Browse Topic: Chassis

Items (49,873)

High center of gravity (CG) and moderate Wheel track vehicles such compact SUVs has comparatively low static stability factor (SSF). Making them unstable and highly susceptible for rollover. On the top of that, to enhance the ease of maneuverability in densely populated areas, it is required to have a minimal turning circle diameter (TCD). To do so, variable gear ratio (VGR) steering stands superior to conventional constant gear ratio (CGR) steering, benefiting in both improved roll stability and agility to manoeuvre in compact spaces. To fine-tune VGR steering for specific vehicle requirements, Driver-in-the-Loop (DIL) simulation is used. This method allows for precise adjustments based on real-world driving conditions, ensuring the VGR steering C-factor curve is optimized for ideal vehicle handling performance in on-center, off-center, and transition regions of the steering wheel angle (SWA). Metrics such as SWA gradient at different lateral accelerations and C-factor transitions for

Rewale, Pratik, Kopiec, Jakub, Kumar, Deva, Rasal, Shraddhesh, Hussain, Inzamam, Nehal, S B

A Scientific approach to identify the source of intermittent steering rattle noise and implementing the design solutions

2026-26-03461/16/2026

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

Wheel Corner Module Energy Losses and Potential Improvements

2026-26-00961/16/2026

With the inevitable shift of automotive industry towards E-mobility and mandatory fuel efficiency targets, there is a need to evaluate the energy losses in the vehicle & identify potential areas of improvement. Energy losses are calculated for different components in the corner module system of a passenger car. Contribution of losses (Resistances) from respective component are depicted using simple analytical models. Potential energy saving improvements were identified and analyzed basis emerging technologies in respective areas.

Raghatate, Kumar Shreyas, Vedartham, Raghavendra, Khanger, Rakesh, Bisht, Arun

Comprehensive research study examining Tyre wear and its Indian perspective.

2026-26-06041/16/2026

Automobile emissions refer to the gases and particles released into the atmosphere by vehicles during their operation. These emissions contribute to environmental pollution and have an impact on human health and the environment. This paper assimilates findings from a comprehensive research study examining tyre wear and its Indian perspective. Tyre wear understood as a factor affecting road safety, environmental health, and economic sustainability. The study identifies factors affecting tyre wear and provides overview regarding tyre wear generation in India, encompassing road infrastructure, vehicle characteristics, driving patterns, and environmental factors. Moreover, it examines the adverse effects of these particles on human health, such as respiratory ailments and cardiovascular diseases, as well as their impact on ecosystems. This paper delves measures to measure tyre wear and safeguard both environmental and public health. It also covers the tyre wear measurement methodologies to

Joshi, Amol, Khairatkar, Vyankatesh, Belavadi Venkataramaiah, Shamsundara

Refinement of Road Induced Steering Wheel Vibration in Electric Vehicle

2026-26-03371/16/2026

Nowadays, customers expect excellent cabin insulation and superior ride comfort in electric vehicle. OEMs focuses on fine tuning the suspension system in electric vehicle to isolate the road shocks which finally offers superior ride quality. This paper focuses on the enhancing the ride comfort by reducing the steering wheel vibration which mainly originates due to road inputs. Higher steering wheel vibrations are perceived on the test vehicle when driven on rough road at the speed of 50 kmph. To determine the predominant force transfer path, Multi reference Transfer Path Analysis (MTPA) is performed on the front and rear suspension. Based on the finding from MTPA, various recommendations are explored and the effect of each modification is discussed. Apart from this, Operational Deflection Shape (ODS) analysis is carried out on the entire steering system to identify the deflection shape at the operating condition. Based on ODS findings, recommendations like dynamic stiffness

S, Nataraja Moorthy

Regenerative braking control strategy for electric commercial bus under Indian road condition using artificial neural network

2026-26-06451/16/2026

The main objective of this research is to create a more efficient regenerative braking control strategy for electric commercial buses operating under Indian road conditions. The strategy uses Artificial Neural Networks (ANNs) to optimize the regenerative braking process. Regenerative braking helps to recover energy that would otherwise be lost during braking and convert it back into usable power for the vehicle. The challenge is to design a system that works effectively on the diverse and often challenging road conditions found in India, such as varying gradients, traffic patterns, and road surface types. This study begins by collecting data (which includes vehicle speed, road gradient, traffic condition, etc.) from real-world driving conditions and aims to train an Artificial Neural Network (ANN) using a large set of driving data collected under various conditions to predict the most efficient regenerative braking settings for different driving scenarios. While the results are

Saurabh, Saurabh, Bhardwaj, Rohit, Patil, Nikhil, Gadve, Dhananjay, Amancharla, Naga Chaithanya

Determining Optimal Suspension & Body in White Mountings to maximize Off-Road Capability of Passenger Vehicles

2026-26-00981/16/2026

The automotive market is shifting toward SUVs, with rising customer demand for off-road capability in passenger vehicles. While pure off-roaders offer advanced performance, the goal is to achieve similar functionality in passenger vehicles through minimal design changes. A key factor in off-road performance is wheel articulation, which ensures tire contact and stability on uneven terrain by allowing independent wheel movement. Wheel articulation plays a critical role in determining a vehicle's off-road capability. The vehicle is designed with key parameters like hard point configuration, strength and durability to meet performance targets. While Kinematic and Compliance setup suits standard ride and handling needs, adapting it for off-road capability exceeds its current design limits and requires further enhancements beyond conventional development. Relationship between wheel articulation and off-road performance, emphasizing the role of suspension design and geometry in enhancing

Siddiqui, Arshad, Iqbal, Shoaib, Dwivedi, Sushil

Niobium Alloyed Brake Disc for reduced NVH and emission control

2026-26-02851/16/2026

Recent regulations limiting brake dust emissions have presented many challenges to the brake engineering community. The objective of this paper is to provide a low cost, mass production solution utilizing well known existing technology to meet brake emissions requirements. The proposed process is to alloy the Gray Cast Iron with Niobium. The Niobium addition will reduce wear debris and improve NVH (Noise Vibration Harshness). The test methodology included: Manufacture of disc samples alloyed with Niobium, and Evaluation of airborne wear debris utilizing a pin-on-disc tribometer equipped with emission collection capability. The airborne emission and wear surfaces were further analyzed by Scanning Electron Microscopy, Energy Dispersive techniques (SEM-EDS), X-Ray Diffraction and Optical Microscopy. The cast iron test matrix included four groups; Unalloyed eutectic 4.3% Carbon Equivalent (CE), Unalloyed hypereutectic >4.3% CE, Niobium alloyed Eutectic and Niobium alloyed hypereutectic

Barile, Bernardo, Holly, Mike

Smart Stability: Dual-Mode Hill Hold and Parking Brake Strategy in Electric Tractors Using Motor Torque and Electro-Hydraulic Actuation

2026-26-02051/16/2026

Operating tractors on Sloped Terrains presents safety challenges, especially during shuttle operations, loader use, or start-stop maneuvers at slopes. Unlike Diesel Counterparts, feedback from the prime mover (Motor) is minimal and silence often masks terrain feedback. Driver response tends to vary, leading to rollback & challenges to safety demanding skill & expertise for safe operation. Based on field observations across Mahindra tractor platforms, we identified start-stop maneuver task to be offloaded from the operator to improve control and consistency and take skill element out of picture. This paper outlines the approach derived based on dual-mode Hill Hold and Parking Brake system, developed using traction motor torque control and SAHR-based hydraulic braking via proportional valves. The VCU works at the heart of this system to dynamically choose between electric and hydraulic modes based on vehicle state, ignition, and motor conditions. Parking brake automation logic has been

M, Rojer, P, Velusamy, Natarajan, Saravanan, devakumar, Kiran, T, Ganesan, sundaram, Pavithra, Muniappan, Balakrishnan

Road noise improvement of a passenger vehicle through end-to-end CAE-Simulation using Transfer Path Analysis (TPA) approach

2026-26-04311/16/2026

Refined NVH performance of a vehicle is a mark of premium quality. Achieving the desired NVH performance in different vehicle operating conditions is always a Herculean task and early stage “CAE design recommendations” play crucial role in overall vehicle design development. This becomes tougher when the program is very much cost, weight and timeline sensitive. This paper explores simulation approach for addressing a major noise issue for a vehicle running at a constant speed on a rough road. The first and the most critical step is to identify the exact root cause of the issue. Hence, we propose a detailed full vehicle level “contribution analysis (CA) + transfer path analysis (TPA)” methodology (everything done through the simulation) and then go for the design recommendations to improve the performance. We used road excitation power spectral density (PSD) as the input at all the four wheels (spindle locations) calculated through MBD software. The first step i.e. contribution analysis

Mahajani, Mihir, Nascimento, Fabio, ADINARAYANA REDDY, KODIDELA, Matyal, Mahantesh, Tenagi, Irappa, Sardar, Chenna

Evaluation of Thermo-Mechanical behavior of brake discs in vehicles using Multidisciplinary approach

2026-26-04331/16/2026

The objective of this paper is to evaluate the thermal performance of the brake discs in the design stage of its life cycle by developing a methodology to replicate the dynamometer testing using multi-disciplinary Finite Element Analysis (FEA) methods. A simulation workflow was formulated in which Computational Fluid Dynamics (CFD) was used to create temperature and velocity dependent Heat Transfer Coefficients (HTC) which were in turn used in Computer Aided Engineering (CAE) to do a thermo-mechanical analysis. With this workflow various designs of the brake discs were analyzed. A sensitivity study was done to determine critical design features that affected its thermal performance. A final design was fixed that met both the weight and thermal performance targets. This design was evaluated in dynamometer testing, and 95% correlation was achieved. Thus, the developed simulation workflow ensured that a first-time right brake disc can be finalized in the design stage, which will meet the

Balaji, Praveen, K, Karthikeyan, S, KESAVPRASAD, S Kangde, Suhas

Steel-based Laminates for Lithium-ion Pouch Cell of Electric Vehicles

2026-26-01861/16/2026

Aluminium foils have gained traction with EV battery manufacturers for their pouch cell format. Over the years it has evolved as a material of choice, but it is still plagued by issues of stress concentration, swelling due to lower strength and stiffness of base aluminium layer. Preliminary investigation revealed that laminates using steel foil material (thickness <0.1mm) could be a potential candidate for EV pouch cell casing. Thus, steel-based laminate was developed meeting key functional requirements (e.g. barrier performance, insulation resistance, peel strength, electrolyte resistance, formable without cracking at edges, and heat sealing compliant). This innovative patented steel-based laminate was further used to manufacture pouch cell prototypes (maximum capacity 2.5Ah) for key performance tests (e.g. cell cycling, nail penetration and thermal runaway). The study paves the way for a low cost, sustainable and flexible yet strong steel-based laminate packaging material solution

Singh, Pundan Kumar, Raj, Abhishek, Kumar, Ankit, Chatterjee, Sourabh, Verma, Rahul Kumar, Samantaray, Bikash, Gautam, Vikas, Pandey, Ashwani

Digital Twin-Enhanced Chassis Dynamometer for EV Drivetrain Testing

2026-26-03631/16/2026

Accurate prediction of drivetrain performance and energy efficiency in electric vehicles (EVs) remains a challenge due to the limitations of conventional chassis dynamometer testing, which often overlooks dynamic vehicle-roller interactions, suspension responses, and regenerative braking effects. This paper presents a novel digital twin-enabled testing framework using a compact, two-roller chassis dynamometer integrated with real-time multibody dynamics and electromechanical co-simulation. The physical test bench is coupled with a virtual model of the EV, including suspension geometry, rear-to-front axle load distribution, tire–roller contact mechanics, and motor-inverter dynamics. By enabling bi-directional data exchange between the physical and virtual domains, the system emulates real-world load shifts, torque demand variations, and energy recovery under standardized drive cycles. This integrated approach enhances simulation fidelity, supports certification-compliant testing, and

Kumar, Akhilesh, V, Yashvati

Boosting the development of a BEV Rear Twist Beam suspension through a pioneering approach: ADAMS Real Time on Driving simulator

2026-26-03971/16/2026

Twist beam suspensions are widely utilised in passenger vehicles because of their simplicity and cost-efficiency, yet they provide engineers with a complex challenge as their performance depends entirely upon the structural properties of the beam itself. Traditional methodologies rely on the generation of Modal Neutral Files (MNF) based upon vehicle dynamics requirements and packaging constraints, which is a highly time-consuming process that starts failing to fulfil the demands of a market where development times are being exponentially reduced. Besides this, part of flexible body’s real behaviour might be lost in the process of converting multibody models into parametric ones, which, in turn, presents difficulties in modifying compliant-related items. Thanks to a novel approach followed jointly by Mahindra and IDIADA, quick identification and optimisation of key tuneable items is achieved by employing a hybrid solution that combines full flexible and FE elements in ADAMS Car

Osorio, Alejandro García, Prabhakara Rao, Vageesh, Asthana, Shivam, Rasal, Shraddhesh

Enhanced Methodologies for predicting Automotive Wheel Bearing life and damage using RLDA

2026-26-04821/16/2026

The durability of wheel bearings is assessed in terms of raceway life and flange life. Raceway life focuses on the performance and damage tolerance of rolling elements, while flange life evaluates the structural integrity of wheel flanges under operational stresses. Traditionally, durability predictions relied on conventional design methods and analytic formulas for raceway spalling, as well as static load assumptions for flange fatigue analysis. Recently, integrating design of experiments (DOE) with traditional approaches has enhanced these methods, enabling systematic evaluation of design variables and loading conditions. This paper introduces a methodology for analysing raceway life and damage in automotive wheel bearings using RLDA (Road Load Data Acquisition) data. The process involves acquiring raw deterministic load data, filtering it to preserve high-peaked signals, and transforming the filtered data into block cycles derived from load time histories. Each block cycle contains

Narendra, Vishwanath, Mane, Yogiraj, Paua, Ketan, Singh, Ram Krishnan, Vellandi, Vikraman

Development of a Lightweight Front-End Structure Using Injection Molding Technology

2026-26-03041/16/2026

This paper presents the development of a lightweight, functionally integrated Front-End Module (FEM) utilizing plastic-metal hybrid injection molding technology. The objective is to achieve modularization, part consolidation, weight reduction, and cost efficiency. The proposed design integrates multiple components into a single module which makes assembly faster and easier. A mounting strategy with fixation features was integrated into the structure to effectively support various components.To ensure structural performance, component-level Finite Element Analysis (FEA) was performed, including static strength, bending and torsional stiffness, hood retention tests, and modal analysis. Ribbing patterns were optimized to meet design stiffness targets while minimizing weight. Moldflow analysis was carried out to evaluate manufacturability, focusing on gate design, weld lines , warpage, and flow balance. Necessary design corrections were implemented prior to tool development to ensure

Srivastava, Sanjay, Thakoor, Shruti Ghanashyam, Sonkusare, Shailesh

Smart Multilink Cabin Suspension with Detachable Stabilizer Mechanism for Improved Ride Comfort and Maintenance Efficiency in Vehicle Cabins.

2026-26-00881/16/2026

This paper presents the design and development of a novel suspension system for vehicle cabins, specifically aimed at improving ride comfort and reducing maintenance time and costs. The system features a detachable stabilizer bar pivotally coupled to a pair of brackets connected to the vehicle chassis. The stabilizer bar is removably connected to a pair of connecting links, which in turn are oupled to a second pair of brackets attached to the cabin. This configuration allows for easy access to the engine bay during maintenance without disassembling the entire suspension system. Additionally, the system includes damper units and pivot arms that enhance ride comfort by isolating vibrations from the chassis. The proposed design is particularly beneficial for commercial vehicles with fixed cabins, as it reduces idle time during engine overhaul and improves overall ride quality for occupants.

K, Akilan, Pardeshi, Mahesh, Mistri, Pratikkumar, Navsariwala, Prashant

Optimizing Collision Warnings: A Shift from Time to Collide to Time to Brake

2026-26-00471/16/2026

In automotive safety systems, Time to Collide (TTC) is traditionally used to trigger warnings in auto-emergency braking systems. However, TTC can lead to premature or inaccurate warnings as it is calculated based on the relative speed and distance between the ego and an obstacle. TTC does not consider the vehicle's braking dynamics, such as brake prefill lag which varies across different vehicles, maximum deceleration, and the effectiveness of braking systems and assumes constant speed which may not always be realistic. We propose Time to Brake (TTB) as a more effective parameter for driver warnings. TTB directly relates to the action a driver needs to take—braking. It provides a clear indication of when braking should begin to avoid a collision, whereas TTC only tells us about the possibility of a collision. To calculate TTB we utilize the brake profile, which incorporates both deceleration and system jerk for improved accuracy. The proposed warning time is the sum of variable brake

Singh, Ashutosh Prakash, Kumawat, Himanshu, Gupta, Sara

Experimental Evaluation of Tyre Vertical Dynamic Stiffness and Damping for Ride Model Applications Using Flat Trac

2026-26-06071/16/2026

The damping and vertical dynamic stiffness of a tyre are critical to ride comfort and overall dynamics, particularly for low-frequency excitations in urban and highway driving. Accurate ride models depend on precise tyre parameterization, as tyres are the primary interface between the vehicle and the road, absorbing surface irregularities before the suspension engages. This study investigates an experimental methodology characterizing the vertical dynamic behaviour of pneumatic tyres using a Flat Trac test machine. Contrary to the conventional approaches that depend on intricate shaker rigs or frequency dependence function models, the proposed technique uses a realistic force displacement loop-based technology which is appropriate for ride model applications. Dynamic stiffness is calculated as the peak force divided by peak displacement during vertical sinusoidal excitation. Damping is derived from hysteresis energy loss per cycle. The tests were conducted under various conditions by

Duryodhana, Dasari, Sethumadhavan, Arjun, Tomer, Avinash, Ghosh, Prasenjit, Mukhopadhyay, Rabindra

Methodology for optimizing the bench testing of Steering I shaft using vehicle level data to reduce overall product development time and 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

Comprehensive Evaluation of Bolster Behavior: Field Data Insights for Design Modifications

2026-26-04971/16/2026

Bogie suspension systems are increasingly being used in tipper vehicles to enhance their performance and durability, especially in demanding environments like construction and mining areas. Bolsters play a very crucial role in the bogie suspension systems of tipper vehicles, contributing significantly to their overall performance and durability. Bolsters help in evenly distributing the load across the suspension system, reducing stress on individual components and enhancing the vehicle’s stability. They act as shock absorbers, mitigating the impact of rough terrains and heavy loads, which is essential for maintaining the structural integrity of the vehicle. By dampening vibrations, bolsters improve ride comfort and reduce wear and tear on the vehicle’s components, leading to longer service life. Bolsters assist in maintaining proper alignment of the suspension system, ensuring optimal performance and safety. This study focuses on the comprehensive testing and evaluation of bolsters to

V Dhage, Yogesh, Kolage, Vikas

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

2026-26-01351/16/2026

Path planning is a key element of autonomous vehicle navigation, allowing vehicles to calculate feasible paths in challenging environments. Algorithms such as Hybrid A*, Reeds-Shepp, and Dubins paths effectively generate collision-free paths but tend to create curvature discontinuities. These discontinuities result in sudden steering transitions, which create control instabilities, higher mechanical stress, and lower passenger comfort. To overcome these issues, this paper suggests a path-smoothing technique based on the pure-pursuit algorithm to produce curvature-continuous, distortion-free paths appropriate for real-world driving. This method utilizes the practical approach of the original path but removes sudden transitions that destabilize control. By ensuring smooth curvature, the vehicle undergoes fewer jerky steering actions, enhanced energy efficiency, less actuator wear, and improved high-speed tracking. Experimental verifications, such as real-time tests on autonomous vehicles

S, Shriniyathi, A, Josana, Edwin J, Joel, T, Akshayaa, M, Senthil Vel, Kumar PhD, Vimal

DC Link Capacitor Size Reduction Using Phase-Shifted PWM Techniques for Pole Phase Modulated Induction Machine Drive

2026-26-01701/16/2026

Multiphase machines i.e. electrical machines with more than three phases have many advantages compared to the three-phase machines for high power density applications. The major advantages of multiphase machines include lower space harmonics thereby reduced losses and improved efficiency, reduced torque pulsations leading to lesser vibrations and acoustical noise, higher fault tolerance which retains the self-starting ability with minimum deration in the output power in case of fault in one or more phases and enhancement of torque density by adding higher order harmonic currents into the stator currents. Requirement of power electronic switches with reduced rating compared three phase motor drives for a given power rating is another important advantage which supports employing multiphase machines in high power applications. Wider speed and torque ranges are other important requirements of a drive for high power traction and propulsion application. Conventional machines need to be over

A, Rajeshwari

EVALUATION OF DRIVELINE NVH PERFORMANCE USING LINEAR DYNAMIC FINITE ELEMENT SIMULATION

2026-26-03221/16/2026

Automotive driveline design plays an important role in the NVH characteristics of the overall vehicle. Driveline systems are an integral part of delivering torque from the engine/transmission to the tires which propel the vehicle and drivelines often experience a wide frequency of excitation which poses unique NVH challenges. With the increasing trend in the automotive industry to introduce turbocharged engines with fewer cylinders while delivering the same torque / power, the driveline systems are excited with increased lower frequency torsional vibration in addition to other vibrations transmitted from powertrain and road. In this paper, we address the key design consideration for developing an optimal driveline system with consideration to NVH while keeping durability and other functional requirements in perspective. We consider the example of a front wheel drive-based vehicle architecture with independent suspension. The effect of fundamental prop shaft frequency to determine

JOSHI, ATUL KAMALAKARRAO, Subramanian, MANOJ

Driver-in-the-Loop Optimization of Tire-Vehicle Dynamics using Virtual Tire Development approach through CD Tire Models

2026-26-00991/16/2026

This study provides a virtual development process using VI-Grade Driving Simulator and Adams simulation integrating CD tire models to modify all-terrain tire performance for an altered and new proposed version of an existing production vehicle. The proposed alteration introduces ride height changes, weight distribution changes, and centre of gravity changes from existing vehicle design. The proposed new vehicle variant also introduces tire change from highway terrain type to all-terrain type as it was intended to deliver some off-roading capabilities, thereby vehicle dynamics and kinematics recalibration & tuning required. The conventional development cycles through physical prototypes are time-consuming and expensive. Alternatively, this solution combines high-fidelity tire simulation, driver-in-the-loop (DIL) simulation, and multi-body dynamics analysis to reduce development time and prototype cycles. The proposed method begins with baseline correlation, augmenting Adams vehicle

Shrivastava, Apoorv, Asthana, Shivam

Achieving ride comfort in bus suspension by varying air spring performance

2026-26-00811/16/2026

Air springs are widely used in commercial buses to obtain better quality of ride and comfort. Selecting the right air spring is a critical aspect of suspension design. However, this selection process is often constrained by the limited availability of off-the-shelf components as the development of a custom air spring involves long lead time and high tooling cost. This can be justifiable only at high production volumes. Air springs are tunable as compared to conventional mechanical metal springs. Their performance can be adjusted by varying the internal air pressure and volume, enabling them to accommodate a wide range of vehicle load conditions. In actual design practice, component packaging constraints and fixed mounting dimensions often restrict the choice of air spring. Additionally, Front and rear suspension requires air springs with different characteristics. To overcome these limitations, an auxiliary air tank is also called a ping tank that can be used along with an existing

Patre, Kamlesh, Salunkhe, Swapnil, Paranjape, Shekhar

Determination of Acrylonitrile Content in Nitrile Butadiene Rubber Vulcanizates by Py-GCMS Techniques

2026-26-05461/16/2026

Nitrile Butadiene Rubber (NBR), a copolymer of butadiene and acrylonitrile is known for its superior resistance to hydrocarbon oil, low gas permeability and excellent thermal stability. It is extensively used in seals, O-rings, conveyor belts and pneumatic tires. It is worth mentioning that these performance attributes are predominantly influenced by acrylonitrile content. While solid-state 13C Nuclear Magnetic Resonance (NMR) is an established technique for structural characterization of rubber vulcanizates, its high cost and accessibility limits its application in routine industrial analysis. This study aims to develop Pyrolysis-Gas Chromatography/Mass Spectrometry (Py-GCMS) as a robust, precise, cost-effective alternative to determine acrylonitrile content in NBR vulcanizates. This research demonstrates and establish a method to determine the acrylonitrile (ACN) content in finished rubber vulcanizates through pyrolysis gas chromatography-mass spectrometry (Py-GCMS). This method

Samanta, Rajyasree, Ghosh, Debojit, Anjana, Kanhaiya, Sen, Amit, Guria, Biswanath, Chanda, Jagannath, Samui, Barun, Ghosh PhD, Prasenjit, Mukhopadhyay, Rabindra

A methodology to evaluate steering performance using Hardware in Loop Testing

2026-26-05441/16/2026

In the present generation, steering system plays a major role in vehicle performance and factors like vehicle stability and control. This is because it is a direct interface to the driver. But to tune the steering system to the required standard, it takes several months for an OEM. This increases the lead time and development cost. Steering test benches have been increasingly popular in the recent automobile development process as they offering great advantages. They offer high level of control over system parameters which helps tune the performance of a steering system, especially for the perception of steering feel while driving. There are various steering test benches being developed to solve concerns that OEMs are facing while tuning and validating. A new methodology is defined involving the Steering Test Bench which can perform Hardware in Loop (HIL) and Driver in Loop (DIL) simulations. The objective of this paper is to establish correlation between Vehicle level & Virtual level

Agarwal, Gourav, Rajput, Srijan, Rasal, Shraddhesh, ahire, Manoj, Naidu, Kethireddi, Kumar, Deva, Prusty, B Rabi

Self-supervised diagnostics & prognostics framework for predictive maintenance in electric vehicles

2026-26-06731/16/2026

Predictive maintenance is essential for enhancing the reliability, safety, and operational efficiency of connected vehicles. However, traditional supervised learning approaches for fault prediction depend heavily on large, labeled datasets of failure events, which are often scarce and expensive to obtain in real-world automotive environments. This paper proposes an original self-supervised anomaly detection framework that predicts emerging failures using only healthy operational data, eliminating the need for explicit failure labels. The approach employs self-supervised pretext tasks, such as masked signal reconstruction and future telemetry prediction, to learn robust representations of normal multi-sensor behavior (e.g., temperature, pressure, current, vibration). An unsupervised anomaly detection model then identifies deviations from these learned patterns. This integrated with data-informed predictive models enable early detection of faults across critical subsystems such as

Kumar, Pankaj, Deole, Kaushik, Hivarkar, Umesh

Predictive Simulation Framework for Tyre Curb Impact Durability Assessment and Design Optimization

2026-26-03961/16/2026

Tyre structural durability validation is a critical aspect of automotive design, considering the worsening road conditions. One of the key validation tests for assessing structural integrity is the curb impact test, which evaluates the tyre's ability to withstand sudden and concentrated impacts. Typically, this process involves physical testing of preliminary tyre samples, followed by iterative modifications to the tyre's construction to meet durability requirements. However, this approach often compromises ride performance, necessitating a more efficient and predictive methodology. To address this challenge, a frugal simulation-based prediction methodology has been developed to evaluate tyre curb impact durability before vehicle-level testing. This allows for the optimization of tyre design parameters early in the development process, ensuring structural performance while minimizing ride and handling (R&H) tuning iterations. By reducing the number of iterations, the methodology

Sundaramoorthy, Ragasruoban, LENKA., VISWESWARA

Digital Rack Load Estimation Methodology for Electric Power Steering to Optimize Motor Sizing

2026-26-03831/16/2026

Electric Power Assisted Steering (EPAS) systems are integral to modern passenger vehicles, contributing to improved steering performance, enhanced safety, and enabling the integration of advanced driver assistance systems (ADAS). A critical aspect of EPAS design is precise motor sizing, which has a direct impact on steering dynamics, driver input effort, and overall system efficiency. The selection of an appropriate motor is governed by several parameters, including peak rack load, maximum steering speed, electrical supply constraints, thermal limitations, and spatial packaging considerations. This study specifically addresses the accurate estimation of rack force, a primary parameter guiding motor selection and assist control calibration. Previous researchers have explored multiple EPAS motor sizing methodologies such as iterative physical testing and simplified analytical modelling. Out of these, iterative physical testing incurs high resource costs and may hamper the development

Adsul, Sourabh, Iqbal, Shoaib

Novel Approach on Material characterization Testing of various Wiring Harness

2026-26-05481/16/2026

The automotive wiring harness (length of 4-5 km) is a very important and complex system in the development of a modern car due to a lot of new electric & electronic components and sensors. It is a very sensitive material unlike metals and is considered as a composite which is highly anisotropic in nature, as it consists of several different layers of copper/aluminum strands and insulation. Because of insulation, wiring harness exhibits viscous plastic behavior which is crucial in determining the durability and long-term performance of the cables. Material properties play an important role in determining the behavior of wiring harness after assembly into the car. Wiring harness may undergo Bending, Torsion and Tension loads, causing the stress and strain in the individual electrical wires. The lack of CAE validation of the wiring harness routing may lead to extra costs for the automotive OEMs over a period. This paper describes the novel method of Testing the Cables and Bundles used in

Beesetti, Siva, Kalkala Balakrishna, Prasad, James Aricatt, John, SHAH, Dipam, Tas, Onur, Krogmann, Stephan

Simulation-Driven Load Spectrum Prediction_ Virtual RLDA for Chassis and Suspension System

2026-26-00951/16/2026

In the rapidly evolving and highly competitive automotive industry, manufacturers are under immense pressure to bring products to market quickly while meeting customer expectations. As a result, optimizing the product development timeline has become essential. Structural integrity analysis for chassis and suspension systems lies in the accurate acquisition of operational load spectra, conventionally executed through Road Load Data Acquisition (RLDA) on instrumented vehicles subjected to proving ground excitation. At this point, RLDA is mainly used for final validation and fine-tuning. If any performance shortfalls, such as premature component failure or durability issues, are discovered, they often trigger design revisions, prototype rework, and additional testing This study proposes a Virtual Road Load Data Acquisition (vRLDA) methodology employing a high-fidelity full-vehicle multibody dynamic (MBD) representation developed in Adams Car. The system is parameterized and uses high

Goli, Naga Aswani Kumar, PRASAD, TEJ PRATAP

Drive Cycle Based Energy Audit & Range Estimation for 4X2 Electric Truck

2026-26-01631/16/2026

Transportation sector in India accounts for 18% of total energy consumption. Demand of energy consumption is being met by the imported crude oil, which makes transportation sector more vulnerable to fluctuating international crude oil prices. India is mindful of its commitment in 2016 Paris climate agreement to reduce GHG emissions by 35% by 2030 as compared to 2005 levels. To fast track the decarbonization of transportation sector, commercial vehicle manufacturers have been exploring other viable options such as battery electric vehicles (BEVs) as a part of their fleet. As on today, BEV has its own challenges such as range anxiety & high total cost of ownership. Range anxiety can be certainly addressed by optimum sizing of electric powertrain, reduction in specific energy consumption (SEC) & use of effective regeneration strategies. Higher SEC can be more effectively addressed by doing vehicle energy audit thereby estimating the energy losses occurring at each powertrain component of

Gijare, Sumant, Karthick, K., Juttu, Simhachalam, Thipse, Sukrut S., A, Jothikumar, J, Frederick Royston, SR, Subasree, G, Harini, M, Senthil Kumar

Balancing Ride Comfort: Optimizing Semi-Active Suspension Systems Through Multi-Objective Parameter Tuning

2026-26-05941/16/2026

Optimizing semi-active suspension systems for ride comfort presents significant challenges due to the inherently conflicting requirements of different ride conditions. Enhancing primary ride associated with low-frequency body motions—may compromise the system’s ability to handle secondary ride, which involves mid-frequency road irregularities. Conversely, tuning for impact loadcases like potholes or road discontinuities often introduces trade-offs that can worsen comfort or suspension performance under regular driving conditions. These conflicts necessitate a systematic approach to identify balanced suspension behavior across diverse frequency bands. This study focuses on the parameter tuning of a smart damper within a semi-active suspension system to optimize overall ride performance. The investigation is carried out using a high-fidelity vehicle model in ADAMS Car, while mode-FRONTIER is employed to perform multi-objective optimization. This approach targets specific tunable blocks

Mishra, Satyakam, Verma, Rahul Ranjan, PRASAD, TEJ PRATAP

Algorithm development for AI driven Path planning using Augmented reality for navigating in Indian complex road scenarios

2026-26-00381/16/2026

The road infrastructure in India has complex navigational challenges, with 82% roads being unstructured according to Ministry of Roads Transports and Highways (MoRTH). Decision-making becomes a challenge for drivers in unpredictable environments such as narrow roads or sometimes flooded roads and heavy traffic. In this paper, an augmented reality (AR) driver assistance algorithm has been proposed that improves awareness to safely maneuver in these conditions.The methodology for development and validation of this AR algorithm contains multiple steps. Firstly, extensive data collection is conducted using real time capture and benchmark datasets like Berkeley Deep Drive (BDD) and Indian Driving Dataset (IDD). Secondly, A machine learning model consisting of the collected data are labelled and trained to rightly identify the complex scenario. In third step, an AR navigation algorithm is developed, integrating these models to accurately detect floods and estimate road widths and provide

Anandaraj, Prem Raj, Sivakumar, Vishnu, Thanikachalam, Ganesh, L, Radhakrishnan, Motoki, Yaginuma, Selvam, Dinesh Kumar

Performance Evaluation and Optimization of Engine Brake System using Chassis Dynamometer

2026-26-05111/16/2026

Engine braking is a deceleration technique that leverages the internal friction and pumping losses within the engine. By closing the throttle and potentially selecting a lower gear, the engine creates a retarding force that slows the vehicle. This practice contributes to better fuel economy, decreased brake system load, and improved vehicle handling in specific driving scenarios, such as steep declines or slippery road surfaces. To alleviate stress on their primary braking systems and prevent overheating, heavy vehicles frequently incorporate engine-based braking. While older trucks relied on simple exhaust brakes with a butterfly valve to restrict exhaust flow, these had limited impact. Hence contemporary heavy vehicles almost exclusively use more advanced engine braking technologies. Traditionally, our heavy-duty vehicles use Exhaust brake system to elevate the braking performance on hilly terrains. Hence an improved sample of Engine brake was developed for enhanced braking

M, Vipin Prakash, Rajappan, Dinesh Kumar, R, Suresh, N, Gopi Kannan

Analysis of High voltage fuse failures due to reverse surge currents flow in the Power distribution unit of Electric vehicles

2026-26-01821/16/2026

Commercial Electric vehicles are revolutionizing the transportation industries with zero emission, lower noise level and increased efficiency. But, High voltage (HV) fuse failures due to reverse surge currents in the Power distribution unit (PDU) hampers the field operation and raise the sensitive safety concerns. This paper embarks on an in-depth exploration of the Reverse surge current flows from the DC-DC converter and Auxiliary (AUX) inverters high voltage input side to Traction system high voltage input point. Failures of HV fuses can lead to the unintentional shutdown of the e-compressor system and steering motor system while operating the EV, which raises critical safety concerns. If the steering motor fails, the bus will lose power steering assistance, making the steering wheel much harder to turn. If the e-compressor fails, it could result in loss of braking assist. This could make it difficult to stop the vehicle, especially in an emergency situation or when driving at high

Bamania, Mihir, kinjalkar, Milind, Amancharla, Naga Chaithanya, Salunke, Pradeep

Prediction of Trimmed BIW Noise transfer function based on BIW response using Machine Learning

2026-26-06401/16/2026

This research focuses on the prediction of the Noise Transfer Function (NTF) in a trimmed Body-in-White (BIW) structure by leveraging machine learning technique considering BIW-level NTF, dynamic stiffness at engine mount attachment points, and Vibration Transfer Function (VTF). The study employs an iterative methodology, adjusting the thickness of various BIW panels to analyse their impact on noise transfer characteristics. Frequency response functions are generated at the BIW attachment points to assess the effectiveness of these modifications. By systematically increasing and decreasing panel thicknesses, and stiffness at the attachment point and trimmed BIW level responses the study aims to optimize the acoustic performance of the BIW structure. The findings provide critical insights into the relationship between structural modifications and noise transfer, offering valuable guidance for automotive design and engineering during early design stage to reduce the development time.

Kulkarni, Prasad Ramesh, Bijwe, Vilas, Kulkarni, Shirish, Sahu, Dilip, Inamdar, Pushpak

Evaluating Passenger Car Tyre Performance: Lateral and Longitudinal Dynamics in Varied Testing Conditions

2026-26-05781/16/2026

The lateral and longitudinal dynamics of passenger car tyres are crucial for vehicle safety, handling and stability, thus having a direct influence on the braking, acceleration, and cornering performance of a vehicle. This study investigates the influence of key input parameters, namely inflation pressure, vertical load, and inclination angle, on the tyre behaviour using a dual approach: Indoor testing using a Flatbed machine for controlled conditions and Outdoor testing using a traction trailer for real-world evaluations. Lateral dynamics is evaluated across a range of slip angles to analyse lateral force and aligning moment characteristics. The quantification of the influence of inclination angle, inflation pressure, and load on lateral characteristics is done by evaluating the cornering stiffness and aligning stiffness. The indoor tests are conducted in both sweep and steady-state modes. The outdoor tests rely solely on sweep testing due to practical limitations. The longitudinal

Sethumadhavan, Arjun, Duryodhana, Dasari, Tomer, Avinash, Ghosh, Prasenjit, Mukhopadhyay, Rabindra

Systematic Study To Understand And Resolve Brake Pull In Commercial Vehicles Using Simulation And Proving Ground Tests

2026-26-00831/16/2026

In traditional commercial vehicles with leaf spring suspension and Recirculating Ball Joint (RCBT) steering systems often experience undesirable pulling due to unsymmetrical steering mechanism during braking, especially when the suspension and steering hardpoints are not properly tuned. This study investigates the causes behind such pulling behavior, specifically focusing on brake steer and bump steer, which occur due to misalignments in the suspension and steering geometries. Brake steer happens when the braking forces generate a torque, causing the vehicle to pull towards one side. On the other hand, bump steer refers to the unwanted changes in the wheel alignment when the suspension undergoes travel, leading to instability or unintended steering input. These two phenomena, if not controlled, can result in undesirable vehicle handling, especially under heavy braking conditions. The study aims to understand and quantify these mechanisms, providing insights into how they can be

Pandhare, Vinay Ramakant, M, Anantha Padmnabhan, NIZAMPATNAM, BALARAMAKRISHNA, Londhe, Abhijit, Doundkar, Vikas

Agricultural tractor brake linkage efficiency prediction and correlation using Flexible Multibody Dynamics model

2026-26-01031/16/2026

In agricultural tractors, braking actuation is usually done through control linkages consisting of a series of connected four-bar linkages with multiple pivots from the pedal to the brake pads. The quality of force transmission is critical as it directly affects the braking performance of the tractor. Forces measured at the end of the control linkage or brake pull rod often show deviation with theoretically-based mechanical advantage calculations. This is due to various factors such as linkage transmission angle, elasticity, and friction in joints not considered, which contribute to loss in force transfer. A standardized simulation method needs to be developed and validated to predict the losses in the control linkage system. In this paper, the author proposes a simulation approach using multi-body dynamics, which includes contribution factors such as transmission angle, linkage elasticity, and friction in joints. MBS model for brake linkage system for three different tractors

Subbaiyan, Prasanna Balaji, Nizampatnam, Balaramakrishna, Redkar, Dinesh, Arun, G, K, Vinoth, R, Sengottu, Paulraj, Lemuel

Investigation of Fatigue Durability Failure Mechanisms in High-Pressure Hydraulic Pipes of Power Steering Systems

2026-26-05421/16/2026

Abstract—The high-pressure hydraulic pipeline in the power steering system is a vital component for ensuring optimal performance. During warranty analysis, leakage incidents were observed at the customer end within the warranty period. The primary factors contributing to these failures include pipe material thickness, material composition, mechanical properties, and engine-induced vibrations. This study investigates fatigue-related failures through detailed material characterization and Computer-Aided Engineering (CAE) based on real world usage road load data collected. The objective is to identify the root causes by examining the influence of varying pipe thickness on fatigue life. The investigation discovered that crack initiation predominantly occurred on the concave side of bent pipe sections, specifically on the engine-side high-pressure steering line, which is connected to the power steering pump mounted on the engine. Fracture surfaces exhibited characteristics consistent with

SURVADE, LALIT, Koulage, Dasharath Baliram, Biswas, Kaushik

Sound quality refinement and vibration reduction during Horn Application in Electric Vehicles

2026-26-03381/16/2026

This paper focuses on the cabin sound quality refinement and the tactile vibration reduction during horn application in the electric vehicle. Horn cracking sound is perceived in the cabin while pressing the horn. Higher vibrations are also perceived in accelerator pedal during the particular event. Sound diagnosis is carried out to identify the frequencies contributing to cracking noise. Transfer path analysis is conducted to identify the nature of noise and the predominant path through which forces transfer. Based on finding from TPA, various recommendations are evaluated which reduced the noise to a certain extent. Operational Deflection Shape(ODS) is conducted on the horn, horn mounting bracket and on the body to identify the component having higher deflection at the problematic frequencies . Based on the outcome of ODS, recommendations like dynamic stiffness improvement on the horn bracket and the body is assessed and the effect of each outcome is discussed. With all the

S, Nataraja Moorthy

Study of Style wheel rim failure Due to Rim and disc assembly interference

2026-26-05411/16/2026

This study focuses on the investigation of wheel rim failures near weld zone during repeated cornering induced by interference between the rim and disc during the wheel manufacturing assembly process. Strain gauges were employed to capture real-time stress and strain distributions at critical zones during interference fitting. The experimental results revealed that improper interference levels lead to significant stress concentrations, often surpassing the material's elastic limit, initiating micro-crack formation and promoting fatigue failure. Detailed strain analysis indicated that both radial and axial stresses contribute to long-term structural degradation. The study highlights the critical role of dimensional tolerances, surface finishes, and assembly forces in minimizing stress-induced failures. Recommendations are provided for optimizing design and assembly practices to enhance the durability and reliability of automotive wheels.

P, Praveen, DEsigan, Lakshmipathy, K, CHANDRAMOHAN, C, Santhosh

Static Rollover Stability Analysis of Heavy Tipper vehicle

2026-26-00901/16/2026

Heavy tipper vehicles are primarily utilized for transporting ores and construction materials. These vehicles often operate in challenging locations, such as mining sites, riverbeds, and stone quarries, where the roads are unpaved and characterized by highly uneven elevations in both the longitudinal and lateral directions of vehicle travel. During the unloading process, the tipper bodies are raised to significant heights, which increases the vehicle's centre of gravity, particularly if the payload material does not discharge quickly. Such conditions can lead to tipper rollover accidents, causing severe damage to life and substantial vehicle breakdowns. To analyse this issue, a study is conducted on the vehicle design parameters affecting the rollover stability of a 35-ton GVW tipper using multi-body simulations in ADAMS software. The tilt table test was simulated to determine the table angle at which wheel lift occurs. Initially, simulations are performed with the rigid body model

Vichare, Chaitanya Ashok, Patil, Sudhir, Gupta, Amit

Design and Validation of a Collapsible Brake Pedal System for Lower-Leg Protection in Frontal Impacts

2026-26-05001/16/2026

Indian Passenger car accident data indicates that approximately 44% of crashes are frontal impacts. Among the injuries sustained in these crashes, lower leg injuries are notably critical, contributing to nearly 25% of driver occupant injuries. To evaluate such injuries, the Bharat New Car Assessment Program (BNCAP) includes lower leg injury metrics as part of the Frontal Offset Deformable Barrier (ODB64) test. While the overall injury performance is assessed at the vehicle level, BNCAP also monitors vehicle interior intrusions—particularly pedal intrusions—as key contributors to lower limb injury severity. A major challenge in frontal crashes is the intrusion of the vehicle's front-end structure into the occupant compartment. Rigid components, particularly the brake pedal assembly, can be displaced rearward during a crash, significantly increasing the risk of lower leg injuries. Therefore, minimizing pedal intrusions into the driver footwell is critical to enhancing lower leg

Shetti, Rahul R., Kudale, Shailesh, Naik, Nagaraj, Bisen, Badal, Kotak, Vijay, Dudhewar, Swapnil Dudhewar, Bhagat, Amit, Durgaprasad, HNV

Failure Analysis of Dissimilar Metal Weld Joint of an Air Spring Bracket within an Automotive Active Seat Suspension System

2026-26-04871/16/2026

In modern four-wheelers, seat suspension systems play a crucial role in enhancing occupant comfort by mitigating the effects of road unevenness and vibrations. Among these systems, active suspension mechanisms offer advanced performance through complex assemblies involving welded, riveted, and bolted joints. This study investigates the failure of an air spring bracket - a critical component of a pneumatic active suspension system - manufactured by Gas Metal Arc Welding (GMAW) of two dissimilar ferrous materials which are likely to be SAPH440 and S355J2. These different materials were used based on mechanical properties required to perform by their particular part. System level validation tests were conducted to ensure the reliability of the seat suspension system. The one of the validation tests is continuous cyclic fatigue test which is carried out on the complete seat assembly. However, during vibration / cyclic endurance testing, premature failures were observed near the weld joints

Patale Jr, Reshma, PINJARI, JAYANT NAMDEV, BALI, SHIRISH

"Parametric Evaluation of Rolling Resistance in Bias & Radial Tyres and influence of key operational parameters under varying conditions."

2026-26-06061/16/2026

Tyre rolling resistance is a fundamental parameter in automotive engineering, directly impacting vehicle fuel efficiency and overall performance. The Rolling Resistance Coefficient (CRR) is influenced by tyre construction, material properties, and operational conditions such as inflation pressure, vehicle speed, load, ambient temperature, and road surface roughness. This study investigates the influence of critical parameters—including test speed, inflation pressure, load, temperature, and slip angle—on the rolling resistance of tyres of various sizes. While previous research has predominantly focused on radial tyres, this paper extends the analysis to include bias-ply tyres, which remain widely used in ASEAN countries, including India. The findings aim to offer valuable insights for policymakers and researchers by examining the behaviour of bias tyres under real-world conditions. Special focus is given to the influence of slip and camber angles, with experiments conducted on passenger

Joshi, Amol, Khairatkar, Vyankatesh, Belavadi Venkataramaiah, Shamsundara

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