Browse Topic: Analysis methodologies

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Determination of Trace Elements in High Temperature AlloysARP1313E (Current)5/8/2026
This SAE Aerospace Recommended Practice (ARP) describes procedures for the determination of trace elements listed in AMS2280 for Nickel, Cobalt, and Iron-based high temperature alloys.
AMS F Corrosion Heat Resistant Alloys Committee
Vehicle usage Digital Twins - Mobility analysis test case2026-26-03941/16/2026
In the evolving landscape of the automotive industry, this study presents an innovative approach to developing digital twins for driver profiles, establishing a standardized and scalable procedure for collecting and analyzing driving data on a global scale. The proposed methodology centers on the development of a robust cloud infrastructure, including a Data Lake and associated services, designed for efficient storage and processing of large volumes of data from multiple markets and vehicle types. The research introduces a adaptable procedure for data collection campaigns, applicable to diverse global markets and encompassing a wide range of vehicles, from internal combustion engines to electric and hybrid models. A key feature of this approach is the establishment of advanced data decoding protocols, enabling precise interpretation of CAN network information from vehicles of different manufacturers and models, even when the CAN structure is not previously known. The study defines
Arturo, Rubio, Marín Saltó, Anna, Diaz, Francisco, Olivencia, Sergio, Medina, Alba
Durability Validation of Full Vehicle Structures Using Strain Correlation and RLDA-Based Simulations2026-26-05231/16/2026
Durability validation of full vehicle structures is crucial to ensure long-term performance and structural integrity under real-world loading conditions. Accurate strain correlation between physical testing and finite element (FE) simulations plays a key role in the validation, ensuring reliable predictions of vehicle durability. In this paper, a comprehensive methodology for strain correlation on a full vehicle subjected to torture track testing is implemented. Strategic placement of strain gauges is determined through a combination of static analysis, modal analysis, and identification of critical stress regions in the FE model. Strain gauges were installed on key structural locations of a prototype to capture strain responses under severe loading environments. Simultaneously, vehicle wheel loads were recorded on the torture track to build a detailed Road Load Data Acquisition (RLDA) dataset at critical hard points, Loads measured in terms of wheel loads (WFT) are fed to MBD model to
JAJU, MAYUR, Dokhale, Sandeep, Gadre, Nilesh, Patil, Sanjay
Propeller Shaft Yoke Phase and Inclination angle Optimization in Passenger Vehicles through Analytical Method2026-26-03481/16/2026
Customer satisfaction is the most important parameter to achieve the success in the highly competitive automobile industry. Comfortable ride and handling are one of the important aspects for customer viewpoint. Propeller shaft is the critical components in the vehicle to affect the smooth operation of the vehicle. Propeller shaft universal joint (UJ) phase and inclination angle significantly affect the vehicle performance during frequent braking and acceleration. So, for this conditions, comprehensive study of the propeller shaft should be performed for smooth operation. In this paper, Propeller shaft UJ phase and inclination angle optimization is studied through analytical method, which are very essential parameter for optimizing induced vibration performance and comfort. Propeller shaft characteristics influenced by several factors like vehicle torque, propeller shaft joint type, materials properties, UJ phase and inclination angle and shaft unbalance value. By optimizing the above
Kumar, Sarvesh, Sanjay, L, S, Manickaraja, Kanagaraj, Pothiraj
Addressing Seat Belt Discomfort Among Indian Female Driving Population Through Anthropometric Data Collection and Simulation2026-26-00161/16/2026
The rate of female drivers in India is increasing alongside the rapid growth of the Indian automotive industry. A driving comfort survey conducted among female drivers revealed that many experiences dis-comfort when wearing seat belts—whether while driving or as front-seat passengers. This discomfort is primarily due to a phenomenon referred to as “neck cutting.” The root cause of neck cutting is likely related to vehicle design, which is traditionally based on Anthropometric Test Devices (ATD’s) representing the 50th percentile of the global population. However, a literature review indicated that the anthropometric dimensions of the Indian populations are generally smaller than those of the global for the respective candidate. This highlighted the need to collect region-specific anthropometric data for India. During this research work, Indian anthropometric data was collected through the Size India 2.0 project, covering a wide demographic region across India. This study was in
Kulkarni, Nachiket, Chitodkar, Vivek V, Eknath Chopade, Santosh, Yamgar, Babasaheb S, Mahajan, Rahul
Analysis and Optimization of Stick-Slip Behaviour in Metal-Plastic Interfaces for Connected Tail Lamp Assemblies in Electric Vehicles2026-26-03321/16/2026
The seamless and sleek design of connected tail lamps adds a visually striking element to the car's exterior. It aligns with contemporary automotive trends and gives the vehicle a premium and futuristic appearance. Automakers use these lamps as a design signature to establish brand identity. Connected tail lamps improve visibility for drivers behind the vehicle. The assembly of connected tail lamps can pose several challenges, especially due to their complex design and integration requirements. Metal-plastic creak is a common concern in electric vehicles (EVs), often noticeable when driving on uneven roads. This primarily results from stick-slip behaviour at the interface of metal and plastic components, intensified by improper alignment. When the designed geometric dimensioning and tolerancing (GD&T) is not met in real manufacturing conditions, misalignment introduces unintended contact forces, leading to intermittent micro-sliding and frictional energy release, which manifests as an
MICHAEL STEPHAN, NAVIN ESTAC RAJA, C M, MITHUN, Mohammed, Riyazuddin
A Novel Analytical Approach to Predict Vehicle Parking Brake Cable Performance and Optimize Cable Routing2026-26-04831/16/2026
The performance of vehicle parking brake cables are critical for ensuring vehicle safety and functionality. Vehicle manufacturer evaluate the robustness of cable performance at different road gradient conditions. Effort and stroke performance are among the key parameters for evaluating cable performance. While parking brake system should be designed to minimize effort losses through the cable routing, packaging constraints often prevent it. Therefore, it is essential to estimate the losses through cable routing and optimize parameters of the parking brake cable system. Currently, the methods used for evaluating cable performance are either experimental or empirical based. CAE methods using finite element analysis (FEA) and multibody dynamic approaches are computationally expensive and not yet fully established due to modelling and solving complexity of dynamic cable which involves continuously changing and updating contacts. The available analytical approaches incorporates cable system
Iqbal, Shoaib, sabri, SALAH, Siddiqui, Arshad
Experimental and Numerical Investigation of Modal Behaviour in Electric Two-Wheeler Frames2026-26-03101/16/2026
This research investigates the dynamic characteristics of an electric two-wheeler chassis through a combined experimental and numerical approach. The study commences with the development of a detailed CAD model, which serves as the basis for Finite Element Analysis (FEA) to predict the chassis's natural frequencies and mode shapes. These numerical simulations offer initial insights into the structural vibration behaviour crucial for ensuring vehicle stability and rider comfort. To validate the FEA predictions, experimental modal analysis is performed on a physical prototype of the electric two-wheeler chassis using impact hammer excitation. Multiple response measurements are acquired via accelerometers, and the resulting data is processed to extract experimental modal parameters. The correlation between the simulated and experimental mode shapes is quantitatively assessed using the Modal Assurance Criterion (MAC). This matrix provides a measure of the consistency and similarity between
Das Sharma, Aritrya, Iyer, Siddharth, Prasad, Sathish, Anandh, Sudheep
Streamlined Methodology for E-Motor Performance Evaluation using a configurable Universal Inverter2026-26-05101/16/2026
Electric motor benchmarking is often constrained by limited availability of motor-specific data, particularly when dealing with commercially available or third-party electric motors. This paper presents a streamlined and scalable methodology for characterizing unknown eMotors using a configurable universal inverter platform. The proposed approach is specifically designed for OEMs and Tier 1 suppliers seeking to evaluate performance metrics such as torque accuracy, peak and continuous capability, efficiency, and control behaviour—without prior access to key motor parameters or simulation data. A central challenge in this context is the stepwise electromagnetic characterization required to determine the phase current needed for accurate speed and torque control, especially under a Maximum Torque per Ampere (MTPA) or Maximum Torque per Watt (MTPW) strategy. As this requirement is highly dependent on the motor’s topology and electromagnetic properties, most conventional approaches rely on
Kanya, Benjamin, Duchi, Francesco, Ravi, Abhishek
Rear Wiper Motor with Nozzle Integration for Improved wiping performance and Perceived Quality2026-26-06001/16/2026
In the current modern days of driving, rear wiping performance plays a crucial role in safe driving. This study focuses on improving the rear wiping with add on benefits like improved BSR performance, cost saving and perceived quality. This new concept has the rear wiper motor assembly which accommodates the nozzle also thereby making it a single unified assembly with reduced system complexity. This concept eliminates the complex hose routing of washer system for rear wiping which is usually packaged at spoiler or HMSL. It also helps in improved spray coverage and reduced dry wiping which in turn enhances system reliability with clean & quiet operation. This integrated nozzle concept is much more compact than the available products in the market with minimum number of end items. Also, this design comes with non-return valve which ensures there is no delay in the spray execution. And it improves the cleaning efficiency by maintaining consistent fluid pressure. This concept comes with
Dhage, Prashant, K, NAGARAJAN, G, Sabari Rajan
Reverse Engineering and Digital Twins in Powertrain Design: Enhancing Performance and Sustainability2026-26-00651/16/2026
This study explores the application of reverse engineering (RE) and digital twin (DT) technology in the design and optimization of advanced powertrain systems. Traditional approaches to powertrain development often rely on legacy designs with limited adaptability to modern efficiency and emission standards. In this work, we present a methodology combining 3D scanning, computational modeling, and machine learning to reconstruct, analyze, and enhance internal combustion engines (ICEs) and electric vehicle (EV) drivetrains. By digitizing physical components through RE, we generate high-fidelity DT models that enable virtual testing, performance prediction, and iterative improvement without costly physical prototyping. Key innovations include a novel mesh refinement technique for scanned geometries and a hybrid simulation framework integrating finite element analysis (FEA) and multi-body dynamics (MBD). Our case study demonstrates a 12% increase in thermal efficiency for a retrofitted ICE
Bernikov, Mark Alexandrovich, Kurmaev, Rinat
Investigating Thermal Fatigue Cracks in Exhaust Manifolds of Longitudinally Mounted 1.2L 4-Cylinder Engines2026-26-04881/16/2026
This study addresses the challenge of ensuring the durability of closed couple exhaust manifolds in the compact engine bays of modern vehicles, focusing on a longitudinally mounted 1.2L 4-cylinder engine. The original sheet metal Exhaust manifold design failed thermal fatigue bench durability test, requiring a complete redesign to improve strength without changing materials. Initial simulation predictions significantly deviated from physical test results, with repeated cracks observed during accelerated thermal fatigue bench testing, despite simulations predicting a higher number of cycles before failure. This difference highlighted the need for a deeper understanding of the manifold's failure modes, primarily thermal fatigue, and mechanical vibration during engine transients. The design of experiment (DOE) approach was used to find the effect of different parameters e.g., gas temperature, surface temperature, air flow, thermal gradient, on the durability result & also to understand
Krishnan, K.S.Gopala, Mishra, Ashutosh, Yadav, Sanjay Kumar, Kumar, Deepak, Tripathi, Manas, kumar, prabhakar
Test method and set up development for electric parking brake performance and durability validation in vehicle level as per RWUP2026-26-05051/16/2026
The Objective is to develop a testing load case which can assess vehicle electric parking brake (EPB) performance and durability at vehicle level in different project development phases. In current scenario the EPB become one of a primary feature available in many passenger vehicles helps customers to apply this secondary braking system to hold the vehicle when parked. So, it is particularly important to evaluate this feature close to RWUP for the vehicle service life and studying the result before vehicle launch. The test method should be capable of capturing failures related to physical concerns, electrical characteristics, actuation time, gradient vehicle hold, effectiveness during vehicle running and durability. The most important challenge in this test method development is it should simulate the actual sequence followed by user in field on vehicle. A completely automated test set up integrating PLC and COBOT with closed loop feedback developed and discussed in this paper. During
DHANAPAL, M R, Vijayakumar, Narayanan, MAHESH, B, B, VENKATASUBRAMANIAN, Arthanathan, Sankaranarayanan
Dimensional Management in Automotive Vehicle Design & Development for Perceived Quality Improvement in Buses2026-26-04471/16/2026
Perceived quality (PQ) is one of the most important factors in engineering signoff as well as customer delight and product improvement (feel, look & touch). The PQ is something related to feel of the product in terms of gap, flushness, fitment and appearance as per the costumer perceptions and expectations. Validate both design and engineering with the perceived quality review. In today's automotive bus industry this is equally applicable. In this paper we have explored the dimensional management scope in improving the PQ requirements and expectations by utilising the dimensional variation analysis (DVA) approach. We have explored & explained the fundamentals of vehicle aggregates fitment process and impact of fitment tolerances as used in DVA model to resolve vehicle packaging issues (critical gaps & clearance variation as per expected no. of vehicles to be manufactured in future at initial stage of the vehicle design). It is further extended into system level DFMEA to include DVA in
Singh, Vinay Kumar, Dewangan, Ved Prakash, Kumar, Rahul, Deep, Amar
Evaluation of Thermo-Mechanical behavior of brake discs in vehicles using Multidisciplinary approach2026-26-04331/16/2026
The objective of this paper is to evaluate the thermal performance of the brake discs in the design stage of its life cycle by developing a methodology to replicate the dynamometer testing using multi-disciplinary Finite Element Analysis (FEA) methods. A simulation workflow was formulated in which Computational Fluid Dynamics (CFD) was used to create temperature and velocity dependent Heat Transfer Coefficients (HTC) which were in turn used in Computer Aided Engineering (CAE) to do a thermo-mechanical analysis. With this workflow various designs of the brake discs were analyzed. A sensitivity study was done to determine critical design features that affected its thermal performance. A final design was fixed that met both the weight and thermal performance targets. This design was evaluated in dynamometer testing, and 95% correlation was achieved. Thus, the developed simulation workflow ensured that a first-time right brake disc can be finalized in the design stage, which will meet the
Balaji, Praveen, K, Karthikeyan, S, KESAVPRASAD, S Kangde, Suhas
Johnson-Cook model calibration for brittle materials under impact loads2026-26-03671/16/2026
In the assessment of parts subjected to impact loading, the current process relies on static analysis, which overlooks the significant influence of high strain rate on material hardening and damage. The omission of these effects hinders accurate impact simulations, limiting the analysis to comparative studies of two components and potentially misidentifying critical hot spot locations. To address these limitations, this study emphasizes the importance of incorporating the effects of high strain rate in impact simulations. By utilizing the Johnson-Cook material calibration model, which includes both material hardening and damage models, a more comprehensive understanding of material behavior under dynamic loading conditions can be achieved. The Johnson-Cook material hardening model accounts for the strain rate sensitivity of the material, providing an accurate representation of its behavior under high strain rate conditions. This allows for improved prediction of material response
Pratap, Rajat, Apte Sr, Amol, Babar, Ranjit, Dudhane, Karan, Poosarla, Shirdi Partha Sai, Tikhe, Omkar
Coupled Thermo-Mechanical Simulation Framework for Structural Evaluation of Battery Pack2026-26-04141/16/2026
With the rapid adoption of electric vehicles (EVs), ensuring the structural integrity and thermal safety of lithium-ion battery pack has become a critical priority. Battery failures resulting from mechanical abuse, thermal stress, internal pressure build up or electrical faults may lead to structural failure. To address these challenges, it is essential to understand the coupled thermal and mechanical responses of battery structure under extreme conditions. Thermo-mechanical simulation serves as a powerful tool for predictive safety assessment and design optimization, particularly in addressing thermal propagation and pressure-induced failure events. This study presents a comprehensive coupled thermo-mechanical simulation framework designed to evaluate the structural performance of EV battery enclosures under worst-case thermal and overpressure conditions. The methodology involves high-fidelity three-dimensional modeling of the battery pack enclosure, incorporating realistic material
BHAT, SADASHIV C, Sugumar, Mohanraj
A Novel Approach to Deep Drawing Using Hybrid System and Pneumatic-Assisted Forming2026-26-03011/16/2026
ABSTRACT: This paper presents a novel Plunger-Integrated Hybrid System aimed at enhancing the efficiency and performance of deep drawing operations in metal forming processes. The proposed hybrid system strategically combines the mechanical strength of metals with the elastic flexibility of polymers, specifically polyurethane rubber, to improve formability and reduce spring-back, two critical challenges in conventional sheet metal forming. A novel two-stage forming technique is employed, an initial drawing operation using a larger radius with polyurethane rubber, followed by final radius formation using the same rubber in conjunction with a pneumatic cylinder. This integrated approach ensures uniform force distribution via the embedded plunger, significantly minimizing forming defects and enhancing the dimensional accuracy of the final components. The solution has been validated using Finite Element (FE) simulation methods, confirming its capability to produce high-quality parts
Chava, Seshadri Reddy, Singh, Prakhar, DHANAJKAR, NARENDRA, Roy, Amlan, Raju, Gokul
Thermo-Mechanical Fatigue Assessment of Cylinder Heads Using Advanced Simulation Techniques2026-26-04651/16/2026
Thermo-mechanical fatigue (TMF) is a critical durability concern for cylinder heads in internal combustion engines, particularly under severe cyclic thermal and mechanical loads. TMF-induced damage often initiates in geometrically constrained regions with high thermal gradients and can significantly reduce component life. As performance demands increase, understanding and mitigating TMF becomes essential to ensure the structural integrity and long-term reliability of engine components. This study presents a simulation methodology for evaluating thermo-mechanical fatigue (TMF), a temperature-dependent low-cycle fatigue (LCF) mechanism that arises from repeated thermal expansion and contraction under mechanical constraints, leading to cyclic plastic deformation and damage. The methodology consists of two key phases. Phase I involves global finite element (FE) simulations—both thermal and structural—to obtain temperature and displacement fields under rated and idle engine conditions
Ghotekar, Sunil, Kumbhar, Dipak Madhukar, Pendse, Ameya
Development of a Lightweight Front-End Structure Using Injection Molding Technology2026-26-03041/16/2026
This paper presents the development of a lightweight, functionally integrated Front-End Module (FEM) utilizing plastic-metal hybrid injection molding technology. The objective is to achieve modularization, part consolidation, weight reduction, and cost efficiency. The proposed design integrates multiple components into a single module which makes assembly faster and easier. A mounting strategy with fixation features was integrated into the structure to effectively support various components.To ensure structural performance, component-level Finite Element Analysis (FEA) was performed, including static strength, bending and torsional stiffness, hood retention tests, and modal analysis. Ribbing patterns were optimized to meet design stiffness targets while minimizing weight. Moldflow analysis was carried out to evaluate manufacturability, focusing on gate design, weld lines , warpage, and flow balance. Necessary design corrections were implemented prior to tool development to ensure
Srivastava, Sanjay, Thakoor, Shruti Ghanashyam, Sonkusare, Shailesh
Advanced Welding Process Simulation for Prediction and Control of Distortion and Residual Stresses in Automotive Sheet Metal Component Assembly2026-26-04121/16/2026
Welding simulations are transforming industrial manufacturing by enabling a predictive and first-time-right approach for process development. Advanced techniques such as Finite Element Analysis (FEA) help in accurate prediction of temperature distribution, residual stress, distortions and potential defects prior to physical welding which in turn support for addressing key challenges associated with Heat Affected Zones (HAZ) like distortion, fitment issues and post-weld cracking. Early integration of simulation in the development cycle significantly reduces lead time, enhances durability, and improves manufacturing efficiency. This study presents a simulation-based product development approach to mitigate post-weld crack generation issues in a complex multiple weld configuration of an automotive sheet metal assembly. The methodology adopts a two-stage framework: first, identifying the root cause of crack generating through baseline weld simulation; and second, implementing design
Nalawade, Rahul, Deshmukh, Kishor Pandurang, Vidhate, Digambar, Prakash, Ved, Dabhadkar, Mandar Mukund
Sustainable, Innovative, Cost-Effective, Lightweight Roof Design for Automotive Commercial Vehicle2026-26-02931/16/2026
The automotive industry is progressively concentrating on sustainability, cost-efficiency, and safety, prompting the necessity for innovative design solutions. This paper presents the development of a groundbreaking lightweight Roof assembly for commercial vehicles, focusing on the essential aspects of roof strength and crash compliance. The proposed design notably reduces weight while enhancing structural integrity, strength and overall safety, addressing the growing demand for eco-friendly and efficient automotive components. Our research employs comprehensive finite element analysis (FEA) alongside rigorous real-world testing to validate the design's performance. These evaluations demonstrate the roof assembly's ability to withstand significant impact and deformation, ensuring robust safety standards. In addition to performance assessments, we conduct a thorough cost-benefit analysis to evaluate the economic viability of the design. The analysis underscores the potential for
Pandey, Sudheer, Navsariwala, Prashant, Ganesan, Balaji
Material-Optimization in Rib-Stiffened Polymer structures: A Computational & Analytical Study2026-26-04981/16/2026
Background The demand for lightweight yet rigid polymer components continue to drive innovation in structural design, particularly for applications requiring optimal stiffness-to-weight ratios. This study examines an alternative rib-stiffening approach for polypropylene plates, where conventional single-rib geometries are reconsidered in favor of parallel micro-rib configurations. While single ribs have been extensively studied, the potential benefits of distributed rib architecture remain less explored, particularly regarding their combined bending and shear performance. Key objective: This study systematically evaluates how parallel rib configurations influence mechanical performance in polypropylene plates, with specific focus on:  Bending stiffness preservation through optimized moment of inertia distribution  Shear resistance enhancement via controlled rib spacing  Coupled effect of the bending and shear resistance Prior art and their limitations: Current literature primarily
Sreejith, M P, Jain, Deepak, Maheshwari, Pankaj, Kumar, Mandeep, Ravi, Abhikrishna
Comprehensive Evaluation of Bolster Behavior: Field Data Insights for Design Modifications2026-26-04971/16/2026
Bogie suspension systems are increasingly being used in tipper vehicles to enhance their performance and durability, especially in demanding environments like construction and mining areas. Bolsters play a very crucial role in the bogie suspension systems of tipper vehicles, contributing significantly to their overall performance and durability. Bolsters help in evenly distributing the load across the suspension system, reducing stress on individual components and enhancing the vehicle’s stability. They act as shock absorbers, mitigating the impact of rough terrains and heavy loads, which is essential for maintaining the structural integrity of the vehicle. By dampening vibrations, bolsters improve ride comfort and reduce wear and tear on the vehicle’s components, leading to longer service life. Bolsters assist in maintaining proper alignment of the suspension system, ensuring optimal performance and safety. This study focuses on the comprehensive testing and evaluation of bolsters to
V Dhage, Yogesh, Kolage, Vikas
EVALUATION OF DRIVELINE NVH PERFORMANCE USING LINEAR DYNAMIC FINITE ELEMENT SIMULATION2026-26-03221/16/2026
Automotive driveline design plays an important role in the NVH characteristics of the overall vehicle. Driveline systems are an integral part of delivering torque from the engine/transmission to the tires which propel the vehicle and drivelines often experience a wide frequency of excitation which poses unique NVH challenges. With the increasing trend in the automotive industry to introduce turbocharged engines with fewer cylinders while delivering the same torque / power, the driveline systems are excited with increased lower frequency torsional vibration in addition to other vibrations transmitted from powertrain and road. In this paper, we address the key design consideration for developing an optimal driveline system with consideration to NVH while keeping durability and other functional requirements in perspective. We consider the example of a front wheel drive-based vehicle architecture with independent suspension. The effect of fundamental prop shaft frequency to determine
JOSHI, ATUL KAMALAKARRAO, Subramanian, MANOJ
Challenges in Compliance Testing of off-Board Electric Vehicle Chargers: Analysis of Typical Failures and Remedial Measures2026-26-05821/16/2026
As India accelerates the adoption of electric vehicles (EVs) the development of a scalable, reliable, and efficient charging infrastructure becomes critical to ensuring the success of EV adoption. During type testing, the off board AC/DC EV chargers undergo a comprehensive assessment to ensure they meet safety and performance standards required by regulations. The tests examine crucial factors like electrical safety, EMC (electromagnetic compatibility), interoperability, environmental endurance, and mechanical strength. This paper provides information of the mandatory compliance requirements and highlights typical failure modes observed during the validation process of off-board chargers. Emphasis is placed on challenges associated with electrical safety, EMC performance, and interoperability. The objective is to support charger manufacturers to identify potential issues during design and development.
Murumkar, Aditya, Mulay, Abhijit B
Experimental Evaluation of Metro Rail Bogie Frame through Bench Testing2026-26-05611/16/2026
Bogie frame is a main skeleton and structural member in railway system which is carrying all the loads such as Suspensions,Axles,wheels, car body, Motor, Gear box etc. The frame is subjected the exceptional and service stresses in Vertical, Longitudinal, Lateral and twist directions throughout the service life which should be withstand for a life span of 30 years without failure. The purpose of this project is to determine the Structural integrity of the Metro rail bogie frame in consideration with EN13749 standard .This paper is the outcome of bench testing of metro rail bogie frame with the application of multiaxial loading in static and dynamic campaign through which stress data is collected with strain gauge sensors and correlated with the FEA results at design stage. This helps to verify and evaluate the design and validate the quality of metro rail frame as per the requirement specified in EN13749 European standard in early design stages.
Tormal, Uday Bapurao
Powering the Future: Addressing Power Architecture bottlenecks in Next Gen Automotive Platforms.2026-26-06881/16/2026
As the automotive industry moves from conventional function oriented embedded ECU-based systems to Code-driven system, the core electrical and electronic (E&E) architecture is also being redesigned to support more software-driven functionality. Modern and centralized architectures promise scalability and software-driven flexibility, but they also introduce significant challenges in power distribution-an area that remains underexplored despite its critical role in overall vehicle safety and performance. Our paper aims at the adoption of the traditional power distribution approach for Next Gen vehicle architecture. It requires a fresh look at how power is distributed. In a novel E&E architecture, a single power harness supplies battery voltage to each zone. If there's a failure or voltage drop, it can affect multiple functions within that zone at once, and management of voltage regulation, thermal dissipation, and EMI/EMC compliance becomes crucial. Adding to the complexity, safety
Borole, Akash, CHAKRA, PIPUN, Warke, Umakant
Experimental Frequency-Based Substructuring for Full-Vehicle NVH Characterization in Electric Vehicles2026-26-03091/16/2026
Electric vehicles introduce new NVH challenges due to high-frequency excitations from e-motors and associated electronics. These excitations, often in the kilohertz range, are primarily transmitted as structure-borne noise and require advanced experimental methods for accurate characterization and mitigation. Traditional simulation approaches are insufficient to capture the true dynamic behavior of complex components under operational boundary conditions. This study presents a fully experimental Frequency-Based Substructuring (FBS) methodology applied to a complete electric vehicle. Frequency Response Functions (FRFs) of individual subsystems—such as the e-motor, mounting system, inverter housing, and body connection points—are measured and transformed using Virtual Point Transformation to obtain consistent six-degree-of-freedom representations. These Virtual Point models are assembled into a full-vehicle system to investigate the structure-borne transfer paths to the vehicle interior
Kohlhofer, Daniel, Pingle, Pawan Sharad, de Klerk PhD, Dennis
Machine learning model to predict Chest Injury during Thorax Impact on Human Body Models2026-26-06651/16/2026
In recent years, virtual models have been handy in predicting potential injury risk to occupants in vehicle crashes. Virtual models offer detailing of occupant anthropometry and closest possible bio-fidelity over existing test devices. This study focuses on the assessment of chest deflections in frontal thorax impacts using virtual human body models of a few anthropometries and transforming the assessment of injuries of broader range of anthropometries (population). The study utilizes machine learning models to enable injury assessment across a broader range of body types. The study has taken a standard test scenario (Kroell load case) having frontal blunt thoracic impact. The load case is replicated in LS-DYNA and finite element human body models (HBMC) of 05th Female and 50th Male are used. The simulation setup replicates the boundary conditions as per literature, the responses necessary to measure chest deflection were validated & recorded. The outputs from the simulations and data
Sridhar, Raam, Arya, Bibhu, Divakar, Prajwal, R, Udhaya Kumar, Bhutki, Prasad, Kumar PhD, Devendra, Kurkuri, Mahendra, Mohan PhD, Pradeep
Virtual Strain correlation with measured strain test data over Frame using nCode Design Life2026-26-05451/16/2026
Physical tests serve as a benchmark to validate and improve the accuracy of CAE models. If the CAE results correlate well with physical test data, it confirms that the simulation is reliable and can be used for predictive analysis. Earlier for correlation, we use stress output from generic load-cases and single max value of measured strain data which was inappropriate to get exact correlation. Since output of virtual strain gauge is strain history, so entire characteristics can be compared i.e. magnitude and phase. In this paper, we have used nCode Design Life’s virtual strain gauge approach to correlate an FE Model’s (Frame) result with measured strain gauge data of RLDA test. If the model has been properly meshed, loaded, and constrained, the predicted virtual strain from Design Life will correlate with the measured strain. In this problem, model (Frame) is loaded with unit force and moment in all three directions at 31 locations (Hardpoints). Virtual Strain gauge calculates the
Kumar, Mohit, Dhole, Avinash, Trigune, Vinayak, Kangde, Suhas
SEooC-Based Design Framework for Integrated EV Power Conversion Systems under ISO 26262 Compliance2026-26-01921/16/2026
The rapid integration of electric vehicle (EV) power conversion elements—such as traction inverters, onboard chargers, and DC-DC converters—into unified architectures poses new challenges for ensuring functional safety compliance as per ISO 26262. This paper presents a system-level framework that leverages the Safety Element out of Context (SEooC) approach to design and validate reusable safety-critical components independent of vehicle-specific applications. By defining clear assumptions of use and ASIL decomposition strategies, the proposed method facilitates early-stage fault analysis and verification. The framework integrates model-based development with Hardware-in-the-Loop (HIL) testing and formal verification techniques to validate both control logic and hardware behavior under diverse fault injection scenarios. The result is a scalable, standards-compliant methodology that reduces time-to-market and enhances reliability in integrated EV power electronics platforms. The work
Uthaman, Sreekumar, Mulay, Abhijit B, Gadekar, Pundlik
Digital Twin for Motor & MCU incorporating Deep learning AI-ML algorithms for intelligent prognostics for Electric vehicles2026-26-04791/16/2026
As electric vehicles (EVs) become more advanced, so ensuring the reliability of critical components like the motor and Motor Control Unit (MCU) is essential. This paper presents a digital twin model designed to predict failures in motor and MCU components using machine learning. The approach focuses on detecting early signs of failure through real-world data and advanced analytics. We collected thermal and performance data from field vehicles, capturing both normal (healthy) and abnormal (faulty) operating conditions. Using this dataset, we developed and trained an Auto Encoder-based machine learning model that learns what “normal” looks like and flags deviations as potential issues. One key outcome of this study is the successful early prediction of Insulated Gate Bipolar Transistor (IGBT) degradation, where the system identified subtle behavioral changes long before any visible failure symptoms appeared. This digital twin acts as a virtual replica of the physical components
Joshi, Pawan, Pandey, Suchit, KONDHARE, Manish, UPADHYAY, ABHAY, JaganMoahanarao, Vana, Tank, Prabhu
Multi-Material Front Structures: A Pathway to Safer and More Sustainable Vehicle Design2026-26-04561/16/2026
Frontal crash structures play a vital role in occupant safety, but traditional designs often involve a trade-off between structural strength and weight efficiency. In the pursuit of safer and more sustainable mobility, this study explores a physics-based methodology that leverages the principle of dynamic equilibrium to guide the integration of dissimilar materials in front-end vehicle structures. Specifically, we examine a novel configuration wherein aluminum High pressure die cast (HPDC) is introduced in swan neck region of the front longitudinal member, while retaining steel in the frontal crush zone. This arrangement aims to redistribute crash loads and control deformation mechanisms, enabling improved energy absorption without compromising structural integrity. To evaluate the proposed strategy, a series of detailed finite element simulations were conducted using LS-DYNA, a widely adopted tool for vehicle crash analysis. The results reveal that the dynamic equilibrium approach
Revanth, Goshika, Bhagat, Milind, Joshi, Vikas, Mankhair, Abhijit, Sudarshan, B.Sudarshan, Kollipara, Jahanavi
Fatigue Life Prediction Methodology for Vehicle Suspension System and correlation with Physical Test2026-26-04591/16/2026
Fatigue Analysis is a safety critical area in design engineering for load bearing members. The design of a durable suspension system forms the foundation of vehicle architecture. The challenge lies in accurately predicting fatigue in critical areas to reduce field failures, primarily due to the absence of a validated methodology for fatigue calculation. This study provides an overview of fatigue assessment for Knuckle assembly/Rear Twist Beam based on digital Road Load/test Data for Finite Element Analysis (FEA) process for design development. This study makes use of Computer Aided Engineering (CAE) solvers such as Optistruct for model setup and fatigue tool such as nCode/FEMFAT for Fatigue Analysis. The methodology used for Fatigue estimation of rear suspension components such as Rear Twist Beam and Knuckle assembly is based on Digital Road Load Data/duty cycle loads applied to the suspension components at the hard point location at assembly level. The fatigue process used for
Kokare, Sanjay, Nagapurkar, Tejas, Iqbal, Shoaib
Automated evaluation of drive file simulation accuracy2026-26-05281/16/2026
In the area of structural durability testing using servo-hydraulic actuators, developing drive files for the actuators is a major step. Testing outcomes depend on ensuring the simulation accuracy of each drive file. These drive files are developed in an iterative process for different test track surfaces at different road and load combinations till the time we achieve better correlation. Evaluation of simulation accuracy of the drive files is an extensive manual review process, making it time-consuming and resource-intensive. To address this challenge, an application has been developed to automate the comparison of actuator signals with predefined target signal files. This tool enables quick and accurate analysis of each drive file in a test run, facilitating a comprehensive review of signal deviations. Each test run has thousands of drive files based on road-load mix and actuator settings. This application helped us significantly optimize the simulation workflow by reducing the manual
SONI, YASH, Katake, Vrishali, Mullapudi, Dattatreyudu, Chaskar, Mithun
Tractor Cabin Structure Borne Noise Reduction in the Virtual Environment2026-26-01011/16/2026
In recent days, cabin variants in the tractor are preferred by the farmers for the Coziness and longer field hour operation with less fatigue. Noise perceived by customer is the most important factor taken into account during the design stage, as it’s directly linked with operator’s comfort. Observed noise levels has to be within the defined limits as per national/international standards Overall cabin noise levels is contributed by the structure borne noise below 630 Hz. Structure borne noise is the noise typically radiated by the door, roof, windshield, floor, fender and structure assembly due to the engine excitation through the transmission housings and backstories. This paper depicts the process of tractor cabin structure borne noise prediction in the virtual environment. Firstly, Engine bearing loads and axle bearings has been extracted in the virtual stage from the vehicle level driveline model using commercially available MBD software. The finite element (FE) model of the cabin
gunasekaran, pandiyanayagam, K, Somasundaram, Chavan, Amit
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-05011/16/2026
Manufacturing tolerances pose considerable challenges in the production of rubber-based components, often leading to dimensional variations that can compromise overall product reliability. These inconsistencies may result in a range of functional issues, including poor sealing, excessive wear, misfit during assembly, and premature failure. Among these components, grommets are especially sensitive due to the complex, non-linear behavior of rubber materials, making precise dimensional control critical to ensure consistent and dependable performance. Even minor deviations in grommet geometry can trigger substantial assembly difficulties. Issues such as misalignment, buckling, insertion challenges, and potential damage to neighboring parts are commonly encountered. These complications typically require multiple rounds of design revisions and physical testing, which extend development timelines and significantly increase production costs. Real-world observations from various automotive
Beesetti, Siva, Hattarke, Mallikarjun, James Aricatt, John, PATHAN, ERAM
A systematic debugging methodology for identifying electric vehicle level EMC issues2026-26-05251/16/2026
Electric two and three-wheelers present unique challenges in electromagnetic compatibility testing due to compact packaging, high-frequency switching, and low shielding practices. This paper presents a systematic debugging methodology for identifying and mitigating radiated emission and radiated immunity issues in these EV platforms. A comprehensive approach is outlined, covering radiated emission measurement, Bulk Current Injection based immunity simulation, and near-field probing techniques. For RI evaluation, BCI testing in the 20 MHz to 400 MHz range is used to simulate radiated threats on the vehicle's power and signal harnesses. For RE diagnosis, conducted emission measurements on vehicle harnesses are performed using current probes to capture high-frequency currents. Additionally, near-field electric probes are used at the component to identify dominant noise sources such as DC-DC converters, Motor control unit, and improperly grounded shielding. Case studies on 2W and 3W EVs
M, Gokul, Patel, Jinay, Mulay, Abhijit B
Study of structural reliability for railway gearbox bolts2026-26-04911/16/2026
With growing advancements in railway industry in India, structural reliability of railway gearboxes is paramount for the safe and efficient operation of railway systems. This study investigates the reliability of bolts connecting gearbox housings using the VDI 2230 standard, a comprehensive guideline for the calculation of high duty bolted joints. The VDI 2230 methodology is employed to evaluate the stress distribution, fatigue life, and failure probabilities of the bolts under various operational conditions. Finite element analysis (FEA) is utilized to simulate real-world loading scenarios, providing a detailed understanding of the stress and strain behavior in the bolts. The theoretical calculations are validated through these simulations, ensuring accuracy and reliability of the results. The findings reveal that adherence to the VDI 2230 standard significantly enhances the structural integrity and longevity of railway gearbox bolts. By following these guidelines, the likelihood of
Kamble, Guruprasad, BODARE, TUKARAM
Multiphysics Simulation based Approach to Evaluate the Thermal Behavior of Electric Motors through Electromagnetic Loss Distribution Mapping2026-26-03871/16/2026
High power and torque density electric motor is finding increasing demands in modern-day electric and hybrid vehicles because of compact and light-weight designs. These high-performance requirements are achieved by increasing the current flow as well as downsizing the motor dimensions and hence can lead to multiple failure modes if not designed properly. Higher current flow results in increased magnitude of losses within the motor components such as ohmic loss, iron loss, hysteresis loss and mechanical losses. All these localized losses contribute to higher operating temperature and temperature gradient that can act as a catalyst to several modes of failure. Hence, accurate prediction of temperature distribution across the motor components is very much crucial to come up with a robust and durable motor design. A common approach of predicting the component temperature is by assuming bulk losses for lamination stack, hairpin and magnets. This approach might be beneficial for comparison
Munshi, Irshad Ahmed, ELANGO, GOKUL, Karmakar, Nilankan, Prasad, Praveen
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-02801/16/2026
This paper presents a comprehensive numerical method intended at developing a coupled process structure simulation that integrates both elastoplastic and anisotropic material behavior for short glass fiber-reinforced injection-molded thermoplastics. Three engineering tools, namely Moldflow, Digimat, and ABAQUS are used in the current numerical methodology to assess material anisotropy and its influence on thermo-mechanical characteristics. The simulation incorporates fiber orientation concerns as well as potential injection molding defects known as weld lines, linking with thermo-mechanical simulations. The behavior of real injection-molded components is computationally represented by the ability to transfer data from injection molding software (Moldflow) to structural software (ABAQUS). Besides, integrating with multi-scale modeling software Digimat as an interface tool, the results of the Moldflow simulations, such as fiber orientations and weld-line properties transmitted directly
T, KALINGA, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Implementation of new educational technologies for training personnel for the transport industry2026-26-02411/16/2026
Today's challenges affect the system of training highly qualified personnel for the transport industry, which is actively transforming through the introduction of innovative educational technologies. Key areas have become digitalization of the educational process, integration of virtual simulators, augmented reality technologies (AR/VR) and platform solutions for managing educational programs. Today, transport education in Russia is focused on advanced training of specialists capable of working with autonomous transport and neural network solutions. Development prospects are associated with further integration of adaptive educational trajectories and global network platforms to ensure the competitiveness of graduates in the digital economy. Taking into account the specifics of the modern Russian transport industry, using an analytical method, the article examines solutions to some priority problems, namely: • Methods of modernizing educational programs through designing «professions of
SHISHANOV, Sergei, Kurmaev, Rinat, revenok, Svetlana
Development of an Software Algorithm Based Semi-automated Data Acquisition System for Gasoline Vehicle Calibration on Chassis Dynamometer2026-26-05351/16/2026
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.2026-26-04891/16/2026
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 Systems2026-26-05421/16/2026
Abstract—The high-pressure hydraulic pipeline in the power steering system is a vital component for ensuring optimal performance. During warranty analysis, leakage incidents were observed at the customer end within the warranty period. The primary factors contributing to these failures include pipe material thickness, material composition, mechanical properties, and engine-induced vibrations. This study investigates fatigue-related failures through detailed material characterization and Computer-Aided Engineering (CAE) based on real world usage road load data collected. The objective is to identify the root causes by examining the influence of varying pipe thickness on fatigue life. The investigation discovered that crack initiation predominantly occurred on the concave side of bent pipe sections, specifically on the engine-side high-pressure steering line, which is connected to the power steering pump mounted on the engine. Fracture surfaces exhibited characteristics consistent with
SURVADE, LALIT, Koulage, Dasharath Baliram, Biswas, Kaushik
Study of Style wheel rim failure Due to Rim and disc assembly interference2026-26-05411/16/2026
This study focuses on the investigation of wheel rim failures near weld zone during repeated cornering induced by interference between the rim and disc during the wheel manufacturing assembly process. Strain gauges were employed to capture real-time stress and strain distributions at critical zones during interference fitting. The experimental results revealed that improper interference levels lead to significant stress concentrations, often surpassing the material's elastic limit, initiating micro-crack formation and promoting fatigue failure. Detailed strain analysis indicated that both radial and axial stresses contribute to long-term structural degradation. The study highlights the critical role of dimensional tolerances, surface finishes, and assembly forces in minimizing stress-induced failures. Recommendations are provided for optimizing design and assembly practices to enhance the durability and reliability of automotive wheels.
P, Praveen, DEsigan, Lakshmipathy, K, CHANDRAMOHAN, C, Santhosh
Accelerating Product Development Life Cycle through Digitalization of Fatigue Life for Structural Components2026-26-04961/16/2026
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 Techniques2026-26-05511/16/2026
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.2026-26-05761/16/2026
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
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