Browse Topic: Analysis methodologies

Items (5,039)

Quantitative Analysis of a Hybrid Electric HMMWV for Fuel Economy Improvement

2024-01-3356

04/23/2025

ABSTRACT This paper presents a quantitative analysis and comparison of fuel economy and performance of a series hybrid electric HMMWV (High Mobility Multi-purpose Wheeled Vehicle) military vehicle with a conventional HMMWV of equivalent size. Hybrid vehicle powertrains show improved fuel economy gains due to optimized engine operation and regenerative braking. In this paper, a methodology is presented by which the fuel economy gains due to optimized engine are isolated from the fuel economy gains due to regenerative braking. Validated vehicle models as well as data collected on test tracks are used in the quantitative analysis. The regenerative braking of the hybrid HMMWV is analyzed in terms of efficiency from the kinetic energy at the wheels to the portion of regenerative power which is retrievable by the battery. The engine operation of both the series hybrid and conventional HMMWV are analyzed using a 2-D bin analysis methodology. Finally, the vehicle model is used to make

Nedungadi, Ashok, Masrur, Abul, Khalil, Gus

Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions

2024-32-003804/18/2025

The arc welding process is essential for motorcycle frames, which are difficult to form in one piece because of their complex shapes, because a single frame has dozens of joints. Many of the damaged parts of the frames under development are from welds. Predicting the strength of welds with high reliability is important to ensure that development proceeds without any rework. In developing frames, CAE is utilized to build up strength before prototyping. Detailed weld shapes are not applicable to FE models of frames because weld shapes vary widely depending on welding conditions. Even if CAE is performed on such an FE model and the evaluation criteria are satisfied, the model may fail in the actual vehicle, possibly due to the difference between CAE and actual weld bead geometry. Therefore, we decided to study the extent to which the stresses in the joint vary with the variation of the weld bead geometry. Morphing, a FE modeling method and design of experiment method, was utilized to

Hada, Yusuke, Sugita, Hisayuki

Statistical Analysis of Data Acquired from Propagating Flames in Gasoline Engines Using a Multiple Ion Probe

2024-32-003504/18/2025

Multiple-ion-probe method consists of multiple ion probes placed on the combustion chamber wall, where each individual ion probe detects flame contact and records the time of contact. From the recorded data, it is also possible to indirectly visualize the inside of the combustion chamber, for example, as a motion animation of moving flame front. In this study, a thirty-two ion probes were used to record flames propagating in a two-stroke gasoline engine. The experiment recorded the combustion state in the engine for about 3 seconds under full load at about 6500 rpm, and about 300 cycles were recorded in one experiment. Twelve experiments were conducted under the same experimental conditions, and a total of 4,164 cycles of signal data were obtained in the twelve experiments. Two types of analysis were performed on this data: statistical analysis and machine learning analysis using a linear regression model. Statistical analysis calculated the average flame detection time and standard

Yatsufusa, Tomoaki, Okahira, Takehiro, Nagashige, Kohei

Enhancements in Hydrogen Low Pressure Injection on Small Two-Stroke Engines

2024-32-004704/18/2025

The use of small 2-stroke crankcase scavenged engines running on hydrogen is very attractive for low power rates, when low cost and compact dimensions are the fundamental design constraints. However, achieving optimal performance with hydrogen fuel presents challenges, including uneven air-fuel mixtures, fuel losses, and crankcase backfiring. This research focuses on a small 50cc 2-stroke loop-scavenged engine equipped with a patented Low-Pressure Direct Injection (LPDI) system, modified for hydrogen use. Experimental results demonstrate performance comparable to the gasoline counterpart, but further optimizations are needed. Consequently, CFD-3D simulations are employed to analyses the injection process and guide engine development. The numerical analysis focuses on a fixed operating condition: 6000 rpm, Wide Open Throttle (WOT), with a slightly lean mixture and injection pressure fixed at 5 bar. A numerical model of the entire engine is set up with the primary objective of improving

Caprioli, Stefano, Schoegl, Oliver, Oswald, Roland, Kirchberger, Roland, Mattarelli, Enrico, Rinaldini, Carlo Alberto

Analysis of Lane Departure Caused by Inadequate Motorcycle Driving Maneuvers Due to Road Alignment

2024-32-003404/18/2025

There are many riders who drive motorcycles on winding mountain roads and caused single motorcycle traffic accidents on curved roads by lane departure. Driving a motorcycle requires subtle balancing and maneuvering. In this study, in order to clarify the influence of lane departure caused by inadequate driving maneuvers against road alignment, the authors analyzed the required curve initial operation and driving maneuvers in curves depending on the traveling speed using a kinematics simulation for motorcycle dynamics. In addition, it was analyzed how inadequate driving maneuvers for curved roads can easily cause lane departure. As a result, it shows that the steering maneuvers and the lean of motorcycle body during the curves are highly affected by the vehicle speed, and the required maneuvers increases rapidly with increasing speed. The inadequate maneuver in the curves, especially for the lean of motorcycle body and steering torque, even by 10%, may cause failure to follow the

Kuniyuki, Hiroshi, Takechi, So

Mechanical Property Analysis of Triply Periodic Minimal Surface Structure with a Novel Hybrid Structure

2025-01-8215

04/03/2025

Abstract Triply periodic minimal surface (TPMS) structure, demonstrates significant advantages in vehicle design due to its excellent lightweight characteristics and mechanical properties. To enhance the mechanical properties of TPMS structures, this study proposes a novel hybrid TPMS structure by combining Primitive and Gyroid structures using level set equations. Following this, samples were fabricated using selective laser sintering (SLS). Finite element models for compression simulation were constructed by employing different meshing strategies to compare the accuracy and simulation efficiency. Subsequently, the mechanical properties of different configurations were comprehensively investigated through uniaxial compression testing and finite element analysis (FEA). The findings indicate a good agreement between the experimental and simulation results, demonstrating the validity and accuracy of the simulation model. For TPMS structures with a relative density of 30%, meshing with

Tang, Haiyuan, Xu, Dexing, Sun, Xiaowang, Wang, Xianhui, Wang, Liangmo, Wang, Tao

Intelligent Courier Delivery Scheduling Based on XGBoost Feature Selection and Reinforcement Learning: A Case Study Using Chongqing Cainiao Express Data

2025-01-717602/21/2025

This study tackles the issue of order delays in logistics using XGBoost for feature analysis and reinforcement learning for intelligent courier scheduling. Pickup order data from May 1 to October 31, 2023, in Chongqing is analyzed using spatio-temporal statistical methods. Key findings include that order placement peaks at 9:00 a.m., delays peak at 10:00 a.m., and the delay rate is 8.6%. A significant imbalance exists between the regional daily average of dispatchable couriers and order volumes.XGBoost is employed to predict order delays, revealing that pickup location is the most influential factor (27%), followed by courier pickup location (22%). These factors and their relationships are identified as key drivers of delays.To address these issues, a reinforcement learning-based courier scheduling optimization model is developed. The model defines courier location, current time, and pending orders as state variables and adopts an epsilon-greedy strategy for action selection

Wang, Manjun, Yu, Xinlian

test rejection

SAE-PP-0945901/27/2025

test

Rickard, Christopher

Test GV Document 2

JTEST1620251 (Current)01/06/2025

test

Ground Vehicle European Prospect Committee

Quantitative Analysis of a Hybrid Electric HMMWV for Fuel Economy Improvement

2024-01-3356-TEST-REC11/15/2024

Nedungadi, Ashok, Masrur, Abul, Khalil, Gus

Influences of Lubricant Viscosity and Metallic Content on Diesel Soot Oxidation Reactivity

2024-01-508408/23/2024

This study examined the effects of lubricant viscosity and metallic content on the oxidation reactivity of diesel particles. In the first part, the factors affecting thermogravimetric analysis (TGA) experiments was discussed and confirmed. The influences of initial soot mass, heating rate, and airflow rate on soot oxidation rate and experimental reproducibility were investigated to develop an optimized TGA method. On the basis of these experiments, an initial soot mass of 2.0 mg, airflow rate of 4.8 L/h, and heating rate of 2.5°C/h were used for all subsequent TGA tests. It could be found that the TGA experiments had high repeatability, and the differences were less than 0.1%. In the second part, a four-cylinder diesel engine was lubricated with seven kinds of lubricant with different viscosity and metallic content by the use of viscosity index improver (VII), antioxidant and corrosion inhibitor (ACI), and ashless dispersant (AD). Particle samples were subjected to TGA to test their

Meng, Hao, Yang, He, Zhang, Weili, Xing, Jianqiang, Xu, Yan, Wang, Yajun

Transportation Ecosystem and Autonomy: Vol. 2

EPRCOMPV20202305/03/2024

On-road vehicles equipped with driving automation features are entering the mainstream public space. This category of vehicles is now extending to include those where a human might not be needed for operation on board. Several pilot programs are underway, and the first permits for commercial usage of vehicles without an onboard operator are being issued. However, questions like “How safe is safe enough?” and “What to do if the system fails?” persist. This is where remote operation comes in, which is an additional layer to the automated driving system where a human assists the so-called “driverless” vehicle in certain situations. Such remote-operation solutions introduce additional challenges and potential risks as the entire chain of “automated vehicle, communication network, and human operator” now needs to work together safely, effectively, and practically. And as much as there are technical questions regarding network latency, bandwidth, cybersecurity, etc., aspects like human

Beiker, Sven, Muelaner, Jody E., Razdan, Rahul

An eleventh one for CUR-1174

PC11-CUR-1174 (Current)04/02/2024

Italic

Flight Simulator Engineering and Maintenance Committee

Machine-Learning-Accelerated Simulations for the Design of Airbag Constrained by Obstacles at Rest

2023-22-0001

03/04/2024

Abstract Predicting airbag deployment geometries is an important task for airbag and vehicle designers to meet safety standards based on biomechanical injury risk functions. This prediction is also an extraordinarily complex problem given the number of disciplines and their interactions. State-of-the-art airbag deployment geometry simulations (including time history) entail large, computationally expensive numerical methods such as finite element analysis (FEA) and computational fluid dynamics (CFD), among others. This complexity results in exceptionally large simulation times, making thorough exploration of the design space prohibitive. This paper proposes new parametric simulation models which drastically accelerate airbag deployment geometry predictions while maintaining the accuracy of the airbag deployment geometry at reasonable levels; these models, called herein machine learning (ML)-accelerated models, blend physical system modes with data-driven techniques to accomplish fast

Valenzuela del Rio, Jose E., Lancashire, Richard, Chatrath, Karan, Ritmeijer, Peter, Arvanitis, Elena, Mirabella, Lucia

Machine-Learning-Accelerated Simulations for the Design of Airbag Constrained by Obstacles at Rest

2023-22-0001-TEST-REC03/04/2024

Valenzuela del Rio, Jose E., Lancashire, Richard, Chatrath, Karan, Ritmeijer, Peter, Arvanitis, Elena, Mirabella, Lucia

A computational approach to Fretting Wear prediction of Steel Gaskets under Thermo-Mechanical load using Archards wear model

2024-26-027301/16/2024

IC Engine is the heart of an automobile. The failure in any component of the engine will directly affect the performance of the vehicle. The gaskets are among the many vital parts of an IC engine that are essential in ensuring appropriate sealing to prevent gas and liquid leakage and maintain optimal engine efficiency. Engines use a variety of gasket types to accommodate various sealing requirements. Among them the exhaust manifold gaskets is one of the critical gasket elements in IC engines which seals between Cylinder head and extremely hot Exhaust Manifold, this prevents the leakage of hot exhaust gasses produced during combustion. The gaskets are crucial components because they endure extremely high mechanical loads from the exhaust manifold sliding and banana-shaped bending brought on by thermal expansion, as well as extremely high thermal loads from the high exhaust gas temperatures, which are around 1000°C. These gaskets are additionally subjected to extremely high bolt loads

Reddy, Rajavardhan, Kulkarni, Sanjeev, R B, Govind, Mueller, Frank Oliver

Enhanced Development Process for UPDs – Digital Approach

2024-26-023901/16/2024

Underrun Protections devices (UPDs) are specially designed barriers fitted to the front, side, or rear of heavy trucks. In case of accidents, these devices prevent small vehicles such as bikes and passenger cars going underneath and thus minimizing the severity of such accident. Design and strength of UPD is such as to absorb the impact energy and minimise deflection to avoid the under run. Compliance to UPD safety regulations provides stringent requirements in terms of device design, dimensions, and its behaviour under loading. Since accuracy of Computer Aided Engineering (CAE) predictions have improved, use of numerical tools like Finite element method (FEM) are extensively used for design, development, optimisation, and performance verification with respect to regulatory requirements. For improved accuracy of prediction of results through FEA, correct representation of sub-systems is very important. One such sub-system in UPDs is bolted connections, which require accurate methods to

Ugale, Dinesh, D, Dileep Kumar, Mohod, Pravin, Khaleelullah, Abdul, Bandru, Shreenu

Development of Duty Cycle for Transmission System Components in a Two-Wheeled Electric Vehicle

2024-26-031801/16/2024

A two-wheeler is exposed to various dynamic loads transferred from roads and input given by the vehicle prime mover, which leads to the occurrence of torque on the wheel and transmission. The torque generated depends on the terrain and riding pattern of users, so it becomes important to develop a duty cycle of transmission considering multiple events enabling us to understand the durability standard of the component designed. The tests performed were on an EV two-wheeler that uses a belt drive transmission. The paper will focus on the following aspects, which cover the customization of the torque cell for the pulley system in the transmission, followed by the testing on different selected terrain conditions and analysis methodology for generating the duty cycle for different systems in transmission of the vehicle. A customized torque cell using strain gauges was developed with locations identified from finite element analysis performed on the wheel pulley. Strain gauge locations are

Ganju, Shubham, R S, Mahenthran, Prasad, Sathish Kumar, Balakrishnan, Sivakumar

Gasket joint sealing behavior prediction using simplified FEA approach.

2024-26-031101/16/2024

Gaskets are used widely for sealing of a bolted joint. This paper focuses on Rubber over metal (ROM) gaskets which are widely used in automotive industry. Finite Element Analysis (FEA) of ROM gasket is complex and involves material (hyperelastic), contact and geometric nonlinearity. Gasket could be flat or have one or multiple beads. Analytical approaches are available in literature for flat gaskets without bead patterns. This paper focuses on analysis of ROM gaskets with beads used in automotive axle differential carrier housing and cover pan. Instead of modelling ROM gaskets using three dimensional (3-D) elements, this work suggests an innovative methodology which uses one- and two-dimensional elements with derived attributes for gasket joints. This problem can be viewed as displacement controlled because the gasket is compressed up until the limiter height subjected to bolt preload. 3-D FEA results are used to validate the results of this approach. This method successfully predicts

Samshette, Shivkumar, SHEDGE, Vikram, Nilangekar, Abhijit

Soot sensor elimination with DPF substrate failure monitoring.

2024-26-015301/16/2024

The automobile industry is going through one of the most challenging times, with increased competition in the market which is enforcing competitive prices of the products along with meeting the stringent emission norms. One such requirement for BS6 phase 2 emission norms is the inclusion of PM (Soot) sensor in diesel passenger cars. PM sensor detects soot leakage in case of DPF substrate failure. There is a cost factor along with extensive calibration efforts which are needed to ensure sensor works flawlessly. This paper deals with the development of an algorithm with which robust detection of DPF substrate failure is achieved. In order to achieve this, a thermodynamic model of DPF substrate was created using empirical relations between parameters like exhaust flow rate, exhaust gas temperature and soot mass content. The modeling was done in both empty (no soot) and filled (threshold soot content) substrate conditions. There were two methodologies, namely integration method and

Jain, Praveer Kirtimohan, Yadav, Omkar, Chendil, Chellapandi

A New Holistic Approach for System-Level Development of Seat Features

2024-26-038101/16/2024

System engineering-based approach is now ubiquitous in the automotive industry. It is a disciplined approach that ensures that targets are clearly defined and met through a structured and holistic approach. In this paper, we report an application of a systems engineering-based methodology for developing seating system features. It starts with a Business Requirement Document (BRD), which enlists the business requirements of a feature. We then developed a Logical Architecture Diagram (LAD) on a Simulink environment, which serves as an initial proposal for the design of the logic that would realize the desired functionality. As a next step, we perform Functional Failure Analysis (FFA) on the LAD to identify potential failure modes. We propose a few ways to mitigate the identified failures or modify the design so that these failures are rendered inconsequential to the end user. Based on the updated LAD, a System Requirement Document (SRD) is created, which contains all the requirements

Ghosh, Soumik, Vidhu, Nandagopal

Airless tyres in the LEON-T project: How can they be modelled?

2024-26-037501/16/2024

For more than a century, pneumatic (air-inflated) tyres have totally dominated the market for road vehicle tyres. However, in the recent two decades, interest has grown in developing airless tyres. Some of the authors were involved in design of an early version in composite material 15-30 years ago for passenger cars. Presently, the EU project LEON-T includes a part in which prototypes for innovative heavy goods vehicle (HGV) tyres are developed, with the main purpose to reduce noise emission by 6 dB. To reduce noise that much it is believed that airless tyres are needed. A special challenge is to get a durable design able to carry typical truck tyre loads. This paper introduces the principal design of airless tyres. Airless tyre prototypes are intended to be developed by partner Euroturbine, in cooperation with mainly Applus+ IDIADA, VTI and subcontractor Lightness by Design. The tyre consists of a rim, load-carrying spokes, composite belt and rubber tread. The primary focus is on the

Anantharamaiah, Bharath, Fragerberg, Linus, Sandberg, Ulf, Hansson, Hans-Erik, Garcia, Juan J.

Outrigger design & development for vehicle testing as per AIS 133

2024-26-035001/16/2024

The outrigger is mounted on the test vehicle during handling test maneuvers, such as double lane change, constant radius cornering, J-turn, etc. The aim of these outriggers is to protect the driver & vehicle with minimum effect on the vehicle's inertia while testing vehicle stability during sudden turns as per AIS 133 which might result in the rollover of the vehicle. The paper discusses design which includes load path analysis, material comparison to maximize strength per unit weight, shape, dimensional finalization, etc. Torsion is generated when the skidpad comes in contact with the ground which we have tried to balance in the free body diagram (FBD) by changing the skidpad contact point for reducing the stress. From the FBD, the following points have been carefully observed to only put material where it is required:- 1. Vertical bending load 2. Longitudinal bending load due to friction 3. Torsion 4. Compressive load 5. Moment due to compressive load 6. Buckling load Finite element

Rathore, Gopal Singh, chawla, Shubham

Lightweighting of Two-Wheeler Frame with CAE - Multi Domain Optimization (MDO)

2024-26-026101/16/2024

Lightweighting in the automotive industry without the use of finite element methodologies is now inconceivable. With the development and enhancement of various CAE tools available in the market, CAE-driven optimization has become part of the product development cycle. Using a variety of CAE techniques in a lightweight optimization process can significantly reduce product development lead time with good results. Traditional light weighting can be done through different iterative approaches with different manual inputs from cross-domain teams, which is usually time consuming and leads to repeated analyses, etc. The current method describes the case of a multi-domain optimization (MDO) approach involving E-Motorcycle frame weight reduction while taking into account various important cross-domain load cases using CAE methodologies. For frame optimization, the most important loads - stiffness, durability/strength (Normal & Abusive), and NVH (Modes & Vibration) - were taken into account, as

S, Vishnu, kakanur, Ashok, U PE, Manjunatha, Bhat, Sachin, POOJARY, KIRAN, V N, Kishor

Simulation methodology development for vibration test of Bus Body Structure code AIS 153:2018

2024-26-024901/16/2024

A bus is integral part of public transportation in both rural and urban areas. It is also used for scheduled transport, tourism, and school transport. Buses are common mode of transport all over the world. The growth in economy, the electrification of public transport, demand in shared transport, etc., is leading to a surge in the demand for buses and accelerating the overall growth of the bus industry. With increased number of buses, the issue of safety of passengers and the crew assumes special importance. The comfort of driver and passenger in the vehicle involves the vibration performance and therefore, the structural integrity of buses is critically important. The bus safety act depicts the safety and comfort of bus operations, management of safety risks, continuous improvement in bus safety management, and public confidence in the safety of bus transport, appropriate stakeholder involvement and the existence of a safety culture among bus service providers. In order to provide

Bijwe, Vilas B., Mahajan, Rahul, Vaidya, Rohit, Patel, Kaustubh, Hiwale, Diwakar, Walke, Abhijit Ashok

Electromechanical Multiphysics simulation of Motor

2024-26-025001/16/2024

These days, the use of virtual Multiphysics simulations through finite element analysis methodology is increasing exponentially during the development phase of automotive products. Thereupon, the automotive industries are becoming competent enough to build an ingenious and creative design with optimal performance within the coherent time. Huge number of electromagnetic forces are being generated inside the Motor, when it is undergoing extreme driving conditions of the application. Hence it becomes vital to reduce the risks, if any, during the development phase by providing an optimal factor of safety within the electromechanical system of the motor. The present study gives details about conducted finite element analysis on an automotive motor to determine its mechanical strength and behaviour. Numerical analysis will also be performed to determine the possibilities of further design optimization within a Motor. This study also focuses on finding the structurally critical regions over

Karale, Ajinkya Sujay

OPTIMIZATION OF OIL QUANTITY IN MANUAL TRANSMISSION AND REDUCING CHURNING LOSS

2024-26-034601/16/2024

Gearbox efficiency losses are contributed by Oil seal rubbing, Synchro friction rubbing, Gear losses, bearing preload friction, windage losses, churning losses etc. Here in this experiment we have focused on quantifying and reducing the churning losses as well as verifying the lubrication requirements satisfactorily in all terrains and conditions. The paper establishes the effective way for evaluating same with over 80 trials conducted for conclusive proof. Gearboxes must work efficiently to get the job done properly and lubrication is vital to this efficiency. Lubricating oil is like the circulation system of a gearbox. If the oil levels fall too low, the gearbox will likely fail. Gearbox failure can lead to expensive repairs that could be prevented. Besides added costs due to replacement or repair, costs associated with a loss of production could be significant. These issues are why it is important to understand the consequences of having low lubricant levels. Similarly, higher oil

Lakshamanan, sundar

A Predictive Approach to Estimate Tyre Wear Characteristics

2024-26-031301/16/2024

Tyre wear is a significant concern for the automotive industry due to multiple reasons that include vehicle performance, safety, economy, environmental (particulate matter emission) aspects, etc. Therefore, ensuring higher tyre tread wear resistance is one of the most important criteria while developing a new tyre. Tyre wear phenomenon is influenced by various factors, such as, road conditions, driving habits, maintenance practices and tyre design parameters (construction, geometry and material). The wear assessment through classical field-testing approach consumes significant time and resources. Therefore, digital predictive tools are very useful in predicting wear characteristics at the early stage of tyre development process. In this study, an attempt has been made to capture the impact of tread geometry, tread material, vehicle geometry, vehicle speed, test track geometry, etc. on tyre wear. A commercial finite element code, Abaqus was utilized for tyre structural simulation and

Bedi, Vinay Kumar, Rana, Kashif, Mahata, Pundarik, Ghosh, Prasenjit, Mukhopadhyay, Rabindra

Fatigue Assessment & Test Correlation of Seam Welded Joints using Force Based Equivalent Structural Stress Solid Weld Approach

2024-26-026801/16/2024

The fatigue life of typical welded structures is governed by the stress concentration at welded joints & small crack propagation from some pre-existing discontinuities at notched regions. There are numerous weld fatigue assessment approaches available which are unified using commercial fatigue software codes in conjunction with traditional finite element methods. However, FEM stress-based approaches predict extensively conservative results. Considerable efforts & subjective decision making is required to arrive at desired level of weld life correlation with physical test results, in terms of weld life and failure location. This is majorly because of inconsistency & inaccuracy in capturing the hot spot stress results due to stress singularities occurring at the notched regions owing to the mesh sensitivity. Hence to address these concerns, a force based equivalent structural stress solid weld approach in commercial weld fatigue code fe-safe VERITY™ was used for developing correlation

Pendse, Ameya, Babar, Ranjit, Patil, Sanjay

Numerical Modelling of Stone Lofting by a Treaded Tyre

2024-26-027001/16/2024

Stone Chipping, it is the mechanical damage caused to the vehicle by small flying stones, from the tyre. This damage to the vehicle affects aesthetics, accelerates corrosion, and reduces safety, making it vital for the manufacturer to provide stone chipping protection mechanisms. The aim is to avoid stone chipping related damage to the bodywork and assembly components in the early development phase. Therefore, it is necessary to predict the degree of damage to figure out the suitable measures against stone chipping, and numerical simulation provide a promising approach to model stone lofting. The numerical multiphysics model proposed couples Discrete Element Method (DEM) for stones, Finite Element Method (FEM) for tyre deformation, Multi-body Dynamics (MBD) for suspension geometry. Initially the proposed methods ability to predict contact patch is examined, which shows that vertical deformation and contact length strongly agree with literature. For the stone lofting prediction, the

Kumar, Sourav, Babbar, Ritvik, Pattankar, Rohan, Venkatarama, Nithin, Yenugu, Srinivasa, Duggirala, Ravi

Crash simulation of palisade security fencing

2024-26-028101/16/2024

Palisade fencing can be effectively used for security purposes. For high-security establishments, palisade fences are being used as effective security barriers which can withstand high-speed vehicle impact and maintain a stand-off distance between the vehicle and the environment to be protected. The test setup being costly, the simulation-based approach will help in identifying the performance at the design stage itself. This paper discusses the explicit dynamic finite element analysis of the high-speed truck impact on the palisade fence as per ASTM F2656 standard using RADIOSS solver. Detailed finite element modeling of the fence for simulation is explained using various material models, load, and boundary conditions. Analysis output includes a variation of several parameters with time and some of such parameters include truck velocity, displacement and stress levels during the impact, energy absorption, etc.

Rathore, Gopal Singh, Kumar, Ankit

Utilizing Computed Tomography for Cell Characterization, Quality Assessment, and Failure Analysis

2024-26-018901/16/2024

This abstract presents an experimental study on using Computed Tomography (CT) scan technology for analyzing battery cell failures. Lithium-ion battery cells with known failure modes were subjected to cyclic test under different temperature and C-rates. CT scans provided high-resolution cross-sectional images of internal structures, revealing failure-related features. The advanced image processing techniques quantitatively assessed electrode morphology, active material distribution, and separator integrity. The study demonstrated CT scan's potential in non-destructive analysis, enabling a deeper understanding of failure mechanisms and informing improvements in cell design and manufacturing processes.

Singh, Sathya Prakash, Baidya, Kapil Krishna, ADHALE, Pratik

Tire-Rim Impact failure prediction using mathematical model

2024-26-031401/16/2024

Early design or concept phase involve decision of key Chassis & Suspension parameters finalization, in which tire size selection is one of the most important aspect. Tire size affects overall vehicle ride & handling, steering performance and styling. In addition, it will dictate the majority of suspension packaging in subsequent design phase. An improper tire size selection can lead to major design changes in later stages and cause delay in the project deliverables. Conventional method of tire size selection mainly based on load rating using Tire standards like ETRTO, JATMA etc. is sufficient for vehicle application & basic durability point of view but lacks the insight for typical tire-rim impact failure mode. Aim of the study is to develop the methodology of predicting durability failure especially kerb strike event using simplified suspension-tire mathematical model, which will help in selection of optimal tire size or its specifications in early design phase to mitigate the impact

Atal, Abhishek, Lakhera, Vivek

Scientific Approach for Pickup Cargo Weight Reduction

2024-26-019201/16/2024

Due to increasing competitiveness, the arrival of industry giants, product pricing, etc., the automobile market in India is becoming more dynamic to adopt the changes. Apart from this, the product needs to be competitive to capture market by lowering the benefit margin. After launch and gaining of mass volume of the market, the Value Analysis and Value Engineering (VAVE) helps in minimizing the design and development costs through removal of non-value adding processes and activities by understanding the product's value, functions, features, customer demand, quality, and Real-World Usage Pattern (RWUP) without affecting the performance and eventually help in increasing the profit margin of organization. In this study, the benchmarked based statistical Light Weight Index (LWI) technique is developed for the predicting the world in class optimum weight. For these four statistical Light weight Index numbers is derived based on the geometrical dimensions. This strategy is used for the

Patel, Mayank, Balasubramani, Sritharkumar, Pandurangan, Raman, Cornelio, Ronald, Senrayaperumal, Sakthivel, ved, Kapil, Mohan, Aravind

A General Workflow for Static Failure Criteria and Allowable Defect Size Calculation in Presence of Defects due to Manufacturing Process and Abusive Loads

2024-26-030501/16/2024

Manufacturing processes such as casting, welding and additive manufacturing (AM) are prone to internal porosity and high surface roughness on the manufactured parts. These defects are inherent in the process and cannot be completely eliminated. Handling, transport and maintenance of manufactured parts can also lead to defects such as scratches and dents due to abusive loads. The defects can be characterized in a number of ways, assuming they resemble a U-notch or V-notch, elliptical pores, or a continuous distribution of consecutive defects in combination with surface roughness. The designer utilizes existing analytical and empirical equations to predict stress concentration due to presence of various types of defects and compute factor of safety to ensure structural integrity of design subjected to various load cases. The applicability of existing analytical and empirical equations is studied, and modifications are suggested to improve the predictions. The limits of analytical

Kishore, Prateek, Mishra, Suraj, Vemula, Sai, Puranik, Shashank, Jivani, Chinmay, Aher, Ravi

Test Methodology Development For Rig Level Validation Of Light Weight Stabilizer Link Of EV Bus Suspension

2024-26-035701/16/2024

In the modern and fast growing automotive sector, reliability & durability are two terms of utmost importance along with weight ad cost optimization. Therefore it is important to explore new technology which has less weight, low manufacturing cost and better strength. The new technology developed always seek for a quick, cost effective and reliable methodology for its design validation so that any modification can be made by identifying the failures. This paper presents the rig level test methodology to validate and to correlate the CAE derived strain levels, life cycle & failure mode of newly developed light weight stabilizer link for EV Bus suspension. Stabilizer link replaces the existing separate arrangement of anti-roll bar and parallel rods and light in weight by 30kg.This stabilizer link arrangement is having the short lever arms which are connected through torsion bar which goes under twisting moment and the short lever arms are intended to control wheel motion in longitudinal

Tangade, Atul Bandu, Babar, Sunil, Bankar, Milind Achyutrao, Mehendale, Ravindra, Dhumal, Kailas, Bhusari, Deepak

Controlled Production Quantity Release Applicability Determination Method

2024-26-035501/16/2024

During product development or design change, the aim is to fully validate all potential issues. On programs with significant complexity, it is difficult or impossible to fully retire all combinations of risk factors even with comprehensive analysis and testing approaches. These complex projects have the highest risk to launching with hidden defects can result in high warranty costs and erosion of customer satisfaction. This paper discusses a conservative approach called Controlled Production Quantity Release (CPQR) to manage the risks of these complex releases or changes by presenting a decision framework executed by a cross-functional team to identify those complex releases that deserve the methodical and monitored approach necessary to manage risk. The purpose of this method is to gain early concurrence with the program team with documented decision criteria rather than relying on individual opinions. This paper focus on structured approach of determining the applicability criterion

Mohammed, Zubair, Freeland, James, Soma, Nagaraju, Quadri, Danishuddin S.F.

Testing and evaluation of Integrated Starter Generator system’s performance and durability characteristics in rig level using automation.

2024-26-036901/16/2024

Automobiles are incorporated with advanced technologies to improve riding experience, safety, and vehicle management. Considering riding experience, major concern prevails in starting and charging system. For quick start and stop, implemented Integrated Starter Generator (ISG) in two wheelers. ISG system consists of ISG machine and ISG controller. ISG machine acts as motor during cranking and generator during charging, controlled by ISG controller. Automation kit is made with help of real sensors, actuators, and microcontroller to monitor and log the performance characteristics of ISG system during testing in rig level. Sensors continuously monitors the performance parameters and once the parameters not meeting the specification, actuators stop the testing and rise the indication. All tested data stored in cloud and taken for analysis. This automation kit served two purposes. One is eliminated test running on the failure sample for full long testing duration. Second is from logged data

K, Vishali, Patil, Pratik, Kumaran, Adm V

Effect of environmental factors on the function of an Automotive Luggage Cover of a passenger vehicle – A case study

2024-26-022801/16/2024

Abstract: - Automobile OEMs, universally, have always given high priority to the Luggage Area of the vehicle. Luggage Area primarily includes a Load Floor (the load bearing part), Side & Rear garnishes & the Luggage Shelf (or the Parcel Tray) for covering the luggage. The Parcel Tray makes the Luggage Area look neat and aesthetically appealing & is occasionally also used for carrying small items like files, papers, cushion, tissue box etc. The article under consideration in this paper is a Luggage Cover made from thermoplastic composite such as PP-Compounds (with Glass-fiber or Wood-powder), with rotating hinges towards the cabin side. Such types of Covers are predominantly in use in many markets including India. In the vehicle, the Luggage shelf is suspended on the Side Trims or Garnishes & has an elastomer interface with the back Door. The back door tends to be opened and closed in frequent intervals and the elastomer tends to harden with time. This leads to increased load on

Sreejith, M P, Khandelwal, Lokesh, Sandilya, Arnab, Natu, Mandar R, Ray, Amulya Kali, Handa, Rajat

Dynamic Stress-Strain and Fatigue Life Estimation Using Limited Set of Measured Accelerometer Data on Exhaust System using System equivalent reduction and expansion process (SEREP)

2024-26-025101/16/2024

The dynamic response of structures to operating or occasional loads is crucial for design considerations, as it directly impacts the cumulative fatigue life and structural health monitoring. However, accurately determining the actual loading and structural condition, encompassing boundary conditions, environmental factors, geometry, and mechanical properties, presents challenges in practice. Significant efforts are invested in identifying these factors and developing suitable prediction models. Nonetheless, the estimated forces and boundary conditions remain approximations, leading to uncertainties and influencing the overall predicted response and resulting stress-strain analysis during subsequent evaluations. Many researchers commonly approximate the forces exciting the system using limited sets of measurement points. This approach involves estimating the forces and applying them to determine the finite element displacement and subsequent stress-strain distributions. However, this

Pratap, Rajat, Apte Sr, Amol, Poosarla, Shirdi Partha Sai

Reduction of carbon footprint using Additive Inspired design in Tractor Hydraulic systems

2024-26-007001/16/2024

Tractor usage is growing due to introduction of wide range of implements and applications. Tractor plays a major role in Agri and Construction applications. Due to the environmental factors, restrictions are set on the tractor emissions. This brings new challenge in the tactor industry to reduce the carbon footprint. By reducing the weight of the tractor, Co2 emissions can be reduced. Many of the components in the Hydraulic systems are made of metal casting. Conventional casting process involves preparation of die & mold, material removal at unwanted regions, machining in the final stage to get the desired final product. Contrary to conventional manufacturing process, Additive Manufacturing process is a transformative approach to industrial production that enables creation of lighter and stronger parts. The process involves creation of 3D component by adding material layer by layer. The advantage of this method is the minimum wastage of raw material and possibility of integrated

Dumpa, Mahendra Reddy, Perumal, Solairaj, K, Bheshma, Gomes, Maxson, Magendran, G, Redkar, Dinesh, Londhe, Abhijit

This is a testing Title

SM-SESSION-12052023-907AM12/05/2023

Finite Element Analysis (FEA) has been an indispensable tool for design simulation for several decades but this wide spread use has been limited to simple types of analyses. Relatively recently, more advanced analyses have given easy-to-use interfaces enabling design engineers to simulate problems formerly reserved for analysts. FEA Beyond Basics targets the FEA users who wish to explore those advanced analysis capabilities. It will demonstrate how to move past the ubiquitous linear structural analysis and solve structural nonlinear problems characterized by nonlinear material, large displacements, buckling or nonlinear connectors. The discussion will help participants identify, set up and solve complex nonlinear problems and as well as use results of nonlinear analysis to support the product design process. All topics are illustrated using FEA software, SolidWorks® Simulation, for which participants will be provided a student license (compatible with 64-bit Windows 7 SP1, 8.1, 10; IE

Friction Performance Analysis of Mine Wet Multi-Disc Brake

02-17-01-0001

10/28/2023

Abstract This article takes the wet multi-disc brake used in mining Isuzu 600P as the research object, establishes a simplified three-dimensional model of its key components through SOLIDWORKS and imports it into ANSYS Workbench to establish the flow field and structure field model of the wet brake. Based on the fluid–solid coupling, the finite element simulation of the temperature field and stress field of the friction pair of the wet brake under different braking pressures, braking initial speeds, and fluid viscosities was carried out, and then the position changes of the friction pairs at high temperature hot spots and high stress points were analyzed to determine the stability of its friction performance. Finally, by comparing the temperature change curves of the same point during the braking process under different braking conditions, the validity of the finite element analysis results is verified. The results show that the flow field pressure inside the wet brake is opposite to

Zhang, Chuanwei, Jin, Xiaohe, Zhao, Dawei, Liu, Jinpeng

Weld Fatigue Assessment of Rail Track Maintenance Machinery: Regulatory Compliance and Practical Insights

SAE-PP-0874609/29/2023

The use of appropriate loads and regulations is of great importance in weld fatigue assessment of rail on-track maintenance equipment and similar vehicles for optimized design. The regulations and available loads however are often generalized for several categories which proves to be overly conservative for some specific categories of machines. The work presented in this paper is about the strength and weld fatigue assessment of self-propelled rail on-track maintenance machines or similar equipment. It outlines the methodology and challenges associated with utilizing existing regulatory loads for weld fatigue assessment, specifically employing the endurance limit approach, also known as the infinite life approach. In cases where an endurance limit is undefined, particularly for welds, the fatigue strength limit at expected life cycles can be employed within the endurance limit approach. Availability of track-induced fatigue load data for the cumulative damage approach in track

Dongari, Madhukar

Applications of Neural Networks to Metallic Flexor Geometry Optimization of Flat Wipers

15-17-01-0002

09/09/2023

Abstract In recent years, demands of flat wipers have rapidly increased in the vehicle industry due to their simpler structure compared to the conventional wipers. Procedures for evaluating the appropriate metallic flexor geometry, which is one of the major components of the flat wiper, were proposed in the authors’ previous study. However, the computational cost of the aforementioned procedures seems to be unaffordable to the industry. The discrete Winkler model regarding the flexor as the Euler–Bernoulli beam is established as the mathematical model in this study to simulate a flexor compressed against a surface at various wiping angles. The deflection of the beam is solved using a finite difference method, and the calculated contact pressure distributions agree fairly with those based on the corresponding finite element model. Flexor designs are paired with various windshield surfaces to accumulate a sufficiently large simulation database based on the mathematical model. An

Chu, Yi-Tzu, Huang, Ting-Chuan, Liao, Kuo-Chi

Topological Optimization of Non-Pneumatic Unique Puncture-Proof Tire System Spoke Design for Tire Performance

15-17-01-0001-TEST-REC07/18/2023

Abstract Non-pneumatic tires (NPTs) have been widely used due to their advantages of no occurrence of puncture-related problems, no need of air maintenance, low rolling resistance, and improvement of passenger comfort due to its better shock absorption. It has a variety of applications as in earthmovers, planetary rover, stair-climbing vehicles, and the like. Recently, the unique puncture-proof tire system (UPTIS) NPT has been introduced for passenger vehicles segment. The spoke design of NPT-UPTIS has a significant effect on the overall working performance of tire. Optimized tire performance is a crucial factor for consumers and original equipment manufacturers (OEMs). Hence to optimize the spoke design of NPT-UPTIS spoke, the top and bottom curve of spoke profile have been described in the form of analytical equations. A generative design concept has been introduced to create around 50,000 spoke profiles. Finite element model (FEM) model is developed to evaluate the stiffness and

Dhrangdhariya, Priyankkumar, Maiti, Soumyadipta, Rai, Beena

Topological Optimization of Non-Pneumatic Unique Puncture-Proof Tire System Spoke Design for Tire Performance

15-17-01-0001

07/18/2023

Dhrangdhariya, Priyankkumar, Maiti, Soumyadipta, Rai, Beena

This is a testing Title

SM-SESSION-11272023-353PM07/13/2023

This is a testing Title

SM-SESSION-11292023-107/13/2023

This is a testing Title

SM-SESSION-11282023-301PM07/13/2023

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