Browse Topic: Analysis methodologies

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Development of an Software Algorithm Based Semi-automated Data Acquisition System for Gasoline Vehicle Calibration on Chassis Dynamometer2026-26-0535To 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
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 Systems2026-26-0542To 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
Study of Style wheel rim failure Due to Rim and disc assembly interference2026-26-0541To 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
Accelerating Product Development Life Cycle through Digitalization of Fatigue Life for Structural Components2026-26-0496To 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
A Novel Approach to Optimal Strain Gauge Placement for Structural Assessment: Integrating Close Looping Configuration with Calibration Techniques2026-26-0551To 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
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 assets2026-26-0527To 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
A Model Based Framework for Safety Risk Assessment using Systems Theoretic Process Analysis for ASIL Justification According to ISO 262622026-26-0022To 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 ATDs2026-26-0019To 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
Virtual Prototyping: Accelerating Traction Motor Development for Commercial Electric Vehicles2026-26-0152To 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 Learning2026-26-0633To 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
Numerical Investigation of Cowl Water Drainage in Automotive Design2026-26-0393To 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
Next Gen Automotive EDS Architecture design verification using real-time function mode simulation & failure condition analysis2026-26-0454To 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
Dog Clutch Engagement Probability Simulation for Heavy-Duty Automated Mechanical Transmissions2026-26-0437To 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
Effect of pipe bending by rotary tube bending process on durability of frame structure2026-26-0370To 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
Utilization of an improved hardening model for finite element analysis and experimental correlation of a tractor ROPS Structure2026-26-0404To 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
A fluid-structure- interaction based methodology to evaluate aero-thermal performance of deformable air guides2026-26-0364To be published on 01/16/2026
An air guide in a car directs fresh air onto the Heat Exchangers (HXs) to facilitate efficient thermal management. It is of paramount importance that the air guide creates a proper sealing and prevents any leakage of the incoming fresh air. It is achieved in two ways – 1) In the design condition, the air guide is manufactured in a way so that it overlaps/intersects with the surrounding components 2) the air-guide is made flexible with a highly elastic rubber seal at the edge. When the air-guide is assembled, the rubber portion of the air-guide deforms to produce a proper fit leading to a sealed air-intake pathway. At high-speed condition as well as high airflow conditions by the radiator fan during idling/stationary, like DC charging – incase of BEV, etc., the air guide encounters high pressure. Being elastic and flexible, these conditions make the air guide susceptible to deformation with potential leakage of incoming air. Digital evaluation of the air guide deformation at different
GADASU, RAVISHASTRI, CHOUDHURY, SATYAJIT, Umesh, Acharya Vaibhav, Kumar, Saravanan, Yenugu, Srinivasa, Zander, Daniel, Beesetti, Siva, Hattarke, Mallikarjun
DESIGN & STATIC STRUCTURAL ANALYSIS OF COMPOSITE PROPELLER SHAFT: A COMPARATIVE STUDY2026-26-0297To be published on 01/16/2026
Advanced Fiber Reinforced Polymer (FRP) composites have emerged as an important class of engineering materials for load bearing applications with all round properties for many engineering and social applications. Composite materials are created by combining two or more dissimilar materials with a viewpoint to improve the properties or to create materials with desired properties. Substituting composite structures for conventional metallic structures has many advantages because of higher specific strength and stiffness of composite materials. The role of composite material in weight reduction and fuel saving in automobiles is highly significant. Advanced composite seems ideally suited for long, power drive shaft applications. Their elastic properties can be tailored to increase the torque and the rotational speed at which they operate. Composite driveshaft is designed based on filament winding technology for higher strength and torque applications. In the present work, a comparative
Indla, Veneil Sai, REDDY, NEERATI, Kopparapu, Laxmi kanth
A High-Fidelity Transient Fluid-Structure-Interaction Methodology for Evaluation of Rear Bumper Flutter of a Vehicle2026-26-0410To be published on 01/16/2026
The need for fuel efficient and pedestrian safe cars leads to the use of thinner and lighter car exteriors. Interaction of these exterior car components at high speed with an aerodynamic load can lead to undesirable aero-elastic vibration and flutter. Early identification and mitigation of such vibration can bring significant cost and time benefit, by reducing dependence on prototype testing and recalibration of prototype tooling at later stages. The present work demonstrates a transient Fluid-Structure-Interaction based numerical methodology for estimation of aerodynamic-induced flutter of the rear bumper of an SUV. The proposed method performs coupled-high fidelity transient full vehicle aerodynamic Finite Volume based and dynamic rear bumper structural Finite Element based simulations required for flutter estimation. The method has been put through a two-step validation against experimental wind tunnel test data of a prototype car with modified bumper for the specific test-case. The
CHOUDHURY, SATYAJIT, Yenugu, Srinivasa, Walia, Rajat, Zander, Daniel, Gullapalli, Atchyut, BALAN, ARUN, Astik, Pritesh
Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application2026-26-0286To be published on 01/16/2026
Quality of the Shear Trimmed edge of HSLA 550 steels is significantly affected by process variations such as Shear Trimming Clearance, trim tolerance, burr height and clamping force. All these parameters largely influence the characteristics of the Shear Affected Zone, a region on sheet metal where it undergoes deformation during the trimming process. The Shear Affected Zone is predominantly vulnerable to failure due to work hardening and the effects of strain rate, induced by the tonnage during the trimming operation. To assess the edge ductility of these materials, Tensile, Fatigue Strength, Die Punch Clearance, Roughness and Hardness Tests are carried out. These tests are crucial for applications that demand high formability and resistance to edge failure. Virtual simulation of edge trimming operation using elastoplastic material models in LS-Dyna have been performed to gain insights into burr formation and damage evolution during shearing. These simulations act as a precursor to
Thota, Badri Vishal, Kashyap, Amit, Bhuvangiri, Jaydev
Simulating Performance of Adhesive-Bonded Joints for Automotive Applications2026-26-0415To be published on 01/16/2026
Adhesive joining techniques have rapidly gained momentum in the automotive industry over the past decade, offering several advantages over traditional joining methods. The complex design requirements of modern automobiles have increased the demand for intricately shaped components, where conventional spot/seam welding and mechanical fastening are often not feasible. Unlike spot and arc welding, adhesives do not degrade the properties of the substrate. Moreover, they enable the joining of components made from dissimilar materials, thus contributing to the overall weight reduction of assemblies. Adhesives also provide damping effects, reducing noise, vibration, and harshness (NVH), thereby contributing to a quieter and more comfortable ride. Additionally, adhesives enhance structural integrity by distributing stresses more uniformly across the joints. Consequently, understanding the simulation and failure prediction of adhesive joints has become essential. Traditional failure criteria
Parambathuvalappil, Rahul, Patil, Sanjay
Evaluating the Suitability of ADC12 for Sand Casting: Filling, Solidification, and Mechanical Properties2026-26-0296To be published on 01/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Jichkar, Pawan
Study, design, electro-chemical testing and validation of fuel cell fixture of single cell assembly towards custom stationary application.2026-26-0265To be published on 01/16/2026
Fuel cell - as name suggests, it generates energy from fuel (Hydrogen). A three-input system produces three different outputs: electrical energy, heat, and pure water. Fuel cell can produce decent power depending on design of active area and possible current density. Overall required power output which is generated by a series of cells stacked together. The design once meets all the required performance parameters at single cell level, can be extrapolated to stack level design. The present work elaborates successful testing and validation of a compact, light weigh single cell fuel cell fixture. Further the design will be scaled to a fuel cell stack design with a capacity of 5 kW to cater various stationary application such as back-up/ stand-alone power generator for remote location. The same design philosophy will also be implemented in fuel cell stack design for automobile applications. The membrane electrode assembly (MEA) is heart of the fuel cell which produces the output while
Pandit`, Abhishek Rajshekhar, Chougule, Abhijeet, Khot, Ranjit, chaudhari, Shirish
A study on the thermal degradation of chlorinated Polyethylene rubber2026-26-0276To be published on 01/16/2026
Elastomeric materials are essential in advanced automotive engineering for mobility, isolation, damping, fluid transfer (cooling, steering, fuel, and brake), and sealing because of their unique physio mechanical properties. Elastomers are commonly used in both static and dynamic components, such as hoses, mounts, bushes, and tires. Engine emission standards and weight optimization have caused higher temperature exposure conditions for automotive components. The steering system uses special purpose elastomers like Chlorinated Polyethylene that can deteriorate under abnormal conditions during vehicle operation or manufacturing process due to the high temperature exposure. Therefore, it is crucial to comprehend the causes and consequences of thermal degradation of elastomers. Thermal degradation is a significant phenomenon that changes the physical and chemical properties of elastomers, which results in a product not meeting functional requirements. This study investigates the thermal
THIRUPPATHI, ANANDHI, Mishra, Nitish, Krishnamoorthy, Kunju
An investigation into the Structural Impacts of Off-Road Manoeuvres on Rear Axle upper Link Mounting Bracket2026-26-0490To be published on 01/16/2026
Multi-link rigid axle suspension is widely used as a rear suspension system for body-on-frame SUVs. The upper link in a multi-link rear suspension plays a critical role in managing the vertical and longitudinal positioning of the axle, while the lower link ensures stability by regulating the axle's movement in the horizontal plane. This coordinated functionality of upper and lower link allows for controlled axle dynamics during compression and rebound, significantly enhancing ride comfort and improving vehicle handling characteristics. This study examines the failure of an upper link mounting bracket on the rear axle of an SUV during off-road events, despite no failures observed in other durability tests. Root cause analysis is conducted on failed samples to determine the specific reasons for failure only in off-road conditions. Additionally, the investigation focuses on understanding the dynamic loads experienced by the upper link during vehicle operation across various durability
J, Akhil, Senthil Raja, T, Ghumare, Dheeraj, Chilakala, Raghavendra, Kundan, Lal, Mohapatra, Durga Prasad
Q-Series Child Dummy FE model development and validation for child occupant safety assessment in Automotive crashes2026-26-0390To be published on 01/16/2026
The Ministry of Road Transport and Highways (MoRTH), Government of India has established BHARAT NCAP to provide a fair, meaningful, and objective assessment of the crash safety performance of cars. This program evaluates vehicles across three key areas, including Child Occupant Protection (COP). A critical component of the COP assessment involves dynamic testing using Q-series child dummies representing a 1½-year-old (Q1.5) and a 3-year-old child (Q3). As per the BHARAT NCAP protocol these dummies are placed in the second-row outboard seating position within Child Restraint Systems (CRSs) and subjected to two primary dynamic impact tests: Offset Deformable Barrier (ODB) conducted at speed of 64 km/hr. and Mobile Deformable Barrier (MDB) Side Impact tests conducted at 50 km/hr. The dynamic assessment of these child dummies is primarily focused on the head, neck, and chest regions to evaluate the effectiveness of the CRSs and overall vehicle safety system in protecting young occupants
Khopekar, Maria, Lakshminarayana, Apoorva, Mohan, Pradeep, Kurkuri, Mahendra
Simulation Research on Torque Vectoring, Braking, Chassis control Strategies for Electric & hybrid Vehicles using System Simulation2026-26-0423To be published on 01/16/2026
Electric Vehicles and Plug-in Hybrids alleviate the energy crisis but pose a unique challenge for vehicle dynamics. Though significant developments in motor control strategy and energy density management are evolving, we face significant challenges in Torque Management with several ADAS features being integral part of the EV's/xHEV's. It demands high-fidelity physical and control model exchanges between electric-chassis, ride-handling, tire modelling, Steering Assist, powertrain and validate using 0D-1D platform. This paper explicates a unified strategy for improving overall vehicle performance by intelligently distributing and coordinating drive torque to enhance traction, stability, and drivability across diverse operating conditions through the co-simulation. Co-Simulation platform includes physical models in AMESIM, and control strategies integrated in MATLAB/Simulink. The platform features comprehensive representations of digital vehicle that requires detailed modelling of
Eruva, Patrickxavier, Sarapalli Ramachandran, Raghuveeran, Chougule, Sourabh, Natanamani-Pillai, Siva Subramanian, Scheider, Clement, Leclerc, Cedric, Natarajasundaram, Balasubramanian
Incorporation of strain hardening and sheet thinning effects during forming process for an accurate prediction of buckling loads on sheet metal axle parts2026-26-0391To be published on 01/16/2026
In this competitive automotive world, shorter development time and quicker time to market for new models are vital to product success. This can be achieved by digitalization, thereby avoiding over-design of parts and the need for physical prototypes, resulting in cutting down on material and development efforts respectively. In this study, the deviation of load carrying capacity of chassis sheet metal axle links in comparison with hardware testing and simulation results were investigated. A multi-step forming simulation is carried out, which involves simulating all stages of the forming process to accurately predict the plastic strains leading to material strain hardening and thickness distribution leading to thinning. The forming simulation is performed using the anisotropic material model Banabic-Barlat-Comsa (BBC) to capture the anisotropy effects. This model uses several coefficients to precisely characterize the yield surfaces, considering both uniaxial and biaxial yield stresses
R B, Govind, Selvaraj, Nirmal Velgin
Numerical Analysis of Rear Windshield Deicing with Heating Wires2026-26-0373To be published on 01/16/2026
Motivation: Windshield deicing is a crucial safety feature in vehicles, typically associated with the front windshield. However, the rear windshield also plays a significant role in ensuring safety and needs to be clear. Deicing of the front windshield is usually done using the hot air nozzle from the HVAC system. Modern rear windshields are equipped with heating wires that generate heat upon electrical supply to facilitate deicing. However, excessive use of these heating wires can lead to unnecessary energy consumption, impacting the vehicle's overall efficiency. This is the key motivation behind the development of an optimized heating system for the rear windshield. Problem: Design an optimized heating system for rear windshields that balances effective deicing with minimal energy usage, enhancing both safety and energy efficiency in vehicles. Methodology: This paper explores the numerical application of heating methods using CFD software to deice the rear windshield. The study
Kumaravel, Rajarajeshwari, Ibrahim, Sayyaf, Mathew, Ronnie
Integration of virtual testing methods in automotive safety: Methodology validation for rollover protection system (ROPS)2026-26-0375To be published on 01/16/2026
During recent years, the integration of virtual testing methodologies has gained significant importance in vehicle development for the passive safety evaluation. The accuracy of simulation results depends basically on the correct replication of physical test into the virtual model, for example to assign the realistic material properties from the structural components and following the boundary conditions replicated from real conditions. In this study the safety standards ISO 3471_2008 and ANSI ROHVA/OPEI-2016 have been considered as references of the safety validation process of hollow section roll-over protective structure (ROPS) integrated into a vehicle. A key objective is to stablish a virtual test methodology that could be applicable across different standards considering various industry markets, as for example European, American and Asian. A sensitivity analysis is necessary to evaluate what are the main aspects that gives significant deviations in results and in which we can
Laso Rodríguez, Manuel, Hanumantha, Chandrashekhar, Singh, Amit Kumar, Lal, Kundan
Multiphysics Analysis of Heat Sink Designs for Efficient Thermal Performance in Power Electronics Systems2026-26-0446To be published on 01/16/2026
The thermal management capability of power electronic (PE) systems has a critical impact on the performance and efficiency of electric, fuel cell, or hybrid vehicles. Bus bars, high resistance sensor devices, semiconductor switches, power capacitors are the primary components, which has major contribution in total heat generation in electrical drive unit. As PE packaging sizes are projected to become smaller, the challenge of managing increased heat dissipation becomes more critical. Hence, this paper numerically compares conventional and advanced cooling strategies to determine the best possible thermal management scenario. A multi-physics finite element model, integrating fluid, electrical, thermal, and structural fields, is employed to analyze heat generation within the PE system and the associated cooling mechanisms. Due to the significant impact of surface roughness and topology on electrical and thermal contact resistance, the Cooper-Mikic-Yovanovich (CMY) correlation is utilized
Singh, Praveen Kumar, Natarajan, Nesamani, Murali, Sariki
Dual-Stage Compressor Bracket NVH Optimization for High-Performance 4x4 Electric Vehicles2026-26-0327To be published on 01/16/2026
The increasing demand for high-performance 4x4 electric vehicles (EVs) has necessitated advancements in Noise, Vibration, and Harshness (NVH) optimization, particularly in critical components such as compressor brackets. This study focuses on the NVH optimization of a dual-stage compressor bracket, comparing its performance against a conventional single-stage design. The dual-stage bracket is evaluated for isolation effectiveness, modal frequency alignment, and overall NVH performance, while ensuring compliance with stiffness and durability targets. Through finite element analysis (FEA) and experimental validation, the dual-stage bracket demonstrates superior vibration isolation, achieving a 30% reduction in transmitted forces compared to the single-stage design. Modal analysis reveals that the dual-stage configuration effectively shifts critical frequencies away from operational ranges, reducing resonance risks. Additionally, the dual-stage design meets stringent stiffness
Hazra, Sandip, Tangadpalliwar, Sonali
BEARING CREEP PREVENTION IN EV TRANSMISSION2026-26-0598To be published on 01/16/2026
As the trend shifts from Internal Combustion Engine (ICE) vehicles to Electric Vehicles (EVs), the operating speeds of prime movers have significantly increased. Commercial EV manufacturers prefer high-speed, low-torque motors coupled with transmissions over low-speed, high-torque motors due to higher efficiency and power density. This combination of high-speed, low-torque motors coupled with transmission is essential for achieving the required gradeability and enhances operational efficiency. However, the increased operating speeds of these EV transmissions have inherently increased the risk of ‘bearing creep’. The “bearing creep” is the phenomenon where unintended relative motion occurs between bearing races and their mounting surfaces, leading to premature wear of mounting surfaces. This issue can lead to a series of failure modes such as increased gear mesh misalignment, bearing damage, seal damage, etc. These problems result into elevated transmission vibrations eventually leading
Bagad, Sachin Sunil, Kanase, Ashish, Hiremath, Satalingayya, Nevarekar, Sandip
Advanced Sensor less Machine Learning Technique for Early Detection of Engine Oil Degradation2026-26-0656To be published on 01/16/2026
Maximizing vehicle uptime and reducing maintenance costs are critical objectives in modern automotive systems, making efficient resource utilization a top priority. One key factor is engine oil degradation, which directly affects engine performance, longevity, and overall vehicle efficiency. Current Conventional oil monitoring approaches are real time based on dedicated sensors—can be inefficient, costly, or poorly adapted to varying usage conditions. While earlier studies have explored sensor-based or chemical analysis methods for oil health monitoring, these solutions often lack scalability and cost-effectiveness for widespread adoption. This paper introduces a Machine Learning-based Engine Oil Degradation Detection System that operates non-intrusively using existing vehicle CAN signals, requiring no additional sensors. Key engine parameters such as RPM, Torque, Gear Position, Engine Power, Coolant Temperature, and Odometer readings are trained with tri-bological properties
Dusane, Mangesh, Tade, Vilas, Iqbal, Shoaib
A Method to Improve the System Efficiency of an Electronic Drive Unit: Variable Switching Frequency-Loss Optimization2026-26-0062To be published on 01/16/2026
In electrical engineering, designing and improving inverter and induction motor systems is very important for many industrial uses. Even though these systems are flexible and widely used, one of the main challenges is accurately measuring how much power is lost when they run. Usually, people check the system’s efficiency, but that doesn’t fully explain how or why the power loss happens inside these systems. This paper presents a new way to study power losses without focusing on efficiency. Instead, it uses analytical methods supported by MATLAB programming. The goal is to explore the complex reasons behind power losses in both inverters and induction motors. To do this, the study develops mathematical formulas that describe the different types of losses, such as those from conduction, switching, and magnetic effects. These formulas are based on basic physics and are turned into MATLAB code, which helps connect theory with real-world application. In the end, the project creates a
BANDA, Gururaj, Sengar, Bhan
Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly2026-26-0302To be published on 01/16/2026
This research paper investigates the failure of an isolator clip used in the seat slider assembly, which guides and restricts the sliding motion of the tooth bracket within the seat. The component is made of C80 high-carbon spring steel, known for its high strength. According to the manufacturing process details, zinc plating was applied to the component for corrosion protection, as confirmed by EDS analysis. A fractographic examination of the failed part revealed a brittle, intergranular fracture morphology with visible cracks. Certain areas also exhibited micro-void coalescence, indicating a dimpled fracture surface. The primary failure mode was intergranular (IG) fracture. The delayed fracture was attributed to intergranular fracture mechanisms, micro-void coalescence, and the high strength of the steel, which made the component susceptible to hydrogen embrittlement. Hydrogen embrittlement occurs when hydrogen atoms become trapped along the grain boundaries, where they form hydrogen
Saindane, Mehul Kishor, BALI, SHIRISH
Value-Engineered Design Optimization of a Reinforced Plastic Bracket to Meet Natural Frequency Targets in Passenger Vehicles.2026-26-0355To be published on 01/16/2026
The transition from metal to plastic in the design of engine mount brackets marks a pivotal step toward sustainable and value-driven automotive engineering. This study investigates the optimization of plastic engine mount brackets, focusing on material selection, structural performance, and alignment with NVH (Noise, Vibration, and Harshness) targets. Recycled polymer composites were chosen for their favorable mechanical properties, environmental resilience, and contribution to circular economy goals. The primary objectives were weight reduction, cost-effectiveness, and manufacturability, without compromising structural integrity or long-term durability. A combination of Finite Element Analysis (FEA), CAE-based durability simulations, modal analysis, and comprehensive vehicle-level validation was conducted to assess dynamic performance. Results demonstrated that the optimized plastic brackets not only satisfy critical natural frequency and durability requirements but also offer a
Hazra, Sandip, Gupta, Deepak, Khan, Arkadip, Gite, Yogesh
Data analytics methodology for vehicle quality complaint analysis2026-26-0654To be published on 01/16/2026
Automobiles have become a part of people's everyday life. Customers base their trust on a brand's reputation while making a buying decision. With the evolving trends, feature advancements, automobiles have become a complex system. Ensuring product quality amidst system complexities is necessary to maintain the brand value & ensure customer satisfaction. Efficient addressal of customer quality complaints is pivotal in maintaining product quality. Until recent times, manual analysis using traditional data processing tools has been used for vehicle complaint analysis. However, considering the large quantum of data in new age vehicles with more number of control units, it becomes time-consuming, expertise dependent and susceptible to human errors. Given this & the advent of new age machine learning techniques & data analysis tools that can handle large amount of data, it is imperative to adopt them for vehicle complaint analysis. This research paper puts forth a method to analyze vehicle
Venkatesan, Prasanna, Raju, Vivek
FATIGUE FAILURE ANALYSIS FOR AUTOMOTIVE TRASNMISSION2026-26-0577To be published on 01/16/2026
A fatigue failure in the transmission input shaft was identified during a bench-level endurance test under 2nd gear loading conditions. The test transmission’s input shaft comprises fixed 1st, reverse, and 2nd gears, with the remaining gears mounted as floating. The shaft was subjected to cyclic torsional loads, and failure occurred after a defined number of cycles. Metallurgical analysis revealed a brittle fracture surface with crack initiation at the outer surface, propagating to core in a helical pattern, ultimately resulting in complete shaft fracture. To monitor and replicate the failure, the test setup was instrumented with a Reilhofer Delta Analyzer for early fault detection. TTL signals from accelerometers mounted on the transmission and a bench speed sensor were fed into the system, which generated FFT spectra and trend indices. A warning alarm triggered upon deviation in the trend index, indicating premature damage initiation. The test was subsequently halted for component
Navale, Pradeep, Kushwaha, Rakesh, Patel, Hiral
Tailgate Stiffness Mitigation and Engineering Strategy for Y-to-Y Tailgate-Mounted Tail Lamp Integration2026-26-0494To be published on 01/16/2026
The tailgate, as the rearmost vehicle opening, plays a pivotal role in defining the rear aesthetic theme while ensuring structural durability and maximizing luggage space. Contemporary automotive design trends highlight an increasing demand for Y-to-Y tailgate-mounted tail lamp configurations, which deliver a bold and dynamic visual appeal. Enhanced by animated lighting features, these designs cater to the preferences of Gen Z customers, becoming a decisive factor in purchasing decisions. However, integrating these complex tail lamp structures introduces significant engineering challenges, including increased X-dimension volume, reduced design space, and intricate mounting schemes constrained by stamping limitations. These factors necessitate the development of innovative joinery strategies and structural definitions to maintain durability targets, including achieving 25,000–30,000 slam cycles without failure, while preserving luggage space. This paper explores a comprehensive approach
Beryl, Joshua, Mohanty, Abhinab, Unadkat, Siddharth, Selvan, Veera
AI-Powered Innovation: Harnessing Data Analytics and AI in Modern Powertrain Development2026-26-0641To be published on 01/16/2026
The proposed presentation will delve into the transformative role of artificial intelligence (AI) in the automotive industry, specifically focusing on product development from concept to series support. The presented effort is driven by the need to enhance development efficiency, reduce time to market, improve product quality, and lower production costs. AI was explored as a solution to address challenges such as late availability of hardware components, issues during software integration, and high warranty costs. The AI applications discussed are primarily in the automotive industry, covering areas such as vehicle concept development, usage space analysis, root cause analysis, battery health monitoring, and failure prediction and health monitoring. The methodologies used include advanced AI methods to shorten the time from customer expectations to target agreements, statistical driving data analysis to understand user behaviour, machine learning (ML) surrogate models to identify key
Mayr, Christian, Keuth, Nikolaus
Influence of Tipping Angles and Body Shapes on Payload Discharge Efficiency in Dump Trucks2026-26-0493To be published on 01/16/2026
The payload retention and material outflow pattern during the unloading process of dump trucks are critical factors influencing the efficiency and effectiveness of operations in construction and mining industries. This paper investigates the impact of tipping angles and the shape of the dump truck body on payload retention and outflow characteristics. Using FEA methodology, we explore the material outflow pattern for different body geometries such as box body, scoop body etc. for comparative analysis in order to optimize the shape for better & effective unloading. The results demonstrate a comparative estimation for an optimal body shape configuration to effectively unload payload and correlation of payload retention at various tipping angles.
phukan, Prerna, Sahu, Hemant, Dave, Rajeev
Vibration modelling of high-pressure fuel lines driven by pressure pulsation.2026-26-0319To be published on 01/16/2026
When the flow of fluid within a high-pressure line is abruptly halted, pressure pulsations are generated. This phenomenon is known as the water hammer effect. This may lead to significant stress and, in the worst-case scenario, result in various types of failures within the highly pressurized system. Similar issue is observed in diesel high pressure fuel line where pressure is well above 1600 bar. Due to multiple injection on off event, pressure pulsation gets created inside high pressure fuel lines (HPFL) which leads problems such as high strain on high pressure fuel lines, mechanical damage, uneven fuel injected quantity, vibration beyond specification limits for rail pressure sensor or in worst case extreme noise. Due to pressure pulsation, fluid will have its own natural frequency, and resonance occurs when it interacts with structural frequency. In this work, A comparative FEA analysis is conducted to evaluate strain in two distinct high-pressure fuel lines, with pressure
Bawache, Krushna Ramesh, Sethy, Girija Kumari
Improvement study of Style steel wheel durability in Multiple pothole impacts2026-26-0539To be published on 01/16/2026
This study focuses on improving the durability of steel wheel rims subjected to Multiple Pothole which is commonly found in Indian village roads - a critical scenario affecting vehicle safety and wheel lifespan. Initial steel wheel designs often face significant deformation or failure under repeated strikes and resulting in tyre air loss due to wheel bend, prompting the need for enhanced performance standards. In this research, a combination of finite element modelling, experimental impact testing, and material optimization strategies were employed to assess and improve the structural integrity of steel rims. Key parameters such as rim profile geometry & material composition were systematically varied to evaluate their influence on impact resistance. Results demonstrate that strategic design modifications and material enhancements can significantly increase the rim's ability to absorb energy and resist bending without substantial weight penalties. The findings offer practical
DEsigan, Lakshmipathy, P, Praveen, K, CHANDRAMOHAN, C, Santhosh
Multi-Physics Simulation and Reliability Analysis of Onboard EV Charger2026-26-0499To be published on 01/16/2026
The rapid advancement of electric vehicle (EV) technology has created a demand for reliable and Thermal - efficient electronic components for power electronics and control systems on printed circuit boards (PCBs). The research looks at the overall simulation and study of a PCB for Electric Vehicles, including how it handles heat, stress, and reliability in real working conditions like considering casing (Heat Sink) in which PCB is held, into the simulation. We have used numerical based methods (reliability), Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) methods to simulate heat performance looking at steady-state and changing load profiles common in EV powertrains. We ran structural and thermal simulations to check the PCB's toughness against heat expansion and shaking loads often seen in cars. We also did a reliability check looking at heat cycling life for PCB components, and possible ways it could break to guess long-term toughness. The results show critical
kanbarkar, Suraj Omana, Deore, Uday, Patil, Nishikant, Nayak, Shibabrata
Hardware in Loop Validation of Gear Selection Switch2026-26-0540To be published on 01/16/2026
The increasing complexity of modern automotive drive control systems necessitates the adoption of robust validation methods to ensure functional safety, reliability and customer satisfaction. This paper presents the development and implementation of a comprehensive Hardware-in-the-Loop (HIL) testing framework designed specifically for a specific ECU known as Gear Selection Switch (GSS)/Drive control switch (DCS) system. Hardware-in-the-Loop (HIL) Testing is a simulation-based testing technique where real physical hardware (like an electronic control unit, switch or sensor) is tested by connecting it to a virtual simulation of the rest of the system — instead of testing it inside a real vehicle. Following the analysis of all the field failure incidents reported till date for GSS, detailed root cause investigations were conducted using in-house testing and Ishikawa diagram analysis. A critical failure mode was identified and addressed through targeted mechanical design modification and
Bhuyan, Anurag, Jahagirdar, Shweta, Khandekar, Dhiraj Baburao
Advancing Welding Excellence through Numerical Simulation Based Approach: A Multi Pass Welding Case Study on Cast Iron Coupons2026-26-0457To be published on 01/16/2026
The Automotive industry extensively uses cast iron for its exceptional mechanical performance and cost-effectiveness. However, repair welding or assembly of cast iron components remain highly challenging due to the material’s high carbon content, inherent brittleness, rapid thermal conductivity, and complex microstructural transformations. Multi-pass welding exacerbates these challenges by subjecting materials to repeated thermal cycling, accumulating residual stress, and inducing distortion – all of which potentially degrade the integrity of welded joints. A comprehensive understanding of welded joint behavior is essential to effectively mitigate these effects. Finite element analysis (FEA) serves as a powerful tool, enabling accurate prediction of thermal profiles, phase transformations, residual stress development, and resulting deformations. These valuable insights are critical for optimizing welding processes and enhancing overall joint quality. This study investigates and
Vidhate, Digambar, Nalawade, Rahul, Dabhadkar, Mandar, Vaidya, Abhijit, AMMASI, VINOTH, Rajagopalan, Sridhar
Conceptual Crash Analysis in Automotive Applications with Reduced Computational Effort2026-26-0451To be published on 01/16/2026
In the realm of automotive safety engineering, the demand for efficient and accurate crash simulations is ever-increasing. As finite element (FE) modeling of components becomes increasingly detailed and the availability of advanced material models improves, crash simulations for full vehicles can become time-consuming. Evaluating the crash performance of any vehicle subsystem requires full vehicle simulations at the industry level, which are complex and time-consuming. This paper introduces a novel methodology for replicating full vehicle crash simulations using Principal Component Test (PCT) cut-model level. Adapting PCT simulations, a significant reduction in computational time and resource usage is achieved, thereby optimizing CPU cluster performance. The proposed method has been successfully implemented across various crash load cases, including frontal 100 percent overlap, 40 percent overlap, small overlap crash, side impact, rear impact, underbody impact and low speed impact
Moncayo, David, Malipatil, Anand, Prasad, Rakesh, kunnath, Allwin
Cabin Heat-up Thermal Assessment for Human Comfort in Passenger Car2026-26-0408To be published on 01/16/2026
The HVAC (Heating, Ventilation and Air conditioning) system is designed to fulfil the thermal comfort requirement inside vehicle cabin. Thermal comfort is significantly subjective which predominantly dependent on occupant’s physiological condition. Vehicle AC performance is evaluated by air flow and local temperature thus, thermal comfort assessment is carried out by mapping of velocity and temperature at various places inside cabin. There is need to have Simulation methodology for heating cabin during cold climate to assess ventilation system effectiveness. Thermal comfort modelling involves human manikin, complex cabin material along with environmental condition in expensive transient simulation. Present study employed with LBM (Lattice-Boltzmann Method) based PowerFLOW solver coupled with finite element based PowerTHERM solver to simulate the cold soaking and heating up of cabin. Thermal comfort is subjective to human physiological modelling thus in-built Berkeley human comfort
Baghel, Devesh Kumar, Kandekar, Ambadas, Kumar, Ravi, Dimble, Nilesh
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