Browse Topic: Design Engineering and Styling

Items (55,436)

An analysis of material damping characteristics: A comparison of Oberst Bar Method and Center Impedance Method and their relationship to Component Level.

2026-26-0317To be published on 01/16/2026

Damping materials exhibit advantageous mechanical and acoustic characteristics that enhance the structural integrity of systems. These materials find extensive applications across various industries, including automotive, aerospace, and building acoustics, and are widely employed in the development of soundproofing materials. The damping characteristics of materials primarily pertain to the dissipation of vibrational energy, the reduction of oscillations, and the controlling and subsequent attenuation of vibration-induced noise emanating from structures. To improve both structural integrity and acoustic performance, it is crucial to accurately assess the damping properties of these materials. The Oberst bar test method is a standard method used in the automotive, railway and building industry for initial optimization of damping material However, questions have arisen about the degree to which the outcomes of the Oberst test truly reflect real-world applications. Numerous experimental

Kamble, Prashant Prakash, Joshi, Manasi, Jain, Sachinkumar

Simulation based optimization of the NVH characteristics in modern high speed engine during development phase

2026-26-0326To be published on 01/16/2026

Engine noise mitigation is paramount in powertrain development for enhanced performance and occupant comfort. Identifying NVH problems at the prototype stage leads to costly and time-consuming redesigns and modifications, potentially delaying the product launch. NVH simulations facilitate identification of noise and vibration sources, informing design modifications prior to physical prototyping. Early detection and resolution of NVH problems through simulation can significantly shorten the overall development cycle and multiple physical prototypes and costly redesigns. During NVH simulations, predicting and optimizing valvetrain and timing drive noise necessitates transfer of bearing, valve spring, and contact forces to NVH simulation models. Traditional simulations, involved continuous force data export and NVH model evaluation for each design variant, pose efficiency challenges. In this paper, an approach for preliminary assessment of dB level reductions across design iterations is

Rai, Ankur, Deshpande, Ajay Mahadeo, YADAV, RAKESH

Modelling of Turbulent Combustion of Liquid Ammonia in Dual Fuel CI Engine

2026-26-0442To be published on 01/16/2026

Combustion of fossil fuel results in CO2 emission which is considered to be a leading cause of global warming. Alternative fuels with little or no carbon foot is being actively considered. Direct combustion of ammonia is being actively investigated as it is considered to be a carbon neutral fuel that does not emit CO 2 . It is one of the largest industrially produced chemicals and is easy to store and transport with a well-established supply-chain system. Compared to conventional fuels, ammonia has inferior combustion properties like high ignition delay, low flame speed and a high propensity to produce NOx due to the availability of fuel bound nitrogen. This study uses numerical simulations and a chemical kinetic model to examine the combustion characteristics of ammonia and diesel blend in a dual fuel compression ignition IC engine. Both liquid ammonia and diesel are directly injected into the cylinder, with ammonia as the primary fuel and diesel as a pilot to initiate combustion. An

Warghat, Ketan Vinayak, Prabhakaran, Dinesh, Banerjee, Sayak, kolhe, Pankaj, Banerjee, Raja

Development of a GUI-Based Pitch Sequence Optimization Tool for Tyre Noise Reduction

2026-26-0330To be published on 01/16/2026

Minimizing tyre noise is essential for enhancing ride comfort, especially in electric vehicles where the absence of engine noise makes tyre-generated sound more prominent. This work presents the development of a GUI-based pitch sequence optimization tool to support tyre design engineers in generating acoustically optimized tread sequences. The tool operates in two modes: without constraints, where the pitch sequence is optimized freely to reduce tonal noise levels; and with constraints, where specific design rules are applied to preserve pattern consistency and manufacturability. This tool plays a pivotal role in the tire development process, serving as one of the key evaluation criteria for tread pattern approval before mould fabrication. By enabling engineers to generate balanced, low-noise pitch sequences that align with both acoustic targets and engineering constraints, the tool facilitates faster design iterations and smooth integration with downstream processes. Its successful

Sampathraghavan, Lakshmi, Ramarathnam, Krishna Kumar, Mantripragada PhD, Krishna Teja, Ramachandran, Neeraj

Strategic Design of Intake Systems for Crafting a Sporty Acoustic Signature in Passenger Vehicles

2026-26-0328To be published on 01/16/2026

In pursuit of a distinct sporty interior sound character, the present study explores an innovative strategy for designing intake systems in passenger vehicles. While most existing literature primarily emphasizes exhaust system tuning for enhancing vehicle sound quality, the current work shifts the focus toward the intake system’s critical role in shaping the perceived acoustic signature within the vehicle cabin. In this research work, target cascading and settings were derived through a combination of benchmark and structured subjective evaluation study and aligning with literature review. Quantitative targets for intake orifice noise was defined to achieve the desired sporty character inside cabin. Intake orifice targets are engineered based on signature and sound quality parameter required at cabin. Systems are designed by using advanced CAE techniques, Specific identified acoustic orders were enhanced in the intake system to reinforce the required signature in acceleration as well

Sadekar, Umesh Audumbar, Titave, Uttam, Patil, Jitendra

Virtual Validation of ADAS Algorithms Using Driver-in-the-Loop Simulation

2026-26-0050To be published on 01/16/2026

Driver-in-the-Loop (DIL) simulators have become crucial tools across automotive, aerospace, and maritime industries in enabling the evaluation of design concepts, testing of critical scenarios and provision of effective training in virtual environments. With the diverse applications of DIL simulators highlighting their significance in vehicle dynamics assessment, Advanced Driver Assistance Systems (ADAS) and autonomous vehicle development, testing of complex control systems is crucial for vehicle safety. A comprehensive review of current research trends reveals key areas of focus such as realism of simulated experiences through improved vehicle dynamics models and advanced sensory feedback. The integration of virtual and augmented reality technologies help to create more immersive and informative simulations to improve the cost-effectiveness and accessibility of DIL simulation platforms. By examining the current landscape of DIL simulator use cases, this paper critically focuses on

Sharma, Chinmaya, Bhagat, Ajinkya, Kale, Jyoti Ganesh, Karle, Ujjwala

Development of an Software Algorithm Based Semi-automated Data Acquisition System for Gasoline Vehicle Calibration on Chassis Dynamometer

2026-26-0535To be published on 01/16/2026

Vehicle level testing is one of the crucial part of the calibration development. In this, chassis dynamometer is used to collect the vehicle level data. Different engine and vehicle level parameters are logged at various speed and load points covering the entire engine operational zone. This data acquisition is a repetitive activity and covers over 30-40% of the total testing duration. This phase includes base calibration verification, transient development, and emissions-related calibrations, all of which follow a standardized and repetitive sequence. However, these tasks are predominantly performed manually, leading to potential human error and inefficiencies. This paper presents a novel and comprehensive algorithm developed using INCA FLOW software; the first of its kind for this application. Here, crucial vehicle data acquisition activities are identified, mapped into detailed steps. The algorithm introduces a semi-automated, stepwise process for data acquisition during chassis

Kavekar, Pratap Chandrashekhar, Tyagarajan, Sethuramalingam, Agarwal, Nishant Kumar, Shaikh, Wasim, Karadi, Subramanya

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

2026-26-0103To be published on 01/16/2026

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

Application of DOE Techniques to Identify Factors Influencing Gearbox Synchronizer Wear and Life.

2026-26-0489To be published on 01/16/2026

Gearbox synchronizers are essential components for ensuring smooth gear shifting in both manual and automated manual transmissions. The lifespan of a synchronizer is influenced by a complex interplay of several factors, including synchro geometry, lubrication, friction material properties, clutch design parameters, powertrain vibrations, and various operating conditions. These factors contribute to the wear and degradation of synchronizers over time, affecting the overall performance and durability of the transmission system. This paper investigates the influence of various design and operational parameters on the synchronizer's life using a Design of Experiments (DOE) approach. A comprehensive experimental plan was meticulously developed to systematically vary key factors such as synchronizer friction material, the number of cones, lubricant viscosity, and clutch stiffness, among others. The resulting experimental data was analyzed through statistical methods, particularly regression

Jagtap, Amol Shivaji, Koulage, Dasharath, Rudramath, Sagar

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

2026-26-0542To be published on 01/16/2026

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

Early Prediction of CNG Filling Time using Artificial Intelligence for Design Optimization

2026-26-0662To be published on 01/16/2026

The CNG fuel system is a critical component in vehicle development and typically includes large-volume gas cylinders (up to 800 liters). As these vehicles often operate over long distances daily, frequent refueling is necessary, making a short gas filling time highly desirable. Currently, CNG filling time is evaluated after prototype development to determine the refueling duration. If the filling time is excessive, design changes to the fuel system are required, leading to significant cost and time penalties and causing delays in the vehicle product development cycle. By integrating AI/ML technology, a mathematical model has been developed based on various influencing parameters. This model will predict CNG gas filling time across all commercial vehicle platforms at the initial Zero design release gateway. This early prediction will enable further optimization to improve gas filling time. The goal of this research work to optimising the filling time for various platform before physical

Choudhary, Aditya Kant, Petale, Mahendra, Dutta, Surabhi, Bagul, Mithilesh

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

2026-26-0541To be published on 01/16/2026

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

Standard SWS Requirement based Integration testing for classic AUTOSAR modules.

2026-26-0507To be published on 01/16/2026

In the development of automotive ECUs, to keep performance in desired level, what remains constant is to verify, evaluate and validate ECU. Nowadays, Cars have multiple ECUs even in range of 50. Software is validated using target ECU, CAN communication and some I/O simulation techniques. Also, in some applications, virtual environment is created for testing. In this paper, method of Integration testing of AUTOSAR modules is presented which uses AUTOSAR SWS as its input. This makes standard test cases as SWS remains same for a AUTOSAR standard release. It enables a platform to efficiently test all layers of a AUTOSAR BSW modules after integration. For demonstration, we will use TriCore micro controller TC377TX from Infineon. Same controller is usually used in the development of automotive ECUs for various applications. Using winIDEA debugger from iSYSTEM, setup becomes easier to operate for any new person as it supports both debug and flash mode operation. Simplistic approach will be

Kelkar, Renu, Patil, Vardhman

Accelerating Product Development Life Cycle through Digitalization of Fatigue Life for Structural Components

2026-26-0496To be published on 01/16/2026

In today’s competitive market, accelerating product development without compromising durability is critical. Durability is a key benchmark for assessing the quality and reliability of automotive products. To meet rising customer expectations and regulatory demands, the industry must develop vehicles that offer high performance and reduced weight while ensuring safety. A well-engineered vehicle must retain structural integrity and functionality under normal operating conditions and withstand extreme load events without critical failure. Achieving this requires effective Road Load Data Acquisition (RLDA), integrated with robust design practices and efficient validation processes. However, physical RLDA is time-consuming and costly, as it depends on prototype vehicles that are often available only in the later development stages. Failures identified during these late-stage tests can delay the product launch significantly. To address these challenges, this paper introduces a digital

Kokare, Sanjay, Dwivedi, Sushil, Siddiqui, Arshad, Iqbal, Shoaib

Static Rollover Stability Analysis of Heavy Tipper vehicle

2026-26-0090To be published on 01/16/2026

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

Developing Advanced CAE Model for Door Glass Regulator Operating Noise Reduction through TEST/CAE Correlation

2026-26-0311To be published on 01/16/2026

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

Indian City Electric Bus Powertrain Optimization Using Active Learning Simulation Methodology

2026-26-0657To be published on 01/16/2026

Public transport electrification is going to play a massive role in India's COP26 pledge to achieve net zero emissions by 2070. India plans to electrify 800,000 buses in a push towards 30% EV penetration by 2030. Further encouraged by government incentives under National Electric Bus Program (NEBP), eBus market is expected to grow at a CAGR of ~86% annually over the next 5 years. With most OEMs going for fleet electrification for reducing CO2 emissions and to cater to growing demand in Indian cities for cleaner public transport, improving powertrain efficiency and performance of state-of-the-art eBuses is a natural progression of e-mobility sector development in India. The first step in designing powertrain for an electric city bus is to determine the motor(s) size and transmission specifications (number of gears, gear ratios etc.). Complications arise due to a wider and non-linear operation range of eBus. This study focuses on powertrain optimization for a medium duty electric city

Emran, Ashraf, Berry, Sushil, Xia, Feihong, Chen, Bicheng, Sandhu, Rouble

Revolutionary EV Motors Innovation in E-mobility in Depth Analysis of Emerging Technologies, Comparative Insights & Their Ground Breaking Impact on Electric Vehicle Performance

2026-26-0073To be published on 01/16/2026

This paper delivers a forward-looking data-driven assessment of the transformative innovation in electric vehicle motor systems with targeting breakthroughs in the power density, energy efficiency, thermal robustness, manufacturability & better intelligent control. A rigorous Multi Criteria Decision Making (MCDM) framework is done to systematically evaluate and defining the rank of emerging motor technologies across eight weighted performance indicators. The findings reveal that which design strategies & material advancements offering the greatest potential for redefine propulsion performance that enabling lighter more compact & more efficient drivetrain capable of sustained high power operation. High ranking solution exhibit strong alignment with the industry's push toward scalable, low cost & rare earth-independent systems while other are identified as high risk/high reward pathway requiring targeted research to overcome critical problems. By integrating engineering performance

Jain, Gaurav, PREMLAL, P, Pathak, Rahul, Gore, Pandurang

Optimisation of frontal impact force scheme to accelerate the target setting process for development of front-end structures in vehicles.

2026-26-0001To be published on 01/16/2026

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

Model Based Design of Gear Shift Control for Twin Clutch AMT

2026-26-0054To be published on 01/16/2026

Model Based Design (MBD) uses mathematical modelling to create, test and refine systems in simulated environment, primarily applied in control system development. This paper discusses an approach to control gear shifting using shift logic on vehicle level for twin clutch transmission using prototype controller. Twin clutch transmission is a concept with two clutches, one at input end of the transmission called primary clutch and the other at output end of the transmission called secondary clutch. This concept is proposed to counter the challenges with conventional transmission which include increased gear shift time and effort in lower gears, potential rollback of vehicle in uphill condition and chance of missed shifts. The advantages of this concept include reduced gear shift effort and improved synchronizer life with potential for reducing the size of the synchro pack. This paper proposes a methodology to develop shift logic, integrate hardware with software, flashing and calibration

Patel, Hiral, Thambala, Prashanth, Tongaonkar, Yogesh, Mosthaf, Joerg, Malpure, Khushal

Development of Door Impact Loads Using Frugal use of Pedal Force Sensor

2026-26-0538To be published on 01/16/2026

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

Optimization of Electric Drive Unit Mounting for Vibration Isolation in EV Powertrains Using Multibody Dynamics

2026-26-0080To be published on 01/16/2026

With growing significance of electric vehicles (EVs), their powertrains—while naturally quieter than internal combustion engine (ICE) powertrains—pose new NVH (Noise, Vibration, Harshness) challenges. These are triggered mainly from high-frequency disturbances caused by electric motors and gear interactions. Isolation of such excitations is essential for securing cabin refinement and customer expectations for acoustic comfort. This paper offers a simulation-based approach to optimal placement of the electric drive unit (EDU), which houses the electric motor and gearbox, with the objective of reducing vibration transfer to the chassis of the vehicle. The methodology explores the effect of spatial mount repositioning under actual dynamic load conditions through multibody dynamics (MBD) modeling and integrated optimizer using advanced multibody dynamics simulation software – Virtual Dynamics. The suggested workflow helps in effective investigation of mount positioning within packaging

Mane, Prashant, Shah, Swapnil, Back PhD, Arthur, Pinjari, Abrar, Emran, Ashraf, Mane PhD, Shrikala

A Novel Approach to Optimal Strain Gauge Placement for Structural Assessment: Integrating Close Looping Configuration with Calibration Techniques

2026-26-0551To be published on 01/16/2026

Addressing the challenge of optimal strain gauge placement on complex structural joints and pipes, this research introduces a novel methodology combining strategic gauge configurations with numerical optimization techniques. Traditional methods often struggle to accurately capture combined loading states and real-world complexities, leading to measurement errors and flawed structural assessments. For intricate joints, a looping strain gauge configuration is proposed to comprehensively capture both bending and torsional effects, preventing the bypassing of applied loads. A calibration technique is used to create strain distribution matrices and access structural behavior under different loading conditions. Optimization algorithms are then applied to identify gauge placements that yield well-conditioned matrices, minimizing measurement errors and enhancing data reliability. This approach offers a cost-effective solution by reducing the number of gauges required for accurate stress

shingate, Uttam, Yadav, Dnyaneshwar

Proactive AI-Enhanced Cybersecurity for Next-Gen Automotive Infotainment ECU

2026-26-0619To be published on 01/16/2026

Abstract With the rapid advancement of connected vehicle technologies, infotainment Electronic Control Units (ECUs) have become central to user interaction and connectivity within modern vehicles. However, this enhanced functionality has introduced new vulnerabilities to cyberattacks. This paper explores the application of Artificial Intelligence (AI) in enhancing the cybersecurity framework of infotainment ECUs. The study introduces AI-powered modules for threat detection and response, presents an integrated architecture, and validates performance through simulation using MATLAB, CANoe, and NS-3. This approach addresses real-time intrusion detection, anomaly analysis, and voice command security. Key benefits include zero-day exploit resistance, scalability, and continuous protection via OTA updates. The paper references real-world automotive cyberattack cases such as Tesla's OTA vulnerability patches, BMW ConnectedDrive exploits, and Jeep Cherokee's Uconnect hack, emphasizing the

More, Shweta, Kulkarni, Shraddha, Kumar, Priyanshu, GHANWAT, HEMANT, Joshi, Vivek

A Mathematical Modelling Approach Based on Artificial Neural Network for Estimation of Key Parameters in Internal Combustion Engine

2026-26-0659To be published on 01/16/2026

In a conventional powertrain driven by Internal combustion (IC) engines, there are many key sensors such as intake manifold temperature sensor, exhaust temperature sensor, Nitrogen oxide (NOx) sensors etc. to monitor engine performance and emissions. For enabling various diagnostics strategies and engine monitoring, virtual sensors or modelled values of such sensors play an important role. Conventional strategies incorporate the use of regression models, map-based models and physics-based models. There are a few drawbacks with conventional models in terms of accuracy and model calibrations efforts. Data driven models or neural networks have fairly better accuracy and reliability for estimating complex parameters. Representing the neural network with a mathematics-based model would help to eliminate drawbacks associated with conventional modelling approach. The proposed methodology uses artificial intelligence technique called artificial neural network (ANN) for estimation, for example

Jagtap, Virendra Shashikant, Shejwal, Sanket, Mitra, Partha

Swarm-Inspired Cooperative Mapping for Urban Autonomous Navigation

2026-26-0635To be published on 01/16/2026

Urban autonomous vehicles today largely rely on individually built maps or centralized cloud services—both rigid under intermittent connectivity and rapid scene changes (construction, pop-up events). Inspired by how ant colonies collectively explore, we introduce a decentralized protocol: each vehicle broadcasts compressed “map particles” embedded with virtual pheromone values that highlight zones of high uncertainty or recent change. Neighboring vehicles incorporate these signals to prioritize sensing and route planning. A lightweight consensus algorithm merges local graphs into a shared dynamic map, resilient to network splits. The result, a bio-inspired SLAM that enables fleets to adapt on the fly to evolving cityscapes, boosting safety, efficiency, and robustness.

Bhargav, Anirudh S, Subbarao, Chitrashree

Condition-Based Monitoring for Prompt Identification of Component Failures to Safeguard the Entire System.

2026-26-0576To be published on 01/16/2026

Condition-based monitoring (CBM) has emerged as a transformative approach in predictive maintenance, enabling the proactive identification of potential component failures. It offers numerous advantages like Cost Savings, Increased Equipment Lifespan, RCA of failed parts, Optimized Resource Utilization, Reduced Disruptions, Enhanced Reliability and Safety and many more making it a vital approach for effective maintenance and operational efficiency. This paper presents a comprehensive methodology for monitoring and analyzing vibration trends to predict and prevent the breakdown of critical components in IC Engine in its testing phase. The good part here is that this methodology is not just limited to IC Engine but can be applied across wide range of industries and mechanical systems as from the literature and past vibration data, it was observed that before any such failure engine vibration increases. If the engine is stopped at that moment, it can be preserved, allowing for further

Gupta, Gaurav, Verma, Vivek

Comprehensive Technology Framework for effective and early leveraging of test assets

2026-26-0527To be published on 01/16/2026

The automotive industry is going through a tremendous technological change and its impact on the way we test the functionalities that we offer to the end consumer is continually evolving. This includes the ever-growing need to embed software-based functions to support more and more end user functionality, while at the same time retaining existing and well-established functions, all within short development timelines. This presents both opportunities and challenges, with greater potential for reuse or leverage of test assets, although the actual percentage of leverage on real world projects is practically less than anticipated for a multitude of reasons. As part of paper, we collate the various factors which effect the practical leverage of test assets from one project to another, including various workflows and the interaction across components amongst applications lifecycle management systems. Through this paper, we would describe the current practices of basis analysis in isolation

Venkata, Parameswaran, Kulkarni, Apoorva, RAJARAM, Saravanan, Ganesh, Chamarthi

"Design and process Optimization of Suspension Components Under RWUP-based Loading Conditions"

2026-26-0514To be published on 01/16/2026

Title: Challenges faced during design and manufacturing of POM (Polyoxymethylene) ring in Macpherson strut suspension. Abstract: Designing and manufacturing a POM (Polyoxymethylene) ring for a MacPherson strut suspension system brings a unique set of challenges due to the high-performance and durability demands for Indian road application. POM ring along with bump used in the shock absorber is designed to absorb the strong shock coming from the road inputs when suspension travel reached to the maximum limit there by absorbing the impact energy and preventing it from transferring it to the body. A bump stopper for a suspension of a vehicle is made of poly urethane (PU) and POM ring (Polyoxymethylene). The bump stopper forms of a bellows shape during the absorption of impact energy. Bellow or wrinkle in which concaves and convexes are repeated is formed on the outer surface of the bump stopper. POM ring is placed in the concaves of bump stopper which will define load, deflection

Koritala, Ashok Kumar, Malekar, Amit, kulkarni, Purushottam, S, SIVASHANKAR, Mishra, Harshit, Ganesh, Mohan Selvakumar, Patnala, Avinash, J, Ramkumar, NAYAK, Bhargav, M, Sudhan

A Model Based Framework for Safety Risk Assessment using Systems Theoretic Process Analysis for ASIL Justification According to ISO 26262

2026-26-0022To be published on 01/16/2026

With advancements in automotive systems, particularly in autonomous and electric vehicles, the increasing complexity of modern vehicular systems is challenging the traditional safety analysis methods prescribed by ISO 26262. Failure-based safety analysis techniques often struggle to identify systematic risks arising from software interactions, human factors, and emergent behaviors. This paper addresses this gap by providing a framework that utilizes Systems-Theoretic Process Analysis (STPA) to complement ISO 26262’s hazard analysis methods by considering emergent hazards during the justification of Automotive Safety Integrity Levels (ASIL). The aim of this paper is to present a model-driven hybrid methodology that combines traditional fault-based approaches with STPA for traceable ASIL justification, thereby enhancing ISO 26262’s Hazard Analysis and Risk Assessment (HARA) process. This approach allows for the integration of contemporary safety analysis techniques like STPA into

NAG, PRAMIT, Ali, Sam, Roy Choudhury, Diyanjan

Integrated Evaluation of Pre-Crash Braking and Crash Injury Outcomes Using Human Body Models and ATDs

2026-26-0019To be published on 01/16/2026

Traditionally, vehicle occupant safety research has focused on passive safety aspects like crashworthiness and occupant restraint systems. However, with the advent of Active Safety technologies such as Forward Collision Warning (FCW) and Autonomous Emergency Braking (AEB), research has expanded to include occupant kinematics during the pre-crash phase. AEB, by inducing occupant movement, often leads to out-of-position (OOP) behavior, compromising available space during the crash phase. Current Anthropometric Test Devices (ATDs) are limited in simulating occupant kinematics during the pre-crash phase, especially in the neck and torso regions. These devices are rigid and unable to replicate human body dynamics during low-acceleration events like AEB. To address this gap, Human Body Models (HBMs) such as THUMS, GHBMC, and SAFER are used to provide more biofidelic simulations. This study begins with physical vehicle trials conducted with human volunteers at various speeds to measure

Pendurthi, Chaitanya Sagar, THANIGAIVEL RAJA, T, Kondala, Hareesh, Sudarshan, B.Sudarshan, Nehe, Vaibhav, Rao, Guruprakash

Design optimization of the propeller shaft and transfer case for high-speed 4WD vehicles

2026-26-0343To be published on 01/16/2026

Nowadays, vehicle enthusiasts often vary their driving patterns, ranging from driving at very high speeds to off-roading. Due to these driving patterns, 4WD vehicle demand is continuously growing day by day. A 4WD vehicle used to have better traction control with enhanced stability. The 4WD vehicle performance and reliability at high speed are critically influenced by driveline stiffness and natural frequency. Driveline stiffness and natural frequency are very critical parameter for high-speed vehicles, that significantly influenced by the propeller shaft and transfer case. This study focuses on the design optimization of the transfer case and critical frequency of propeller shafts to enhance vehicle performance at high speeds. The analysis begins with a comprehensive study of the factors affecting power transfer path, transfer case stiffness, critical frequency, including material properties, propeller shaft geometry and the boundary conditions. Advanced computational methods are

Kumar, Sarvesh, Yadav, Sahdev, S, Manickaraja, Sanjay, L, Kanagaraj, Pothiraj, Jain, Saurabh Kumar, Deole, Subodh M

Design Robustness of Electronic Locking Differential for enhanced off-road performance

2026-26-0502To be published on 01/16/2026

The Electronic Locking Differential (ELD) is a critical component for enhancing off-road vehicle performance by ensuring optimal traction in challenging terrains. This paper addresses intermittent engagement issues observed in the ELD system during off-road trials, which impacted its reliability and functionality. It presents a comprehensive study of design robustness improvements implemented to resolve these concerns and optimize the ELD’s performance, ensuring enhanced customer satisfaction in demanding off-road environments. The analysis begins with identifying factors contributing to the intermittent engagement and disengagement of the ELD system upon actuation. These factors include residual magnetism, material properties, temperature effects, and the stack-up characteristics of transfer path components under various boundary conditions. To address these challenges, three key design modifications were introduced: (1) reduction of residual magnetism through an increased air gap

S, Mohd Imtiaz, AP, Baaheedharan, Ghumare, Dheeraj, Kanagaraj, Pothiraj, Jain, Saurabh Kumar

Virtual Prototyping: Accelerating Traction Motor Development for Commercial Electric Vehicles

2026-26-0152To be published on 01/16/2026

This paper presents the virtual prototyping of traction motor in commercial EV to make an early prediction of the performance parameters of the machine without spending an enormous cost in building a physical structure. A 48/8 slot-pole configuration of IPMSM is used to demonstrate the electromagnetic and thermal co-simulation in ANSYS MotorCad. The key dimensions were calculated on the basis of the permanent-magnet field theory, and the 2D finite element method (FEM) model of the IPM motor using Ansys MotorCad electromagnetic simulation tool. The influence of geometrical parameters on the performances of traction motor are evaluated based on FEM. The temperature distribution of the motor under rated operating condition and the condition of maximum speed were also analyzed. Alongside, the effects of saturation, demagnetization analysis, and the impact of PM flux linkage on inductances are also considered in this paper. At last, the simulation and analytical results of the IPMSM motor

Murty, V. Shirish, Rathod, Sagarkumar, Gandhi, Nikita, Tendulkar, Swati, Kumar, Kundan, Thakar, Dhruv, Sethy, Amanraj

AI-Driven Stress and Fatigue Life Prediction of Engine Connecting Rods using Geometric Deep Learning

2026-26-0633To be published on 01/16/2026

The connecting rod is one of the critical components of the engine which is subjected to complex cyclic loading, demanding precise evaluation of stress distribution and fatigue life. Conventional Finite Element Method (FEM)-based simulations, while accurate, are computationally expensive and time-intensive—especially when iterating through multiple design variations. To address this, we present an AI/ML-based predictive framework using Graph Neural Networks (GNNs) and Geometric Deep Learning (GDL) techniques to efficiently predict stress and fatigue life of the connecting rod. The methodology involves representing FEM mesh data as graph structures, where nodes and edges capture geometric and physical relationships. GNN architectures, including MeshCNN and PointNet++, are trained on historical simulation data to learn spatial dependencies and nonlinear mappings between geometry, load conditions, and resulting stress/life outputs. The framework significantly reduces computation time

Pathan, Mohammed Shakil, K, Karthikeyan, pilla, sashanka, S Kangde, Suhas

Engine compartment front end module layout placements to achieve maximum volumetric efficiency

2026-26-0588To be published on 01/16/2026

The increasing demand for electric vehicles has led to design considerations prioritizing visual brand consistency across both electric vehicles (EV) and internal combustion engine (ICE) vehicles. Front grille is one such area where efforts are taken to have similar looking features between both EV and ICE. This has lead to low front grille opening and low air flow through the front. A critical consequence of this design trend: the suboptimal thermal performance, high engine bay and air intake temperatures of snorkel-type air intake systems in ICE vehicles when paired with front grille designs intended to mimic EV aesthetics. Factors such as snorkel positioning, airflow patterns must be optimized to maintain cooler intake air. Effective system design ensures that the engine receives air at an optimal temperature, improving combustion efficiency, throttle response, and reducing the likelihood of knock. This paper emphasizes the importance of controlling intake air temperature through

SONONE, SAGAR DINESH, Kolhe, Vivek M, Singh, Nil Kanth

Reverse Gear Duty Cycle Generation Using Virtual RLD Simulation

2026-26-0405To be published on 01/16/2026

Keywords: RLD (Road Load Data), AVL VSM, AVL Route Studio, Duty Cycle, Transmission, Reverse Gear, Durability The development of transmission systems involves creating duty cycles for bench-level durability evaluations for both forward and reverse gears. For forward gear, vehicles are driven under various real-world conditions over thousands of kilometers, equipped with numerous sensors and components tailored for data collection. In contrast, duty cycles for reverse gear are often based on prior experience or rough estimations due to the lack of clear definition of real world use case. Reverse gear RLD is particularly scarce, especially for heavy-duty vehicles operating in off-road or mining environments, where specific reverse driving paths are not typically followed. This paper presents a detailed methodology highlighting the importance of reverse gear duty cycles by leveraging virtual RLD simulations on various gradients using tools such as AVL Route Studio and AVL VSM. By

Kansagara, Smit, Patel, Hiral, kira, Lucas, Sutar, Suresh, Soor, Debasis

Numerical Investigation of Cowl Water Drainage in Automotive Design

2026-26-0393To be published on 01/16/2026

Motivation Improper drainage of cowl water (accumulated at the base of the windshield) leads to critical issues in automotive design. Early-phase evaluation of drainage efficiency is critical to avoid costly late-stage design revisions and warranty issues. Traditional physical testing methods are often time-intensive, costly and limited in scope. Therefore, leveraging simulation-driven optimization enables proactive prediction of failure modes and accelerates robust design validation. The Problem Inadequate cowl drainage causes: 1. HVAC system degradation due to moisture ingress (mold growth, blower motor failure). The accumulated water can also enter the cabin. 2. Rust and corrosion in the cowl panel, windshield frame, and adjacent electronics due to accumulation of stagnant water Methodology We investigated multiple design strategies to enhance cowl drainage performance. The following approaches were studied by using STAR-CCM+: 1. Multiphase volume of fluid (VOF) Simulation - To

Mathew, Ronnie, Ibrahim, Sayyaf, Nikumbh, Nayan

Use Of Digital Wind Tunnel For Improved Aerodynamic Prediction

2026-26-0372To be published on 01/16/2026

In the automotive industry, external aerodynamic evaluations in digital environments are commonly conducted using simplified, large box tunnels with vehicle being static. These approaches are computationally efficient and ensure faster turnaround times. To closely replicate physical wind tunnel testing or real-world conditions, these simulations are often augmented with moving ground and rolling tire configurations. While such setups provide valuable directional feedback for aerodynamic drag improvements, they frequently exhibit significant discrepancies when compared to physical wind tunnel test data. It is observed that key factors such as wind tunnel blockage effects, boundary layer suctions, when not properly accounted for, distort the local flow field dynamics and introduce errors in the simulations. With OEMs aiming to accelerate time-to-market for new vehicle launches, many aspire to minimize reliance on physical testing and maximize use of digital methods for design sign-off

sharma, Sandeep Kumar, Chalipat, Sujit, Maiyya, Sandeep

Design Optimization of Hydrogen Engine Vanity Cover for PSHA Compliance using CFD leakage analysis

2026-26-0263To be published on 01/16/2026

Abstract: The integration of hydrogen (H2) as a fuel source in internal combustion engines (ICE) necessitates stringent design measures to mitigate leakage risks and ensure operational safety. This study focuses on the design optimization of vanity cover for hydrogen engines which only serves the purpose for hiding fuel system, wire harness & engine aesthetic else there is no engineering function like sealing, load factor associated with it. This paper addresses the challenges and risks of using Vanity cover on Internal combustion engines, if fuel joints inside the cover start leaking and forms hydrogen cloud which if not ventilated or diluted properly will have safety risk considering low ignition of hydrogen. Computational fluid dynamics (CFD) analysis is carried out to assess and control hydrogen leakage through fuel rail connections, injector interfaces and associated high pressure fuel system components. Detailed modelling of hydrogen flow behavior, diffusion characteristics of

Veerbhadra, Swati Ashvinkumar, Sahu, Abhay Kumar, Singh, Rahul

Virtual Paint Shop: Automotive E-coating Process

2026-26-0365To be published on 01/16/2026

The automotive paint shop is one of the most energy-intensive processes in vehicle manufacturing. This drives automotive OEMs to continuously improve production efficiency and reduce operational costs through digital twin technologies. Additionally, the push for shorter time-to-market emphasizes the need for simulation-based manufacturing processes—such as virtual testing and CAE simulations—to enable faster, data-driven decision-making early in the product development cycle, ultimately reducing cost and development time. Among the various stages in the paint shop, two of the most critical are: 1. Electro-dip coating (E-coating), also known as Electro-Deposition coating, which applies a corrosion-resistant primer to the Body-in-White (BIW). 2. Oven curing, which ensures the primer is properly bonded and cured for long-term protection and finish quality. To optimize these processes, a Dip-Drain-E-Coating simulation was developed using Siemens Simcenter STAR-CCM+. This simulation

Gundavarapu, V S Kumar, p, Vivekaanandan, Garg, Manish, Navelkar, Tanay, BS, Balachandran

A Performance-driven Numerical Approach for Optimizing the Plenum Opening Area of Cowl Box

2026-26-0461To be published on 01/16/2026

There is a scarcity of research in literature regarding the determination of Plenum Opening Area of cowl box. The area of the plenum opening in the cowl box significantly affects the airflow rate in fresh airflow modes, such as face and defrost modes, as well as issues related to water ingress. Primarily, the size of the plenum opening is determined by the necessary HVAC airflow rate. This study aims to investigate how the plenum opening area impacts both airflow discharge and the water ingress issue in the HVAC module. A novel approach is introduced in this research to determine the optimal plenum opening area of the cowl box, taking into account both airflow rate and water ingress concerns. The ANSYS FLUENT software is utilized to analyze airflow discharge in both face and defrost modes, while the SPH (Smooth Particle Hydrodynamics) based Preonlab tool is employed for water ingress analysis. Airflow discharge is evaluated for various plenum opening sizes in both modes, and the area

Baskar, Subramaniyan, A Sr, Mahesh, Gopinathan, Nagarajan

Next Gen Automotive EDS Architecture design verification using real-time function mode simulation & failure condition analysis

2026-26-0454To be published on 01/16/2026

In current automotive electrical design practices, simulation and functional verification of the Electrical Distribution System (EDS) at the design stage are largely absent. Typically, the validation of controller behaviour and EDS wiring is performed only during HIL, SIL, MIL, prototype testing, or physical vehicle trials, often revealing issues late in the development cycle. This delay leads to costly redesigns, prolonged timelines, and increased chances of failure during vehicle integration. Therefore, there is a critical need for an early-stage simulation methodology that ensures robust EDS and controller design, enabling "first-time-right" readiness at the design stage itself. The proposed simulation framework introduces a function mode-based structural approach, where individual vehicle functions are mapped to their corresponding electrical circuits within the vehicle’s wiring system. Resistance values are allocated to specific paths depending on the active function or

Jaisankar, Gokulnath, Warke, Umakant

UNIQUE HYBRID PANORAMIC HEADLINER CLIP WITH HIGH TOLERANCE TO REPLACE DUAL LOCK FASTENERS

2026-26-0299To be published on 01/16/2026

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

Dog Clutch Engagement Probability Simulation for Heavy-Duty Automated Mechanical Transmissions

2026-26-0437To be published on 01/16/2026

This study presents a simulation-based approach to estimate the dog clutch engagement probability maps under different vehicle operating conditions. The developed probability function incorporates multiple critical parameters including initial speed differential between engaging components, application of countershaft brake, dog tooth quantity, friction coefficients at tooth interfaces, applied actuation force, dog tooth geometry, and component inertia. Using MATLAB and Simulink, comprehensive simulation models were developed to analyse engagement dynamics and produce detailed probability maps at different vehicle speeds, effectively outlining optimal operational zones for successful engagement while identifying critical regions prone to tooth clash and engagement failure. The effect of tooth geometry on engagement probability has been investigated using simulation model results. The resulting engagement maps serve as valuable diagnostic tools for identifying potential system

Khan, Mohammad Adeeb, KHAN, Dr. NURUZZAMA MEHADI, Koona, Rammohan

Facilitating Virtual Testing at an Industrial Level by Simulation Data Management

2026-26-0440To be published on 01/16/2026

Automotive OEMs can derive significant cost savings by reducing the quantity of physical crash tests and thereby accelerate product development, when they follow the Euro NCAP Virtual Testing guidelines. It helps in optimizing the overall vehicle development process via more efficient simulations, as well as facilitates in early adoption of new safety regulations. In this pursuit, companies must comply with strict Euro NCAP requirements, which includes transparency and traceability of virtual tests. A major challenge therein is model validation – which requires highly precise detailing and extensive use of data for accurately replicating real physics of the problem. Deploying these workflows into an existing simulation process can be a complicated and time-consuming task, particularly when integrating various simulation and testing methods. A powerful simulation and process data management system (SPDM) can thereby assist companies to automate their entire simulation process, ensures

Thiele, Marko, Sharma, Harsh

Effect of pipe bending by rotary tube bending process on durability of frame structure

2026-26-0370To be published on 01/16/2026

For Original Equipment Manufacturers (OEMs), ensuring the overall quality of two-wheeler frames hinges on robust process capability and meticulous design considerations. A comprehensive Computer-Aided Engineering (CAE) simulation approach, integrating manufacturing processes and design elements, is vital for achieving optimal durability. This study focuses on developing such an approach through detailed finite element analysis of Cold Electric Welded (CEW) annealed round pipes used in frame construction. We simulate the bending process, capturing structural deformation and residual stresses. A 3D mechanical model with realistic tooling geometries and contact interactions accurately represents shape changes, ovality, and wall thickness redistribution. Unlike Electric Resistance Welded (ERW) pipes, CEW pipes, due to annealing, offer a stress-free initial state, allowing precise deformation analysis. Simulation results demonstrate significant geometric alterations in the bend zone

Rajwani, Ishwar, khare, Saharash

Integrating V2V and V2I Communications for Enhanced Traffic Safety and Efficiency in Connected Vehicular Networks

2026-26-0271To be published on 01/16/2026

This paper presents a new approach to improve road safety and traffic flow by combining vehicle-to-vehicle (V2V) and vehicle-to-infrastructure (V2I) communications. Our study focuses on a system that connects vehicles with each other and with traffic signals to share real-time data about speed, position, and road conditions. Using both analytical models and experimental simulations built in MATLAB/Simulink, we developed a system that predicts and advises the optimal speed for vehicles approaching an intersection. In our design, a Green Light Optimized Speed Advisory (GLOSA) feature suggests an ideal speed for drivers so that they can pass through green lights without unnecessary stopping. This not only improves traffic flow but also reduces fuel consumption and lowers the risk of accidents. We validated our system through a series of simulations and real-time traffic scenarios. The results show that our approach can adapt dynamically to changes in vehicle behavior and traffic density

PINTO, COLIN AUBREY, Shah, Ravindra, Karle, Ujjwala

Utilization of an improved hardening model for finite element analysis and experimental correlation of a tractor ROPS Structure

2026-26-0404To be published on 01/16/2026

In recent years, virtual validation using finite element analysis (FEA) has become a key step in designing an agricultural tractor roll over-protective structure (ROPS). With the advancement of computation power and ability of finite element solver to handle bigger models; a higher fidelity model can be built to improve virtual validation accuracy. More & more advanced material model can be used to improve accuracy of the results. Along with ROPS, its mounting chassis and mounting bolts can also be validated. Virtual validation at the design phase not only saves time of new product development cycle; but also optimizes the weight & cost of the design. This study focusses on the application of advanced material models in simulating a real-life tractor ROPS system. For the ROPS structure, both conventional isotropic hardening models (employing bilinear and piecewise multilinear stress-strain curves) and advanced kinematic hardening models based on the multi-component Armstrong-Frederick

PANDEY, MANOJ KUMAR, Kumar, Arun, Redkar, Dinesh, THIRUGNANAM, Vivekanndan, Magendran, G, MANI, SURESH

Exhaust Hot end system Transient Heat Transfer Analysis using Heat Transfer Coefficient (HTC) approach, Thermo-Mechanical Fatigue Analysis to evaluate thermal durability and physical validation through Thermo-Shock Testing

2026-26-0224To be published on 01/16/2026

Exhaust system suppliers are continuously enhancing their processes by adopting advanced simulation techniques and expedited testing procedures for optimizing exhaust systems. This aims to reduce time to market, accelerate vehicle launches, and ensure first-time right and consistent compliance with performance and durability standards. Traditionally, the CFD team conducts Conjugate Heat Transfer (CHT) analysis on the exhaust hot end system using input conditions such as engine-out gas temperature and maximum mass flow rate. The CAE team then performs steady-state heat transfer analysis by sharing the structural CAE model with CFD for CHT skin temperature mapping. Once steady state heat transfer analysis complete, skin temperature plots are to be compared with CFD to match CHT temperature results. These results are used for steady-state thermo-mechanical analysis across all heat-up cycles and assume system under ambient temperature for all cool-down cycles to evaluate system thermal

Natarajan, Suresh, J Y, Raja Shangara Vel

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