Browse Topic: Simulation and modeling

Items (10,152)

Simulation based optimization of the NVH characteristics in modern high speed engine during development phase

2026-26-0326To be published on 01/16/2026

Engine noise mitigation is paramount in powertrain development for enhanced performance and occupant comfort. Identifying NVH problems at the prototype stage leads to costly and time-consuming redesigns and modifications, potentially delaying the product launch. NVH simulations facilitate identification of noise and vibration sources, informing design modifications prior to physical prototyping. Early detection and resolution of NVH problems through simulation can significantly shorten the overall development cycle and multiple physical prototypes and costly redesigns. During NVH simulations, predicting and optimizing valvetrain and timing drive noise necessitates transfer of bearing, valve spring, and contact forces to NVH simulation models. Traditional simulations, involved continuous force data export and NVH model evaluation for each design variant, pose efficiency challenges. In this paper, an approach for preliminary assessment of dB level reductions across design iterations is

Rai, Ankur, Deshpande, Ajay Mahadeo, YADAV, RAKESH

Modelling of Turbulent Combustion of Liquid Ammonia in Dual Fuel CI Engine

2026-26-0442To be published on 01/16/2026

Combustion of fossil fuel results in CO2 emission which is considered to be a leading cause of global warming. Alternative fuels with little or no carbon foot is being actively considered. Direct combustion of ammonia is being actively investigated as it is considered to be a carbon neutral fuel that does not emit CO 2 . It is one of the largest industrially produced chemicals and is easy to store and transport with a well-established supply-chain system. Compared to conventional fuels, ammonia has inferior combustion properties like high ignition delay, low flame speed and a high propensity to produce NOx due to the availability of fuel bound nitrogen. This study uses numerical simulations and a chemical kinetic model to examine the combustion characteristics of ammonia and diesel blend in a dual fuel compression ignition IC engine. Both liquid ammonia and diesel are directly injected into the cylinder, with ammonia as the primary fuel and diesel as a pilot to initiate combustion. An

Warghat, Ketan Vinayak, Prabhakaran, Dinesh, Banerjee, Sayak, kolhe, Pankaj, Banerjee, Raja

Virtual Validation of ADAS Algorithms Using Driver-in-the-Loop Simulation

2026-26-0050To be published on 01/16/2026

Driver-in-the-Loop (DIL) simulators have become crucial tools across automotive, aerospace, and maritime industries in enabling the evaluation of design concepts, testing of critical scenarios and provision of effective training in virtual environments. With the diverse applications of DIL simulators highlighting their significance in vehicle dynamics assessment, Advanced Driver Assistance Systems (ADAS) and autonomous vehicle development, testing of complex control systems is crucial for vehicle safety. A comprehensive review of current research trends reveals key areas of focus such as realism of simulated experiences through improved vehicle dynamics models and advanced sensory feedback. The integration of virtual and augmented reality technologies help to create more immersive and informative simulations to improve the cost-effectiveness and accessibility of DIL simulation platforms. By examining the current landscape of DIL simulator use cases, this paper critically focuses on

Sharma, Chinmaya, Bhagat, Ajinkya, Kale, Jyoti Ganesh, Karle, Ujjwala

Agricultural tractor brake linkage efficiency prediction and correlation using Flexible Multibody Dynamics model

2026-26-0103To be published on 01/16/2026

In agricultural tractors, braking actuation is usually done through control linkages consisting of a series of connected four-bar linkages with multiple pivots from the pedal to the brake pads. The quality of force transmission is critical as it directly affects the braking performance of the tractor. Forces measured at the end of the control linkage or brake pull rod often show deviation with theoretically-based mechanical advantage calculations. This is due to various factors such as linkage transmission angle, elasticity, and friction in joints not considered, which contribute to loss in force transfer. A standardized simulation method needs to be developed and validated to predict the losses in the control linkage system. In this paper, the author proposes a simulation approach using multi-body dynamics, which includes contribution factors such as transmission angle, linkage elasticity, and friction in joints. MBS model for brake linkage system for three different tractors

Subbaiyan, Prasanna Balaji, Nizampatnam, Balaramakrishna, Redkar, Dinesh, Arun, G, K, Vinoth, R, Sengottu, Paulraj, Lemuel

Early Prediction of CNG Filling Time using Artificial Intelligence for Design Optimization

2026-26-0662To be published on 01/16/2026

The CNG fuel system is a critical component in vehicle development and typically includes large-volume gas cylinders (up to 800 liters). As these vehicles often operate over long distances daily, frequent refueling is necessary, making a short gas filling time highly desirable. Currently, CNG filling time is evaluated after prototype development to determine the refueling duration. If the filling time is excessive, design changes to the fuel system are required, leading to significant cost and time penalties and causing delays in the vehicle product development cycle. By integrating AI/ML technology, a mathematical model has been developed based on various influencing parameters. This model will predict CNG gas filling time across all commercial vehicle platforms at the initial Zero design release gateway. This early prediction will enable further optimization to improve gas filling time. The goal of this research work to optimising the filling time for various platform before physical

Choudhary, Aditya Kant, Petale, Mahendra, Dutta, Surabhi, Bagul, Mithilesh

Standard SWS Requirement based Integration testing for classic AUTOSAR modules.

2026-26-0507To be published on 01/16/2026

In the development of automotive ECUs, to keep performance in desired level, what remains constant is to verify, evaluate and validate ECU. Nowadays, Cars have multiple ECUs even in range of 50. Software is validated using target ECU, CAN communication and some I/O simulation techniques. Also, in some applications, virtual environment is created for testing. In this paper, method of Integration testing of AUTOSAR modules is presented which uses AUTOSAR SWS as its input. This makes standard test cases as SWS remains same for a AUTOSAR standard release. It enables a platform to efficiently test all layers of a AUTOSAR BSW modules after integration. For demonstration, we will use TriCore micro controller TC377TX from Infineon. Same controller is usually used in the development of automotive ECUs for various applications. Using winIDEA debugger from iSYSTEM, setup becomes easier to operate for any new person as it supports both debug and flash mode operation. Simplistic approach will be

Kelkar, Renu, Patil, Vardhman

Accelerating Product Development Life Cycle through Digitalization of Fatigue Life for Structural Components

2026-26-0496To be published on 01/16/2026

In today’s competitive market, accelerating product development without compromising durability is critical. Durability is a key benchmark for assessing the quality and reliability of automotive products. To meet rising customer expectations and regulatory demands, the industry must develop vehicles that offer high performance and reduced weight while ensuring safety. A well-engineered vehicle must retain structural integrity and functionality under normal operating conditions and withstand extreme load events without critical failure. Achieving this requires effective Road Load Data Acquisition (RLDA), integrated with robust design practices and efficient validation processes. However, physical RLDA is time-consuming and costly, as it depends on prototype vehicles that are often available only in the later development stages. Failures identified during these late-stage tests can delay the product launch significantly. To address these challenges, this paper introduces a digital

Kokare, Sanjay, Dwivedi, Sushil, Siddiqui, Arshad, Iqbal, Shoaib

Static Rollover Stability Analysis of Heavy Tipper vehicle

2026-26-0090To be published on 01/16/2026

Heavy tipper vehicles are primarily utilized for transporting ores and construction materials. These vehicles often operate in challenging locations, such as mining sites, riverbeds, and stone quarries, where the roads are unpaved and characterized by highly uneven elevations in both the longitudinal and lateral directions of vehicle travel. During the unloading process, the tipper bodies are raised to significant heights, which increases the vehicle's centre of gravity, particularly if the payload material does not discharge quickly. Such conditions can lead to tipper rollover accidents, causing severe damage to life and substantial vehicle breakdowns. To analyse this issue, a study is conducted on the vehicle design parameters affecting the rollover stability of a 35-ton GVW tipper using multi-body simulations in ADAMS software. The tilt table test was simulated to determine the table angle at which wheel lift occurs. Initially, simulations are performed with the rigid body model

Vichare, Chaitanya Ashok, Patil, Sudhir, Gupta, Amit

Indian City Electric Bus Powertrain Optimization Using Active Learning Simulation Methodology

2026-26-0657To be published on 01/16/2026

Public transport electrification is going to play a massive role in India's COP26 pledge to achieve net zero emissions by 2070. India plans to electrify 800,000 buses in a push towards 30% EV penetration by 2030. Further encouraged by government incentives under National Electric Bus Program (NEBP), eBus market is expected to grow at a CAGR of ~86% annually over the next 5 years. With most OEMs going for fleet electrification for reducing CO2 emissions and to cater to growing demand in Indian cities for cleaner public transport, improving powertrain efficiency and performance of state-of-the-art eBuses is a natural progression of e-mobility sector development in India. The first step in designing powertrain for an electric city bus is to determine the motor(s) size and transmission specifications (number of gears, gear ratios etc.). Complications arise due to a wider and non-linear operation range of eBus. This study focuses on powertrain optimization for a medium duty electric city

Emran, Ashraf, Berry, Sushil, Xia, Feihong, Chen, Bicheng, Sandhu, Rouble

Model Based Design of Gear Shift Control for Twin Clutch AMT

2026-26-0054To be published on 01/16/2026

Model Based Design (MBD) uses mathematical modelling to create, test and refine systems in simulated environment, primarily applied in control system development. This paper discusses an approach to control gear shifting using shift logic on vehicle level for twin clutch transmission using prototype controller. Twin clutch transmission is a concept with two clutches, one at input end of the transmission called primary clutch and the other at output end of the transmission called secondary clutch. This concept is proposed to counter the challenges with conventional transmission which include increased gear shift time and effort in lower gears, potential rollback of vehicle in uphill condition and chance of missed shifts. The advantages of this concept include reduced gear shift effort and improved synchronizer life with potential for reducing the size of the synchro pack. This paper proposes a methodology to develop shift logic, integrate hardware with software, flashing and calibration

Patel, Hiral, Thambala, Prashanth, Tongaonkar, Yogesh, Mosthaf, Joerg, Malpure, Khushal

Optimization of Electric Drive Unit Mounting for Vibration Isolation in EV Powertrains Using Multibody Dynamics

2026-26-0080To be published on 01/16/2026

With growing significance of electric vehicles (EVs), their powertrains—while naturally quieter than internal combustion engine (ICE) powertrains—pose new NVH (Noise, Vibration, Harshness) challenges. These are triggered mainly from high-frequency disturbances caused by electric motors and gear interactions. Isolation of such excitations is essential for securing cabin refinement and customer expectations for acoustic comfort. This paper offers a simulation-based approach to optimal placement of the electric drive unit (EDU), which houses the electric motor and gearbox, with the objective of reducing vibration transfer to the chassis of the vehicle. The methodology explores the effect of spatial mount repositioning under actual dynamic load conditions through multibody dynamics (MBD) modeling and integrated optimizer using advanced multibody dynamics simulation software – Virtual Dynamics. The suggested workflow helps in effective investigation of mount positioning within packaging

Mane, Prashant, Shah, Swapnil, Back PhD, Arthur, Pinjari, Abrar, Emran, Ashraf, Mane PhD, Shrikala

A Novel Approach to Optimal Strain Gauge Placement for Structural Assessment: Integrating Close Looping Configuration with Calibration Techniques

2026-26-0551To be published on 01/16/2026

Addressing the challenge of optimal strain gauge placement on complex structural joints and pipes, this research introduces a novel methodology combining strategic gauge configurations with numerical optimization techniques. Traditional methods often struggle to accurately capture combined loading states and real-world complexities, leading to measurement errors and flawed structural assessments. For intricate joints, a looping strain gauge configuration is proposed to comprehensively capture both bending and torsional effects, preventing the bypassing of applied loads. A calibration technique is used to create strain distribution matrices and access structural behavior under different loading conditions. Optimization algorithms are then applied to identify gauge placements that yield well-conditioned matrices, minimizing measurement errors and enhancing data reliability. This approach offers a cost-effective solution by reducing the number of gauges required for accurate stress

shingate, Uttam, Yadav, Dnyaneshwar

Proactive AI-Enhanced Cybersecurity for Next-Gen Automotive Infotainment ECU

2026-26-0619To be published on 01/16/2026

Abstract With the rapid advancement of connected vehicle technologies, infotainment Electronic Control Units (ECUs) have become central to user interaction and connectivity within modern vehicles. However, this enhanced functionality has introduced new vulnerabilities to cyberattacks. This paper explores the application of Artificial Intelligence (AI) in enhancing the cybersecurity framework of infotainment ECUs. The study introduces AI-powered modules for threat detection and response, presents an integrated architecture, and validates performance through simulation using MATLAB, CANoe, and NS-3. This approach addresses real-time intrusion detection, anomaly analysis, and voice command security. Key benefits include zero-day exploit resistance, scalability, and continuous protection via OTA updates. The paper references real-world automotive cyberattack cases such as Tesla's OTA vulnerability patches, BMW ConnectedDrive exploits, and Jeep Cherokee's Uconnect hack, emphasizing the

More, Shweta, Kulkarni, Shraddha, Kumar, Priyanshu, GHANWAT, HEMANT, Joshi, Vivek

A Mathematical Modelling Approach Based on Artificial Neural Network for Estimation of Key Parameters in Internal Combustion Engine

2026-26-0659To be published on 01/16/2026

In a conventional powertrain driven by Internal combustion (IC) engines, there are many key sensors such as intake manifold temperature sensor, exhaust temperature sensor, Nitrogen oxide (NOx) sensors etc. to monitor engine performance and emissions. For enabling various diagnostics strategies and engine monitoring, virtual sensors or modelled values of such sensors play an important role. Conventional strategies incorporate the use of regression models, map-based models and physics-based models. There are a few drawbacks with conventional models in terms of accuracy and model calibrations efforts. Data driven models or neural networks have fairly better accuracy and reliability for estimating complex parameters. Representing the neural network with a mathematics-based model would help to eliminate drawbacks associated with conventional modelling approach. The proposed methodology uses artificial intelligence technique called artificial neural network (ANN) for estimation, for example

Jagtap, Virendra Shashikant, Shejwal, Sanket, Mitra, Partha

Engine compartment front end module layout placements to achieve maximum volumetric efficiency

2026-26-0588To be published on 01/16/2026

The increasing demand for electric vehicles has led to design considerations prioritizing visual brand consistency across both electric vehicles (EV) and internal combustion engine (ICE) vehicles. Front grille is one such area where efforts are taken to have similar looking features between both EV and ICE. This has lead to low front grille opening and low air flow through the front. A critical consequence of this design trend: the suboptimal thermal performance, high engine bay and air intake temperatures of snorkel-type air intake systems in ICE vehicles when paired with front grille designs intended to mimic EV aesthetics. Factors such as snorkel positioning, airflow patterns must be optimized to maintain cooler intake air. Effective system design ensures that the engine receives air at an optimal temperature, improving combustion efficiency, throttle response, and reducing the likelihood of knock. This paper emphasizes the importance of controlling intake air temperature through

SONONE, SAGAR DINESH, Kolhe, Vivek M, Singh, Nil Kanth

Reverse Gear Duty Cycle Generation Using Virtual RLD Simulation

2026-26-0405To be published on 01/16/2026

Keywords: RLD (Road Load Data), AVL VSM, AVL Route Studio, Duty Cycle, Transmission, Reverse Gear, Durability The development of transmission systems involves creating duty cycles for bench-level durability evaluations for both forward and reverse gears. For forward gear, vehicles are driven under various real-world conditions over thousands of kilometers, equipped with numerous sensors and components tailored for data collection. In contrast, duty cycles for reverse gear are often based on prior experience or rough estimations due to the lack of clear definition of real world use case. Reverse gear RLD is particularly scarce, especially for heavy-duty vehicles operating in off-road or mining environments, where specific reverse driving paths are not typically followed. This paper presents a detailed methodology highlighting the importance of reverse gear duty cycles by leveraging virtual RLD simulations on various gradients using tools such as AVL Route Studio and AVL VSM. By

Kansagara, Smit, Patel, Hiral, kira, Lucas, Sutar, Suresh, Soor, Debasis

Use Of Digital Wind Tunnel For Improved Aerodynamic Prediction

2026-26-0372To be published on 01/16/2026

In the automotive industry, external aerodynamic evaluations in digital environments are commonly conducted using simplified, large box tunnels with vehicle being static. These approaches are computationally efficient and ensure faster turnaround times. To closely replicate physical wind tunnel testing or real-world conditions, these simulations are often augmented with moving ground and rolling tire configurations. While such setups provide valuable directional feedback for aerodynamic drag improvements, they frequently exhibit significant discrepancies when compared to physical wind tunnel test data. It is observed that key factors such as wind tunnel blockage effects, boundary layer suctions, when not properly accounted for, distort the local flow field dynamics and introduce errors in the simulations. With OEMs aiming to accelerate time-to-market for new vehicle launches, many aspire to minimize reliance on physical testing and maximize use of digital methods for design sign-off

sharma, Sandeep Kumar, Chalipat, Sujit, Maiyya, Sandeep

Design Optimization of Hydrogen Engine Vanity Cover for PSHA Compliance using CFD leakage analysis

2026-26-0263To be published on 01/16/2026

Abstract: The integration of hydrogen (H2) as a fuel source in internal combustion engines (ICE) necessitates stringent design measures to mitigate leakage risks and ensure operational safety. This study focuses on the design optimization of vanity cover for hydrogen engines which only serves the purpose for hiding fuel system, wire harness & engine aesthetic else there is no engineering function like sealing, load factor associated with it. This paper addresses the challenges and risks of using Vanity cover on Internal combustion engines, if fuel joints inside the cover start leaking and forms hydrogen cloud which if not ventilated or diluted properly will have safety risk considering low ignition of hydrogen. Computational fluid dynamics (CFD) analysis is carried out to assess and control hydrogen leakage through fuel rail connections, injector interfaces and associated high pressure fuel system components. Detailed modelling of hydrogen flow behavior, diffusion characteristics of

Veerbhadra, Swati Ashvinkumar, Sahu, Abhay Kumar, Singh, Rahul

Virtual Paint Shop: Automotive E-coating Process

2026-26-0365To be published on 01/16/2026

The automotive paint shop is one of the most energy-intensive processes in vehicle manufacturing. This drives automotive OEMs to continuously improve production efficiency and reduce operational costs through digital twin technologies. Additionally, the push for shorter time-to-market emphasizes the need for simulation-based manufacturing processes—such as virtual testing and CAE simulations—to enable faster, data-driven decision-making early in the product development cycle, ultimately reducing cost and development time. Among the various stages in the paint shop, two of the most critical are: 1. Electro-dip coating (E-coating), also known as Electro-Deposition coating, which applies a corrosion-resistant primer to the Body-in-White (BIW). 2. Oven curing, which ensures the primer is properly bonded and cured for long-term protection and finish quality. To optimize these processes, a Dip-Drain-E-Coating simulation was developed using Siemens Simcenter STAR-CCM+. This simulation

Gundavarapu, V S Kumar, p, Vivekaanandan, Garg, Manish, Navelkar, Tanay, BS, Balachandran

A Performance-driven Numerical Approach for Optimizing the Plenum Opening Area of Cowl Box

2026-26-0461To be published on 01/16/2026

There is a scarcity of research in literature regarding the determination of Plenum Opening Area of cowl box. The area of the plenum opening in the cowl box significantly affects the airflow rate in fresh airflow modes, such as face and defrost modes, as well as issues related to water ingress. Primarily, the size of the plenum opening is determined by the necessary HVAC airflow rate. This study aims to investigate how the plenum opening area impacts both airflow discharge and the water ingress issue in the HVAC module. A novel approach is introduced in this research to determine the optimal plenum opening area of the cowl box, taking into account both airflow rate and water ingress concerns. The ANSYS FLUENT software is utilized to analyze airflow discharge in both face and defrost modes, while the SPH (Smooth Particle Hydrodynamics) based Preonlab tool is employed for water ingress analysis. Airflow discharge is evaluated for various plenum opening sizes in both modes, and the area

Baskar, Subramaniyan, A Sr, Mahesh, Gopinathan, Nagarajan

Next Gen Automotive EDS Architecture design verification using real-time function mode simulation & failure condition analysis

2026-26-0454To be published on 01/16/2026

In current automotive electrical design practices, simulation and functional verification of the Electrical Distribution System (EDS) at the design stage are largely absent. Typically, the validation of controller behaviour and EDS wiring is performed only during HIL, SIL, MIL, prototype testing, or physical vehicle trials, often revealing issues late in the development cycle. This delay leads to costly redesigns, prolonged timelines, and increased chances of failure during vehicle integration. Therefore, there is a critical need for an early-stage simulation methodology that ensures robust EDS and controller design, enabling "first-time-right" readiness at the design stage itself. The proposed simulation framework introduces a function mode-based structural approach, where individual vehicle functions are mapped to their corresponding electrical circuits within the vehicle’s wiring system. Resistance values are allocated to specific paths depending on the active function or

Jaisankar, Gokulnath, Warke, Umakant

Dog Clutch Engagement Probability Simulation for Heavy-Duty Automated Mechanical Transmissions

2026-26-0437To be published on 01/16/2026

This study presents a simulation-based approach to estimate the dog clutch engagement probability maps under different vehicle operating conditions. The developed probability function incorporates multiple critical parameters including initial speed differential between engaging components, application of countershaft brake, dog tooth quantity, friction coefficients at tooth interfaces, applied actuation force, dog tooth geometry, and component inertia. Using MATLAB and Simulink, comprehensive simulation models were developed to analyse engagement dynamics and produce detailed probability maps at different vehicle speeds, effectively outlining optimal operational zones for successful engagement while identifying critical regions prone to tooth clash and engagement failure. The effect of tooth geometry on engagement probability has been investigated using simulation model results. The resulting engagement maps serve as valuable diagnostic tools for identifying potential system

Khan, Mohammad Adeeb, KHAN, Dr. NURUZZAMA MEHADI, Koona, Rammohan

Facilitating Virtual Testing at an Industrial Level by Simulation Data Management

2026-26-0440To be published on 01/16/2026

Automotive OEMs can derive significant cost savings by reducing the quantity of physical crash tests and thereby accelerate product development, when they follow the Euro NCAP Virtual Testing guidelines. It helps in optimizing the overall vehicle development process via more efficient simulations, as well as facilitates in early adoption of new safety regulations. In this pursuit, companies must comply with strict Euro NCAP requirements, which includes transparency and traceability of virtual tests. A major challenge therein is model validation – which requires highly precise detailing and extensive use of data for accurately replicating real physics of the problem. Deploying these workflows into an existing simulation process can be a complicated and time-consuming task, particularly when integrating various simulation and testing methods. A powerful simulation and process data management system (SPDM) can thereby assist companies to automate their entire simulation process, ensures

Thiele, Marko, Sharma, Harsh

Integrating V2V and V2I Communications for Enhanced Traffic Safety and Efficiency in Connected Vehicular Networks

2026-26-0271To be published on 01/16/2026

This paper presents a new approach to improve road safety and traffic flow by combining vehicle-to-vehicle (V2V) and vehicle-to-infrastructure (V2I) communications. Our study focuses on a system that connects vehicles with each other and with traffic signals to share real-time data about speed, position, and road conditions. Using both analytical models and experimental simulations built in MATLAB/Simulink, we developed a system that predicts and advises the optimal speed for vehicles approaching an intersection. In our design, a Green Light Optimized Speed Advisory (GLOSA) feature suggests an ideal speed for drivers so that they can pass through green lights without unnecessary stopping. This not only improves traffic flow but also reduces fuel consumption and lowers the risk of accidents. We validated our system through a series of simulations and real-time traffic scenarios. The results show that our approach can adapt dynamically to changes in vehicle behavior and traffic density

PINTO, COLIN AUBREY, Shah, Ravindra, Karle, Ujjwala

Exhaust Hot end system Transient Heat Transfer Analysis using Heat Transfer Coefficient (HTC) approach, Thermo-Mechanical Fatigue Analysis to evaluate thermal durability and physical validation through Thermo-Shock Testing

2026-26-0224To be published on 01/16/2026

Exhaust system suppliers are continuously enhancing their processes by adopting advanced simulation techniques and expedited testing procedures for optimizing exhaust systems. This aims to reduce time to market, accelerate vehicle launches, and ensure first-time right and consistent compliance with performance and durability standards. Traditionally, the CFD team conducts Conjugate Heat Transfer (CHT) analysis on the exhaust hot end system using input conditions such as engine-out gas temperature and maximum mass flow rate. The CAE team then performs steady-state heat transfer analysis by sharing the structural CAE model with CFD for CHT skin temperature mapping. Once steady state heat transfer analysis complete, skin temperature plots are to be compared with CFD to match CHT temperature results. These results are used for steady-state thermo-mechanical analysis across all heat-up cycles and assume system under ambient temperature for all cool-down cycles to evaluate system thermal

Natarajan, Suresh, J Y, Raja Shangara Vel

A Noval methodology of compact cooling unit design for Truck applications by using CAE CFD simulation

2026-26-0460To be published on 01/16/2026

The implementation of AC unit on truck as compulsory as per government guideline demands the AC supplier to design a compact and modular AC unit within the available package space. The installation of AC unit inside the vehicle helps the driver to drive safely due to better cabin comfort. This will reduce fatigue due to the long driving of the truck drivers. Thereby the safety of the truck and driver will be saved with the implementation. But there are challenges for AC manufactures to design the compact size AC unit. The challenges like performance, durability, cost and less noise to be met as per customer requirement. To overcome the issue of design at the early stage and compact AC unit within small space is possible with the support of simulation software. AE and CFD plays a major role in this regard. So first unit level CAE and CFD analysis conducted to predict the result. AE used for checking the strength of the mounting bracket of cooling unit and CFD used for verifying the air

Parayil, Paulson

Evaluation of Shear Trim Edge in HSLA Steel for Automotive Application

2026-26-0286To be published on 01/16/2026

Quality of the Shear Trimmed edge of HSLA 550 steels is significantly affected by process variations such as Shear Trimming Clearance, trim tolerance, burr height and clamping force. All these parameters largely influence the characteristics of the Shear Affected Zone, a region on sheet metal where it undergoes deformation during the trimming process. The Shear Affected Zone is predominantly vulnerable to failure due to work hardening and the effects of strain rate, induced by the tonnage during the trimming operation. To assess the edge ductility of these materials, Tensile, Fatigue Strength, Die Punch Clearance, Roughness and Hardness Tests are carried out. These tests are crucial for applications that demand high formability and resistance to edge failure. Virtual simulation of edge trimming operation using elastoplastic material models in LS-Dyna have been performed to gain insights into burr formation and damage evolution during shearing. These simulations act as a precursor to

Thota, Badri Vishal, Kashyap, Amit, Bhuvangiri, Jaydev

Novel Approach for Predicting Steering Rack Load Using Multibody Simulation

2026-26-0378To be published on 01/16/2026

In the initial stages of a vehicle development program, the sizing of various components is a critical deliverable. The steering system, in particular, requires a precise estimation of the rack load for the appropriate sizing of the rack and assist units. Accurately predicting the load on the system during the early stages of development is challenging, especially in the absence of benchmark or legacy data. Commonly used processes for estimating parking steering effort often employ simplistic approaches that may fail to account for parameters such as tire size, vertical stiffness, and steering geometry, leading to reduced accuracy. This paper introduces an advanced methodology for predicting steering rack loads, which incorporates considerations such as contact patch size and pressure variation, as well as the tire jacking effect. The methodology involves mathematical modeling of the contact patch using mesh-grids, utilizing common inputs available in the early stages of vehicle

Shirke, Umesh, Dabholkar, Aniruddh, bardia, Vivek, Srivastava, Harshit, PRASAD, TEJ PRATAP

Low-speed steering returnability analysis and improvements through mathematical modeling and CAE simulation for SUV

2026-26-0573To be published on 01/16/2026

In driving, steering serves as the input mechanism to control the vehicle's direction. The driver adjusts the steering input to guide the vehicle along the desired path. During maneuvers such as parking or U-turns, the steering wheel is often turned fully from lock to lock and then released. It is expected that the steering wheel quickly returns to its original position. Steering returnability is defined as the ratio of the difference between the steering wheel position at lock to lock and the steering wheel angle after 3 seconds of release, to the steering wheel angle at the lock position, under steady-state cornering conditions at 10 km/h. Industry standards dictate that the steering system should achieve 75% returnability under these conditions within 3 seconds. Achieving proper steering returnability characteristics is a critical aspect of vehicle design. Vehicles equipped with Electric Power-Assisted Steering (EPS) systems can more easily meet returnability targets since the

Singh, Ram Krishnan, ahire, Manoj, JAIN, PRIYA, Vellandi, Vikraman, SUNDARAM, RAGHUPATHI, Paua, Ketan

A numerical approach to optimize the flow characteristics for the enhancement of casting soundness of Al 6061 alloy die-casting

2026-26-0284To be published on 01/16/2026

The optimization of flow characteristics such as filling time, flow velocity, viscosity and temperature play a vital role in the die-casting to enhance the casting soundness. Experimental trial and error methods for optimizing the flow characteristics of mold filling are costlier and time-consuming methods. A digital approach could significantly minimize the cost and time for the prediction of the flow characteristics of the casting. Z-Cast Pro is the casting simulation software used for simulating the whole casting process such as filling, solidification etc. This software basically utilizes the finite difference and finite volume approximation techniques to numerically unravel the molten metal flow and solidification equations. In this study, A 3D model of the valve housing is used to analyze the mold-filling behavior through high and low-speed plunger movement of the molten Al 6061 alloy using Z-Cast Pro software version 24. Higher-speed plunger movement required a total mold

Choudhary, Chandan, Subramaniam, Anand, Karle, Manish, Karle, Ujjwala

Digital Twin-Driven Systems Engineering for Complex Automotive Features

2026-26-0379To be published on 01/16/2026

The automotive industry faces increasing challenges in managing vehicle lifecycle complexity, including inefficiencies in design, manufacturing, and maintenance. Traditional reactive maintenance approaches often lead to unexpected downtimes, increased costs, and a diminished customer experience. Moreover, rapidly evolving technologies demand agile and adaptive development processes. The Digital Twin concept which involves leveraging advanced technologies to create virtual representations of physical systems offers a promising solution by enabling real-time simulation, prediction, and optimization throughout the vehicle lifecycle. By bridging the physical and digital realms, Digital Twins provide a powerful tool for improving system efficiency, adaptability, and quality. This paper highlights the tangible benefits of applying Digital Twin principles at the systems engineering level, offering a path toward more resilient, innovative, and customer-centric vehicle systems. This study

Agarwal, Ujjwal, Sabharwal, Shambhavi

Systemic modelling and simulation approach to estimate Brake response time in a Pneumatic brake systems

2026-26-0469To be published on 01/16/2026

Brake response time in truck air brake systems is crucial for ensuring safety and operational efficiency. This paper presents the development of a simulation model designed to meet all necessary regulatory requirements for Brake response time and as an input to the stopping distance calculations. The actual pneumatic circuit, including brake valves, relay valves, brake chambers, and plumbing have been replicated. The focus is on utilizing 1D simulations to predict the compliance of response time during both the pressurizing (brakes applied) and depressurizing (brakes released) phases of the brake system. A mathematical model is developed using a commercially available 1D simulation tool. This model employs a lumped parameter approach for the pneumatic components, with governing equations derived from compressible flow theory and empirical valve flow characteristics. A parametric study is carried out on variables such as plumbing length, system pressure, and valve orifice diameters. The

Kumbar, Praful, Murugesan, Karthik, Shannon, Rick

Simulation Research on Torque Vectoring, Braking, Chassis control Strategies for Electric & hybrid Vehicles using System Simulation

2026-26-0423To 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

Advancing Complete Vehicle Engineering with ADAS Simulation through Virtual Development and Global Collaboration

2026-26-0409To be published on 01/16/2026

The automotive industry is currently undergoing a profound transformation, driven not only by the shift toward renewable propulsion systems but also by the increasing emphasis on the software-defined vehicle. In combination with accelerating project timelines, this shift creates challenges in integrating electrical and electronic systems throughout the complete vehicle. Magna Vehicle Engineering (MVE) faces these challenges by intensifying the use of virtual development, a strategy that spans the entire vehicle development process and necessitates global collaboration among engineering teams. This publication presents a real-world example of how the automotive sector can transition from a traditional on-premises-environment (OPE) simulation setup to a Simulation-as-a-Service (SIMaaS) model. Our primary focus is on operational and collaborative dimensions, illustrating the significant influence these new approaches have on engineering processes and the wider implications for innovation

Wellershaus, Christoph, Wakharde, Sagar, Bernsteiner, Stefan

Simulation-Based Thermal Performance Study of a DC-DC Converter for EVs.

2026-26-0481To be published on 01/16/2026

The low voltage systems are used for lighting applications, horns, infotainment system, sensors and control units as per lower operating rated voltage. Operating temperature is the main factor causing more than 50% of all power electronics failures. The DC-DC converter convert one level of DC voltage to another required level as per applications in the vehicle. To reduce weight, cost and having better vehicle packaging, manufacturers use DC-DC converter to meet the low voltage operating range usually 12V to 24V. In order to maintain the regulated output voltage above or below the range, step-up or step-down DC-DC converter are useful. Thermal design of a DC-DC Converter through thermal modelling and simulation approach is becoming more popular as it is less expensive compared to experimental approach. This study is performed to develop a thermally optimized DC-DC converter against higher power losses and to maintain the operating temperature of power generating components below its

Chaudhari, Prashant H., Patil, Nishikant, Nayak, Shibabrata

Incorporation of strain hardening and sheet thinning effects during forming process for an accurate prediction of buckling loads on sheet metal axle parts

2026-26-0391To be published on 01/16/2026

In this competitive automotive world, shorter development time and quicker time to market for new models are vital to product success. This can be achieved by digitalization, thereby avoiding over-design of parts and the need for physical prototypes, resulting in cutting down on material and development efforts respectively. In this study, the deviation of load carrying capacity of chassis sheet metal axle links in comparison with hardware testing and simulation results were investigated. A multi-step forming simulation is carried out, which involves simulating all stages of the forming process to accurately predict the plastic strains leading to material strain hardening and thickness distribution leading to thinning. The forming simulation is performed using the anisotropic material model Banabic-Barlat-Comsa (BBC) to capture the anisotropy effects. This model uses several coefficients to precisely characterize the yield surfaces, considering both uniaxial and biaxial yield stresses

R B, Govind, Selvaraj, Nirmal Velgin

CAE driven seam weld optimization for stiffness and fatigue calculations

2026-26-0478To be published on 01/16/2026

Structural parts are joined using seam welds, spot welds and bolted connections. The strength and stiffness of any structural part are strongly influenced by the properties of their joints. Seam welds are used extensively in the automotive industry to join panels. The design and the positioning of the seam welds have a significant impact on the technical cost of the project. In the automotive industry, structural optimization and fatigue simulation have become standard applications during any development process. The conventional approach in identifying the position and number of seam welds and its length is time consuming and leads to over design. Current paper highlights developing a simulation process for seam weld optimization in identifying the optimal position and length of seam welds. The optimization workflow is set up in CAE with design objective of minimizing the number of seam welds and finding the optimal length by meeting stiffness targets and fatigue life of seam welds

Gudipati, Raja Shekar Reddy

Efficient simulation modelling technique using automatic mesh and contact interface generation

2026-26-0392To be published on 01/16/2026

Computer-Aided Engineering (CAE) users often follow traditional meshing and contact generation processes, which are time-consuming, repetitive, and heavily dependent on user experience and perspective. The method described herein presents a system for generating a mesh and contact interfaces that ensures standardized and consistent output for a model. The system stores multiple mesh configurations, each containing a set of predefined geometric features to create standard meshes for users. The process begins by receiving data for a CAD model of an object and capturing user input through a graphical user interface. Users specify several parameters, including the desired body type, global mesh size, and a selected mesh configuration from the available options. Using these inputs, the system generates a mesh for the model, incorporating the selected mesh configuration’s geometric features along with the specified body type and size. The contact generation process offers several key

DABADGAONKAR, ANAND, Kamble, Amardeep

Analysis of design parameters of fuel cell stack design for vehicle level performance enhancement

2026-26-0264To be published on 01/16/2026

The design of the fuel cell stack for enhanced power and voltage characteristics is essential as it impacts the drivability of the vehicles. While many experimental approaches have been explored to improve the performance of the fuel cell stack by refining its design, they are largely limited to trial-and-error based approaches. Hence, the task of identifying the critical parameters affecting the performance of the fuel cell stack becomes tedious. The process is further complicated when many parameters have a counterbalancing impact on the stack performance. To help refine the design process of the fuel cell stack for enhancing the performance, a sensitivity analysis based approach is proposed in this paper in which a mathematical model of the fuel cell stack relating the parameters and stack power, and voltage is used. As a baseline the reliability of the mathematical model is presented first demonstrating its utility for the current study. The parameters used include membrane

Inapakurthi, Ravi kiran, Kumar, Bharat

Optimization of the Rodip CED Process Suitability through Strategic Fixture System for Enhanced Hood Gap and Flushness Control in Automotive Manufacturing

2026-26-0486To be published on 01/16/2026

The Ro-dip Cathodic Electrodeposition (CED) process is latest technology used by Automotive Manufacturers for higher quality corrosion protection in new generation Automobiles. This process involves multiple 360-degree rotation of automotive body in white (BIW) which exert higher hydrostatic forces on large surface panels like Hood. For maintaining consistent gaps & flushness control at vehicle level, it is important to safeguard the dimensional stability of light weight (crash performance sensitive) steel Hood panel while undergoing through this CED process. This study investigates the enhancement of hood panel alignment through strategic optimization of support rod placement and quantity within the Ro-dip CED system. By conducting experimental trials and computational simulations, the research identifies critical deformation points and evaluates the impact of varying support rod configurations on dimensional stability. The outcome results demonstrate that positioning support rods at

Tile, Vikrant, Unadkat, Siddharth, ASKARI, HASAN, Jadhav, Devidas

Analysis of Energy Consumption for Heating City Electric Buses and Ways to Reduce It

2026-26-0156To be published on 01/16/2026

For regions with cold climates, the driving range of electric buses becomes a significant obstacle to the broader adoption of this type of transport. The increased energy consumption affects not only the range of autonomous operation but also the lifespan of battery packs, the scheduling of bus departures, and the load on the charging infrastructure. In this context, finding ways to reduce the energy consumption of the climate control system is an actual issue. The aim of the presented research is to experimentally and computationally determine the energy consumption for heating the driver's cabin and passenger compartment of an electric bus during the autumn-winter operation period, as well as to identify and analyze ways to reduce this energy consumption. To determine the air temperature in the passenger compartment, a mathematical model based on heat balance equations was used. This model was validated using data from real-world tests. The research was conducted at a proving ground

Kozlov, Andrey, Terenchenko, Alexey, Stryapunin, Alexander

Cross-ICA Trust Mechanism in Automotive Cybersecurity

2026-26-0615To be published on 01/16/2026

With the ever increasing complexity and connectivity in modern vehicles, cybersecurity has become an indispensable technology. In the era of Software Defined Vehicles (SDVs) and Ethernet-based architectures, robust authentication between Electronic Control Units (ECUs) is critical to establish a trust. Further, the cloud connected ECUs must perform authentication with backend servers. These authentication requirements often demand multiple certificates to be provisioned within a vehicle, ensuring secure communication between various combinations of ECUs. As a result, a single ECU may end up storing multiple certificates, each serving a specific purpose. This work proposes a method to limit the number of certificates required in a given ECU without compromising security. We introduce a Cross-Intermediate Certificate Authority (Cross-ICA) Trust Architecture, which enables the use of a single certificate per ECU for inter-ECU communication as well as backend server authentication. In this

Venugopal, Vaisakh, Goyal, Yogendra, Raja J, Solomon, Rai, Ajay, Rath, Sowjanya

Development and Validation of a 1D Model for Evaluating Transmission Efficiency in Vehicles

2026-26-0066To be published on 01/16/2026

This study develops a one-dimensional (1D) model to enhance transmission efficiency by evaluating power losses within a transmission system. The model simulates power flow and identifies losses at various stages such as gear mesh, bearing, churning, and windage losses. Using ISO/TR 14179, which provides a method for calculating the thermal transmittable power of gear drives with an analytical heat balance model, the 1D model ensures accurate thermal capacity evaluation under standard conditions. A key advantage of this 1D model is its efficiency in saving time compared to more complex 3D modelling, making it particularly useful during the conceptual stage of transmission system development. This allows engineers to quickly assess and optimize transmission efficiency before committing to more detailed and time-consuming 3D simulations. To validate the model, experimental tests were conducted at various motor speeds (RPM) and torque values, using high-precision sensors and dynamometers

Bandi, Nagendra Reddy

A Method to Improve the System Efficiency of an Electronic Drive Unit: Variable Switching Frequency-Loss Optimization

2026-26-0062To be published on 01/16/2026

In electrical engineering, designing and improving inverter and induction motor systems is very important for many industrial uses. Even though these systems are flexible and widely used, one of the main challenges is accurately measuring how much power is lost when they run. Usually, people check the system’s efficiency, but that doesn’t fully explain how or why the power loss happens inside these systems. This paper presents a new way to study power losses without focusing on efficiency. Instead, it uses analytical methods supported by MATLAB programming. The goal is to explore the complex reasons behind power losses in both inverters and induction motors. To do this, the study develops mathematical formulas that describe the different types of losses, such as those from conduction, switching, and magnetic effects. These formulas are based on basic physics and are turned into MATLAB code, which helps connect theory with real-world application. In the end, the project creates a

BANDA, Gururaj, Sengar, Bhan

Experimental Study to Investigate and Control Image Blurriness due to IRVM Vibration

2026-26-0321To be published on 01/16/2026

Vibration is one of the prominent factors that determine the quality & comfort level of a vehicle. Moreover, if vibration occurs in areas that are almost entirely within customer touchpoints (during either city or highway driving conditions), it could become a critical factor behind the deterioration of brand image within the market. The interior rear-view mirror (IRVM) is one of the important components inside passenger cabin, providing drivers with a clear view of the rear traffic. However, vibrations induced by engine operation, road irregularities, and aerodynamic forces can cause the IRVM to oscillate, leading to image blurriness and compromised visibility and safety. This paper investigates the underlying causes of IRVM vibrations and their impact on image clarity. Through a combination of experimental analysis and computational modelling, we identify key factors contributing to mirror instability. The findings indicate the specific frequencies of vibration, particularly those

Khan, Aamir Naved, Saraswat, Vivek, Jha, Kartik, SINGH, HEMENDRA, Seenivasan, Gokulram, Khan, Nafees

Integrated Powertrain Domain Controller Using Wide Band Gap Devices For EV Applications

2026-26-0055To be published on 01/16/2026

The rapid evolution of electric vehicles (EVs) has amplified the demand for highly integrated, efficient, and intelligent powertrain architectures. In the current automotive landscape, EV powertrain systems are often composed of discrete ECUs such as the OBC, MCU, DC-DC Converter, PDU, and VCU, each operating in isolation. This fragmented approach adds wiring harness complexity, control latency, system inefficiency, and inflates costs making it harder for OEMs to scale operations, lower expenses, and accelerate time-to-market. This paper addresses the core issue of fragmented control architectures in EV powertrains by proposing an integrated domain controller-based solution for EV powertrain. The technical gap lies in the absence of a centralized intelligence capable of seamlessly managing and synchronizing the five key powertrain aggregates: OBC, MCU, DC-DC, PDU, and VCU under a unified software and hardware platform. This fragmentation leads to redundancy in computation, increased

Kumar, Mayank, Deosarkar, Pankaj, Inamdar, Sumer, Tayade, Nikhil

Analytical and Experimental Study of Cam Follower Wear in a Diesel Engine

2026-26-0106To be published on 01/16/2026

The valve train system plays a critical role in the performance and longevity of internal combustion engines. This paper presents a comprehensive investigation into the performance and durability of valve train systems in diesel engines, uncovering significant findings during durability validation. Extensive durability evaluations were conducted, including valve train overspeed test cycles and fatigue test cycles, to simulate real-world scenarios and assess component resilience. This study focuses on wear patterns observed in the cam and follower arrangements, highlighting their critical influence on engine performance and lifespan. The research investigates the root cause of wear by analysing wear patterns and evaluating the kinematic and dynamic behaviour of the valve train system through analytical calculations. The impact of combustion forces, pushrod rotation at the hydraulic rocker arm, and follower rotation are also explored in depth. Leveraging insights from these evaluations

Roop Rai PE, Vishnu, singh, Shakti Kumar

Enhancing Range Prediction Accuracy for the BEV: Bridging the Gap Between Simulation and Real-World Testing

2026-26-0521To be published on 01/16/2026

Accurate range estimation in battery electric vehicles (BEVs) is essential for optimizing performance, energy efficiency, and customer expectations. This study investigates the discrepancies between physical test data and simulation predictions for the Jeep Wagoneer model. A detailed range delta analysis identifies key contributors to the observed deviations, including regenerative braking inefficiencies, increased propulsion demand, auxiliary loads, and estimated drivetrain losses within the Electric Drive Module (EDM) during traction and regen. Results indicate that the test vehicle exhibits lower regenerative braking efficiency and higher traction and lower regen consumption than predicted by simulations, primarily due to EDM inefficiencies and friction brake usage during regeneration. The study underscores the importance of refining simulation methodologies by integrating real-world, test based EDM loss maps to improve accuracy and better align predictive models with actual vehicle

ali, Shoaib, Mahajan, Prasad

Optimizing Brake Pedal Feel and Driver Comfort in Buses with Pneumatic Braking Systems

2026-26-0536To be published on 01/16/2026

Brakes are a critical safety component in vehicles, and every parameter of the braking system plays a vital role in vehicle operation. Among these, brake pedal feel and driver confidence are key factors, in addition to achieving the required brake force, deceleration, and stopping distance. These aspects depend on the system-generated torque, available pneumatic pressure, lining material properties, and Electronic Braking System (EBS) parameters. This paper focuses on the factors influencing brake pedal feel while maintaining a balance between driver comfort and confidence during bus operation. Under optimal braking conditions, brake pedal response and brake torque gradient must align with the driver’s deceleration demands. The braking system must respond promptly, completing the application in the shortest possible duration. The brake torque gradient values specified in the EBS file should neither be too low nor too high, and the brake pedal feel must remain consistent throughout the

Pujari, Sachin, Salunkhe, Swapnil, Ali, Tauqeer

Advancing Automotive Radar Characterization: OTA HIL Testing for Enhanced ADAS Safety

2026-26-0043To be published on 01/16/2026

The increasing demand for reliable Advanced Driver-Assistance Systems (ADAS) and autonomous driving technologies necessitates the precise validation of automotive radar sensors. Traditional on-road testing, while effective, presents challenges such as limited repeatability, high costs, and safety concerns. To address these limitations, this paper introduces an Over-the-Air (OTA) Hardware-in-the-Loop (HIL) methodology for radar characterization, providing a controlled and repeatable lab-based validation approach. This methodology enables dynamic testing of key radar parameters, including range estimation, angle of arrival measurement, Doppler velocity analysis, and object detection accuracy. The proposed setup supports diverse testing scenarios, such as variable target distances, relative speeds, multiple object simulation, and environmental effects, ensuring a comprehensive evaluation of radar behaviour under complex and safety-critical conditions. Through OTA testing, developers can

Jadhav, Tejas, Karle, Ujjwala, Paul, Harshit, SNV, Karthik

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