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The dynamic mechanical behavior and cushioning performance of honeycomb sandwich panels, which are extensively employed in product cushioning packaging due to their exceptional energy absorption capabilities, were examined using a combination of experimental and numerical methods. Several factors, such as maximum acceleration–static stress, cushioning coefficient–static stress, and other curves, were analyzed under various impact conditions. The simulated stress–strain, deformation modes, cushioning coefficients, and other parameters demonstrate consistency with the experimental results. The acceleration, maximum compression, and cushioning coefficient obtained from the experiment and simulation calculation were 30.68 g, 15.44 mm, and 2.65, and 31.96 g, 14.91 mm, and 2.79, respectively. The results indicate that all error values were less than 5%, confirming the precision and reliability of the model. Furthermore, the model was utilized to simulate and predict the cushioning performance of honeycomb sandwich panels with different cell structures and paper thicknesses. These results provide a solid basis for enhancing the design of subsequent honeycomb element structures. [ABSTRACT FROM AUTHOR]

The study aims to present the results of paper compression under an axial load. Different heights of samples subjected to compression were taken into account. The main goal of the analysis was to determine experimentally the maximum compression load. In addition, numerical models based on the finite element method (FEM) were validated to refer to empirical results. The performed numerical simulations were founded on Green–Lagrangian nonlinear equations for large displacements and strains. The progressive failure of the compressed orthotropic material after exceeding maximum stresses was based on Hill's anisotropy theory. Nonlinear calculations were conducted by using a typical Newton–Raphson algorithm for achieving a sequence convergence. The accuracy of the developed model was confirmed experimentally in compression tests. The technique of analysing the shape of the compressed paper sample on the basis of images recorded during the measurement was used. The obtained test results are directly applicable in practice, especially in the calculation of the mechanical properties of corrugated cardboard and in determining the load capacity of cardboard packaging. Knowing the maximum compressive stress that packaging paper can withstand allows packaging to be properly designed and its strength assessed in the context of the transport and storage of goods. [ABSTRACT FROM AUTHOR]

Embossing is a converting process in which the surface of a tissue paper sheet is changed under high pressure, allowing different functions. In this work, the authors intend to study how the embossing pressure affects the main properties of tissue paper, using a laboratory embossing system. An optimum pressure was achieved at 2.8 bar to this embossing laboratory set-up. The effect of pressure when densifying the paper sheet gives it a gain in mechanical strength but no differences in terms of liquid absorbency. The two embossing patterns present different behaviors but both evidence losses in mechanical and softness properties. On the other hand, the finite element method (FEM) does not show clear evidence of how the pressure affects the paper strength. For the deco die, it is possible to observe that the amount of yielding is slightly higher for lower pressure (2.4 bar), but this plasticity state parameter is very similar for 2.8 bar and 3.2 bar. For the micro die, FEM simulations of the manufacturing pressure do not show a considerable impact on the amount of plasticity state of the material; only for 3.2 bar, it shows a change in the pattern of the plasticity state of the paper during the embossing processes. In the end, to achieve a final product with excellent quality, it is important to make a compromise between the various properties. [ABSTRACT FROM AUTHOR]

This paper reports the effect of process orientation on the mechanical behavior and piezoelectricity of electroactive paper (EAPap) made from natural cotton pulp. EAPap is fabricated by a casting and wet drawing of cellulose film after dissolving cotton with LiCl and DMAc solvent. During the fabrication, permanent wrinkles, a possible factor for performance deterioration, were found in the films. Finite element method was introduced to identify the formation mechanism behind the wrinkles. The simulation results show that the wrinkles were caused by buckling and are inevitable under any conditions. The tensile and piezoelectric tests show that the orientation dependency of the stretched EAPap gives the anisotropic characteristics on both mechanical and piezoelectric properties. In this research, the anisotropic elastic moduli and Poisson's ratios are reported. The piezoelectric charge constant of EAPap in the linear elastic is calculated. The piezoelectric charge constants of EAPap are associated with the alignment angle in the order of 45° > 0° > 90° due to the strong shear effect. The higher stretching ratio gives the higher piezoelectricity due to the alignment of the molecular chains and the microstructure in EAPap. The highest piezoelectric charge constant is found to be 12 pC/N at a stretching ratio of 1.6 and aligning angle of 45°. [ABSTRACT FROM AUTHOR]

Based on the classical grid theory and related regulations, a structure model of a fiber-wound composite gas cylinder was designed in this paper. Based on the design results, a finite element model of a fully wound composite cylinder of an aluminum alloy inner liner with a working pressure of 35 MPa was established based on the ABAQUS software, and its stress distribution under working pressure and minimum burst pressure was analyzed. According to engineering experience, the pressure tolerance of composite cylinders can be improved by proper autofrettage pressure before working pressure, so the influence of autofrettage pressure was analyzed in this paper. The optimum autofrettage pressure was selected by setting the autofrettage gradient, and damage analysis was carried out on the cylinder with nominal working pressure of 35 MPa based on the Hashin failure criterion. The results show the initial damage sequence: matrix stretching occurs before the fiber stretching, and the damage generally starts from the spiral-wound layer. The tensile damage first appears in the transition section between the head and the barrel body, and the damage of the spiral-wound layer develops from the inner layer of the wound layer to the outer layer, while the damage of the circumferentially wound layer develops from the outer layer to the inner layer. [ABSTRACT FROM AUTHOR]

The edge crush test is the most popular laboratory test in the corrugated packaging industry. It measures the edge crush resistance of a sample in the cross-fiber direction (CD), also known as the ECT index. This parameter is widely used for the specification of the board by its producers. It is also utilized in most analytical formulas describing the load capacity of the packaging. On the other hand, the ECT value can be estimated from both analytical and numerical models based on the basic parameters of each constituent paper. Knowing the compressive strength in CD (commonly known as SCT) and the elastic properties of the individual layers, the sample geometry (i.e., the period and height of the corrugated layer), as well as the boundary conditions, the ECT value can be calculated. This is very useful as new boards can be virtually analyzed before being manufactured. In this work, both detailed numerical models based on finite elements (FE) methods and very simple analytical (engineering) models were used for the ECT calculations. All presented models were validated with experimental data. The surprising consistency and high precision of the results obtained with the simplest approach was additionally analyzed in the study. [ABSTRACT FROM AUTHOR]

In order to further investigate the grouped stud effect on the force properties of stud connectors, based on the premise that the correctness of the finite element simulation method, in this paper, a finite element model of grouped stud connectors was developed, and the grouped stud effect and its sensitivity factors were analyzed in order to validate the recommended formula for calculating the shear capacity of grouped stud connectors. Results show that the number of grouped stud rows and stud row spacing have a significant influence on the grouped stud effect, and the unevenness coefficient of grouped stud force is negatively correlated with the number of grouped stud rows as well as the grouped stud row spacing. Grouped stud connectors with commonly used concrete grades greater than C50 and height-to-diameter ratios of greater than 4 in steel–concrete composite structural bridges are insensitive to changes in the concrete strength grades and the length of the studs. The direction of force transmission for grouped stud changes with the change in loading angle and the unevenness coefficient of force for the grouped stud will therefore be reduced. By comparing the results of the 62 existing groups of grouped stud connectors push-out tests, the mean of the tested to calculated value ratio was found to be 1.12, the variance was 0.023, the dispersion was small, and it was shown that the recommended formula has a high degree of accuracy. The results of this paper can be used as a theoretical basis for the study of the shear stress performance of grouped stud connectors. [ABSTRACT FROM AUTHOR]

Determining the mechanical properties of a composite material represents an important stage in its design and is generally a complicated operation. These values are influenced by the topology and geometry of the resulting composite and the values of the elastic constants of the components. Due to the importance of this subject and the increasing use of composite materials, different calculation methods have been developed over the last fifty years. Some of the methods are theoretical, with results that are difficult to apply in practice due to difficulties related to numerical calculation. In the current paper, using theoretical results offered by the homogenization theory, values of engineering elastic constants are obtained. The finite element method (FEM) is used to determine the stress and strain field required in these calculations; this is an extremely powerful and verified calculation tool for the case of a material with any type of structure and geometry. In order to minimize errors, the paper proposes the method of least squares, a mathematical method that provides the best estimate for the set of values obtained by calculating FEM. It is useful to consider as many load cases as possible to obtain the best estimates. The elastic constants for a transversely isotropic material (composite reinforced with cylindrical fibers) are thus determined for a real case. [ABSTRACT FROM AUTHOR]

For insulated gate bipolar transistor (IGBT) modules using wire bonding as the interconnection method, the main failure mechanism is cracking of the bonded interface. Studying the mechanical properties of the bonded interface is crucial for assessing the reliability of IGBT modules. In this paper, first, shear tests are conducted on the bonded interface to test the bonded interface's strength. Then, finite element–cohesive zone modeling (FE-CZM) is established to describe the mechanical behavior of the bonded interface. A novel machine learning (ML) architecture integrating a convolutional neural network (CNN) and a long short-term memory (LSTM) network is used to identify the shape and parameters of the traction separation law (TSL) of the FE-CZM model accurately and efficiently. The CNN-LSTM architecture not only has excellent feature extraction and sequence-data-processing abilities but can also effectively address the long-term dependency problem. A total of 1800 sets of datasets are obtained based on numerical computations, and the CNN-LSTM architecture is trained with load–displacement (F–δ) curves as input parameters and TSL shapes and parameters as output parameters. The results show that the error rate of the model for TSL shape prediction is only 0.186%. The performance metric's mean absolute percentage error (MAPE) is less than 3.5044% for all the predictions of the TSL parameters. Compared with separate CNN and LSTM architectures, the proposed CNN-LSTM-architecture approach exhibits obvious advantages in recognizing TSL shapes and parameters. A combination of the FE-CZM and ML methods in this paper provides a promising and effective solution for identifying the mechanical parameters of the bonded interfaces of IGBT modules. [ABSTRACT FROM AUTHOR]

Strip shape control is a hotspot and challenge in strip rolling, where the development trend of rolling technology is towards high strength, high toughness, and a large width-to-thickness ratio. The influence of material microstructure evolution on strip shape control is being increasingly emphasized. In this paper, a Nb-Ti microalloyed steel is taken as the research object. Thermodynamic and kinetic models focusing on the precipitation of the austenite phase are established to quantify the precipitation process. A coupled model of rolls and strips is built using ABAQUS 2022 software, where the precipitation strengthening model and high-temperature constitutive model are embedded into the finite element model (FEM) through subroutines. A two-dimensional alternating differential model is employed to acquire real-time temperature differences in the width direction of the strip. The effects of precipitation inclusion and exclusion on the strip crown under different operating conditions are compared and analyzed. The results indicate that as the temperature decreases, the strengthening effect increases, reaching around 40 MPa at temperatures above 1000 °C and 96.6 MPa at 800 °C. Furthermore, the inclusion of crown in the precipitation consideration is more sensitive to overall temperature changes, but as the strip width decreases, the sensitivity of crown to temperature decreases. The research findings of this paper provide guidance for improving strip shape control and reducing abnormalities during the rolling process. [ABSTRACT FROM AUTHOR]

This research focuses on investigating the buckling strength of thin-walled composite structures featuring various shapes of holes, laminates, and composite materials. A parametric study is conducted to optimize and identify the most suitable combination of material and structural parameters, ensuring the resilience of structure under both mechanical and thermal loads. Initially, a numerical approach employing the finite element method is used to design the C-section thin-walled composite structure. Later, various structural and material parameters like spacing ratio, opening ratio, hole shape, fiber orientation, and laminate sequence are systematically varied. Subsequently, simulation data from numerous cases are utilized to identify the best parameter combination using machine learning algorithms. Various ML techniques such as linear regression, lasso regression, decision tree, random forest, and gradient boosting are employed to assess their accuracy in comparison with finite element results. As a result, the simulation model showcases the variation in critical buckling load when altering the structural and material properties. Additionally, the machine learning models successfully predict the optimal critical buckling load under mechanical and thermal loading conditions. In summary, this paper delves into the study of the stability of C-section thin-walled composite structures with holes under mechanical and thermal loading conditions using finite element analysis and machine learning studies. [ABSTRACT FROM AUTHOR]

Modeling the dynamic properties of wood and wood-based composites is a challenging task due to naturally growing structure and moisture-dependent material properties. This paper presents the finite element modeling of plywood panels' dynamic properties. Two panels differing in thickness were analyzed: (i) 18 mm and (ii) 27 mm. The developed models consisted of individual layers of wood, which were discretized using three-dimensional finite elements formulated using an orthotropic material model. The models were subjected to an updating procedure based on experimentally determined frequency response functions. As a result of a model updating relative errors for natural frequencies obtained numerically and experimentally were not exceeding 2.0%, on average 0.7% for 18 mm thick panel and not exceeding 2.6%, on average 1.5% for 27 mm thick panel. To prove the utility of the method and at the same time to validate it, a model of a cabinet was built, which was then subjected to experimental verification. In this case, average relative differences for natural frequencies of 6.6% were obtained. [ABSTRACT FROM AUTHOR]

The aim of the work presented in this paper was development of a thermodynamically consistent constitutive model for orthotopic metals and determination of its parameters based on standard characterisation methods used in the aerospace industry. The model was derived with additive decomposition of the strain tensor and consisted of an elastic part, derived from Helmholtz free energy, Hill's thermodynamic potential, which controls evolution of plastic deformation, and damage orthotopic potential, which controls evolution of damage in material. Damage effects were incorporated using the continuum damage mechanics approach, with the effective stress and energy equivalence principle. Material characterisation and derivation of model parameters was conducted with standard specimens with a uniform cross-section, although a number of tests with non-uniform cross-sections were also conducted here. The tests were designed to assess the extent of damage in material over a range of plastic deformation values, where displacement was measured locally using digital image correlation. The new model was implemented as a user material subroutine in Abaqus and verified and validated against the experimental results for aerospace-grade aluminium alloy 2024-T3. Verification was conducted in a series of single element tests, designed to separately validate elasticity, plasticity and damage-related parts of the model. Validation at this stage of the development was based on comparison of the numerical results with experimental data obtained in the quasistatic characterisation tests, which illustrated the ability of the modelling approach to predict experimentally observed behaviour. A validated user material subroutine allows for efficient simulation-led design improvements of aluminium components, such as stiffened panels and the other thin-wall structures used in the aerospace industry. [ABSTRACT FROM AUTHOR]

Honeycomb structures made of carbon-fiber-reinforced plastic (CFRP) are increasingly used in the aerospace field due to their excellent energy absorption capability. Attention has been paid to CFRP structures in order to accurately simulate their progressive failure behavior and discuss their ply designability. In this study, the preparation process of a CFRP corrugated sheet (half of the honeycomb structure) and a CFRP honeycomb structure was illustrated. The developed finite element method was verified by a quasi-static test, which was then used to predict the low-velocity impact (LVI) behavior of the CFRP honeycomb, and ultimately, the influence of the ply angle and number on energy absorption was discussed. The results show that the developed finite element method (including the user-defined material subroutine VUMAT) can reproduce the progressive failure behavior of the CFRP corrugated sheet under quasi-static compression and also estimate the LVI behavior. The angle and number of plies of the honeycomb structure have an obvious influence on their energy absorption under LVI. Among them, energy absorption increases with the ply number, but the specific energy absorption is basically constant. The velocity drop ratios for the five different ply angles are 79.12%, 68.49%, 66.88%, 66.86%, and 60.02%, respectively. Therefore, the honeycomb structure with [0/90]s ply angle had the best energy absorption effect. The model proposed in this paper has the potential to significantly reduce experimental expenses, while the research findings can provide valuable technical support for design optimization in aerospace vehicle structures. [ABSTRACT FROM AUTHOR]

The impact of perforation patterns on the compressive strength of cardboard packaging is a critical concern in the packaging industry, where optimizing material usage without compromising structural integrity is essential. This study aims to investigate how different perforation designs affect the load-bearing capacity of cardboard boxes. Utilizing finite element method (FEM) simulations, we assessed the compressive strength of packaging made of various types of corrugated cardboards, including E, B, C, EB, and BC flutes with different heights. Mechanical testing was conducted to obtain accurate material properties for the simulations. Packaging dimensions were varied to generalize the findings across different sizes. Results showed that perforation patterns significantly influenced the compressive strength, with reductions ranging from 14% to 43%, compared to non-perforated packaging. Notably, perforations on multiple walls resulted in the highest strength reductions. The study concludes that while perforations are necessary for functionality and aesthetics, their design must be carefully considered to minimize negative impacts on structural integrity. These findings provide valuable insights for designing more efficient and sustainable packaging solutions in the industry. [ABSTRACT FROM AUTHOR]

Laser shock peening (LSP) is a formidable cold working surface treatment that provides high-energy precision to enhance the mechanical properties of materials. This paper delves into the intricacies of the LSP process, offering insights into its methodology and the simulation thereof through the finite element method. This review critically examines various points, such as laser energy, overlapping of shots, effect of LSP on residual stress, effect of LSP on grain refinement, and algorithms for simulation extrapolated from finite element analyses conducted by researchers, shedding light on the nuanced considerations integral to this technique. As the significance of LSP continues to grow, the collective findings underscore its potential as a transformative technology for fortifying materials against mechanical stress and improving their overall performance and longevity. The discourse encapsulates the evolving landscape of the LSP, emphasizing the pivotal role played by finite element analysis in advancing our understanding and application of this innovative surface treatment. [ABSTRACT FROM AUTHOR]

This paper presents an optimized design approach using nonlinear dynamic analysis and finite element methods to ensure the structural integrity of square-shaped containers made from ductile cast iron for intermediate- and low-level radioactive waste packaging. Ductile cast iron, with its spherical graphite structure, effectively distributes stress throughout the material, leading to a storage capacity increase of approximately 18%. Considering the critical need for containers that maintain integrity under extreme conditions like earthquakes, the design focuses on mitigating stress concentrations at the corners of square structures. Nonlinear dynamic analyses were conducted in five drop directions: three specified by ASTM-D5276 standards and two additional directions to account for different load patterns. Fractures were observed in four out of the five scenarios. For each direction where fractures occurred, equivalent loads causing similar displacement fields were applied to linear static models, which were then used for multi-load topology optimization. Three optimized models were derived, each increasing the volume by 1.4% to 1.6% compared to the original model, and the design that best met the structural integrity requirements during drop scenarios was selected. To further enhance the optimization process, weights were assigned to different load conditions based on numerical analysis results, balancing the impact of maximum stress, average stress, and plastic deformation energy. The final model, with its increased storage capacity and enhanced structural integrity, offers a practical solution for radioactive waste management, overcoming limitations in previous designs by effectively addressing complex load conditions. [ABSTRACT FROM AUTHOR]

This paper presents the results of computer simulations of fracture in three laboratory tests: the three-point bending of a notched beam cut from sandstone, the pull-out test of a self-undercutting anchor fixed in sandstone, and the pull-out test of a bar embedded in concrete. Five material failure criteria were used: Rankine, Coulomb–Mohr, Drucker–Prager, Ottosen–Podgórski, and Hoek–Brown. These criteria were implemented in the Abaqus® FEA system to work with the crack propagation modeling method—extended finite element method (X-FEM). All criteria yielded similar force–displacement relationships and similar crack path shapes. The improved procedure gives significantly better, close-to-real crack propagation paths than can be obtained using the standard subroutines built into the Abaqus® system. [ABSTRACT FROM AUTHOR]

Graphene platelets (GPLs) are gaining popularity across various sectors for enhancing the strength and reducing the weight of structures, thanks to their outstanding mechanical characteristics and low manufacturing cost. Among many engineering structures, wind turbine blades are a prime candidate for the integration of such advanced nanofillers, offering potential improvements in the efficiency of energy generation and reductions in the construction costs of support structures. This study aims to explore the potential of GPLs for use in wind turbine blades by evaluating their impact on material costs as well as mechanical performance. A series of finite element analyses (FEAs) were conducted to examine the variations of mechanical performances—specifically, free vibration, bending, torsional deformation, and weight reductions relative to conventional fiberglass-based blades. Details of computational modeling techniques are presented in this paper. Based on the outcomes of these analyses, the mechanical performances of GPL-reinforced wind turbine blades are reviewed along with a cost–benefit analysis, exemplified through a 5MW-class wind turbine blade. The findings affirm the practicality and benefits of employing GPLs in the design and fabrication of wind turbine blades. [ABSTRACT FROM AUTHOR]

In this paper, we propose a new approach for numerically simulating the growth of cracks in unidirectional composite materials, termed extended isogeometric analysis, evaluating the maximum stress intensity factor and T-stress. To validate our approach, we used a small anisotropic plate with two edge cracks, beginning with formulating the governing equations based on the energy integral method, Stroh's Formula, and the Elastic Law describing the behaviour of anisotropic materials, while considering boundary conditions and initial states. A MATLAB code was developed to solve these equations numerically and to post-process the tensile stress and the stress intensity factor (SIF) in the first mode. The results for the SIF closely match those obtained using the extended finite element method (X-FEM), with a discrepancy of only 0.0021 Pa·m0.5. This finding underscores the credibility of our approach. The extended finite element method has demonstrated robustness in predicting crack propagation in composite materials in recent years, leading to its adoption by several widely used software packages in various industries. [ABSTRACT FROM AUTHOR]

In this paper, the development of a 3D adaptive probabilistic explicit cracking model for concrete is reported. The contribution offered herein consists in a new adaptive mesh strategy designed to optimize the use of interface elements in probabilistic explicit cracking models. The proposed adaptive mesh procedure is markedly different from other strategies found in the literature, since it takes into account possible influences on the redistribution of stresses after cracking and can also be applied to purely deterministic cracking models. The process of obtaining the most appropriate adaptive mesh procedure involved the development and evaluation of three different adaptivity strategies. Two of these adaptivity strategies were shown to be inappropriate due to issues related to stress redistribution after cracking. The validation results demonstrate that the developed adaptive probabilistic model is capable of predicting the scale effect at a level similar to that experimentally observed, considering the tensile failure of plain concrete specimens. The results also show that different softening levels can be obtained. The proposed adaptive mesh strategy proved to be advantageous, being able to promote significant reductions in the simulation time in comparison with the classical strategy commonly used in probabilistic explicit cracking models. [ABSTRACT FROM AUTHOR]

Direct current (DC) bias induced by the DC transmission and geomagnetically induced current is a critical factor in the abnormal operation of electrical equipment and is widely used in the field of power transmission and distribution system state evaluation. As the main affected component, the vector magnetization state of a transformer core under DC bias has rarely been studied, resulting in inaccurate transformer operation state estimations. In this paper, a dynamic vector hysteresis model that considers the impact of rotating and DC-biased fields is introduced into the numerical analysis to simulate the distribution of magnetic properties, iron loss and temperature of the transformer core model and a physical 110 kV single-phase autotransformer core. The maximum values of B, H and iron loss exist at the corners and T-joint of the core under rotating and DC-biased fields. The corresponding maximum value of the temperature increase is found in the main core limb area. The temperature rise of the 110 kV transformer core under various DC-biased conditions is measured and compared with the FEM (Finite Element Method) results of the proposed model and the model solely based on the magnetization curve B||H. The calculation error of the temperature rise obtained by the improved model is approximately 3.76–15.73% and is much less than the model solely based on magnetization curve B||H (approximately 50.71–66.92%). [ABSTRACT FROM AUTHOR]

The internal pore structural characteristics and microbubble distribution features of concrete have a significant impact on its frost resistance, but their size is relatively small compared to aggregates, making them difficult to visually represent in the mesoscopic numerical model of concrete. Therefore, based on the ice-crystal phase transition mechanism of pore water and the theory of fine-scale inclusions, this paper establishes an estimation model for effective thermal conductivity and permeability coefficients that can reflect the distribution characteristics of the internal pore size and the content of microbubbles in porous media and explores the evolution mechanism of effective thermal conductivity and permeability coefficients during the freezing process. The segmented Gaussian integration method is adopted for the calculation of integrals involving pore size distribution curves. In addition, based on the concept that the fracture phase represents continuous damage, a switching model for the permeability coefficient is proposed to address the fundamental impact of frost cracking on permeability. Finally, the proposed estimation models for thermal conductivity and permeability are applied to the cement mortar and the interface transition zone (ITZ), and a thermal–hydraulic–mechanical coupling finite element model of concrete specimens at the mesoscale based on the fracture phase-field method is established. After that, the frost-cracking mechanism in ordinary concrete samples during the freezing process is explored, as well as the mechanism of microbubbles in relieving pore pressure and the adverse effect of accelerated cooling on frost cracking. The results show that the cracks first occurred near the aggregate on the concrete sample surface and then extended inward along the interface transition zone, which is consistent with the frost-cracking scenario of concrete structures in cold regions. [ABSTRACT FROM AUTHOR]

The article is a continuation of two previous review papers on the fracture mechanism of structural metals through the nucleation, growth and coalescence of voids. In the present paper, the literature on the numerical modelling of void nucleation and development has been reviewed. The scope of the work does not include porous material models and their numerical implementation. As part of the discussion on void initiation, nucleation around second phase particles and nucleation as an effect of the discontinuity of the crystal structure were discussed separately. The basic void cell models, finite element method (FEM) models of periodically distributed particles/voids and models based on the results of the observations of the actual microstructure of materials have been characterised. Basic issues related to the application of the cohesive approach in void nucleation modelling have been considered. A separate issue is the characteristics of atomistic simulations and peridynamic modelling, which have been developed in recent years. Numerical approaches to modelling the growth and coalescence of voids are described, with particular emphasis on the influence of the stress state and strain localisation. Basic conclusions from the simulation are presented, pointing to the contribution of FEM modelling to the understanding of microstructural phenomena leading to ductile fracture. [ABSTRACT FROM AUTHOR]

The paper evaluates the possibility of using dissimilar materials joined by welding technology in the construction of agricultural machinery. The desire to design larger and more efficient structures requires designers to combine materials with different mechanical and structural properties. In such a case, it is very important to properly select welding parameters so that, on the one hand, the quality of the joint meets the standard requirements, and on the other, the welding process is not too energy-intensive. In this paper, overlay joints connecting S355 steel with Strenx 700 steel were analyzed in terms of strength for three different values of welding parameters and different thicknesses. The starting point was the reference parameters recommended by the company's welding technologists, which were reduced by 10 and 20% according to the linear welding energy. The study compared the strength, ductility and macrostructure of the joints, as well as the energy intensity of the process. The proposed dissimilar joints achieved approximately a 10% increase in the strength limit of the components in comparison to the previously recommended welding parameters. Additionally, finite element analysis calculations of the improved designs showed significant weight reduction (up to 40%) for the relevant agricultural machinery components. [ABSTRACT FROM AUTHOR]

Well integrity is currently defined through the concept of well barriers, in which one or more barriers are used to prevent unwanted fluid flow. Many papers have highlighted that the casing–cement interfacial bonding is critical for well integrity, but many discrepancies between laboratory experiments and field data have been noticed. The use of finite element analysis is now established as an alternative to complex in situ tests, but these simulations are sensitive to the input parameters, which results in many discrepancies across published works. Currently, the cohesive zone material (CZM) method is considered to offer good results if the correct parameters are selected or experimentally determined. The novelty of this paper lies in the development of a better workflow that enables the simulation of three processes that are acting on the laboratory-scale casing–cement system: temperature changes, debonding, and post-debonding behavior. The aim of this paper is to fully understand the debonding process within laboratory-scale samples, and thus to eventually enable upscaling in the near future. The paper presents a new workflow generated using FEM that allows us to determine the contact stresses at the casing–cement interface during temperature changes at the moment of debonding and post-debonding. The results presented within this paper show that temperature samples tested according to the push-down setup will provide similar interfacial bonding shear strength values; however, post-debonding, there is a remaining frictional force slightly higher than that of the room-temperature samples. In this case, the results are within a 5% error of the average field data, which is slightly higher than in our previous experiments, where only room temperature data were considered. A major outcome of our paper is the demonstration of the existence of friction forces after debonding, which are a result of radial stresses induced during the debonding process. [ABSTRACT FROM AUTHOR]

The large thickness COPV is designed by netting theory and the finite element simulation method, but the actual performance is low and the cylinder performance still cannot be improved after increasing the thickness of the composite winding layer. This paper analyzes the reasons for this and puts forward a feasible solution: without changing the thickness of the winding layer, the performance of COPV can be effectively increased by increasing the proportion of annular winding fiber. This method has been verified by tests and is supported by theory. [ABSTRACT FROM AUTHOR]

The finite element method is a widely used numerical method to analyze structures in virtual space. This method can be used in the packaging industry to determine the mechanical properties of corrugated boxes. This study aims to create and validate a numerical model to predict the compression force of corrugated cardboard boxes by considering the influence of different cutout configurations of sidewalls. The types of investigated boxes are the following: the width and height of the boxes are 300 mm in each case and the length dimension of the boxes varied from 200 mm to 600 mm with a 100 mm increment. The cutout rates were 0%, 4%, 16%, 36%, and 64% with respect to the total surface area of sidewalls of the boxes. For the finite element analysis, a homogenized linear elastic orthotropic material model with Hill plasticity was used. The results of linear regressions show very good estimations to the numerical and experimental box compression test (BCT) values in each tested box group. Therefore, the numerical model can give a good prediction for the BCT force values from 0% cutout to 64% cutout rates. The accuracy of the numerical model decreases a little when the cutout rates are high. Based on the results, this paper presents a numerical model that can be used in the packaging design to estimate the compression strength of corrugated cardboard boxes. [ABSTRACT FROM AUTHOR]

The application of the digital image correlation (DIC) contactless method has extended the possibilities of reliable assessment of structure strain fields and deformations throughout the last years. However, certain weak points in the analyses using the DIC method still exist. The fluctuations of the results caused by different factors as well as certain deficiencies in the evaluation of DIC accuracy in applications for hybrid steel/composite structures with adhesive joints are one of them. In the proposed paper, the assessment of DIC accuracy based on the range of strain fluctuation is proposed. This relies on the use of a polynomial approximation imposed on the results obtained from the DIC method. Such a proposal has been used for a certain correction of the DIC solution and has been verified by the introduction of different error measures. The evaluation of DIC possibilities and accuracy are presented on the examples of the static tensile tests of adhesively bonded steel/composite joints with three different adhesives applied. The obtained results clearly show that in a non-disturbed area, very good agreement between approximated DIC and FEM results is achieved. The relative average errors in an area, determined by comparison of DIC and FEM strains, are below 15%. It is also observed that the use of approximated strains by polynomial function leads to a more accurate solution with respect to FEM results. It is concluded that DIC can be successfully applied for the analyses of hybrid steel/adhesive/composite samples, such as determination of strain fields, non-contact visual detection of faults of manufacturing and their development and influence on the whole structure behavior during the strength tests, including the elastic response of materials. [ABSTRACT FROM AUTHOR]

Metamaterials, characterized by unique structures, exhibit exceptional properties applicable across various domains. Traditional methods like experiments and finite-element methods (FEM) have been extensively utilized to characterize these properties. However, exploring an extensive range of structures using these methods for designing desired structures with excellent properties can be time-intensive. This paper formulates a machine-learning-based approach to expedite predicting effective metamaterial properties, leading to the discovery of microstructures with diverse and outstanding characteristics. The process involves constructing 2D and 3D microstructures, encompassing porous materials, solid–solid-based materials, and fluid–solid-based materials. Finite-element methods are then employed to determine the effective properties of metamaterials. Subsequently, the Random Forest (RF) algorithm is applied for training and predicting effective properties. Additionally, the Aquila Optimizer (AO) method is employed for a multiple optimization task in inverse design. The regression model generates accurate estimation with a coefficient of determination higher than 0.98, a mean absolute percentage error lower than 0.088, and a root mean square error lower than 0.03, indicating that the machine-learning-based method can accurately characterize the metamaterial properties. An optimized structure with a high Young's modulus and low thermal conductivity is designed by AO within the first 30 iterations. This approach accelerates simulating the effective properties of metamaterials and can design microstructures with multiple excellent performances. The work offers guidance to design microstructures in various practical applications such as vibration energy absorbers. [ABSTRACT FROM AUTHOR]

Warm mix flame retardant asphalt mixture can reduce the energy dissipation and harmful gas emissions during asphalt pavement construction, as well as mitigate the adverse effects of road fires. For this, this paper studies the design and performance of a mixture modified with a combination of warm mix agent and flame retardant, and the pavement performance and flame retardancy of the modified mixture are evaluated. Additionally, a flame retardancy prediction model based on the radial basis function (RBF) neural network model is established. On this basis, the principal components analysis (PCA) model is used to analyze the most significant evaluation indicators affecting flame retardancy, and finally, a three-dimensional finite element model is developed to analyze the effects of loading on the pavement structure. The results show that compared to virgin asphalt mixture, the modified mixture shows a reduction in mixing and compaction temperatures by approximately 12 °C. The high-temperature performance of the mixture is improved, while the low-temperature performance and moisture stability slightly decrease, but its flame retardancy is significantly enhanced. The RBF neural network model revealed that the established flame retardancy prediction model has a high accuracy, allowing for precise evaluation of the flame retardancy. Finally, the PCA model identified that the combustion time has a significant effect on the flame retardancy of the asphalt mixture, and the finite element model revealed that the displacements of the warm mix fire retardant asphalt mixture were lower than virgin asphalt mixture in all directions under the loading. [ABSTRACT FROM AUTHOR]

The paper presents a static analysis of the buckling and post-buckling state of thin-walled cold-formed steel (TWCFS) lipped channel section beam-columns subjected to eccentric compression. Eccentricity is taken into consideration relative to both major and minor principal axes. An analytical–numerical solution to the buckling and post-buckling problems is described. The solution is based on the theory of thin plates. Equations of equilibrium of section walls are derived from the principle of stationary energy. Then, to solve the problem, the finite difference (FDM) and Newton–Raphson methods are applied. Linear (buckling) and nonlinear (post-buckling) analyses are performed. As a result, pre- and post-buckling equilibrium paths are determined. Comparisons of the obtained numerical results, FE simulation results, and experimental test results are carried out and presented in comparative load-shortening diagrams. Additionally, a comparison of the buckling forces and buckling modes obtained from theoretical analysis and experiments is presented. [ABSTRACT FROM AUTHOR]

This paper attempts to analyze the random fatigue life and failure modes of joints using two calculation methods. Three kinds of tests were carried out, which were the static test, constant amplitude fatigue test and the random fatigue test, and four kinds of joints were designed. After the static test, the joint was subjected to a constant amplitude fatigue test by selecting different percentages of load according to the static strength. In order to predict the random fatigue life more precisely, two calculation methods were carried out, which were the linear cumulative damage method and the equivalent loading finite element method. Based on the linear cumulative damage hypothesis, the fatigue life of the joint was established as a function of the load amplitude, and then, the random life prediction was calculated by the amplitude distribution of the random loading. Another method was the equivalent loading method, which was to obtain the equivalent constant amplitude fatigue loading of the random loading spectrum. The finite element model was established based on the stiffness and strength degradation rule. The equivalent random life and fatigue failure modes of the joint were modeled. The two life prediction methods show good agreement with the fatigue experimental result, and all prediction results were included in a scatter band of the factor of 2. [ABSTRACT FROM AUTHOR]

The electric vehicle (EV) industry challenges battery joining technologies by requiring higher energy density both by mass and volume. Improving the energy density via new battery chemistry would be the holy grail but is seriously hindered and progresses slowly. In the meantime, alternative ways, such as implementing more efficient cell packaging by minimising the electrical resistance of joints, are of primary focus. In this paper, we discuss the challenges associated with the electrical characterisation of laser-soldered joints in general, and the minimisation of their resistive losses, in particular. In order to assess the impact of joint resistance on the overall resistance of the sample, the alteration in resistance was monitored as a function of voltage probe distance and modelled by finite element simulation. The experimental measurements showed two different regimes: one far from the joint area and another in its vicinity and within the joint cross-section. The presented results confirm the importance of the thickness of the filler material, the effective and total soldered area, and the area and position of the voids within the total soldered area in determining the electrical resistance of joints. [ABSTRACT FROM AUTHOR]

As the second-generation high-temperature superconducting conductors, rare earth–barium–copper–oxide (REBCO) coated conductor (CC) tapes have good potential as high-field and high-energy superconductors. In superconducting applications, several joints are required for conjugating comparatively short REBCO CC tapes. Soldering lap joints are the simplest and most commonly applied REBCO CC joints. In addition to joint resistance, the mechanical behavior and electromechanical properties are also crucial for superconducting applications. In this paper, the electromechanical properties and mechanical behaviors of soldering lap joints at 77 K under a self-field were studied. The mechanical behavior was addressed by using a full three-dimensional multilayer elastic–plastic finite element model (FEM) with REBCO CC tape main layers and solder connecting layers. Then, the electromechanical properties were analyzed by using Gao's strain- I c degradation general model on the basis of the FEM results. Both the mechanical behavior and electromechanical properties were verified by experimental results. The effects of soldering lap conditions including lap length, soldering thickness and lap style on the electromechanical properties and mechanical behaviors were discussed. The results indicate that shorter overlap lengths and a thinner solder can reduce the premature degradation of Ic due to stress concentrations nearby the joint edges; moreover, the irreversible critical strain is significantly higher in the back-to-back joint approach compared to the widely used face-to-face joint approach. [ABSTRACT FROM AUTHOR]

In the finite element analysis of asphalt concrete (AC), it is nowadays common to incorporate the information from the underlying scales to study the overall response of this material. Heterogeneity observed at the asphalt mixture scale is analyzed in this paper. Reliable finite element analysis (FEA) of asphalt concrete comprises a set of complex issues. The two main aspects of the asphalt concrete FEA discussed in this study are: (1) digital reconstruction of the asphalt pavement microstructure using processing of the high-quality images; and (2) FEA of the asphalt concrete idealized samples accounting for the viscoelastic material model. Reconstruction of the asphalt concrete microstructure is performed using a sequence of image processing operations (binarization, removing holes, filtering, segmentation and boundaries detection). Geometry of the inclusions (aggregate) are additionally simplified in a controlled mode to reduce the numerical cost of the analysis. As is demonstrated in the study, the introduced geometry simplifications are justified. Computational cost reduction exceeds of several orders of magnitude additional modeling error occurring due to the applied simplification technique. Viscoelastic finite element analysis of the AC identified microstructure is performed using the Burgers material model. The analysis algorithm is briefly described with a particular focus on the computational efficiency aspects. In order to illustrate the proposed approach, a set of 2D problems is solved. Numerical results confirm both the effectiveness of the self-developed code and the applicability of the Burgers model to the analyzed class of AC analysis problems. Further research directions are also described to highlight the potential benefits of the developed approach to numerical modeling of asphalt concrete. [ABSTRACT FROM AUTHOR]

Aiming to address the vibration noise problems on ships, we constructed a piezoelectric phononic crystal (PC) plate structure model, solved the governing equations of the structure using the partial differential equations module (PDE) in the finite element softwareCOMSOL6.1, and obtained the corresponding energy band structure, transmission curves, and vibration modal diagrams. The application of this method to probe the structural properties of two-dimensional piezoelectric PCs is described in detail. The calculation results obtained using this method were compared with the structures obtained using the traditional plane wave expansion method (PWE) and the finite element method (FE). The results were found to be in perfect agreement, which verified the feasibility of this method. To safely and effectively adjust the bandgap within a reasonable voltage range, this paper explored the order of magnitude of the plate thickness, the influence of the voltage on the bandgap, and the dependence between them. It was found that the smaller the order of magnitude of the plate thickness, the smaller the order of magnitude of the band in which the bandgap was located. The magnitude of the driving voltage that made the bandgap change became smaller accordingly. The new idea of attaching the PC plate to the conventional plate structure to achieve a vibration damping effect is also briefly introduced. Finally, the effects of lattice constant, plate width, and thickness on the bandgap were investigated. [ABSTRACT FROM AUTHOR]

This paper introduces a unique finite element analysis (FEA) technique designed to predict elastic response in polymer matrix composites (PMCs). Extensive research has been conducted to model the manufacturing process of multiple 'L'-shaped components, fabricated from SPRINTTM materials (GLP 43 and GLP 96) at two thicknesses (15 mm and 25 mm). Three distinct FEA methodologies were utilised to determine the impact of thermal loads and rigid fixtures. An error deviation of 3.23% was recorded when comparing simulation results to experimental data, thereby validating the effectiveness of the FEA methodology. [ABSTRACT FROM AUTHOR]

A steel-wire wound reinforced thermoplastic pipe (SWW-RTP) has been widely utilized in many industrial areas, and a soil landslide is an inevitable hazardous extreme condition for the SWW-RTP as it is usually buried underground. It is imperative to study the mechanical failure behavior and the failure criterion of the SWW-RTP under the combination of internal pressure and soil landslide conditions, and this paper is the first study to investigate the topic. In this paper, groups of stress–strain curves of high-density polyethylene (HDPE) and steel wires were obtained by uniaxial tensile tests at different strain rates, with the help of a Digital Image Correlation device (DIC). A rate-dependent constitutive model was employed to represent the mechanical behavior of the HDPE and to help deduce the stress–strain curve of the HDPE under the required strain rate, estimated from the static simplification of the dynamic soil landslide. Afterwards, a finite element model of the SWW-RTP, embedded in a cubic of soil, was established with the software ABAQUS. The SWW-RTP model was composed of HDPE solid elements, embedded with steel-wire truss elements, and the soil was characterized with the extended Drucker–Prager model. A quartic polynomial displacement distribution was applied to the soil model to represent the soil landslide. Then, the mechanical response of the SWW-RTP was analyzed. It was found that the failure criterion of the HDPE yield was more suitable for the pipe subjected to internal pressure and soil landslide conditions, instead of the steel-wire strength failure criterion always used in traditional research on the SWW-RTP. Further, the influence of landslide width, internal pressure and steel-wire number were discussed. The larger the width of the landslide area, the gentler the deformation of the pipeline; this resulted in an increase in the maximum landslide and a decrease in the maximum curvature with the width of the landslide area. The relatively high internal pressure was beneficial to the safety of the SWW-RTP under landslide, because the internal pressure could increase the stiffness of the pipeline. The number of steel wires had a limited influence on the maximum landslide required for the SWW-RTP's failure. This work can be useful for the design and safe assessment of the SWW-RTP under internal pressure and soil landslide conditions. [ABSTRACT FROM AUTHOR]

In view of the complexity of the pile foundation underpinning structure system and the stringent requirements of the construction process, this paper briefly describes the necessity of introducing epoxy resin reinforcing adhesive of planting rebar in the design of pile foundation underpinning beam structure to improve the mechanical properties of the reinforced beam new and old concrete joint surfaces and proposes a new type of pile foundation replacement beam system construction method by "chiseling + prestressed reinforcement + epoxy resin reinforcing adhesive". This paper uses an actual pile foundation underpinning project of an urban overpass as a prototype, designs and creates a model structure with a similarity ratio of 1/6, and performs repeated progressive static loading tests to study the load carrying capacity, displacement change, and other properties of the strengthened replacement structure, as well as analyses and distorts the overall working performance and failure mode of them. On this basis, the prototype structure's finite element analysis model was built, and the finite element analysis results were compared with the test results to obtain the mechanical properties and deformation characters of the actual pile foundation underpinning structure system corresponding to the actual underpinning beam load. This paper's study can lay the theoretical and experimental foundation for the smooth development of similar projects. [ABSTRACT FROM AUTHOR]

Friction stir welding (FSW) is a manufacturing process that many industries have adopted to join metals in a solid state, resulting in unique properties. However, studying aspects like temperature distribution, stress distribution, and material flow experimentally is challenging due to severe plastic deformation in the weld zone. Therefore, numerical methods are utilized to investigate these parameters and gain a better understanding of the FSW process. Numerical models are employed to simulate material flow, temperature distribution, and stress state during welding. This allows for the identification of potential defect-prone zones. This paper presents a comprehensive review of research activities and advancements in numerical analysis techniques specifically designed for friction stir welding, with a focus on their applicability to component manufacturing. The paper begins by examining various types of numerical methods and modeling techniques used in FSW analysis, including finite element analysis, computational fluid dynamics, and other simulation approaches. The advantages and limitations of each method are discussed, providing insights into their suitability for FSW simulations. Furthermore, the paper delves into the crucial variables that play a significant role in the numerical modeling of the FSW process. [ABSTRACT FROM AUTHOR]

In this paper, the tensile mechanical behavior and progressive damage morphology of glass-fiber-reinforced magnesium alloy laminate for different numbers of holes in a temperature range of 25–180 °C were investigated. In addition, based on extensive tensile tests, the tensile mechanical behavior and microscopic damage morphology of porous-glass-fiber-reinforced magnesium alloy laminates at different temperatures were observed by finite element simulation and scanning electron microscopy (SEM). Finally, the numerical simulation and experimental results were in good accordance with the prediction of mechanical properties and fracture damage patterns of the laminates, the average difference between the residual strength values of the specimens at ambient temperature was 5.57%, and the stress–strain curves were in good agreement. The experimental and finite element analysis results showed that the damaged area of the bonded layer tended to expand with the increase in the number of holes, which has a lesser effect on the ultimate tensile strength. As the temperature increased, the specimens changed from obvious fiber breakage (pull-out) and the resin matrix damage mode to matrix softening damage and interfacial delamination fracture damage. As the testing temperature of the specimens increased from 25 °C to 180 °C, the tensile strength of the specimens decreased by an average of 51.59%, while the tensile strength of the specimens showed a nonlinear decreasing trend. The damage mechanism of porous-glass-fiber-reinforced magnesium alloy laminates at different temperatures is discussed in this paper, which can provide a reference for engineering applications and design. [ABSTRACT FROM AUTHOR]

In this paper, we deal with the issue of asphalt concrete microstructure recognition for further numerical analysis. An efficient reconstruction of the underlying microstructure makes the composite analysis more reliable. We propose for this purpose a methodology based on the image processing and focus on a two-dimensional case (it can be easily used as a part of the 3D geometry reconstruction, however). Initially obtained geometry of the inclusions is further simplified to reduce the cost of the finite element mesh generation. Three straightforward geometry simplification algorithms are used to perform this process in a controlled way. Subsequently, we present the solutions of two problems, i.e., heat flow and elasticity (plane strain), in order to illustrate the effectiveness of the whole elaborated methodology. The numerical results were obtained using the finite element method. Consequently, an error analysis is demonstrated in order to refer the overkill mesh solutions to the ones presented in this study. The main finding of this paper is the efficient methodology dedicated to a digital reconstruction of the asphalt concrete microstructure by the image processing. It can be also extended to other materials exhibiting similar microstructure. [ABSTRACT FROM AUTHOR]

This paper modelled the cutting process of a bundle consisted of ultra-thin cold-rolled steel sheets using a guillotine. The geometry of a cutting tool with given dimensions was assumed. A bundle of sheets being cut was modelled as deformable, the cutting tool was rigid, and the finite element method along with computer system LS-DYNA was employed. Numerical simulations of the complex state of stress and of the corresponding complex state of strain were carried out. Cutting processes belong to fast changing physical phenomena, and therefore, highly nonlinear dynamical algorithms were applied in order to solve this particular problem. Experimental investigations were also conducted by means of the scanning electron microscopy. It was found that the fracture region consisted of two distinct zones: brittle and ductile separated from each other by the interfacial transition. Morphological features of the brittle, ductile, and the transition regions were identified. The ductile and brittle zones were separated at the depth of ca. 1/5 thickness of the cut steel sheet. Finally, the numerical results obtained by usage of the finite element method as well as experimental ones in the form of microscopic images were compared, showing quite good agreement. [ABSTRACT FROM AUTHOR]

In the heat insulation winding molding process of solid rocket motors, the pressure applied by the press roller directly affects the quality of the winding molding. Insufficient pressure can result in poor bonding quality and may cause defects. This paper aims to provide an optimal design of the press roller to improve the winding molding quality of the heat insulation. The effect of the cylindrical press roller on the pressure distribution was analyzed using the elastic foundation model and a finite element (FE) model, which was assessed by Hertz theory. Subsequently, the press roller was optimized to an elliptical concave design. The effect of the radius of the elliptical concave press roller on the pressure distribution was analyzed. A comparison of the effect of the elliptical concave press roller and the cylindrical press roller on the pressure distribution was conducted using the FE model. The results show pressure uniformity is significantly improved when the elliptical concave press roller is employed on the mandrel with the smallest radius. Additionally, the elliptical concave press roller increases the pressure at the edge of the tape, which reduces the risk of lifted edges and, thereby, improves the winding molding quality of the heat insulation. [ABSTRACT FROM AUTHOR]

This paper proposes a local resonance-type pentagonal phononic crystal beam structure for practical engineering applications to achieve better vibration and noise reduction. The energy band, transmission curve, and displacement field corresponding to the vibration modes of the structure are calculated based on the finite element method and Bloch-Floquet theorem. Furthermore, an analysis is conducted to understand the mechanism behind the generation of bandgaps. The numerical analysis indicates that the pentagonal unit oscillator creates a low-frequency bandgap between 60–70 Hz and 107–130 Hz. Additionally, the pentagonal phononic crystal double-layer beam structure exhibits excellent vibration damping, whereas the single-layer beam has poor vibration damping. The article comparatively analyzes the effects of different parameters on the bandgap range and transmission loss of a pentagonal phononic crystal beam. For instance, increasing the thickness of the lead layer leads to an increase in the width of the bandgap. Similarly, increasing the thickness of the rubber layer, intermediate plate, and total thickness of the phononic crystals results in a bandgap at lower frequencies. By adjusting the parameters, the beam can be optimized for practical engineering purposes. [ABSTRACT FROM AUTHOR]

This paper provides a comparison between the conventional Electromagnetic Forming (EMF) technique and the novel Electromagnetic Hydraulic Forming (EMHF) approach. The EMHF involves the use of finite element analysis coupled with the EM and arbitrary Lagrangian–Eulerian techniques analyzed through LS-DYNA. In the free-bulge configuration, EMF is influenced by the forming coil, resulting in a dead zone and uneven forming. Additionally, EMF can only be used to shape materials with high electrical conductivity. In contrast, EMHF, driven by induced hydraulic pressure from the electromagnetic field-affected drive sheet, is independent of the electrical conductivity of the material and produces dome-shaped workpieces. For rectangular die shapes, EMF is prone to collision owing to the acceleration of the blank, which results in a reduced quality owing to bouncing. However, EMHF exhibits no bouncing effect and successfully achieves the target shape in most cases. The two techniques differ in the strain rate, with EMF at 4850/s, whereas EMHF operates at approximately 1250/s. Despite being slower, EMHF is still a high-speed forming technique. In conclusion, EMHF is a promising technique capable of addressing the shortcomings of conventional EMF and achieving improvements in forming processes. [ABSTRACT FROM AUTHOR]

This paper presents the results of research work on the revised design of a deep hole boring tool. The study was divided into three stages: theoretical, experimental and operational. In the theoretical part, a 3D model of the actual boring bar was created, which was subjected to strength tests using the Finite Element Method (FEM), and then prototypes of new deep hole boring tools were made with structural modifications to the shank part of the tool. For the polymer concrete core of a shank, there was a 14.59% lower displacement, and for the rubber-doped polymer concrete (SBR—styrene butadiene rubber) core of a shank there was a 4.84% lower displacement in comparison to the original boring bar. In the experimental part of the study, the original boring bar and the prototypes were subjected to experimental modal analysis and static analysis tests to compare dynamic and static properties. In the operational part of the study, boring tests were carried out for various workpiece materials, during which the basic parameters of the surface geometric structure (SGS), such as roughness Ra and Rz, were studied. Despite the promising preliminary results of the theoretical and experimental studies, using the described modifications to the boring bar is not recommended. [ABSTRACT FROM AUTHOR]

This paper presents an analysis of the effect of the geometry of the end-coil transition zone on the material stress state of a machined compression spring with a rectangular wire cross-section. The literature relationships for determining the stresses in rectangular wire compression springs neglect the effects associated with the geometry of this zone. A series of non-linear numerical analyses were carried out for models of machined compression springs with a wide range of variation in geometrical parameters. The results of these analyses were used to develop a computational model to estimate the minimum value of the rounding radius ρmin, which ensures that the stresses in this zone are reduced to the level of the maximum coil stresses. The model is simple to apply, and allows the radius ρmin to be estimated for springs with a spring index between 2.5 and 10, a helix angle between 1° and 15°, and a proportion of the sides of the wire section between 0.4 and 5. [ABSTRACT FROM AUTHOR]

The paper concerns the numerical modelling of a new slim-floor system with innovative steel–concrete composite beams called "hybrid beams". Hybrid beams consist of a high-strength TT inverted cross-section steel profile and a concrete core made of high-performance concrete and are jointed with prestressed hollow core slabs by infill concrete and tie reinforcement. Such systems are gaining popularity since they allow the integration of the main structural members within the ceiling depth, shorten the execution time, and reduce the use of concrete and steel. A three-dimensional finite element model is proposed with all parts of the system taken into account and detailed geometry reproduction. Advanced constitutive models are adopted for steel and concrete. Special attention is paid to the proper characterisation of interfaces. The new approach to calibration of damaged elastic traction–separation constitutive model for cohesive elements is applied to concrete-to-concrete contact zones. The model is validated with outcomes of experimental field tests and analytical calculations. A satisfactory agreement between different assessment methods is obtained. The model can be used in the development phase of a new construction system, for instance, to plan further experimental campaigns or to calibrate simplified design formulas. [ABSTRACT FROM AUTHOR]