Browse Topic: Finite element analysis

Items (2,193)

Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions

2024-32-003804/18/2025

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

Hada, Yusuke, Sugita, Hisayuki

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

2025-01-8215

04/03/2025

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

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

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

2023-22-0001

03/04/2024

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

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

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

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

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

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

2024-26-027301/16/2024

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

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

Enhanced Development Process for UPDs – Digital Approach

2024-26-023901/16/2024

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

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

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

2024-26-031801/16/2024

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

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

Gasket joint sealing behavior prediction using simplified FEA approach.

2024-26-031101/16/2024

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

Samshette, Shivkumar, SHEDGE, Vikram, Nilangekar, Abhijit

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

2024-26-037501/16/2024

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

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

Outrigger design & development for vehicle testing as per AIS 133

2024-26-035001/16/2024

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

Rathore, Gopal Singh, chawla, Shubham

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

2024-26-026101/16/2024

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

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

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

2024-26-024901/16/2024

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

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

Electromechanical Multiphysics simulation of Motor

2024-26-025001/16/2024

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

Karale, Ajinkya Sujay

A Predictive Approach to Estimate Tyre Wear Characteristics

2024-26-031301/16/2024

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

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

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

2024-26-026801/16/2024

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

Pendse, Ameya, Babar, Ranjit, Patil, Sanjay

Numerical Modelling of Stone Lofting by a Treaded Tyre

2024-26-027001/16/2024

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

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

Crash simulation of palisade security fencing

2024-26-028101/16/2024

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

Rathore, Gopal Singh, Kumar, Ankit

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

2024-26-030501/16/2024

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

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

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

2024-26-025101/16/2024

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

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

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

2024-26-007001/16/2024

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

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

This is a testing Title

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

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

Friction Performance Analysis of Mine Wet Multi-Disc Brake

02-17-01-0001

10/28/2023

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

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

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

SAE-PP-0874609/29/2023

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

Dongari, Madhukar

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

15-17-01-0002

09/09/2023

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

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

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

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

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

Dhrangdhariya, Priyankkumar, Maiti, Soumyadipta, Rai, Beena

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

15-17-01-0001

07/18/2023

Dhrangdhariya, Priyankkumar, Maiti, Soumyadipta, Rai, Beena

This is a testing Title

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

This is a testing Title

SM-SESSION-11292023-107/13/2023

This is a testing Title

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

This is a testing Title

SM-SESSION-11282023-301PM-New07/13/2023

This is a testing Title

SM-TEST-11282023-302PM07/13/2023

Experimental Characterization of a Steel Spring Mount using Virtual Point Transformation

2025-01-004605/05/2023

The application of virtual point transformation for determining the transfer dynamic stiffness of a steel spring mount is demonstrated in this experimental study. Rigid fixtures are attached to both ends of the spring, and frequency response functions are measured using impact hammer excitation. These measured frequency response functions are transformed to the virtual points, analogous to nodes in finite element analysis, with six degrees of freedom. This allows for high-quality frequency response functions to be obtained through specialized post-processing techniques. The six degrees of freedom transfer dynamic stiffness is then extracted using the inverse sub-structuring method, which eliminates the influence of the fixture dynamics. The results are validated by a direct measurement approach. Additionally, the study investigates the effects of liquid sprayed damping material coatings on the spring's transfer dynamic stiffness, revealing that certain damping materials significantly

Neihguk, David, Herrin, David, de Klerk PhD, Dennis

Study on the Aspiration Effect of Glassrun Seal System Based on Time-Varying Pressure Difference Between Vehicle Exterior and Interior

2025-01-003005/05/2023

When the vehicle is driven at high speed, there exist very complex flow and vortex shedding phenomenon at the side window area with intense pressure fluctuations. When the dynamic pressure difference between vehicle exterior and interior is large enough, the side window sealing system is prone to poor sealing and generates leakage noise, which can severely affect vehicle interior acoustic comfort. To study the dynamic aspiration mechanism of the sealing system, a nonlinear finite element model of the glassrun seal was established to simulate the quasi-static installation deformation process of the sealing strip, and to obtain the deformed geometric shape and residual stress. Then, the exterior flow field of the glassrun sealing area of a simplified vehicle model was calculated with CFD simulation to obtain the hydrodynamic pressure excitation acting on the outer surface of the sealing strip at different vehicle speeds, and the results were subsequently validated through wind tunnel

Li, Hanqi, He, Yinzhi, Zhang, Yongfeng, Zhang, Lijun, Yu, Wuzhou, Jiang, Zaixiu

Comprehensive Analysis and Optimization of Door Closing Sound Quality of a Heavy Truck

2025-01-006605/05/2023

Based on the objective and subjective experiment and finite element analysis, the influencing factors on the door closing sound quality of a heavy-duty truck is analyzed and optimized. Results show that the loudness and sharpness can be reduced apparently by increasing stiffness and damping of the door. The sound quality can be enhanced by increasing the pressure release area, which can decrease the air resistance of dooring closing. By adding holes on the inner liner and changing the pressure release location, the dooring closing air resistance is reduced from 289 Pa to 181 Pa. In terms of the rebound sound, the sound level is positively relative to the door closing force. Increasing the protrusion height and decreasing the stiffness of the vibration absorber of the handle can improve the rebound sound quality. Optimizing the absorbers on both ends and adding damping material can decrease the loudness by 47.8%, reduce the cavity sound, dismiss the trembling and improve the compact

Wang, Jian, Zhang, Yongshen, Feng, Lei, Xie, Chenhao, Lin, Jiewei, Sun, Changchun

Horn sound digital validation for ECE-R28 regulation compliance

2025-01-000805/05/2023

Every vehicle has to be certified by the concerned governing authority that it matches certain specified criteria laid out by the government for all vehicles made or imported into that country. Horn is one of the components that is tested for its function and sound level before a vehicle is approved for production and sale. Horn, which is an audible warning device, is used to warn others about the vehicle’s approach or presence or to call attention to some hazard. The vehicle horn must comply with the ECE-R28 regulation in the European market. Digital simulation of the horn is performed to validate the ECE-R28 regulation. In order to perform this, a finite element model of a cut model of a vehicle, which includes the horns and other components, is created. Fluid-structure coupled numerical estimation of the sound pressure level of the horn, with the appropriate boundary conditions, is performed at the desired location as per the ECE-R28 regulation. The simulation results thus obtained

Ramachandran, Balachandar, Raveendran, Roshin, Mondal, Arghya

Modeling of Air Spring Dynamical Characteristics using Fractional Derivative Model and Thermal Hysteresis

2025-01-004505/05/2023

Air springs are one of the most common used groups of vibration isolators and their dynamical characteristics are extensively studied. One of the main challenges of modeling of air spring dynamical characteristics is to model for hysteresis characteristics of air spring. Hysteresis characteristics of air spring are contributed by friction and viscosity of rubber bellow and by thermal hysteresis of compressed air inside air spring. In this paper, dynamic behaviors of air spring are modeled and analyzed. Firstly, force versus displacement data are obtained by the tests under static, harmonic and random excitations. Secondly, a nonlinear model is presented to capture the measured air spring’s behaviors. The model is consisted of Berg’s friction and fractional derivative model to describe rubber bellow behaviors and heat exchange model to describe thermal hysteresis of air. Furthermore, the proposed model parameters are identified using finite element model and test data. Finally, the air

Xia, Zhao

A Theoretical and Experimental Investigation of NVH of In-Wheel Reduced Motor System

2025-01-000605/05/2023

To enhance the power density of the system and reduce production costs, the in-wheel reduced motor system (IWRMS), characterized by its integrated design and control, is poised to become the future development trend. However, the high speeds of motors and gear reducers can lead to challenges such as system stability and issues related to NVH (Noise, Vibration, and Harshness). This paper specifically addresses the NVH concerns associated with the IWRMS. Firstly, a bench test scheme was established, and vibration and noise tests were conducted under a range of conventional operating conditions. The results indicated that at the torque of 200 Nm and the speed of 5500 rpm, the noise sound pressure level reached 86.2 dB, highlighting significant vibration and noise issues within the system. Subsequently, operating deflection shapes (ODS) testing and analysis were performed on the IWRMS. Vibration responses of 48th order show that breathing mode of the motor housing bring resonance

Huang, Chao, Xiong, Lu, Meng, Dejian, gong, Yu, Guo, Han, Zhang, Mengyuan

High-Fidelity NVH Model Development for Electric Motors using Deep learning and Machine Learning Algorithms

2025-01-012305/05/2023

Electric motor whine is a significant source of noise in electric vehicles (EVs). To improve the noise, vibration, and harshness (NVH) performance of electric propulsion systems, it is essential to develop a physics-based, high-fidelity stator model. In this study, a machine learning (ML) model is developed using an artificial neural network (ANN) method to accurately characterize the material properties of the copper winding, varnish, and orthotropic stator laminate structure. A design of experiments (DOE) approach using Latin hypercube sampling of parameters is implemented after evaluating alternative surrogate models. A finite element (FE) model is constructed using the nominal stator design parameters to train the ANN model using 121 DOE variables and 72,000 data points. The ML-trained ANN model is then verified to predict the driving point frequency response function (FRF) spectrum with reasonable accuracy. Subsequently, modal tests are conducted on the electric stator, and the

Rao, Bhyri Rajeswara, GSJ, Gautam, He, Song

Noise analysis and optimization of thermal management integrated module

2025-01-008105/05/2023

Abstract：The thermal management integration module is a multifunctional integrated component. The thermal management integration module includes water pumps, flow channel plates, brackets, sensors, etc. However, due to the large range of speed changes, the water pump will generate a wide range of frequency excitation. This excitation will cause the integrated module to vibrate and generate noise. This article studies and analyzes an integrated module that generates noise. An integrated module of a certain new energy vehicle is used as an example. Firstly, a vehicle experiment was conducted. It was found that the noise came from the integrated module. And then use finite element method to analyze the causes of noise generation. Based on the characteristics of multiple integrated module components, high integration degree, and complex structure. This article simplifies components such as brackets, heat exchangers, sensors, etc. And they are replaced by centralized quality points

XU, shenao

Determination of optimum location of active tuned mass dampers to obtain improved NVH performance during cylinder de-activation events

2025-01-011005/05/2023

Cylinder deactivation has been a proven technique to improve fuel economy for several years now. But on the flip side during cylinder deactivation events, high amplitude torque pulsations are generated at the crankshaft of the engine over a wide frequency range creating a potential risk for NVH performance of the vehicle. As passive tuned mass dampers are effective only in a narrow frequency range, active tuned mass dampers (ATMD) have become a popular choice to mitigate the risk. Often, engineers rely on finite element (FE) models of vehicle structures to make design decisions during the early stages of vehicle development. However, there is relatively little literature available on simulation of ATMD using FE techniques. Consequently, in most cases, ATMDs are not included in the FE models of vehicle structures. Several details related to the ATMD design are decided through physical testing at the latter stages of vehicle development. To address this issue, a methodology to simulate

Maddali, Ramakanth, mogal, Akbar, Haider, Syed, Jahangir, Yawar

NVH Analysis and Optimization of Electric Drive System in Over Modulation and Six-Step Regions

2025-01-008205/05/2023

Pulse width modulation (PWM) and the corresponding modulation index (MI) value are of critical importance to the performance of electric drive systems for electric vehicle applications. For interior permanent magnet (IPM) machines, operating in overmodulation (OVM) and six-step modes increases the voltage output beyond the linear region, allowing the motor to achieve higher torque and power with reduced inverter loss. However, the resulting distorted current waveforms and higher current ripple harmonics lead to a notable increase in the motor noise. A multi-disciplinary approach has been developed to analyze the NVH performance of a three-phase 8-pole IPM motor when it operates in the OVM and six-step regions at high speed. The PWM current ripple harmonics induced by voltage-source inverters are predicted using different MIs and subsequently validated through experiments. The current ripple data are used for the prediction of electric motor efficiency, including an analysis of copper

He, Song, Chang, Le, Gong, Cheng, Zhang, Peng, GSJ, Gautam

Evaluation of Material Damping Ratio of Electronic Ignition Switch Module to Enhance its Finite Element Model Physics for Harmonic Response

2025-01-010905/05/2023

The present paper investigates the material damping ratio parameter in detailed manner for different Electronic Ignition Switch Module (EISM) utilized in two-wheeler automobiles. At first, investigation is carried out for developing a Finite Element Method (FEM) based simulation model. The simulation is performed by matching the failure areas of critical component in assembly with physical sinusoidal vibration based shaker table test results (particularly breakage) by utilizing different damping ratios for the assembly. The damping ratio parameter is further utilized to perform FEM based harmonic response analysis for different EISM and evaluate critical structural breakage zones. The breakage zones predicted by simulation were found to be aligned with breakage zones shown by shaker table test results. The results are validated, specifically considering the damping ratio parameter. The FEM based harmonic response analysis is performed for a particular acceleration excitation in between

Shah, Viren, Kalurkar, Shantanu, Kushari, Subrata, KUMAR, Rahul, Miraje, Jitendra, D, Suresh, Parandkar, Parag

Navigating Evolving Vehicle NVH Challenges with Application of Emerging Technologies in Artificial Intelligence and Machine Learning

2025-01-013005/05/2023

The multifaceted, fast-paced evolution in the automotive industry includes noise and vibration (NVH) behavior of products for regulatory requirements and ever-increasing customer preferences and expectations for comfort. There is pressing need for automotive engineers to explore new and advanced technologies to achieve a ‘First Time Right’ product development approach for NVH design and deliver high-quality products in shorter timeframes. Artificial Intelligence (AI) and Machine Learning (ML) are trending transformative technologies reshaping numerous industries. AI enables machines to replicate human cognitive functions, such as reasoning and decision-making, while ML, a branch of AI, employs algorithms that allow systems to learn and improve from data over time. The purpose of the paper is to show an approach of using machine learning techniques to analyze the impact of variations in structural design parameters on vehicle NVH responses. The study begins by executing the Design of

Miskin, Atul R., Parmar, Azan, Raj, Sonia, himakuntla, Uma Maheswar

Modeling Snap-Fit Stiffness for Improved BSR Predictions in Automotive Design

2025-01-008905/05/2023

Squeak and Rattle (S&R) issues present significant challenges in the automotive industry, negatively affecting the perceived quality of vehicles. Early identification of these issues through rigorous testing protocols-such as auditory assessments and dynamic simulations-enables the development of more robust systems while optimizing resource use. Finite Element Method (FEM) simulations are crucial for identifying S&R issues during the design phase, allowing engineers to address potential problems before the creation of physical prototypes. By developing high-fidelity virtual models and accurately simulating flexible connections, these simulations effectively capture rattle effects, enhancing prediction reliability. Traditional snap stiffness calculations typically employ a cantilever-based formulation, which is suitable for simple snap-fit designs but insufficient for more complex geometries that require enhanced stiffness. To address this limitation, the proposed methodology utilizes

Rao, Sohan, Elangovan, Pranesh, Reddy, Hari

Characterization and Modeling of Anisotropic Fracture of Advanced High-Strength Steel Sheets

2023-01-0613

04/11/2023

As an engineering approach of balanced complexity and accuracy, the Generalized Incremental Stress-State dependent damage Model (GISSMO) in LS-DYNAhas now been widely adopted by the automotive industry to predict metallic materials’ fracture occurrences in both forming and crashworthiness simulations. Calibration of the nominal GISSMO is typically based on material characterization data along a certain representative material orientation. Nevertheless, many rolled or extruded metallic materials, such as advanced high-strength steel (AHSS) sheets, exhibit accentuated anisotropic fracture behavior, even though, notably, some of these materials show comparatively weak anisotropic plasticity in the meantime. Accordingly, in this work, the deformation and fracture behavior of a selected AHSS grade, Q&P980 steel, was first characterized based on a series of mechanical experiments under simple shear, uniaxial tension, plane strain, and equi-biaxial tension conditions. Then, material models

Hu, Jun, Pan, Hao, Pavlina, Erik, Thomas, Grant

Study on Influencing Factors of Hippocampal Injury in Closed Head Impact Experiments of Rats Using Orthogonal Experimental Design Method

2023-01-0001

04/11/2023

The hippocampus plays a crucial role in brain function and is one of the important areas of concern in closed head injury. Hippocampal injury is related to a variety of factors including the strength of mechanical load, animal age, and helmet material. To investigate the order of these factors on hippocampal injury, a three-factor, three-level experimental protocol was established using the L(3) orthogonal table. A closed head injury experiment regarding impact strength (0.3MPa, 0.5MPa, 0.7MPa), rat age (eight- week-old, ten-week-old, twelve-week-old), and helmet material (steel, plastic, rubber) were achieved by striking the rat's head with a pneumatic-driven impactor. The number of hippocampal CA3 cells was used as an evaluation indicator. The contribution of factors to the indicators and the confidence level were obtained by analysis of variance. The results showed that impact strength was the main factor affecting hippocampal injury (contribution of 89.2%, confidence level 0.01

Wang, Peng, Song, Xuewei, Zhu, Xiyan, Qiu, Jinlong, Yang, Shuaijun, Zhao, Hui

Tire-Soil Interaction Simulation Using Finite Element Method to Investigate Their Deformation and Sinkage

2023-01-5001

01/03/2023

Abstract This research investigates the tire deformation and sandy soil sinkage on the performance of off-road vehicles. Tire deformation and soil sinkage were simulated with the Finite Element Method (FEM) using ANSYS Workbench 2020 R2 and validated using actual results taken from a previous work of tire size (235/70 R15) under four different tire inflation pressures (50, 100, 150, and 200 kPa) and three soil densities varying from loose, medium dense, and high dense sand. The optimum tire inflation pressures were obtained under various soil densities to achieve flotation pressure of the tires on the soil to generate good performance and accomplish the off-road vehicle missions.

Adel Mohamed, Mahmoud, Elhussieny, Sayed, Emam, Mohamed Ali, Abd Elhafiz, Mohamed M.

Tire-Soil Interaction Simulation Using Finite Element Method to Investigate Their Deformation and Sinkage

2023-19-500101/03/2023

This research investigates the tire deformation and sandy soil sinkage on the performance of off-road vehicles. Tire deformation and soil sinkage were simulated with the Finite Element Method (FEM) using ANSYS Workbench 2020 R2 and validated using actual results taken from a previous work of tire size (235/70 R15) under four different tire inflation pressures (50, 100, 150, and 200 kPa) and three soil densities varying from loose, medium dense, and high dense sand. The optimum tire inflation pressures were obtained under various soil densities to achieve flotation pressure of the tires on the soil to generate good performance and accomplish the off-road vehicle missions.

Tire-Soil Interaction Simulation Using Finite Element Method to Investigate Their Deformation and Sinkage

2023-01-5001-TEST-REC01/03/2023

Adel Mohamed, Mahmoud, Elhussieny, Sayed, Emam, Mohamed Ali, Abd Elhafiz, Mohamed M.

Elasticity Characterization of Particulate Composites: A Computational Evaluation of Topology and Polygon mesh Finite Element Modeling

2022-28-050011/18/2022

In the research and composite material design, predicting elasticity based on phase characteristics is a critical challenge. In comparison to experimental and analytical techniques, there are several advantages of using finite element modelling based microstructure of composite Representative Volume Elements (RVE).Nevertheless; there are some drawbacks to RVE's traditional geometry-based finite element modelling (GB-FEM), such as the time it takes to build usable modelling and produce substantial finite element meshes. To address these problems, we developed and improved a voxel-based finite element modelling (VB-FEM) method. VB-FEM, unlike GB-FEM, creates a homogeneous grid mesh first and then detects components that correspond to inclusions. The remainders of the stages are identical to those in GB-FEM. In two illustrative numerical instances, GB-FEM and VB-FEM were compared in terms of performance. GB-FEM and VB-FEM were compared in terms of performance. In terms of computational

R, Soundar

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