems in automotives are inevitable for the safety of passengers. Seat belts are one such restraint system in automotives that prevent drivers and passengers from being injured during a crash by restraining them back. Seatbelt on automotives has interface with Body-in-white (henceforth called as BIW) and Trim parts in-order to serve its purpose at vehicle level. One such interface part of seat belt is the web guide, which assists and ensures the nylon web’s smooth motion at different seat track positions. Web-guides on automotives ensure the flawless motion of seat belt web at pillar trim areas. In this paper, we are discussing about alternate ways of assisting the seat belt web without the web-guide as a separate part In-order to assist and ensure the motion of nylon web in its trajectory, we have extended the flange of the pillar trim involved. The paper throws light on the advantages of using an extended trim flange as web-guide for seat belt web instead of a separate
D, GOWTHAM, bornare, harshad, GANGAPURAM, SURESH, Deoli, Manish, RITESH, KAKADE, sai, Konduru, Kakani, Phani Kumar
The applications of Acoustic Black Holes to attenuation of Coach/Bus Frame Structure Vibrations2025-01-00655/5/2023
Abstract An acoustic black hole (ABH) is a structure whose cross-sectional thickness decreases exponentially to zero, and the phase velocity and group velocity of wave propagation in those structure acoustic black holes decrease as the thickness decreases until they are zero. ABH produce some very magical physical phenomena. For example, because the wave velocity decreases to zero, the wave can never reach the center of the ABH, so the wave propagation in the acoustic black hole has neither refraction nor reflection; that is to say the vibration wave will not go through the acoustic black hole. As a result, the wave energy is concentrated in the center of the ABH. The arrangements of those acoustic black holes in the structures could change the directions of the vibrational wave propagation in the structures at NVH engineers’ wills. These amazing phenomena could play a magical role in reducing structural vibration, structural noise radiation and structure-borne noise. Basic structures
Huang, Xianli
Evaluation of Automotive Closure Design for High Frequency Acoustics Performance2025-01-00495/5/2023
A good NVH environment in a vehicle plays an important role in attracting a large customer base in the automotive market. Hence, NVH has been given significant priority while considering automotive design. NVH performance is monitored using simulations early during the design phase and testing in later prototype stages in the automotive industry. Meeting NVH performance targets possesses a greater risk related to design modifications in addition to the cost and time associated with the development process. Hence, a more enhanced and matured design process involves Design Point Analysis (DPA), which is essentially a decision-making process in which analytical tools derived from basic sciences, mathematics, statistics, and engineering fundamentals are used to develop a product model that better fulfills the predefined requirement. This paper shows the systematic approach of conducting a Design Point Analysis-level NVH study to evaluate the acoustic performance of vehicle door systems in
Ranade, Amod A., Shirode, Satish, Miskin, Atul, Mahamuni, Ketan, Shinde, Rahul, GHAN, PRAVIN, Choudhury, Ashok
Localisation of Ultra-short Sound Emissions from Automotive Components by Using the Sound Field Scanning Method2025-01-00925/5/2023
Design verification and quality control of automotive components require the analysis of the source location of ultra-short sound events, for instance the engaging event of an electromechanical clutch or the clicking noise of the aluminium frame of a passenger car seat under vibration. State-of-the-art acoustic cameras allow for a frame rate of about 100 acoustic images per second. Considering that most of the sound events introduced above can be far less than 10ms, an acoustic image generated at this rate resembles an hard-to-interpret overlay of multiple sources on the structure under test along with reflections from the surrounding test environment. This contribution introduces a novel method for visualizing impulse-like sound emissions from automotive components at 10x the frame rate of traditional acoustic cameras. A time resolution of less than 1ms eventually allows for the true localization of the initial and subsequent sound events as well as a clear separation of direct from
Rittenschober, Thomas
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