Browse Topic: Failure modes and effects analysis (FMEA)

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Numerical Investigation of Cowl Water Drainage in Automotive Design2026-26-0393To be published on 01/16/2026
Motivation Improper drainage of cowl water (accumulated at the base of the windshield) leads to critical issues in automotive design. Early-phase evaluation of drainage efficiency is critical to avoid costly late-stage design revisions and warranty issues. Traditional physical testing methods are often time-intensive, costly and limited in scope. Therefore, leveraging simulation-driven optimization enables proactive prediction of failure modes and accelerates robust design validation. The Problem Inadequate cowl drainage causes: 1. HVAC system degradation due to moisture ingress (mold growth, blower motor failure). The accumulated water can also enter the cabin. 2. Rust and corrosion in the cowl panel, windshield frame, and adjacent electronics due to accumulation of stagnant water Methodology We investigated multiple design strategies to enhance cowl drainage performance. The following approaches were studied by using STAR-CCM+: 1. Multiphase volume of fluid (VOF) Simulation - To
Mathew, Ronnie, Ibrahim, Sayyaf, Nikumbh, Nayan
Next Gen Automotive EDS Architecture design verification using real-time function mode simulation & failure condition analysis2026-26-0454To be published on 01/16/2026
In current automotive electrical design practices, simulation and functional verification of the Electrical Distribution System (EDS) at the design stage are largely absent. Typically, the validation of controller behaviour and EDS wiring is performed only during HIL, SIL, MIL, prototype testing, or physical vehicle trials, often revealing issues late in the development cycle. This delay leads to costly redesigns, prolonged timelines, and increased chances of failure during vehicle integration. Therefore, there is a critical need for an early-stage simulation methodology that ensures robust EDS and controller design, enabling "first-time-right" readiness at the design stage itself. The proposed simulation framework introduces a function mode-based structural approach, where individual vehicle functions are mapped to their corresponding electrical circuits within the vehicle’s wiring system. Resistance values are allocated to specific paths depending on the active function or
Jaisankar, Gokulnath, Warke, Umakant
Simulating Performance of Adhesive-Bonded Joints for Automotive Applications2026-26-0415To be published on 01/16/2026
Adhesive joining techniques have rapidly gained momentum in the automotive industry over the past decade, offering several advantages over traditional joining methods. The complex design requirements of modern automobiles have increased the demand for intricately shaped components, where conventional spot/seam welding and mechanical fastening are often not feasible. Unlike spot and arc welding, adhesives do not degrade the properties of the substrate. Moreover, they enable the joining of components made from dissimilar materials, thus contributing to the overall weight reduction of assemblies. Adhesives also provide damping effects, reducing noise, vibration, and harshness (NVH), thereby contributing to a quieter and more comfortable ride. Additionally, adhesives enhance structural integrity by distributing stresses more uniformly across the joints. Consequently, understanding the simulation and failure prediction of adhesive joints has become essential. Traditional failure criteria
Parambathuvalappil, Rahul, Patil, Sanjay
Evaluating the Suitability of ADC12 for Sand Casting: Filling, Solidification, and Mechanical Properties2026-26-0296To be published on 01/16/2026
This research investigates the applicability of ADC12 aluminum alloy in sand casting processes and compares its casting behavior and performance with that of conventionally sand-cast alloys such as A356 and AlSi10Mg. ADC12 is primarily utilized in high-pressure die casting (HPDC) and low-pressure die casting (LPDC) due to its excellent castability, pressure tightness, and favorable mechanical properties in thin-walled components. However, its use in sand casting is minimal globally, primarily due to the alloy’s high silicon and iron content, which can lead to poor feeding characteristics, increased porosity, and structural non-uniformity in non-pressurized molds. In this study, 3 mm thick test castings were produced using conventional sand casting methods, with particular attention to mold and core design to simulate challenging flow and solidification conditions. Comparative castings of A356 and AlSi10Mg were also produced under identical conditions to establish performance baselines
Subramani, Rajesh, Jichkar, Pawan
A study on the thermal degradation of chlorinated Polyethylene rubber2026-26-0276To be published on 01/16/2026
Elastomeric materials are essential in advanced automotive engineering for mobility, isolation, damping, fluid transfer (cooling, steering, fuel, and brake), and sealing because of their unique physio mechanical properties. Elastomers are commonly used in both static and dynamic components, such as hoses, mounts, bushes, and tires. Engine emission standards and weight optimization have caused higher temperature exposure conditions for automotive components. The steering system uses special purpose elastomers like Chlorinated Polyethylene that can deteriorate under abnormal conditions during vehicle operation or manufacturing process due to the high temperature exposure. Therefore, it is crucial to comprehend the causes and consequences of thermal degradation of elastomers. Thermal degradation is a significant phenomenon that changes the physical and chemical properties of elastomers, which results in a product not meeting functional requirements. This study investigates the thermal
THIRUPPATHI, ANANDHI, Mishra, Nitish, Krishnamoorthy, Kunju
Simulation Research on Torque Vectoring, Braking, Chassis control Strategies for Electric & hybrid Vehicles using System Simulation2026-26-0423To be published on 01/16/2026
Electric Vehicles and Plug-in Hybrids alleviate the energy crisis but pose a unique challenge for vehicle dynamics. Though significant developments in motor control strategy and energy density management are evolving, we face significant challenges in Torque Management with several ADAS features being integral part of the EV's/xHEV's. It demands high-fidelity physical and control model exchanges between electric-chassis, ride-handling, tire modelling, Steering Assist, powertrain and validate using 0D-1D platform. This paper explicates a unified strategy for improving overall vehicle performance by intelligently distributing and coordinating drive torque to enhance traction, stability, and drivability across diverse operating conditions through the co-simulation. Co-Simulation platform includes physical models in AMESIM, and control strategies integrated in MATLAB/Simulink. The platform features comprehensive representations of digital vehicle that requires detailed modelling of
Eruva, Patrickxavier, Sarapalli Ramachandran, Raghuveeran, Chougule, Sourabh, Natanamani-Pillai, Siva Subramanian, Scheider, Clement, Leclerc, Cedric, Natarajasundaram, Balasubramanian
BEARING CREEP PREVENTION IN EV TRANSMISSION2026-26-0598To be published on 01/16/2026
As the trend shifts from Internal Combustion Engine (ICE) vehicles to Electric Vehicles (EVs), the operating speeds of prime movers have significantly increased. Commercial EV manufacturers prefer high-speed, low-torque motors coupled with transmissions over low-speed, high-torque motors due to higher efficiency and power density. This combination of high-speed, low-torque motors coupled with transmission is essential for achieving the required gradeability and enhances operational efficiency. However, the increased operating speeds of these EV transmissions have inherently increased the risk of ‘bearing creep’. The “bearing creep” is the phenomenon where unintended relative motion occurs between bearing races and their mounting surfaces, leading to premature wear of mounting surfaces. This issue can lead to a series of failure modes such as increased gear mesh misalignment, bearing damage, seal damage, etc. These problems result into elevated transmission vibrations eventually leading
Bagad, Sachin Sunil, Kanase, Ashish, Hiremath, Satalingayya, Nevarekar, Sandip
Hydrogen Embrittlement in Galvanized High Carbon Steel Components of Automotive Seat Slider Assembly2026-26-0302To be published on 01/16/2026
This research paper investigates the failure of an isolator clip used in the seat slider assembly, which guides and restricts the sliding motion of the tooth bracket within the seat. The component is made of C80 high-carbon spring steel, known for its high strength. According to the manufacturing process details, zinc plating was applied to the component for corrosion protection, as confirmed by EDS analysis. A fractographic examination of the failed part revealed a brittle, intergranular fracture morphology with visible cracks. Certain areas also exhibited micro-void coalescence, indicating a dimpled fracture surface. The primary failure mode was intergranular (IG) fracture. The delayed fracture was attributed to intergranular fracture mechanisms, micro-void coalescence, and the high strength of the steel, which made the component susceptible to hydrogen embrittlement. Hydrogen embrittlement occurs when hydrogen atoms become trapped along the grain boundaries, where they form hydrogen
Saindane, Mehul Kishor, BALI, SHIRISH
Hardware in Loop Validation of Gear Selection Switch2026-26-0540To be published on 01/16/2026
The increasing complexity of modern automotive drive control systems necessitates the adoption of robust validation methods to ensure functional safety, reliability and customer satisfaction. This paper presents the development and implementation of a comprehensive Hardware-in-the-Loop (HIL) testing framework designed specifically for a specific ECU known as Gear Selection Switch (GSS)/Drive control switch (DCS) system. Hardware-in-the-Loop (HIL) Testing is a simulation-based testing technique where real physical hardware (like an electronic control unit, switch or sensor) is tested by connecting it to a virtual simulation of the rest of the system — instead of testing it inside a real vehicle. Following the analysis of all the field failure incidents reported till date for GSS, detailed root cause investigations were conducted using in-house testing and Ishikawa diagram analysis. A critical failure mode was identified and addressed through targeted mechanical design modification and
Bhuyan, Anurag, Jahagirdar, Shweta, Khandekar, Dhiraj Baburao
Investigating Thermal Fatigue Cracks in Exhaust Manifolds of Longitudinally Mounted 1.2L 4-Cylinder Engines2026-26-0488To be published on 01/16/2026
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 RWUP2026-26-0505To be published on 01/16/2026
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 Buses2026-26-0447To be published on 01/16/2026
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
Coupled Thermo-Mechanical Simulation Framework for Structural Evaluation of Battery Pack2026-26-0414To be published on 01/16/2026
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
Challenges in Compliance Testing of off-Board Electric Vehicle Chargers: Analysis of Typical Failures and Remedial Measures2026-26-0582To be published on 01/16/2026
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
Powering the Future: Addressing Power Architecture bottlenecks in Next Gen Automotive Platforms.2026-26-0688To be published on 01/16/2026
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
Reliability of Rubber Grommets by Stochastic Analysis of Geometric Tolerances2026-26-0501To be published on 01/16/2026
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 issues2026-26-0525To be published on 01/16/2026
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
Multiphysics Simulation based Approach to Evaluate the Thermal Behavior of Electric Motors through Electromagnetic Loss Distribution Mapping2026-26-0387To be published on 01/16/2026
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
USCAR-29USCAR-29 (Current)12/04/2025
USCAR-29
USCAR
Development and Qualification of Composite Landing GearsAIR5552A (Current)11/26/2025
This information report provides general guidance for the design considerations, qualification in endurance, strength and fatigue of landing gear using composite components as principle structural elements. The information discussed herein includes the development and evaluation of design data considering: the potential for imbedded manufacturing defects, manufacturing process variations, the component operating environment, potential damage threats in service, rework and overhaul, and inspection processes. This AIR mainly discusses the use of thick composites for landing gear structural components. Considerations and recommendations provided in this AIR may therefore differ greatly from considerations and recommendations found in widely accepted composite design references such as CMH-17 and Advisory Circulars such as AC 20-107(B).
A-5B Gears, Struts and Couplings CommitteeNEW
Recommendations and Background Material for Battery Package TestingAIR6840 (Current)11/26/2025
AS 6413 and slash sheets /1 & /2 hold the main information for testing of battery packaging. This document holds further information and expansion of philosophy, clarification etc. surrounding the testing and industry needs.
G-27 Lithium Battery Packaging Performance
Standardized composite training programAIR6671 (Current)11/26/2025
SAE CACRC has produced several standards, each representing the best-practice, recommended minimum training syllabus for the aforementioned target groups. The purpose of this document is to promote the use of these SAE standards, particularly for developing training programs for employee training, qualification in airlines and maintenance organizations, and as reference in regulatory guidance material. It summarizes, as a quick reference, the content of each training document and its relation to and interaction with other training documents. Thereby it allows users to select the appropriate training documents and syllabi to establish a comprehensive, sequential training program build-up customized to the specific needs of the aforementioned functions (see figure). This document does not intend to introduce new training content/syllabus.
AMS CACRC Commercial Aircraft Composite Repair Committee
Aerospace - Test Methodology for Electrohydrostatic ActuatorsARP5879A (Current)11/26/2025
This document provides an overview of the tests and issues related to testing that are unique to Electrohydrostatic Actuators (EHAs). An EHA incorporates a linear or rotary hydraulic actuator and a variable speed, reversible electric servomotor driving a fixed displacement hydraulic pump for actuator control, and associated power drive electronics. The tests and issues documented are not necessarily all-inclusive. This document discusses both, the tests applicable to EHAs and the test methodologies to accomplish the test objectives. This document also lists tests that are not unique to EHAs, but are still applicable to EHAs. In these instances a discussion of such tests is not contained in this document, and as applicable, the reader may reference ARP1281 (Actuators: Aircraft Flight Controls, Power Operated, Hydraulic, General Specification For), which addresses test issues applicable to electrohydraulic flight control servoactuators. In the discussion of the tests and test
A-6B2 Electrohydrostatic Actuation Committee
Guidelines for Specifying LVDTs and RVDTsARP5554 (Current)11/26/2025
As per Committee/Henry E. Harschburger recommendations
A-6B1 Hydraulic Servo Actuation Committee
USCAR 11242025 TestUSCAR11242000000000000000000000-1 (Current)11/24/2025
USCAR 11242025 Test
USCAR
test rejectionSAE-PP-0945901/27/2025
test
Rickard, Christopher
Test GV Document 2JTEST1620251 (Current)01/06/2025
test
Ground Vehicle European Prospect Committee
An eleventh one for CUR-1174PC11-CUR-1174 (Current)04/02/2024
Italic
Flight Simulator Engineering and Maintenance Committee
Test Methodology Development For Rig Level Validation Of Light Weight Stabilizer Link Of EV Bus Suspension2024-26-035701/16/2024
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
Structural development and improvement of SCR Assembly design for Exhaust After Treatment System of a Construction Equipment off highway Vehicle2024-26-009101/16/2024
Construction equipment off highway vehicles are heavy industry vehicles that run on diesel engines. To meet the CEV BS-IV emission norms, these engines have the Exhaust After Treatment System (EATS) which includes two primary subassemblies, i.e., a Diesel Oxidation Catalyst (DOC) subassembly to reduce the HC and CO emissions and a Selective catalytic Reduction (SCR) subassembly to reduce NOx emissions. Because of the excessive vibrations in the engine and continuous heavy-duty usage of the Construction equipment, structural failures leading to excess pollution and consequential functional failure are reported in the field. Hence, understanding the effect of engine vibrations and proposing a cost-effective solution is paramount in designing the EATS system including the SCR assembly. A field-testing failure of BS-IV CEV SCR assembly has been taken in consideration for this study. Several use-cases were simulated for the baseline design using real world acceleration data and Frequency
Rahman, Shahzer, Chakraborty, Abhirup, Perumal, Solairaj, Redkar, Dinesh, Usulamarthi, Ramwarun, Singh, Rajendra
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
Controlled Production Quantity Release Applicability Determination Method2024-26-035501/16/2024
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.
Tire-Rim Impact failure prediction using mathematical model2024-26-031401/16/2024
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
Utilizing Computed Tomography for Cell Characterization, Quality Assessment, and Failure Analysis2024-26-018901/16/2024
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
Weight and Drivetrain optimization via Fuel pump & Vacuum Pump drive by engine camshaft in a pushrod type valve actuated engine.2024-26-004601/16/2024
Optimizing weight, cost and friction is critically focused in most modern powertrains. Lesser components in drive trains makes the systems` lightweight and more efficient. This paper explains the idea of integrating a fuel pump and a vacuum pump drive system on to the main camshaft eliminating many rotating & static parts in a two valve per cylinder push-rod type actuated 4-cylinder diesel engine, thereby reducing overall weight, cost and drive losses. The modified camshaft will now drive oil pump, vacuum pump, fuel pump and valve train together. The existing camshaft is extended with a slot at one end and a three lobed cam made of higher grade material is press fitted on to the said portion with an additional journal bearing face added. Proposed camshaft design is evaluated for handling higher power transmission considering multiple drives are connected. Design verification simulations are run including High cycle fatigue, camshaft bearing EHD, Timing drive dynamics to ensure all
John, Shijino Shaji, Sasikumar, K
A New Holistic Approach for System-Level Development of Seat Features2024-26-038101/16/2024
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
Development of an Accelerated Powertrain Durability Cycle for Mining Dozers: Integration of Customer Usage Patterns and Road Load Data for generation of efficient test cycles2024-26-009001/16/2024
Mining dozers are heavy-duty machines that operate in harsh environments and under extreme loads. The durability of their powertrain components is critical for their performance and reliability. To ensure the durability of these components, they need to be tested under realistic operating conditions. However, field testing is time-consuming, costly and often impractical due to the limited availability of test sites and machines. Therefore, there is a need to develop an accelerated durability cycle that can simulate the field conditions in a laboratory setting. This paper presents a methodology to develop an accelerated powertrain durability cycle for mining dozers based on the integration of customer usage patterns and road load data. The methodology consists of the following steps: (1) system study to identify the powertrain components and their failure modes; (2) instrumentation of a representative mining dozer with sensors and data acquisition system; (3) data collection from field
Tripathi, Ankur, Ghosh, Ratnadeep, Vishe, Prashant Eknath
Dynamic Automatic Transmission Oil Life Prediction Using Machine Learning2024-26-003601/16/2024
Conventional resource conservation for automotive traction and its utilization to maximize efficiency is not only important but also essential for climate change. Automatic transmission fluid (ATF) is one such component, which has enough potential considering the current methods of servicing. It also plays a crucial role in the performance and longevity of the transmission system. Predicting the actual life of the ATF can be challenging due to various factors such as its application, driving conditions, driving behavior, oil grade and maintenance schedules, which can help prevent costly repairs and improve the overall performance of the vehicle. Present work is focused on developing/validating a process, which can predict critical properties of oil at any given instance and give indication to the driver/fleet owner. Data is collected for various oil properties and vehicle parameters as vehicle's usage patterns such as shift density, vehicle load, torque, current gear, lock up state
Badiger, Aishwaryalaxmi, Priyadarshi, Priyamvad, Bhat, Goutam
Simulation Techniques for Liquid Gasket Sealing Performance Prediction2024-26-026701/16/2024
In the automotive industry, silicon adhesive has become increasingly popular due to its benefits in ease of assembly and cost savings associated with material and manufacturing processes. Due to the demand to reduce time and costs in the development phase of the project, it is critical to choose the right gasket material, and a suitable flange design as early as possible in the design process. In order to achieve stringent emission standards such as Real Driving Emission (RDE) and Corporate Average Fuel Economy (CAFE) norms, a better sealing performance is an essential parameter. Various types of liquid gaskets such as silicon rubber based Room Temperature Vulcanizing (RTV) sealants and thermoset plastic based Anaerobic sealants are widely used in an Internal Combustion engine. They are commonly used for the components such as oil sump, bedplate, gearbox housings, etc. Traditional simulation methods could not capture the exact failure modes of the liquid sealants. Hence there is a need
Kumbhar, Dipak Madhukar, Babar, Ranjit, Patil, Sanjay, Bagane, Shivraj
Condition Monitoring of High-Speed Rotating Machinery using Digital Twins & Machine Learning Techniques2025-01-012805/05/2023
In the era of Industry 4.0, maintenance of factory equipment is changing with new maintenance system using predictive or prescriptive methods. These methods leverage condition monitoring through digital twins, AI, & machine learning techniques to obtain early signs of faults, type of faults, locations of fault etc. Bearings and Gears are one of the most common components and cracking/misalignment/rubbing/bowing are the most common failure modes in high-speed rotating machinery. In the present work, an end-to-end automated Machine Learning based condition monitoring algorithm is developed for predicting and classifying internal gear and bearing faults using external vibration sensors. A digital twin model of the entire rotating system consisting of the gears, bearings, shafts, and housing was developed as a co-simulation between MSC ADAMS and MATLAB. The gears and bearing dynamic models were developed in MATLAB and shaft and housing models were developed in MSC ADAMS flexible body. The
Rastogi, Sarthak, SINGHAL, SRIJAN, Ahirrao, Sachin, Milind, T. R.
An Efficient Machine Learning Algorithm for Valve Fault Detection 2022-01-018503/29/2022
Multi-level Miller-cycle Dynamic Skip Fire (mDSF) is a combustion engine technology that improves fuel efficiency by deciding on each cylinder-event whether to skip (deactivate) the cylinder, fire with low (Miller) charge, or fire with a high (Power) charge. In an engine with two intake and two exhaust valves, skipping the cylinder is accomplished by deactivating all valves, while firing with a reduced charge is accomplished by deactivating one of the intake valves. This new ability to modulate the charge level introduces new failure modes. The first is a failure to reactivate the single intake valve, which results in a desired high-fire having the air intake of a low-fire; the second is a failure to deactivate the single intake valve, which results in a low-fire having the air intake of a high-fire. Reliably detecting these two faults has proven challenging for classical techniques that use measured MAP and/or crank angle acceleration to identify characteristic features of the
Serrano, Joe, Ortiz-Soto, Elliott, Chen, S Kevin, Chien, Li-Chun, Joshi, Abhishek
AI-based Signal Integrity Monitoring for Integrated Vehicle Health Management2022-01-025603/29/2022
The increasing complexity of vehicle electronics and software is bringing an abundance of vehicle health related challenges, including quality issues and increasing costs of warranty claims, recalls, maintenance, and downtime. This negatively impacts both OEM and fleet profitability, user experience, and end customer costs. In order to reduce OEM costs and the total cost of ownership for consumers and fleets, new methods are needed to detect, predict, and diagnose vehicle health issues. Existing vehicle health management solutions rely on diagnostics trouble codes (DTC) and limited amounts of telematics data. These solutions can detect known failure modes using hard-coded signal behavior validation rules that are frequently based on thresholds. They also provide alerts based on pre-defined error codes. However, they are unable to detect and diagnose unforeseen failure modes that do not have hard-coded rules, nor can they prognose future vehicle health issues. By using deep learning
Apartsin, Sasha, Stein, Hilik, Reiter, Gil, Williams, Kyle W.
Fatigue Endurance Limit of Fasteners in Automotive Application2022-01-028903/29/2022
Fastener commonly used in automotive industry plays an important role in the safety and reliability of the vehicle structural systems. In practical application, bolted joint would never undergo fully reversed loading, there always will be positive mean stress on bolt. The mean stress has little influence on the fatigue life if the maximum stress is lower than a threshold, which is the yield stress of the bolt. However, when the sum of the mean stress and the stress amplitude exceeds the yield stress, the endurance limit stress amplitude decreases fast as the mean stress increases. The purpose of this paper is to research fatigue endurance limit of fastener and establish the threshold for safe design in automotive application. In order to obtain the fatigue endurance limit at different mean stress levels, various mechanical tests were performed on M12x1.75 and M16x1.5 Class 10.9 fasteners using MTS test systems. Results show that the fatigue failure mode of bolts is different from that
Mao, Jianghui, Lin, Barry, Wu, Zhijun
Creation of a Virtual Framework for Control Logic Development and Validation with a Driver-In-the-Loop (DIL) Simulation2022-01-048703/29/2022
Current simulation tools can help expedite the development and validation of powertrain control systems compared to traditional methods that use actual vehicle testing. In this study, a co-simulation platform has been developed by connecting MATLAB/Simulink, IPG CarMaker, GT-Suite, and PTV Vissim to create virtual calibration and validation environment. The purpose of developing this platform is to save time and reduce cost during vehicle testing by replacing physical calibration and robustness validation with simulation-based processes. The platform enables a virtual environment that replicates the local road networks as well as randomly generated traffic patterns that an ego vehicle can interact with on the virtual road. By combining the strengths of each software listed above, the developed virtual environment can provide realistic drive scenarios for testing new vehicle control algorithms. One of the main challenges in the virtual test platform is that the driver model that creates
Fan, Shihong, Sun, Yong, Lee, Jason, Ha, Jinho, Harber, John
Identifying key aspects of thermal runaway modelling for lithium-ion battery cells2022-01-087003/29/2022
Electrification and hybridization of powerplants in the transportation sector is one of the most important changes in the last few decades. Lithium-ion batteries are the main energy storage systems, but despite the maturity of this technology, it has certain contains compared to traditional internal combustion engines in the day-to-day usage. As the operating conditions of the batteries are pushed to the limits to overcome certain disadvantages relative to other conventional systems like charge and discharge times or vehicle autonomy, new concerns and safety limitations must be considered. High power rates and cooling deficiencies can produce excessive operating temperatures within the cells, leading to problems with degradation or even unchain chemical reactions that can end in thermal runaway, one of the most worrying failure modes attaining electric platforms nowadays. One of the main challenges in the ordeal of designing the system considering these effects is the crossed
Garcia, Antonio, Monsalve-Serrano, Javier, Sari, Rafael, Fogué Robles, Álvaro
An evaluation of an unhealthy part identification using a 0D-1D diesel engine simulation based Digital Twin2022-01-045703/29/2022
Commercial automotive diesel engine service and repair, post a diagnostic trouble code trigger, relies on standard troubleshooting steps laid down to identify or narrow down to a faulty engine component. This manual process is cumbersome, time-taking, costly, often leading to incorrect part replacement and most importantly usually associated with significant downtime of the vehicle. Current study aims to address these issues using a novel in-house simulation-based approach developed using a Digital Twin of the engine which is capable of conducting in-mission troubleshooting with real world vehicle/engine data. This cost-effective and computationally efficient solution quickly provides the cause of the trouble code without having to wait for the vehicle to reach the service bay. The simulation is performed with a one-dimensional fluid dynamics, detailed thermodynamics and heat transfer-based diesel engine model utilizing the GT-Power engine performance tool. The flow, combustion and
Saurabh, Shakti, Sureka, Britant
Moisture absorption behavior and hygrothermal aging life prediction for CFRP adhesive-bonded joints2022-01-038903/29/2022
Effects of moisture absorption on the strength degradation, energy absorption and failure mechanism of CFRP laminates and the adhesive-bonded joints in hygrothermal environment were investigated in this work. Experiments of accelerated moisture absorption, uniaxial tension and three-point bending were performed. SEM observations on the CFRP laminates and the fracture surfaces of the CFRP bonded joints were conducted. Strength degradation and failure mechanism induced by moisture absorption were discussed in detail. The results showed that the strength degradation in tension and in three-point bending of the CFRP laminate due to moisture absorption reached 7.4% and 17.1%, respectively. Different response of CFRP laminate and adhesive layer to the moisture determined the failure mode of the adhesive-bonded joints. Suitable match of CFRP laminate and adhesive was very important to make the failure mode of the joint under control.
Xu, Xianghe, Yu, HaiYan, Xing, Ping
Prediction of Crash Performance of Adhesively Bonded Vehicle Front Rails2022-01-105103/29/2022
Adhesive bonding provides a versatile strategy for joining metallic as well as non-metallic substrates, and also offers the functionality for joining dissimilar materials. For problems of elastic behavior and small strains in vehicle unibody structures such as designing for NVH (Noise, Vibration and Harshness), adhesive bonding of sheet metal parts along flanges provides enhanced stiffening of body and improved acoustics due to sealing of openings between flanges. However, due to the brittle nature of adhesives, they remain susceptible to failure under impact loading conditions which can cause crumpling of sheet metal parts resulting in plasticity and large strains. The viability of structural adhesives as a sole or predominant mode of joining stamped sheet metal panels into closed hollow sections such as hat sections thus remains suspect and requires further investigation. The mechanical behavior of adhesives tends to be significantly different as compared to ductile and isotropic
Ramachandra, Sanketh, Deb, Dr. Anindya, Chou, Clifford
Driveline Parking Brake Test Procedure for Medium Duty VehiclesJ2690_202110 (Current)10/28/2021
This SAE Recommended Practice establishes uniform test procedures for friction based parking brake components used in conjunction with hydraulic service braked vehicles with a gross vehicle weight rating greater than 4500 kg (10 000 lb). The components covered in this document are the primary actuation and the foundation park brake. Various peripheral devices such as application dashboard switches or indicators are not included. These test procedures include the following: a Brake Related Tests 1 Brake Functional Performance 2 Brake Dynamic Torque Performance 3 Brake Corrosion Resistance 4 Brake Endurance with Torque 5 Brake Endurance without Torque 6 Vibration Resistance 7 Brake Ultimate Static Load 8 Brake Lining Wear Adjuster Function b Actuation Related Tests 1 Mechanical Actuator Functional Performance 2 Mechanical Actuator Endurance 3 Mechanical Actuator Quick Release 4 Mechanical Actuator Ultimate Load 5 Spring Apply Actuator Functional Performance 6 Spring Apply Actuator
Truck and Bus Hydraulic Brake Committee
Development of a Simulation for a Shim Durability Test2021-01-128310/11/2021
Shim durability is an important aspect of shim performance. During the brake operation, no mechanical failure of the shim is allowed. Typically, when releasing a shim into production, durability tests must be performed to ensure no failure occurs around the locator holes, and the shim does not walk over the locators. Since the durability test requires an actual pad and shim, the mechanical retention mechanism for the shim (locators) need to be designed, and backplates must be produced. If a failure is detected during these durability tests, either the shim needs to be changed or the retention locators have to be redesigned, which could negatively impact NVH performance and project timing/costs. In this paper, a finite element model is developed to simulate a stop in a shim durability test. The model can be used to predict stress levels at the shim’s locator holes and the failure mode of a shim during a durability test stop. Using this model, the retention mechanism on the back plate
Duvall, Seth
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