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Analysis Techniques for Racecar Data Acquisition [mms update 07.03.25]R-367To be published on 03/22/2099
Data acquisition has become an invaluable tool for establishing racecar - and car/driver - performance. Now that the ability exists to analyze each and every performance parameter for car and driver, accurate use of this data can provide a key advantage on the racetrack. This book provides a thorough overview of the varied methods for analyzing racecar data acquisition system outputs, with a focus on vehicle dynamics.
Segers, Jorge
Acoustic Assessment in a Small Displacement Diesel Engine2014-32-01291/30/2026
In the last years, the increasing concern for the environmental issues of IC engines has promoted the development of new strategies capable of reducing both pollutant emissions in atmosphere and noise radiation. Engines can produce different types of noise: 1) aerodynamic noise due to intake and exhaust systems and 2) surface radiated noise. Identification and analysis of noise sources are essential to evaluate the individual contribution (injection, combustion, piston slap, turbocharger, oil pump, valves) to the overall noise with the aim of selecting appropriate control strategies. Previous paper focused on the combustion related noise emission. The research activity aimed at diagnosing and controlling the combustion process via acoustic measurements. The optimal placement of the microphone was selected, where the signal was strongly correlated to the in-cylinder pressure development during the combustion process. Analysis and processing of the sound emission allowed the acoustic
Chiatti, Giancarlo, Recco, Erasmo, Chiavola, Ornella, Conforto, Silvia
Mitigating Air Flow Sensor Signal Variability to Optimize Engine Operation in Passenger Cars2026-26-05121/16/2026
The need for advanced engine control systems has grown significantly in response to stricter emission regulations and increasing consumer demand for fuel-efficient passenger vehicles. Accurate estimation of intake air flow, coupled with precise fuel control, is essential to overcoming the challenges associated with modern gasoline engine performance. Hot-wire type mass air flow (MAF) sensors are commonly used for measuring intake air flow and are typically mounted on the clean side of the air intake system to protect them from contamination and extend their operational life. Reliable air flow measurement depends on maintaining a consistent and uniform flow across various engine speeds and load conditions. However, the optimal placement of the MAF sensor is often limited by engine packaging constraints, making sensor positioning a critical factor. Incorrect installation can result in inaccurate air flow readings, which negatively impact engine performance and emissions. During the
SONONE, SAGAR DINESH, Kale, Vishal, Kolhe, Vivek M
Development of Flex fuel Vehicle for Indian Market2026-26-01171/16/2026
This paper presents the methodology and outcomes of modifying a 1.2L naturally aspirated (NA) engine to enable flex-fuel compatibility, targeting optimal performance with ethanol blends ranging from E20 to E93. The road map for Ethanol Blending released by Govt of India call for progressively increase in ethanol blending in gasoline, with a target of 20% by April 2025. Ethanol is promoted as a renewable fuel due to its potential to reduce greenhouse gas emissions and provides an additional source of income for farmers. This work is in alignment with the broader push for development of flex-fuel vehicles, which necessitates engine adaptations capable of operating on varying ethanol blends. The primary objective was to retain the performance with E20 while mitigating the fuel consumption penalties when the vehicle is operating on higher ethanol concentrations upto E93. The engine upgrade incorporated key modifications, including optimizing the compression ratio, implementing Variable
Tyagarajan, Sethuramalingam, Pise, Chetan, Kavekar, Pratap, Agarwal, Nishant Kumar
All New 1.2L Turbocharged Gasoline Direct Injection Engine from Tata Motors2026-26-00711/16/2026
A continuous stress on meeting stringent emissions regulations alongside rising consumer expectations for enhanced driving performance and refinement on powertrain applications on passenger cars. To address this customer aspirations Tata Motors has engineered the advanced 1.2L 3-cylinder turbocharged gasoline direct injection engine HYPERION. This next-generation powertrain is designed to maximize efficiency, lower emissions and deliver superior performance with improved noise, vibration, and harshness (NVH) characteristics. Key innovations includes highly optimized fuel injectors injector operating at 35 MPa, CVO-3 (3rd Gen Controlled Valve Operation), Miller Cycle with Electrically actuated VGT turbocharger and an AI-enabled engine management system, which collectively enhances efficiency and performance. The exhaust after-treatment system incorporates a Three-Way Catalyst (TWC) and an integrated Four-Way Conversion Catalyst (FWC+TM) for efficient emission control. The BS6 phase 2
Hosur, Viswanatha, Ghadge, Ganesh Narayan, Joshi, Manoj, Jadhav, Aashish, Panwar, Anupam
Evaluation of Intercooler Effectiveness with No Fan, Single Fan, and Dual Fan: A Simulation and Experimental Study2026-26-05791/16/2026
Turbochargers play a crucial role in modern engines by increasing power output and fuel efficiency through intake air compression, thereby improving volumetric efficiency by allowing more air mass into the combustion chamber. However, this process also raises the intake air temperature, which can reduce charge density, lead to detonation, and create emissions challenges-such as smoke limits in diesel engines and knock in gasoline spark-ignited (GSL) engines. To mitigate this, intercoolers are used to cool the compressed air. Due to packaging constraints, intercoolers are typically long and boxy, limiting their effectiveness, especially at low vehicle speeds where ram air flow is minimal. This study investigates the use of auxiliary fans to enhance intercooler performance. Two methodologies were adopted: 1D simulation using GT-Suite and experimental testing on a vehicle under different fan configurations-no fan, single fan, and dual fans (positioned near the intercooler inlet and outlet
PATRA, SOMNATH, HIBARE, NIKHIL, Ganesan, Thanigaivel, Gharte, Jignesh Rajendra
Design and Optimization of Air Intake Manifold for 4cylinder 4valve Turbocharged CNG Engines: Enhancing Performance Metrics and Emission Compliance2026-26-01241/16/2026
This study presents the development and optimization of an air intake manifold for a 3-liter, 4-cylinder, 4-valve turbocharged engine operating on Compressed Natural Gas (CNG). The intake manifold plays a critical role in determining engine performance, directly influencing parameters such as power output, brake-specific fuel consumption (BSFC), and emissions. A systematic design methodology was adopted, starting with standard design repository, which were refined through iterative improvements focused on manifold volume, runner geometry, injector location, and fuel injection pressure. Computational Fluid Dynamics (CFD) simulations were conducted to evaluate the influence of manifold geometry and injector positioning on air-fuel mixing. The analysis assessed three potential injector locations: the tangential port, the swirl port, and a common upstream point where air splits into individual intake runners. Among these, the common upstream point consistently demonstrated superior air
Lomada, Balaji, Vasudevan, Sindhuja, RAVI, HARIKRISHNAN, N, Harish, UG, Remesh
CAE Approach to Reduce Cylinder Head Development Cycle Time2026-26-04841/16/2026
Traditional engine cylinder head design processes using Finite Element Analysis (FEA) are often iterative and unsystematic. After initial FEA, Computer Aided Design (CAD) changes are implemented to improve initial results, and subsequent designs are explored to identify improved proposals using ad hoc criteria. This iterative process is complex and time-consuming, reducing the likelihood of finding an acceptable, highly durable design. To improve the traditional product development approach, a unique application of FEA techniques that involves morphing and sub modelling is presented in this paper. The study identifies a methodology to assess water jacket durability early in the design process to understand possible design solutions, reducing High Cycle Fatigue (HCF) risks. Critical HCF areas typically occur on the water jacket in the vicinity of the combustion dome, due to the tensile stresses induced by the thermal and combustion pressure loading. Critical areas are identified by
patil, Vijay Ganapati, Shi, Simon
Smart Stability: Dual-Mode Hill Hold and Parking Brake Strategy in Electric Tractors Using Motor Torque and Electro-Hydraulic Actuation2026-26-02051/16/2026
Operating tractors on Sloped Terrains presents safety challenges, especially during shuttle operations, loader use, or start-stop maneuvers at slopes. Unlike Diesel Counterparts, feedback from the prime mover (Motor) is minimal and silence often masks terrain feedback. Driver response tends to vary, leading to rollback & challenges to safety demanding skill & expertise for safe operation. Based on field observations across Mahindra tractor platforms, we identified start-stop maneuver task to be offloaded from the operator to improve control and consistency and take skill element out of picture. This paper outlines the approach derived based on dual-mode Hill Hold and Parking Brake system, developed using traction motor torque control and SAHR-based hydraulic braking via proportional valves. The VCU works at the heart of this system to dynamically choose between electric and hydraulic modes based on vehicle state, ignition, and motor conditions. Parking brake automation logic has been
M, Rojer, P, Velusamy, Natarajan, Saravanan, devakumar, Kiran, T, Ganesan, sundaram, Pavithra, Muniappan, Balakrishnan
Impact of density in simulation model for extreme cold ambient conditions2026-26-03881/16/2026
Battery Electric Vehicles (BEVs) necessitate highly efficient thermal management strategies, as cabin heating directly consumes energy from the finite traction battery, potentially reducing driving range significantly. Early-stage design evaluations of warmup performance commonly rely on one-dimensional (1D) simulations due to their computational speed and efficiency. The accuracy and predictive capability of these models are critically dependent on how well they represent blower operation and account for temperature-induced variations in air density. This fidelity is essential because engineers depend on warmup simulations to set HVAC targets that will deliver real‑world comfort and defrost performance within stringent range constraints. Earlier, warmup simulations employed a Constant Mass Flow (CMF) approach, which simplifies computations by assuming a fixed air density at a standard reference temperature. However, this approach contrasts with real-world blower behavior, where
Subramanian, Karthik, Mishra, Abhishek
Performance Analysis of Filter Resistance, Louver Airflow, and Fan Heat Dissipation to protect Swapping station Charger2026-26-01771/16/2026
Efficient thermal management in electric vehicle (EV) charging stations is critical for ensuring the reliability, safety, and longevity of power electronics. This study presents a comprehensive bench test analysis of three key parameters influencing charger cooling efficiency: filter resistance, louver airflow, and fan heat dissipation. A test bench was developed to measure pressure drop, temperature gradients, and air velocity variations across multiple filter types, louver orientations, and fan configurations. The results show that higher-efficiency filters (e.g., HEPA, MERV13) significantly reduce airflow, increasing thermal stress on electronic components, while optimized louver angles improve directional airflow, reduce turbulence, and enhance cooling performance. High-performance axial and centrifugal fans with adaptive control mechanisms further contribute to effective heat dissipation, maintaining stable operating temperatures under varying load conditions. This study provides
S, Sri Saran, chinnanna, Manjunath, Ajith, Arjun, B, Viswanathan, Kulkarni, Mukund, R, Vigneshwaran, Dhachinamoorthi, Sivanantham
Wetting prediction of power train components under the influence moving components using smooth particle hydrodynamics2026-26-03841/16/2026
Passenger cars are subjected to extensive conditions ranging from driving through wet roads, water puddles, icy roads, and rain. This can affect the performance of different parts over time, one such aspect is the vehicle corrosion, whose impact is felt on a wide spectrum from aesthetics to safety due to loss of material. The general condition for corrosion mainly requires electrolyte to be present on the metal surface, which is transported through self-soiling and foreign soiling. Vehicle soiling is an important aspect for vehicle design. Amongst the many aspects of vehicle soiling, one important aspect is the prediction of water accumulation that enables prediction of corrosion sensitive regions in the vehicle. Power train components like Engine, transmission and corresponding wiring harness are at highest risk of water-wetting, As the vehicle drives through the water pool the components are not just wet by the direct inflow of water but also by water being splashed by moving
Shukrey, Sarthak, Pattankar, Rohan, Yenugu, Srinivasa
Simulation driven design of robust Crank-train systems for elevated In-cylinder combustion pressure2026-26-04001/16/2026
The need for increased in-cylinder pressure to meet the higher engine rating and stringent emissions norms requires special attention on the Main moving components torsional behaviour and the bearing performance. The work presented in this paper utilizes the 1D and 3D simulation potential of AVL EXCITE for the assessment of design changes required in Crank-Train system for the increased in-cylinder pressure from 170bar to 220bar. The key feature of the executed work was that all the design changes were accommodated with minimal changes in packaging / layout interfaces. The given work was executed on 6-Cylinder Turbocharged In-cylinder with Type V valve-train configurations. Initial brain storming & 0d calculation helped in understanding the design optimization required in each and every crank-train parts. Considering the guidelines available in terms of L/d ratio for the bearing, connecting rod length, the overall linkage specification was set up for starting with design work for
Khandelwal, Meha
Simulation Based Approach to Optimize Electric Vehicle Battery Thermal System2026-26-03761/16/2026
The performance and longevity of Li-ion batteries in electric vehicles are significantly influenced by the cell temperature. Hence, efficient thermal management techniques are essential for battery packs. Simulation based optimization approaches can enhance these techniques during early product development and life cycle. In this work, a method to optimize the battery thermal system comprising of cooling plate and external insulation is described. The first part is to optimize the cell heat extraction by the cooling plate. The heat transfer coefficient of the coolant is a parameter which can indicate the thermal efficiency of a cooling plate. At the same time, it's important to keep the coolant pressure drop within a reasonable limit. A 1D simulation methodology is described to optimize the cooling channel height based on pressure drop and heat transfer coefficient targets. This methodology is based on empirical correlations and multi-objective pareto optimization. The advantage of
U, Reghunath, P S, Shebin
Thermo-Mechanical Fatigue Assessment of Cylinder Heads Using Advanced Simulation Techniques2026-26-04651/16/2026
Thermo-mechanical fatigue (TMF) is a critical durability concern for cylinder heads in internal combustion engines, particularly under severe cyclic thermal and mechanical loads. TMF-induced damage often initiates in geometrically constrained regions with high thermal gradients and can significantly reduce component life. As performance demands increase, understanding and mitigating TMF becomes essential to ensure the structural integrity and long-term reliability of engine components. This study presents a simulation methodology for evaluating thermo-mechanical fatigue (TMF), a temperature-dependent low-cycle fatigue (LCF) mechanism that arises from repeated thermal expansion and contraction under mechanical constraints, leading to cyclic plastic deformation and damage. The methodology consists of two key phases. Phase I involves global finite element (FE) simulations—both thermal and structural—to obtain temperature and displacement fields under rated and idle engine conditions
Ghotekar, Sunil, Kumbhar, Dipak Madhukar, Pendse, Ameya
Experimental evaluation of Energy and Exergy of Hydrogen, CNG and Gasoline fuelled High-Speed Spark Ignition Engine2026-26-02581/16/2026
HIGHLIGHTS The maximum power is recorded with Gasoline than CNG and Hydrogen fuel. The maximum exergy and energy efficiency is with Hydrogen, followed by CNG and then Gasoline. Hydrogen fuel has a maximum potential to convert into energy. The maximum energy destruction of 48.7kW for gasoline fuel at 3000 rpm and followed by CNG and hydrogen. The maximum entropy generation of 85.5 W/K with Gasoline and 60.72 W/K and 29.39W/K for CNG and hydrogen engine respectively at 10000 rpm. The entropy generation rate increase with engine speed. The highest rate of heat release is from hydrogen fuel, followed by Gasoline and CNG.   ABSTRACT- The analysis was performed on a single Cylinder, Multivalve, Electronic Fuel Injection, high-speed motor fuelled engine with Gasoline, CNG and Hydrogen to assess energetic and exegetic performance. The engine was evaluated from 3000 rpm to 10000 rpm on each of the three fuels. All tests are led at Wide Open Throttle condition.The Gasoline and CNG
shinde, Apurwa Balasaheb, SHINDE, DR BALU, Kadam, Tushar, karunamurthy, K
Development of high BMEP natural gas engine with knock mitigation2026-26-01211/16/2026
The stringent emission norms over the past few years have driven the need to use low carbon fuels and after treatment technology. Natural gas is a suitable alternative to diesel for heavy duty engines with applications in power generation and transportation sectors. Stoichiometric combustion mode offer the advantages of complete combustion and low carbon dioxide emissions. The combination of turbocharging and cooled exhaust gas recirculation (EGR) technology enhances the power density along with reduced exhaust emissions simultaneously. However, there are several constraints in the operation of natural gas spark ignition engine such as exhaust gas temperature (EGT) limit of 750 °C, sufficient before turbine (BT) pressure for EGR drivability, boost pressure (2.5 bar), peak cylinder pressure limit and knocking. These limits may restrict the brake mean effective pressure (BMEP) of the engine. In the present study, tests were conducted on a V12, 24 litre, dedicated heavy duty natural gas
Khaladkar, Omkar, Marwaha PhD, Akshey
Controls Solutions for Commercial Hydrogen Engines2026-26-01121/16/2026
India’s commitment to carbon neutrality is significantly shaping the future architecture of commercial vehicle powertrains. While the use of CO₂-free technologies such as battery-electric drivetrains has already been successfully demonstrated across various applications, challenges related to limited range and the lack of high-power charging infrastructure continue to hinder widespread adoption, particularly for productivity-critical commercial vehicles. This has shifted the spotlight toward sustainable fuels, which offer the advantage of fast refueling times. Among these, hydrogen internal combustion engines (H₂ ICE) have gained increasing attention in recent years. In regions such as the European Union, the primary motivation for hydrogen is CO₂ reduction. In contrast, for markets like India, hydrogen also presents a strategic opportunity for reducing dependency on fossil fuel imports. Over the past four years, AVL has carried out multiple performance and emission development
Arnberger, Anton, Danninger, Alois, Mannsberger, Stefan, Breitegger, Bernhard
Analysis and Mitigation of Parasitic Noise in Hydraulic Engine Mounts: Addressing Cavitation and Membrane Hitting2026-26-03351/16/2026
Hydraulic engine mounts are widely used in automotive applications to reduce vibration and noise transmission from the engine to the vehicle body by providing high damping at low frequencies and low damping/stiffness at higher frequencies. This is achieved by allowing sufficient clearance between components inside the hydro mount, activating hydraulic damping only with sufficient amplitude inputs. However, this inherently leads to the generation of Parasitic noises emanating from hydraulic engine mounts which significantly degrades the Noise, Vibration, and Harshness (NVH) performance of vehicles, presenting a considerable challenge in the automotive industry. This encompasses phenomena such as cavitation, arising from the formation and subsequent collapse of vapor bubbles within the working fluid due to localized pressure drops below the vapor pressure, and membrane hitting, resulting from the dynamic interaction between the fluid and the elastic membrane within the mount. Both noise
Agrawal, Adheesh, Vineeth, Sekharan, Saxena, Akshansh, Ghosh, Chiranjit, Seenivasan, Gokulram, Nandal, Abhishek, Dhankhar, Dinesh Singh
EVALUATION OF DRIVELINE NVH PERFORMANCE USING LINEAR DYNAMIC FINITE ELEMENT SIMULATION2026-26-03221/16/2026
Automotive driveline design plays an important role in the NVH characteristics of the overall vehicle. Driveline systems are an integral part of delivering torque from the engine/transmission to the tires which propel the vehicle and drivelines often experience a wide frequency of excitation which poses unique NVH challenges. With the increasing trend in the automotive industry to introduce turbocharged engines with fewer cylinders while delivering the same torque / power, the driveline systems are excited with increased lower frequency torsional vibration in addition to other vibrations transmitted from powertrain and road. In this paper, we address the key design consideration for developing an optimal driveline system with consideration to NVH while keeping durability and other functional requirements in perspective. We consider the example of a front wheel drive-based vehicle architecture with independent suspension. The effect of fundamental prop shaft frequency to determine
JOSHI, ATUL KAMALAKARRAO, Subramanian, MANOJ
Evaluation of critical ignition coil parameters for an application On naturally aspirated gasoline engines2026-26-05891/16/2026
Today’s internal combustion engines require highly efficient combustion systems to meet stricter emission and fuel economy regulations. To fulfil to these requirements the ignition system of a gasoline engine plays a critical role. Along with ensuring that it meets the ignition characteristics across all engine operating conditions, it is also possess challenges like to comply with certain On-Board Diagnostics (OBD) norms .To meet these demands modern gasoline engines use inductive type ignition coils which are directly installed at the cylinder head above the spark plug. These ignition coils generate high voltage to produce a certain amount of spark energy and primary coil current which are necessary to meet the targets. However, it has been observed that in a traditional inductive type ignition coil system the ignition coil operating temperature can be a major limiting factor as it cannot exceed a maximum upper limit. The work described in this paper details the various systematic
Ghadge, Ganesh Narayan, Hosur, Viswanatha
Key Parameters for Turbocharger selection & experimental validation for Off-Highway Applications2026-26-01041/16/2026
Customers in off-highway industry are increasingly seeking high-performance capabilities for their tractors due to increasing penetration of mechanisation and labour scarcity. One effective solution to achieve enhanced performance is turbocharging of engines, while meeting emission and highly dynamic transient response of tractor field applications. The process of selecting and validating a suitable turbocharger for tractor field application suitability is significantly time and resources consuming activity due to extensive testbed and field trials. This study focuses on the selection of turbocharger for tractor engines through analytical calculations to freeze key parameters like lambda, boost pressure ratio & temperature within boundaries of exhaust temperature and turbo efficiency maps to deliver best field transient performance and fuel consumption. The selected parameters are further validated under real-world transient operating conditions, involving tractors and their implements
RAWAT, SAURABH, KUMAR, HARISH KUMAR, Singh, Amarinder, Singh, Sachleen, Dogra, DaljitSingh
Unveiling the Dynamics of Methanol-Diesel Dual Direct Injection Compression Ignition Combustion: A Synergistic Experimental and Numerical Study2026-26-01101/16/2026
The pressing global need for de-fossilization of the transport sector, especially within the heavy-duty segment, has intensified the exploration of alternative clean fuels. While light-duty applications are rapidly transitioning towards electrification, the heavy-duty sector remains a challenging frontier due to its high-power demand and extended runtimes. In this context, methanol gained traction due to their renewable production pathways, carbon-neutrality, and are being highly promoted by the Indian government to reduce CO2 emissions by 1 billion tons by 2030. This study presents a comprehensive investigation into the dual direct injection compression ignition (DDICI) strategy using methanol as primary fuel and diesel as a pilot for ignition assistance. In contrast to spark-ignited premixed methanol engines, this strategy involves a diffusion combustion of the methanol flame, thereby eliminating the knocking issue and running with high compression ratios. The work benchmarks the
Emran, Ashraf, Dhongde, Avnish, Singh, Inderpal, Raut PhD, Ankit, Güdden, Arne, Berry, Sushil
Adaptive Control Algorithms for Active Mounts on Diesel Powertrains in Passenger Cars2026-26-03241/16/2026
Diesel powertrains are inherently characterized by high vibration levels and low-frequency excitations, which are extremely demanding for passenger comfort and vehicle refinement. Conventional passive engine mounts often fall short in mitigating such vibrations effectively across a wide range of operating conditions. Passive mounts are inadequate for effectively isolating vibrations in powerful, lightweight vehicles or those without a balancer shaft 3-cylinder engine ordiesel engines. Consequently, this has prompted the consideration of active engine mounts as an alternative solution for solving NVH (Noise, Vibration, Harshness)-related issues. This paper explores the application of adaptive control algorithms in active engine mount systems for diesel powertrains in passenger vehicles. Through the integration of real-time feedback loops with smart control strategies the system adaptively controls mount stiffness and damping to minimize engine-induced vibrations. The study presents
Hazra, Sandip, Khan, Arkadip Amitava, more, Vishwas
Design & analysis of Dual Mass flywheel during Engine startup condition in 3 Cylinder Gasoline application2026-26-03491/16/2026
Modern automotive powertrains are increasingly adopting engine downsizing and down speeding to meet stringent emission regulations and improving fuel efficiency However, these changes result in higher torsional vibrations and excitation amplitudes makes more challenge in NVH (Noise, Vibration, and Harshness) refinement. With growing customer expectations for premium driving experiences conventional clutch are no longer sufficient. To meet the NVH performance targets of the vehicle Dual Mass Flywheels (DMFs) are used In DMF due to lower stiffness and inertia separation there is a great advantage on torsional filtration in normal drive and idle condition. but the resonance frequency of the connected DMF is lower than the idle RPM. Engine startup is a key drawback with DMF equipped vehicles. The proper tuning of starter motor performance & DMF stiffness is required to cross the resonance zone faster otherwise it will lead to DMF to stay in the resonance zone for a longer time leading to
Jayachandran, Suresh kumar, Vijayaragavan, Thirupathi, M, DEVAMANALAN, Kanagaraj, Pothiraj, ahire, Manoj, Vellandi, Vikraman
Advanced Thermal Management for High-Tonnage EVs: Increasing Coolant Flow and Reducing Energy Losses2026-26-01961/16/2026
With the increasing tonnage of electric heavy commercial vehicles, there is a growing demand for higher power and torque-rated traction motors. As motor ratings increase, efficient cooling of the EV powertrain system becomes critical to maintaining optimal performance. Higher heat loads from traction motors and inverters pose significant challenges, necessitating an innovative cooling strategy to enhance system efficiency, sustainability, and reliability. Battery-electric heavy commercial vehicles face substantial cooling challenges due to the high-pressure drop characteristics of conventional traction system cooling architectures. These limitations restrict coolant flow through key powertrain components and the radiator, reducing heat dissipation efficiency and constraining the operating ambient temperature range. Inefficient cooling also leads to increased energy consumption, impacting the overall sustainability of electric mobility solutions. This paper presents a novel approach to
DIXIT, SAMEER, Patil, Bhushan, Ghosh, Sandeep
Evaluating Thermal Control Strategies to Improve Electric Vehicle Range Using GT Suite2026-26-03621/16/2026
This study focuses on enhancing energy efficiency in electric vehicle (EV) thermal management systems through the development and optimization of control logic. A full vehicle thermal management system (VTMS) was modeled using GT-Suite software, incorporating sub-systems such as the high-voltage battery (HVB), e-powertrain (EPT), and an 8-zone cabin. Thermal models were validated with experimental data to ensure accurate representation of key dynamics, including coolant-to-cell heat transfer, cell-to-ambient heat dissipation, and internal heat generation. Control strategies were devised for Active Grille Shutter (AGS) and radiator fan operations, targeting both cabin cooling and e-powertrain thermal regulation. Energy consumption was optimized by balancing aerodynamic drag, fan power, and compressor power across various driving conditions. A novel series cooling logic was also developed to improve HVB thermal management during mild ambient conditions. Simulation results demonstrate
Chothave, Abhijeet, Kumar, Dipesh, Gummadi, Gopakishore, Khan, Parvej, Thiyagarajan, Rajesh, Pandey, Rishabh, S, Ananth, Anugu, Anil, Mulamalla, Sarveshwar, Gangwar, Adarsh
Comprehensive Validation Methodologies for Hydrogen IC Engines: Combustion Analysis and Performance Metrics2026-26-02561/16/2026
The validation of hydrogen-fuelled internal combustion engine (H2 ICE) is critical to assess its feasibility as sustainable transportation with zero carbon emissions. Validation of H2 ICE necessitates a specialized testing & analysis methodologies to achieve reliable test results. This study shows the adverse effects on engine performance due to barometric pressure variation, turbo compressor out temperature variation due to increase in ambient temperature. The analysis also shows experimental results of engine performance variation based on hydrogen gas quality. Charge air quality reduces due to presence of nitrogen and moisture content in hydrogen gas and has direct impact on combustion. Engine Performance variation also observed due to engine components detoriation like valve seat wear & spark plug gap expansion. This study emphasizes the significance of precise instrumentation of thermocouples across engine on cylinder head, intake manifold & exhaust manifold, to detect performance
Vasudevan, Sindhuja, J, Narayana Reddy, Bolar, Yogesh Ganesh, Pandey, Sunil, N, Harish, N R, Varatharaj, Karthikeyan, K, Kumar D, Kishore
Methodology for Reducing Engine-Radiated Noise in Tractors2026-26-00681/16/2026
Engine radiated noise has complex behavior since the diesel engine assembly comprises several components with varied dynamic speeds. The engine noise performance for the open station tractor is a crucial contributor to noise and needs to be optimized. Various engine noise sources have been researched, including structural like the engine block, intake, exhaust, and timing gears. Reducing noise in diesel powertrains by structural improvements entails limiting vibrations and preventing noise transfer from the engine. This can be accomplished by increasing the rigidity of the engine block and other structural components, as well as optimizing structural designs. Local adjustments to structural components have become a significant strategy for reducing noise and vibration problems. Design enhancements in structural components can be predicted and optimized for NVH. NVH testing helps validate changes in engine structure stiffness and assess acoustic improvements. Coupled with simulations
Kamble, Pranit, Baviskar, Shreyas, Ghale, Guruprasad, Chatterjee, Dipankar, Prabhakar, Shantanu, dhobale, Vishwajeet, Bendre, Parag, Thakur, Sunil, Kunde, Sagar
Performance Evaluation and Optimization of Engine Brake System using Chassis Dynamometer2026-26-05111/16/2026
Engine braking is a deceleration technique that leverages the internal friction and pumping losses within the engine. By closing the throttle and potentially selecting a lower gear, the engine creates a retarding force that slows the vehicle. This practice contributes to better fuel economy, decreased brake system load, and improved vehicle handling in specific driving scenarios, such as steep declines or slippery road surfaces. To alleviate stress on their primary braking systems and prevent overheating, heavy vehicles frequently incorporate engine-based braking. While older trucks relied on simple exhaust brakes with a butterfly valve to restrict exhaust flow, these had limited impact. Hence contemporary heavy vehicles almost exclusively use more advanced engine braking technologies. Traditionally, our heavy-duty vehicles use Exhaust brake system to elevate the braking performance on hilly terrains. Hence an improved sample of Engine brake was developed for enhanced braking
M, Vipin Prakash, Rajappan, Dinesh Kumar, R, Suresh, N, Gopi Kannan
Contradictions of Automotive NVH with other Vehicle Performance and TRIZ tools for Innovative problem solving2026-26-03471/16/2026
For safety towards Automotive engineering often faces design contradictions, particularly in Noise, Vibration, and Harshness (NVH) optimization. Traditional approaches rely on trade-offs, but TRIZ (Theory of Inventive Problem Solving) offers a structured methodology to resolve contradictions innovatively. This paper explores in depth the TRIZ-based solutions for 2 key NVH challenges: (1) exhaust systems requiring noise reduction while maintaining low engine back-pressure, (2) engine mounts requiring both softness for vibration isolation and hardness for durability& vehicle stability. By applying principles such as segmentation, dynamization, parameter change, cheap short living objects or mechanics substitution, the novel solutions are proposed to achieve superior performance without traditional compromises. Tuneable valves in the path of the exhaust gas flow and the power-train mounting focused on its Torque Roll Axis were shown to exemplify the TRIZ problem solving effectiveness
A, Milind Ambardekar
Corrosion behavioral study of Sintered materials with Ethanol-Blended Fuels - E20 and E852026-26-02771/16/2026
The increasing adoption of ethanol-blended fuels, such as E20 (20% ethanol and 80% gasoline) and E85 (85% ethanol and 15% gasoline), necessitates a comprehensive understanding of their compatibility with automotive engine components to ensure durability and operational reliability. Fuel compatibility is particularly critical for components in direct contact with ethanol-rich fuels, as improper material selection or insufficient testing can lead to corrosion, material degradation, and compromised engine performance. This study focuses on evaluating the behaviour of sintered materials extracted from potential fuel-contact parts of automotive engines when exposed to E20 and E85 fuels. Testing was conducted in accordance with the SAE J1747 standard, which provides a systematic approach for assessing corrosion resistance and material degradation in fuel environments. Following the exposure tests, post-test evaluations included visual inspection to identify surface changes and Scanning
Karthikeyan, C., Venugopal, Sivakumar, Gopalan, Vijaysankar
An Engineering Perspective on Cradle and Saddle Mount Configurations2026-26-03131/16/2026
The evolution of electric vehicles (EVs) demands optimized powertrain mounting systems to achieve superior Noise, Vibration, and Harshness (NVH) performance. This study presents a comparative evaluation of cradle-type and saddle-type mounting systems in EV applications. Experimental modal analysis and vehicle-level vibration testing were conducted to assess structure-borne and airborne noise transmission across operating conditions. Key factors such as mount stiffness, isolation efficiency, and dynamic load distribution were analyzed. Cradle systems exhibited better low- to mid-frequency isolation, whereas saddle systems offered advantages in packaging flexibility, high-frequency noise control, and reduced load distribution on supporting structures. These findings provide valuable guidance for selecting optimal mount strategies to enhance occupant comfort and acoustic quality in future EV designs. Recommendations for mount system improvements considering evolving EV architectures are
Hazra, Sandip, more, Vishwas, Naik, Sarang Pramod
Prediction of Trimmed BIW Noise transfer function based on BIW response using Machine Learning2026-26-06401/16/2026
This research focuses on the prediction of the Noise Transfer Function (NTF) in a trimmed Body-in-White (BIW) structure by leveraging machine learning technique considering BIW-level NTF, dynamic stiffness at engine mount attachment points, and Vibration Transfer Function (VTF). The study employs an iterative methodology, adjusting the thickness of various BIW panels to analyse their impact on noise transfer characteristics. Frequency response functions are generated at the BIW attachment points to assess the effectiveness of these modifications. By systematically increasing and decreasing panel thicknesses, and stiffness at the attachment point and trimmed BIW level responses the study aims to optimize the acoustic performance of the BIW structure. The findings provide critical insights into the relationship between structural modifications and noise transfer, offering valuable guidance for automotive design and engineering during early design stage to reduce the development time.
Kulkarni, Prasad Ramesh, Bijwe, Vilas, Kulkarni, Shirish, Sahu, Dilip, Inamdar, Pushpak
Simulation based optimization of the NVH characteristics in modern high speed engine during development phase2026-26-03261/16/2026
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
INVESTIGATING THE IMPACT OF CAM LOBE PHASING AND HYDRAULIC TENSIONER CHARACTERISTICS ON CHAIN DYNAMICS2026-26-00601/16/2026
The main objective of this study is to enhance the lifespan of a 2.2-litre automotive diesel engine that has faced challenges of extinction due to advancements in system technology, particularly the Fuel Injection Pump (FIP). Within this engine architecture, the FIP camshaft is linked with the FIP sprocket and driven by the crankshaft sprocket and chain system. The introduction of a new FIP, chosen based on drive ratios to meet fuel quantity requirements, presents a significant challenge in terms of increased chain load dynamics in the engine systems. To address this issue, two primary strategies are proposed: (i) reducing the FIP camshaft drive torque; and (ii) implementing adjustments to the hydraulic tensioner. Optimizing the FIP camshaft drive torque is an important factor for maintaining chain system performance and durability. Reductions in camshaft drive torque are achieved through strategic modifications to the cam lobe lift, phasing angle, and drive ratios. Simulation results
Dharan R, Bharani, KAWATKAR, AMIT, Loganathan, S
Engine Management System Strategies for Mitigating Dual Mass Flywheel Resonance in Gasoline Powertrains2026-26-00521/16/2026
In today's fast paced and competitive automotive market meeting the customers expectations is the key to any OEM. This has led to development of downsized high performance engines with refinement as an important deliverable. However developing such high output engines do come with challenges of refinement, especially higher torsional vibrations leading to transmission noise issues. Hence, it becomes important to isolate the transmission system from these high torsional vibration input. To address this, one of the most common method is to adopt Dual Mass flywheel (DMF) as this component dampens torsional vibrations and isolates the transmission unit from the same. While Dual Mass Flywheel assemblies do great job in protecting the transmission units by not allowing the oscillations to pass through them, they do have their own natural resonance frequency band close to the engine idle (low) engine speeds, which must be avoided for a continuous operation otherwise it may lead to Dual Mass
Raiker, Rajan, viswanatha, Hosur C, Jadhav, Aashish, Jain, Ojase, Jadhav, Marisha
A Mathematical Modelling Approach Based on Artificial Neural Network for Estimation of Key Parameters in Internal Combustion Engine2026-26-06591/16/2026
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
Condition-Based Monitoring for Prompt Identification of Component Failures to Safeguard the Entire System.2026-26-05761/16/2026
Condition-based monitoring (CBM) has emerged as a transformative approach in predictive maintenance, enabling the proactive identification of potential component failures. It offers numerous advantages like Cost Savings, Increased Equipment Lifespan, RCA of failed parts, Optimized Resource Utilization, Reduced Disruptions, Enhanced Reliability and Safety and many more making it a vital approach for effective maintenance and operational efficiency. This paper presents a comprehensive methodology for monitoring and analyzing vibration trends to predict and prevent the breakdown of critical components in IC Engine in its testing phase. The good part here is that this methodology is not just limited to IC Engine but can be applied across wide range of industries and mechanical systems as from the literature and past vibration data, it was observed that before any such failure engine vibration increases. If the engine is stopped at that moment, it can be preserved, allowing for further
Gupta, Gaurav, Verma, Vivek
Electromagnetically levitated engine mount2026-26-03421/16/2026
Nowadays, the highly competitive automotive business industry requires manufacturers to pay more attention to passenger comfort and riding quality. Apart from suspension, engine mounts plays major role in vehicle NVH. Engine mounts is used to support weight of powertrain & to isolate unbalanced engine disturbance forces from vehicle body. Engine mounts are designed in such a way that no metal to metal contact is remained in between powertrain & rest of the vehicle. This idea presents the solution to completely isolate the powertrain from body so that no engine vibrations can be transferred, which will eventually increase the life of Engine mount
Hazra, Sandip, Naik, Sarang Pramod, more, Vishwas
Innovative Multi-Axial Testing approach for Enhanced Reliability of Cooling Modules in Commercial Vehicles2026-26-05301/16/2026
This paper presents an innovative in-lab accelerated testing approach for chassis-mounted components, with a particular focus on the cooling module of commercial vehicles. The proposed method simulates real-time data acquired from field operations and replicates all critical chassis modes, including torsion. Additionally, real-time coolant circulation at specified pressure and temperature maintenance are feasible during durability testing, enhancing the realism of the test environment. The cooling modules, comprising the radiator, intercooler, and charge air cooler (CAC), often experience failures due to various multi-axial inputs and chassis modes. This paper introduces an innovative methodology for replicating field conditions in the lab, utilizing seven servo-hydraulic actuators to simulate multi-axial inputs. The accuracy of in-lab simulation for the acceleration levels at input and response locations of the cooling module exceeds 90%. This makes it a preferred choice for test
V Dhage, Yogesh, Satale, Sunil
AI-Driven Stress and Fatigue Life Prediction of Engine Connecting Rods using Geometric Deep Learning2026-26-06331/16/2026
The connecting rod is one of the critical components of the engine which is subjected to complex cyclic loading, demanding precise evaluation of stress distribution and fatigue life. Conventional Finite Element Method (FEM)-based simulations, while accurate, are computationally expensive and time-intensive—especially when iterating through multiple design variations. To address this, we present an AI/ML-based predictive framework using Graph Neural Networks (GNNs) and Geometric Deep Learning (GDL) techniques to efficiently predict stress and fatigue life of the connecting rod. The methodology involves representing FEM mesh data as graph structures, where nodes and edges capture geometric and physical relationships. GNN architectures, including MeshCNN and PointNet++, are trained on historical simulation data to learn spatial dependencies and nonlinear mappings between geometry, load conditions, and resulting stress/life outputs. The framework significantly reduces computation time
Pathan, Mohammed Shakil, K, Karthikeyan, pilla, sashanka, S Kangde, Suhas
Structural analysis and Design optimization of Cylinder Head of Cummins Light duty Engine for Medium Wheelbase (MWB) pick-up truck2026-26-04951/16/2026
This paper presents the design, structural analysis, and risk assessment done by Cummins to evaluate the structural integrity of Light Duty engine cylinder head for a Medium Wheelbase (MWB) pick-up truck. Initially, Cummins used F2.5L (4-cylinder) engine that has 154hp, but rising market demands for more power, fuel efficiency, lower cost and weight, and future emission compliance led to customer requirements for 177hp (Drive New F2.5L, 15% uprate) and 197hp+ (Drive New F3.0L, 22% uprate) from the same base engine. The increase in power requirement possesses challenges on critical components, especially cylinder heads in terms of thermal and structural limits. This paper addresses the challenges and risks in current cylinder head design driven by new power demands, specifically reduced fatigue margins in the water jacket area and increased temperatures on the combustion face under high thermomechanical loads. It explores the design modifications made to the cylinder head design to
Pathak, Arun Jyoti, Adiverekar, Vaidehi, Singh, Rahul, Biyani, Mayur
"Exploring the Effects of Oil Cooler Deletion on Tractor Engine Operation"2026-26-05471/16/2026
Cost reduction remains a significant challenge for engine manufacturers, particularly for off-highway application vehicles. An optimal engine lubrication system, encompassing engine oil and an oil cooler, is critical for thermal management and minimizing frictional losses. This system ensures adequate lubrication and cooling of engine components, thereby maintaining optimal performance. This study investigates the implications of oil cooler removal in a 45HP inline engine tractor. Various validation trials were conducted, including high ambient temperature tests under worst-case conditions, high coolant temperature scenarios, and a rigorous tractor killer test. In the latter, the tractor underwent 100 hours of operation on a PTO bench at maximum engine RPMs. Despite an observable increase in lubricant oil temperature during these tests, the tractor did not exhibit any component seizure or failure. The findings aim to determine whether the inclusion of an oil cooler is essential for the
Gupta, Deepak, Kumar, Pankaj, Singh, Manjinder, Singh, Gagandeep, Kumar, Munish, SINGH, HARPREET, Singh, Maninder
A Performance-driven Numerical Approach for Optimizing the Plenum Opening Area of Cowl Box2026-26-04611/16/2026
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
A LOW PRESSURE PUMPLESS DEF DOSING SYSTEM BY USING COMPRESSED AIR AND AN AIR ASSISTED DEF INJECTION NOZZLE2026-26-02191/16/2026
This study emphasizes on development of Diesel Exhaust Fluid (DEF) dosing system specifically used in Selective Catalytic Reduction (SCR) of diesel engine for emission control ,where a low pressure pumpless DEF dosing system is developed, utilizing compressed air for pressurizing the DEF tank and discharging DEF through air assisted DEF injection nozzle. SCR systems utilize Diesel Exhaust Fluid (DEF) to convert harmful NOx emissions from diesel engines into harmless nitrogen and water vapor. Factors such as improper storage, handling, or refilling practices can lead to DEF contamination which pose significant operational challenges for SCR systems. Traditional piston-type, diaphragm-type, or gear-type pumps in DEF dosing systems are prone to mechanical failures leading to frequent maintenance, repairs, and costly downtimes for vehicles. To overcome the existing challenges and to create a more reliable and simple DEF delivery mechanism the pumpless DEF Dosing system is developed. The
M, Hareni, Giridharan, Jyothivel, A.l, Suresh, v, yuvaraj, Rajan, Bharath
A fluid-structure- interaction based methodology to evaluate aero-thermal performance of deformable air guides2026-26-03641/16/2026
An air guide in a car directs fresh air onto the Heat Exchangers (HXs) to facilitate efficient thermal management. It is of paramount importance that the air guide creates a proper sealing and prevents any leakage of the incoming fresh air. It is achieved in two ways – 1) In the design condition, the air guide is manufactured in a way so that it overlaps/intersects with the surrounding components 2) the air-guide is made flexible with a highly elastic rubber seal at the edge. When the air-guide is assembled, the rubber portion of the air-guide deforms to produce a proper fit leading to a sealed air-intake pathway. At high-speed condition as well as high airflow conditions by the radiator fan during idling/stationary, like DC charging – incase of BEV, etc., the air guide encounters high pressure. Being elastic and flexible, these conditions make the air guide susceptible to deformation with potential leakage of incoming air. Digital evaluation of the air guide deformation at different
GADASU, RAVISHASTRI, CHOUDHURY, SATYAJIT, Umesh, Acharya Vaibhav, Kumar, Saravanan, Yenugu, Srinivasa, Zander, Daniel, Beesetti, Siva, Hattarke, Mallikarjun
Risk assessment of cold side components using quick modal analysis correlation technique.2026-26-04411/16/2026
Abstract: Modal analysis is performed to determine the natural frequencies and mode shapes of a structure or system. It helps engineers understand how a system vibrates and how external forces, such as mechanical loads, might excite unwanted resonances. To check the stresses due to vibration inputs, certain G levels are assumed, and stresses are scaled to those vibration levels. This gives an understanding of the stresses of component with respect to its EFR limit and design margins are calculated. But, assumed acceleration levels in pre-prototype stage level can over predict or under predict the design margins. A quick modal analysis corelation technique can be used by using test measured accelerations conducted at prototype stage of the program. In this work, a modal analysis corelation technique is used to perform risk assessment of intake manifold. The intake manifold failed due to high vibration levels which were not captured from high cycle fatigue analysis with assumed G-level
Bale, Shrikant Bhaskar, Bawache, Krushna
Cabin modelling approach in 1D simulation for studying the impact of partial recirculation in warmup for BEV at extreme cold ambient conditions2026-26-04501/16/2026
The inclusion of the cabin in HVAC simulations gained more importance with the introduction of BEV’s. Thermal management and efficiency being in the forefront, exploration for the possible opportunities to reduce the energy consumption for meeting the comfort of passengers gained importance. The energy consumed by the Electric coolant or air heaters for heating the cabin at extreme cold ambient temperatures to deliver similar comfort to that of an ICE version is 2 to 3 times that of the energy required for cooling the cabin in a high ambient condition. Even during the sizing of HVAC system, if traditional method of ambient or fresh air conditions is considered for calculating the requirements, the result is we would require a product which will have unrealistic performance demand. Hence to explore different possibilities for studying the system, usage of recirculation air was considered as one of the options. This paper talks about the approach followed in creating the cabin model in
Veerla, Eswar, Subramanian, Karthik
A numerical approach to optimize the flow characteristics for the enhancement of casting soundness of Al 6061 alloy die-casting2026-26-02841/16/2026
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
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