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Eng. Proc., 2025, AIAS 2024

The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design (AIAS 2024)

Naples, Italy| 4–7 September 2024 

Volume Editors:
Umberto Galietti, Politecnico di Bari, Italy
Gabriele Arcidiacono, Università degli Studi Guglielmo Marconi, Italy
Enrico Armentani, Università di Napoli Federico II, Italy
Davide Castagnetti, Università di Modena e Reggio Emilia, Italy
Vigilio Fontanari, Università di Trento, Italy
Aurelio Somà, Politecnico di Torino
Nicola Bonora, Università di Cassino e del Lazio Meridionale, Italy

Number of Papers: 54
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Cover Story (view full-size image): The Italian Scientific Society of Mechanical Engineering Design (AIAS), an institutional community specializing in mechanical engineering design, organizes its annual technical conference to bring [...] Read more.
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11 pages, 9905 KiB  
Proceeding Paper
Production Parameters and Thermo-Mechanical Performance of Twisted and Coiled Artificial Muscles (TCAMs)
by Salvatore Garofalo, Chiara Morano, Leonardo Pagnotta and Luigi Bruno
Eng. Proc. 2025, 85(1), 1; https://doi.org/10.3390/engproc2025085001 - 13 Feb 2025
Viewed by 298
Abstract
High-strength polymer fibers such as nylon 6, nylon 6,6, and polyethylene are utilized to produce Twisted and Coiled Artificial Muscles (TCAMs) through the twisting of low-cost fibers. These artificial muscles exhibit high displacement and specific power, particularly under electrothermal actuation, which requires conductive [...] Read more.
High-strength polymer fibers such as nylon 6, nylon 6,6, and polyethylene are utilized to produce Twisted and Coiled Artificial Muscles (TCAMs) through the twisting of low-cost fibers. These artificial muscles exhibit high displacement and specific power, particularly under electrothermal actuation, which requires conductive elements. An experimental setup was developed to produce, thermally treat, and characterize commercially available nylon 6,6 fibers coated with silver. The results demonstrate that TCAMs can contract by over 15% and generate forces up to 2.5 N with minimal energy input. Key factors such as motor speed, applied load, and fiber geometry affect the overall performance. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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7 pages, 6129 KiB  
Proceeding Paper
Lock-in Thermography for Surface Treatment Characterization in Gears
by Francesca Maria Curà, Luca Corsaro and Ludovica Tromba
Eng. Proc. 2025, 85(1), 2; https://doi.org/10.3390/engproc2025085002 - 13 Feb 2025
Viewed by 227
Abstract
Mechanical gears are essential in power transmission systems across various industrial applications. Their performance is critically influenced by residual stresses from manufacturing processes like induction hardening, case hardening, and shot peening. Surface compressive residual stresses enhance resistance to pitting fatigue, bending fatigue and [...] Read more.
Mechanical gears are essential in power transmission systems across various industrial applications. Their performance is critically influenced by residual stresses from manufacturing processes like induction hardening, case hardening, and shot peening. Surface compressive residual stresses enhance resistance to pitting fatigue, bending fatigue and crack propagation, improving overall hardness. In the present work, a Non-Destructive Thermographic method (Active thermography), based on measurement of the thermal diffusivity parameter, is presented to characterize the surface treatments applied to gears. Surface hardness was measured using a micro-hardness tester, and residual stresses were determined with an X-Ray diffractometer, showing variations due to surface treatments. The variation in the thermal diffusivity parameter, obtained using the Slope Method, was found to be an indicator of the surface treatments’ effectiveness. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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10 pages, 4818 KiB  
Proceeding Paper
Analytical and Numerical Methods for the Identification of Torsional Oscillations and Forcing in Internal Combustion Engines
by Dario Santonocito and Sebastian Brusca
Eng. Proc. 2025, 85(1), 3; https://doi.org/10.3390/engproc2025085003 - 13 Feb 2025
Viewed by 288
Abstract
Crankshafts, present in internal combustion engines, are mechanical parts subject to torsion and bending that vary over time and, if the forcing is close to one of the natural frequencies of the system, they can encounter problems of torsional oscillations. These vibrations can [...] Read more.
Crankshafts, present in internal combustion engines, are mechanical parts subject to torsion and bending that vary over time and, if the forcing is close to one of the natural frequencies of the system, they can encounter problems of torsional oscillations. These vibrations can lead to maximum oscillation amplitudes, with consequent fatigue stresses that would compromise the resistance and correct functioning of the shaft. The aim of this work is to indicate a methodology for identifying the natural frequencies of the crankshaft and the decomposition of the torques, due to gases and inertia, to identify the different harmonics; in fact, if one of these harmonics is close to the natural frequency of the crankshaft, the system will go into resonance. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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8 pages, 5067 KiB  
Proceeding Paper
An Efficient Criterion for Evaluating Fatigue Strength Improvement Through the Stop-Hole Technique
by Bruno Atzori, Luca Vecchiato and Giovanni Meneghetti
Eng. Proc. 2025, 85(1), 4; https://doi.org/10.3390/engproc2025085004 - 13 Feb 2025
Viewed by 259
Abstract
This study investigates the effect of a non-zero fillet radius, ρ, on the fatigue behaviour of notched components under uniaxial loading. A new diagram is introduced, which discusses the relationship between the notch tip radius and the fatigue limit. It also identifies [...] Read more.
This study investigates the effect of a non-zero fillet radius, ρ, on the fatigue behaviour of notched components under uniaxial loading. A new diagram is introduced, which discusses the relationship between the notch tip radius and the fatigue limit. It also identifies a critical radius, ρ**, precisely marking the transition from sharp to blunt notch behaviour. Additionally, its application to the “stop-hole” technique is considered, where both material properties and geometric characteristics are analysed, demonstrating that introducing a fillet radius can improve fatigue resistance. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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10 pages, 5624 KiB  
Proceeding Paper
Fatigue Life Analysis of Traditional and Annealed AISI 304L Specimens by Thermographic Methods
by Davide Crisafulli, Michal Jambor, Miroslav Šmíd, Dario Santonocito and Giacomo Risitano
Eng. Proc. 2025, 85(1), 5; https://doi.org/10.3390/engproc2025085005 - 13 Feb 2025
Viewed by 247
Abstract
AISI 304L is a low-carbon austenitic stainless steel widely used in common engineering applications, according to its good mechanical properties such as high ductility, corrosion resistance, and easy weldability. This material is adopted in various environmental conditions, such as pressure vessels or in [...] Read more.
AISI 304L is a low-carbon austenitic stainless steel widely used in common engineering applications, according to its good mechanical properties such as high ductility, corrosion resistance, and easy weldability. This material is adopted in various environmental conditions, such as pressure vessels or in pipelines where fluid temperature variations occur and affect its mechanical behavior. Nowadays, the applications of advanced investigation methodologies, such as infrared thermography, are widely adopted for the rapid analysis of the fatigue properties of common materials, especially metals. In this work, fatigue properties were evaluated on AISI304L specimens having two different microstructural states, one in the as-received condition and the other one after solution annealing. Fatigue test campaigns were performed with the application of the Risitano Thermographic Method. The microscopic analysis highlights the differences in the microstructure before and after the heat treatment. The characteristics of the microstructures are the main ones responsible for the different fatigue behavior obtained with experimental tests. The Thermographic Method proved to be a valid rapid approach for the fatigue analysis, confirming that the annealing process led to an improvement in the fatigue strength of the material. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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13 pages, 2066 KiB  
Proceeding Paper
Development of Procedures for Disassembly of Industrial Products in Python Environment
by Maurizio Guadagno, Eleonora Innocenti, Lorenzo Berzi, Saverio Corsi and Massimo Delogu
Eng. Proc. 2025, 85(1), 6; https://doi.org/10.3390/engproc2025085006 - 13 Feb 2025
Viewed by 381
Abstract
Circular Design methodology is essential for sustainable industrial practices. This study provides a methodology with a Python-based computational tool that optimizes industrial products’ disassembly sequences, focusing on Design for End of Life (DfEoL) and Design for Disassembly (DfD) to promote Circular Design. The [...] Read more.
Circular Design methodology is essential for sustainable industrial practices. This study provides a methodology with a Python-based computational tool that optimizes industrial products’ disassembly sequences, focusing on Design for End of Life (DfEoL) and Design for Disassembly (DfD) to promote Circular Design. The tool creates disassembly precedence graphs and shows the best disassembly path for target components, facilitating material recovery and environmental sustainability. The tool was applied to a case study on an Axial Flux Permanent Magnet (AFPM) electric motor. The approach provides a flexible and open access solution for optimizing product design within a Circular Design framework. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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12 pages, 2784 KiB  
Proceeding Paper
On the Exploration of the Influence of Seabed Reflected Waves on Naval Structures
by Jacopo Bardiani, Marco Giglio, Claudio Sbarufatti and Andrea Manes
Eng. Proc. 2025, 85(1), 7; https://doi.org/10.3390/engproc2025085007 - 13 Feb 2025
Cited by 2 | Viewed by 320
Abstract
The interaction between naval structures and underwater shock waves generated by explosions is critical in marine engineering. Numerical analysis is pivotal in investigating the effects of reflected waves from the free surface and the seabed on submerged or floating structures. This topic still [...] Read more.
The interaction between naval structures and underwater shock waves generated by explosions is critical in marine engineering. Numerical analysis is pivotal in investigating the effects of reflected waves from the free surface and the seabed on submerged or floating structures. This topic still needs to be explored in the marine engineering literature despite its significance. Understanding the complex dynamics of shock wave reflections is paramount for ensuring marine installations’ structural integrity and safety, including submarines, offshore platforms, and surface vessels. This paper aims to fill this gap by presenting a preliminary numerical study focused on analyzing the influence of reflected waves caused by the seabed on a simple ship-like structure, where the free-surface effects are negligible. A Coupled Eulerian–Lagrangian approach based on the suite MSC Dytran was used to investigate the interaction between shock waves and the seabed, considering a structure represented by an underwater cylinder and several seabed compositions. A deeper understanding of this phenomenon is crucial for enhancing the resilience and safety of marine installations, thereby mitigating potential risks and ensuring sustainable maritime operations. The simulations presented in this work represent the starting point for the creation of datasets to be used in Machine Learning applications. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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12 pages, 1824 KiB  
Proceeding Paper
Investigation of Damage Caused by Chlorine-Contaminated Fuel in Standard Vehicle Components
by Vincenzo La Battaglia, Valerio Mussi, Stefano Marini and Alessandro Giorgetti
Eng. Proc. 2025, 85(1), 8; https://doi.org/10.3390/engproc2025085008 - 13 Feb 2025
Viewed by 659
Abstract
Several car manufacturers have encountered corrosion in certain mechanical components caused by chlorine in fuel. The current regulations governing the quality of fuel allowed for trade are briefly described. Next, this paper analyzes the possible origin of chlorine in damaged components. In particular, [...] Read more.
Several car manufacturers have encountered corrosion in certain mechanical components caused by chlorine in fuel. The current regulations governing the quality of fuel allowed for trade are briefly described. Next, this paper analyzes the possible origin of chlorine in damaged components. In particular, the phenomenon of corrosion found in EGR valves and EGR coolers is analyzed. The analyses conducted to determine the nature of the corrosion and its origin are illustrated. Finally, the effects of the phenomenon on engine operation are analyzed, depending on the type of damaged component. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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9 pages, 3579 KiB  
Proceeding Paper
Lightening the Scissor Lift Platform Using Composite Material
by Luigi Solazzi
Eng. Proc. 2025, 85(1), 9; https://doi.org/10.3390/engproc2025085009 - 13 Feb 2025
Viewed by 266
Abstract
This research presents the main results related to the lightweighting of a specific scissor lift platform with the following key specifications: a working load limit of 3000 N and a platform height of 5.5 m. The design (for both steel and innovative materials) [...] Read more.
This research presents the main results related to the lightweighting of a specific scissor lift platform with the following key specifications: a working load limit of 3000 N and a platform height of 5.5 m. The design (for both steel and innovative materials) was conducted by evaluating the load conditions, some of which were derived from relevant standards. The new solution, which uses aluminum and composite materials instead of structural steel, reduces the overall weight from approximately 24.7 kN to 13.1 kN (a 53.1% reduction). Additionally, the lifting and travel power required for the new design is about half that of the original solution. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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15 pages, 1191 KiB  
Proceeding Paper
A Review of Computational Methods and Tools for Life Cycle Assessment of Traction Battery Systems
by Eleonora Innocenti, Maurizio Guadagno, Lorenzo Berzi, Marco Pierini and Massimo Delogu
Eng. Proc. 2025, 85(1), 10; https://doi.org/10.3390/engproc2025085010 - 13 Feb 2025
Viewed by 419
Abstract
Life Cycle Assessment (LCA) is crucial for evaluating the environmental impact of products, but challenges such as uncertainties and data limitations hinder its effective use in design. This paper reviews LCA computational tools, focusing on traction batteries, and examines aspects such as software [...] Read more.
Life Cycle Assessment (LCA) is crucial for evaluating the environmental impact of products, but challenges such as uncertainties and data limitations hinder its effective use in design. This paper reviews LCA computational tools, focusing on traction batteries, and examines aspects such as software architecture, database integration, and uncertainty analysis. It highlights how these platforms enhance usability for designers by enabling interaction with complex models and integrating multidisciplinary features. By analyzing system boundaries, inventory criteria, and impact assessment, this review offers valuable insights for researchers, practitioners, and policymakers in LCA, addressing the implementation challenges and best practices for sustainable battery design. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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11 pages, 948 KiB  
Proceeding Paper
A Generalized Model to Describe Electromagnetic Shock Absorbers
by Gennaro Sorrentino, Renato Galluzzi, Andrea Tonoli and Nicola Amati
Eng. Proc. 2025, 85(1), 11; https://doi.org/10.3390/engproc2025085011 - 14 Feb 2025
Viewed by 336
Abstract
The development of chassis technologies has pushed significant focus towards electrification for enhanced vehicle efficiency, flexibility, safety, and performance. In this context, the suspension represents a key system, as it strongly influences both vehicle dynamics and comfort. The trend is to replace the [...] Read more.
The development of chassis technologies has pushed significant focus towards electrification for enhanced vehicle efficiency, flexibility, safety, and performance. In this context, the suspension represents a key system, as it strongly influences both vehicle dynamics and comfort. The trend is to replace the usual hydraulic damper with mechatronic actuators. Rotary electromagnetic shock absorbers are among these solutions, featuring a rotary electric machine and a proper rotary-to-linear transmission stage. Far from being ideal force sources, these actuators may introduce inertial, compliance, and friction phenomena to the suspension. This paper proposes a generalized equivalent model to reproduce the mechanical behavior of electromagnetic shock absorbers. The formulation of this tool helps compare different shock absorber technologies in terms of their dynamic response. Furthermore, it can be used to synthesize control strategies that account for intrinsic limitations of chassis actuators. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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9 pages, 2476 KiB  
Proceeding Paper
A Finite Element Analysis of a Lithium-Ion Battery Cell Under Abuse Conditions
by Aljon Kociu, Daniele Barbani, Luca Pugi, Lorenzo Berzi, Niccolò Baldanzini and Massimo Delogu
Eng. Proc. 2025, 85(1), 12; https://doi.org/10.3390/engproc2025085012 - 14 Feb 2025
Viewed by 484
Abstract
Lithium-ion battery cells are the fundamental components of all Energy Storage Systems (ESSs) used in electric vehicles (EVs). Increasing concerns about safety issues, particularly the response of battery cells to mechanical crushes that can lead to internal short circuits (ISCs) and potential thermal [...] Read more.
Lithium-ion battery cells are the fundamental components of all Energy Storage Systems (ESSs) used in electric vehicles (EVs). Increasing concerns about safety issues, particularly the response of battery cells to mechanical crushes that can lead to internal short circuits (ISCs) and potential thermal runaway (TR), necessitate detailed investigation. To evaluate the response of a battery under abuse conditions, a homogeneous finite element (FE) model of a battery cell was developed. This model employs a simplified representation of a battery cell where the internal properties are assumed to be uniform throughout the entire cell. A full factorial approach was utilized to determine the homogenized jellyroll material characteristics. A detailed FEM serves as a benchmark for validating the homogeneous battery model. While requiring less computational effort, the homogeneous model maintains sufficient accuracy, making it suitable for modelling entire battery packs, thanks to the reduced number of elements. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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13 pages, 5158 KiB  
Proceeding Paper
The Design Enhancement of a Pneumatic Cylinder for Valve Actuators by Integrating the “Design-by-Formulas” and “Design-by-Analysis” Approaches with Multiple Integrative Advanced Simulations
by Giovanni Maiocchi, Francesco Fornasari and Luca Collini
Eng. Proc. 2025, 85(1), 13; https://doi.org/10.3390/engproc2025085013 - 17 Feb 2025
Viewed by 239
Abstract
The authors would like to make a meaningful contribution to product development strategies by introducing an original holistic design methodology for pressure-containing equipment. A case study is presented, focusing on the design enhancement of a pneumatic cylinder for valve actuators. The purpose of [...] Read more.
The authors would like to make a meaningful contribution to product development strategies by introducing an original holistic design methodology for pressure-containing equipment. A case study is presented, focusing on the design enhancement of a pneumatic cylinder for valve actuators. The purpose of the discussed methodology is supplying designers with a full picture of the product, usually not directly available, thanks to the extensive use of advanced Finite Element Analysis (FEA) to increase confidence in the safety and reliability of the design at the virtual prototype stage while providing useful insights that can be used during product life in occasions such as root cause analyses. The new design approach is applied to the cylinder by analyzing it in special conditions like during a pressure burst test using an FEA. A comparison with the experimental results confirms that the proposed methodology can potentially contribute to introducing renewed, safe, reliable, and lighter components, reducing the cost and time of development. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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10 pages, 3122 KiB  
Proceeding Paper
A Computational Multiphysics Study of a Satellite Thruster
by Marcello A. Lepore, Marzio Piller, Mario Guagliano and Angelo R. Maligno
Eng. Proc. 2025, 85(1), 14; https://doi.org/10.3390/engproc2025085014 - 14 Feb 2025
Viewed by 1844
Abstract
This work concerns a study of the thermomechanical behaviour of a commercial thruster for aerospace use. The thruster, operated using a bipropellant liquid mixture, is used for the motion and in-orbit altitude control of small telecommunications satellites. The mixture used in the combustion [...] Read more.
This work concerns a study of the thermomechanical behaviour of a commercial thruster for aerospace use. The thruster, operated using a bipropellant liquid mixture, is used for the motion and in-orbit altitude control of small telecommunications satellites. The mixture used in the combustion process is composed of propylene and nitrous oxide, while the wall of the thruster is made of PH15-5 stainless steel. A computational fluid dynamics analysis of conjugate heat transfer determines the spatial–temporal distribution of temperature within the thruster wall. This information is passed to a finite element mechanical model that simulates the stress and the equivalent plastic strain distribution within the thruster wall. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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11 pages, 3638 KiB  
Proceeding Paper
Infrared Thermography for Non-Destructive Testing of Cooling Hole Integrity and Flow Evaluation in Specimens Made with Innovative Technologies
by Ester D’Accardi, Luca Ammannato, Alessandra Giannasi, Marco Pieri, Giuseppe Masciopinto, Francesco Ancona, Giovanni Santonicola, Davide Palumbo and Umberto Galietti
Eng. Proc. 2025, 85(1), 15; https://doi.org/10.3390/engproc2025085015 - 14 Feb 2025
Viewed by 213
Abstract
This study developed a non-destructive testing (NDT) method using infrared thermography to inspect tubes with holes and slots made by electro-erosion and additive manufacturing. CO2 was used as a tracer gas to verify the opening and evaluate the flow shape from the [...] Read more.
This study developed a non-destructive testing (NDT) method using infrared thermography to inspect tubes with holes and slots made by electro-erosion and additive manufacturing. CO2 was used as a tracer gas to verify the opening and evaluate the flow shape from the holes and slots. To improve the signal contrast, a controlled hot background was used as a reference, and infrared cameras monitored the thermal response to detect flow variations caused by different geometries. The tests included different diameters, pitches, and aspect ratios, comparing results between additive manufacturing and electro-erosion under various conditions. Moreover, a preliminary setup using compressed air and inductive heating was developed to assess hole openings by cooling the piece, aiming to eliminate CO2 use. The comparison of results, the post-processing analysis of quantitative indices, and specific thermal features enabled a non-destructive evaluation of the holes by using different technologies, providing an assessment of the opening conditions, outlet, geometry, and flow shape. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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10 pages, 2887 KiB  
Proceeding Paper
Study of Damage and Microplastic Release in Clear Aligners Under Cyclic Loads
by Claudia Barile, Caterina Casavola, Claudia Cianci, Domenico Ciavarella, Giovanni Pappalettera, Carmine Pappalettere and Vimalathithan Paramsamy Kannan
Eng. Proc. 2025, 85(1), 16; https://doi.org/10.3390/engproc2025085016 - 18 Feb 2025
Viewed by 585
Abstract
In this research work, the mechanical performance of a thermoformed clear dental aligner is studied. Its performance is evaluated under the cyclic compression test, which is designed to simulate the occlusal forces applied on the aligner during swallowing operations for its entire usage [...] Read more.
In this research work, the mechanical performance of a thermoformed clear dental aligner is studied. Its performance is evaluated under the cyclic compression test, which is designed to simulate the occlusal forces applied on the aligner during swallowing operations for its entire usage period. The mechanical results show that the aligner exhibit stable energy absorption and stiffness behaviour throughout its use period and thus can potentially be used for clinical applications. The microplastic released from the aligner due to the fatigue-like damage is analysed using optical microscopy. Most of the microplastics released have larger dimensions, which may be excreted from the gastrointestinal tracts and have less possibility to pass through the epithelium passively. Therefore, the use of aligner may not pose any cytotoxic health risks. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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9 pages, 3854 KiB  
Proceeding Paper
The Mechanical Characterization of a Gyroid-Based Metamaterial by Compression Testing
by Andrea Ciula, Gianluca Rubino and Pierluigi Fanelli
Eng. Proc. 2025, 85(1), 17; https://doi.org/10.3390/engproc2025085017 - 18 Feb 2025
Viewed by 302
Abstract
Gyroid-based mechanical metamaterials have garnered increasing attention for their unique mechanical properties, particularly in applications involving complex stress environments. This study focuses on the mechanical characterization of the gyroid cell, a member of the Triply Periodic Minimal Surfaces (TPMS) family, through both experimental [...] Read more.
Gyroid-based mechanical metamaterials have garnered increasing attention for their unique mechanical properties, particularly in applications involving complex stress environments. This study focuses on the mechanical characterization of the gyroid cell, a member of the Triply Periodic Minimal Surfaces (TPMS) family, through both experimental and numerical analyses. Three different gyroid morphologies were generated by varying a single parameter in the parametric equation of the gyroid surface. Specimens were fabricated by 3D printing based on Liquid Crystal Display (LCD) technology, and compression tests were conducted to measure the equivalent Young’s modulus. Numerical models developed using Finite Element Method (FEM) analysis were validated through the experimental findings. The results indicate a good correlation between the experimental and numerical data, particularly in the linear elastic region, confirming the suitability of FEM simulations in predicting the mechanical response of these cellular structures. The study serves as a foundational step towards a broader multi-physical characterization of TPMS-based metamaterials and paves the way for the future development of tailored metamaterials for specific applications, including sacrificial limiters in plasma-facing components of Tokamaks. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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15 pages, 8399 KiB  
Proceeding Paper
An Investigation of the Monotonic and Cyclic Behavior of Additively Manufactured TPU
by Sara Ricci, Alberto Pagano, Andrea Ceccacci, Gianluca Iannitti and Nicola Bonora
Eng. Proc. 2025, 85(1), 18; https://doi.org/10.3390/engproc2025085018 - 18 Feb 2025
Cited by 1 | Viewed by 1797
Abstract
The mechanical properties of rubber-like materials, such as their high flexibility and durability, make them widely applicable across different industrial fields, from aerospace to healthcare and, most notably, the automotive sector. In operative conditions, these materials experience large deformations and repeated loadings, which [...] Read more.
The mechanical properties of rubber-like materials, such as their high flexibility and durability, make them widely applicable across different industrial fields, from aerospace to healthcare and, most notably, the automotive sector. In operative conditions, these materials experience large deformations and repeated loadings, which may result in inelastic and dissipative phenomena. The aim of this study is to investigate the mechanical properties of two thermoplastic elastomeric materials manufactured with the Fused Filament Fabrication (FFF) technique: unfilled thermoplastic polyurethane (TPU) and TPU reinforced with carbon nanotubes (CNTs). Several experimental tests were performed to assess the response of both materials under monotonic and cyclic loadings. The addition of CNTs led to improved stiffness and strength without compromising elasticity. Under repeated loadings, both materials were characterized by the Mullins and viscous effects. However, the presence of CNTs was found to slightly amplify these inelastic phenomena. The integration of additive manufacturing technologies, combined with the use of innovative fillers, can offer design and performance optimization to all those components that strongly rely on elastomers. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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16 pages, 1813 KiB  
Proceeding Paper
Scaling the Response of a Simplified Hull Girder Subjected to Underwater Explosions
by Giovanni Marchesi, Luca Lomazzi, Marco Giglio and Andrea Manes
Eng. Proc. 2025, 85(1), 19; https://doi.org/10.3390/engproc2025085019 - 19 Feb 2025
Viewed by 269
Abstract
Underwater explosions (UNDEXs) represent a significant threat to marine vessels, motivating the analysis of their resulting dynamic response and damage. Conducting experimental investigations on full-scale ships, while being the most consistent strategy, is not always feasible due to obvious economic constraints. Consequently, researchers [...] Read more.
Underwater explosions (UNDEXs) represent a significant threat to marine vessels, motivating the analysis of their resulting dynamic response and damage. Conducting experimental investigations on full-scale ships, while being the most consistent strategy, is not always feasible due to obvious economic constraints. Consequently, researchers usually rely on scaled models designed to replicate real-world scenarios in laboratory environments. Despite the widespread use of this approach, the scaling laws between prototypes and models are not yet satisfactory due to the complexity of the UNDEX phenomena and the variability in boundary conditions. To address this aspect, the present study focuses on the scalability of a simplified vessel, termed a simplified hull girder (SHG). This study is conducted numerically and originates from a comparison with experiments available in the literature. This work has two objectives: firstly, it provides a practical approach to simulating the behaviour of complex architectures that undergo severe deformation due to blast loads, a critical challenge for state-of-the-art computational methods. Secondly, this work aims to assess the reliability of the scaling laws commonly used in UNDEX scenarios and to highlight the importance of strain-rate effects. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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13 pages, 727 KiB  
Proceeding Paper
Innovative Model for Material Selection Within the Automotive Lightweight Eco-Design Field
by Edoardo Risaliti, Arcidiacono Gabriele, Francesco Del Pero and Paolo Citti
Eng. Proc. 2025, 85(1), 20; https://doi.org/10.3390/engproc2025085020 - 19 Feb 2025
Viewed by 251
Abstract
This paper presents an innovative integrated Ashby-VIKOR model for material selection when dealing with the re-design of automotive components under a wide-spectrum range of both sustainability and design aspects. The conceived approach combines the Ashby method, which assesses mechanical properties and costs, with [...] Read more.
This paper presents an innovative integrated Ashby-VIKOR model for material selection when dealing with the re-design of automotive components under a wide-spectrum range of both sustainability and design aspects. The conceived approach combines the Ashby method, which assesses mechanical properties and costs, with the VIKOR multi-criteria decision analysis, including a comprehensive model functional to assess the environmental impact of the considered automotive assets. This study also incorporates the implementation of the methodology to a literature case study (engine bracket for a C-class electric vehicle) to evaluate the robustness of the approach under varying different boundary conditions of the analysis. The results show the usefulness of the method in assessing new lightweight design solutions under an integrated structural integrity/sustainability point of view. In particular, the outcomes of the case study analysis show that significant improvements are offered by the lightweight alternative both in terms of component weight, cost efficiency and carbon footprint, identifying low-alloy steels and aluminum composites as optimal materials for this specific application. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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13 pages, 3082 KiB  
Proceeding Paper
Design of an Electromechanical Testing Machine for Elastomers’ Fatigue Characterization
by Gabriel Testa, Nicola Bonora, Luca Esposito and Gianluca Iannitti
Eng. Proc. 2025, 85(1), 21; https://doi.org/10.3390/engproc2025085021 - 19 Feb 2025
Cited by 1 | Viewed by 294
Abstract
The VITAL-E (Versatile Innovative Testing Low-Cycle Fatigue for Elastomers) project introduces a shift in low-cycle fatigue (LCF) testing by replacing traditional hydraulic systems with an electromechanical solution. Hydraulic machines, although widely used, present issues such as fluid leakage, environmental impact, high maintenance, and [...] Read more.
The VITAL-E (Versatile Innovative Testing Low-Cycle Fatigue for Elastomers) project introduces a shift in low-cycle fatigue (LCF) testing by replacing traditional hydraulic systems with an electromechanical solution. Hydraulic machines, although widely used, present issues such as fluid leakage, environmental impact, high maintenance, and complex feedback control. In contrast, VITAL-E incorporates a zero-backlash linear actuator, addressing a key challenge in electromechanical systems: backlash. This issue, caused by axial movement between the nut and screw during load reversals, can disrupt load application and compromise test accuracy. By eliminating backlash, the chosen actuator ensures continuous and precise load application, especially during critical cycle reversals, enhancing both the accuracy and reliability of LCF testing. Beyond technical improvements, the electromechanical system reduces component complexity, wear, and maintenance needs while offering easier upgrades and adaptability to evolving testing demands. Compared to conventional hydraulic systems, VITAL-E’s design offers an innovative industrial solution, promoting a new generation of LCF test machines that excel in accuracy, reliability, and operational efficiency. This innovation aligns with the growing demand for sustainable and adaptable testing solutions, particularly in the automotive industry, ensuring that LCF testing remains relevant for future research and industrial needs. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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17 pages, 1297 KiB  
Proceeding Paper
Survivability Approach to Increase the Resilience of Critical Systems
by Salvatore Annunziata, Luca Lomazzi, Marco Giglio and Andrea Manes
Eng. Proc. 2025, 85(1), 22; https://doi.org/10.3390/engproc2025085022 - 19 Feb 2025
Viewed by 224
Abstract
The survivability approach necessitates a vulnerability assessment, which quantifies the likelihood that a platform will be rendered inoperative when exposed to a threat—whether man-made or natural. This concept is closely tied to survivability, defined as the probability that a platform will complete its [...] Read more.
The survivability approach necessitates a vulnerability assessment, which quantifies the likelihood that a platform will be rendered inoperative when exposed to a threat—whether man-made or natural. This concept is closely tied to survivability, defined as the probability that a platform will complete its assigned mission. Detection and potential exposure to a threat can significantly reduce a system’s survivability. As a result, vulnerability evaluation has become a critical aspect of designing platforms that operate in high-risk environments. Numerous techniques have been developed for vulnerability assessment, with many studies aimed at achieving increasingly accurate evaluations to improve the reliability and safety of mechanical systems. Notably, in 1985, Ball introduced the concept of survivability, outlining various design solutions and techniques for fixed-wing and rotary-wing aircraft. Since then, several vulnerability assessment programs have been launched, leading to the creation of some of the most resilient platforms in use today. The assessment of vulnerability plays a key role in determining solutions to enhance the likelihood of a system successfully completing its mission. In this context, this paper presents the application of in-house software to analyze a fixed-wing Remotely Piloted Aircraft System (RPAS). The model used to validate the software’s capabilities was developed using publicly available data, enabling a practical demonstration of the software’s functionality. Applied to this case study, the software assesses the RPAS vulnerability against various impact threats. The software not only evaluates vulnerability but also suggests protective solutions to mitigate it. This application demonstrates how the software can enhance the reliability and safety of an existing operational system while also showcasing its potential for use during the preliminary design phase of a broader range of platforms. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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13 pages, 6101 KiB  
Proceeding Paper
Characterisation of Novel Self-Healing Composites Using Acousto-Ultrasonic Testing
by Claudia Barile, Vimalathithan Paramsamy Kannan, Giulia Derosa and Giovanni Pappalettera
Eng. Proc. 2025, 85(1), 23; https://doi.org/10.3390/engproc2025085023 - 19 Feb 2025
Viewed by 169
Abstract
Self-healing composites are designed based on natural healing processes such as bone regeneration and blood coagulation. These composites have polymeric material containing covalent adaptable networks that rearrange their molecular structure when heated, thereby serving as a healing agent. The inclusion of the healing [...] Read more.
Self-healing composites are designed based on natural healing processes such as bone regeneration and blood coagulation. These composites have polymeric material containing covalent adaptable networks that rearrange their molecular structure when heated, thereby serving as a healing agent. The inclusion of the healing polymers into the principal matrix of the fiber-reinforced composites alters their off-axis properties. In addition, the healing agents tend to bleed out of the composite structures upon heating. It is, therefore, essential to characterize the extent of the changes in the off-axis properties of the self-healing composites. In this research work, three different configurations of self-healing composites are subjected to three-point bending tests, and their healing characteristics are studied using Acousto-Ultrasonic tests. Frequencies of the propagating stress waves in the AU tests are used to analyze the different conditions of the self-healing composites, such as virgin, damaged, damaged-partially healed, and damaged-fully healed. The results show that the AU test could potentially be used to evaluate the healing behavior of these fiber-reinforced self-healable composites. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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14 pages, 11264 KiB  
Proceeding Paper
Analytical, Numerical, and Experimental Analysis of Tangential Attraction and Repulsion Forces Between Parallel Magnets in an Automotive Mechanical System
by Carmelo Serraino, Tommaso Carditello, Luca Dusini, Alberto Nicoletta, Dario Santonocito and Giacomo Risitano
Eng. Proc. 2025, 85(1), 24; https://doi.org/10.3390/engproc2025085024 - 18 Feb 2025
Viewed by 229
Abstract
This study highlights the importance of magnets in the advancement of automotive technology, focusing on the forces of attraction and repulsion between two magnets in relative tangential motion. The magnets were tested using a tensile machine developed by KnoWow and adapted to measure [...] Read more.
This study highlights the importance of magnets in the advancement of automotive technology, focusing on the forces of attraction and repulsion between two magnets in relative tangential motion. The magnets were tested using a tensile machine developed by KnoWow and adapted to measure attraction forces as a function of longitudinal and transversal distances. The data collected made it possible to create a detailed map of the interactions of the forces. To validate the experimental results, a finite element analysis (FEA) was performed. The high correspondence between the experimental and simulated data confirmed the reliability of the method, making it usable for future automotive designs requiring optimization of magnetic forces. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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14 pages, 20965 KiB  
Proceeding Paper
Innovative Design and Prototyping of Reconfigurable Run-Flat Tire
by Gabriel Testa, Luca Esposito, Andrea Ceccacci, Gianluca Iannitti and Nicola Bonora
Eng. Proc. 2025, 85(1), 25; https://doi.org/10.3390/engproc2025085025 - 21 Feb 2025
Viewed by 222
Abstract
Tire puncturing is one of the main causes of accidents and/or traffic interruptions, leading to unsafe and unsustainable mobility scenarios. Insert-supporting Run-Flat systems can be a strategic technology to improve tire performance, but further developments are needed to improve system reliability, modularity, and [...] Read more.
Tire puncturing is one of the main causes of accidents and/or traffic interruptions, leading to unsafe and unsustainable mobility scenarios. Insert-supporting Run-Flat systems can be a strategic technology to improve tire performance, but further developments are needed to improve system reliability, modularity, and efficiency. A novel Run-Flat system was proposed in the present study to address specific features. The concept was developed by exploiting numerical simulation tools, enabling a comprehensive system assessment. In addition, a technological demonstrator was manufactured employing rapid prototyping techniques based on 3D printing processes. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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9 pages, 870 KiB  
Proceeding Paper
Sensitivity Analysis of Integrated Sensors Created Through Additive Manufacturing for Monitoring Components Subject to Dynamic Loads
by Agnese Staffa, Massimiliano Palmieri, Giulia Morettini and Filippo Cianetti
Eng. Proc. 2025, 85(1), 26; https://doi.org/10.3390/engproc2025085026 - 23 Feb 2025
Viewed by 237
Abstract
The progress in the development of sensors made using additive manufacturing (AM) techniques has opened up new possibilities for their integration into more complex structures, such as CubeSats. In this study, preliminary tests were conducted on printed sensors by FDM embedded in simple [...] Read more.
The progress in the development of sensors made using additive manufacturing (AM) techniques has opened up new possibilities for their integration into more complex structures, such as CubeSats. In this study, preliminary tests were conducted on printed sensors by FDM embedded in simple structures to evaluate their feasibility under simulated operational conditions, including temperature variations and dynamic loads. The results obtained represent a preliminary step toward the full integration of embedded sensors in 3D-printed structures. With further development, 3D-printed embedded sensors could be used to monitor dynamic loads and vibrations during service, which is essential for structural health monitoring and determining fatigue life. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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16 pages, 4655 KiB  
Proceeding Paper
A Combined Approach of Experimental Testing and Inverse FE Modelling for Determining Homogenized Elastic Properties of Membranes and Plates
by Christian Iandiorio, Riccardo Serenella and Pietro Salvini
Eng. Proc. 2025, 85(1), 27; https://doi.org/10.3390/engproc2025085027 - 23 Feb 2025
Viewed by 219
Abstract
Accurately determining the mechanical properties of complex materials is a key challenge in structural analysis, especially when using the finite element method (FEM). While homogeneous materials can be modeled with relative ease, heterogeneous materials such as composites or biological tissues with multiphase compositions [...] Read more.
Accurately determining the mechanical properties of complex materials is a key challenge in structural analysis, especially when using the finite element method (FEM). While homogeneous materials can be modeled with relative ease, heterogeneous materials such as composites or biological tissues with multiphase compositions pose significant difficulties due to the variability in their internal structures. The most used approach is numerical homogenization, which allows for the estimation of effective material properties by combining the characteristics of individual phases; however, this technique may not always be feasible, especially for materials with irregular or unknown phase distributions. This paper proposes an original methodology that combines non-destructive experimental testing with an inverse finite element modeling to extract the anisotropic elastic properties of quasi two-dimensional structures such as membranes and plates. The method involves modeling the component using membrane or plate finite elements, but managing a global stiffness matrix expressed analytically. While geometric information is incorporated in the global stiffness matrix, the material properties, specifically the components of the anisotropic elasticity matrix, remain unknown. The experimental data, comprising force and displacement measurements, are used to solve a nonlinear system, allowing for the identification of the material’s constitutive properties via numerical computation. To validate this approach, two experimental setups were conducted. The first involved a hyperelastic neoprene membrane, subjected to various biaxial preloading conditions, while the second focused on PLA plates produced through additive manufacturing including both homogeneous and reinforced variants. In both cases, the method successfully captured the full anisotropic elastic response, yielding accurate estimates of Young’s moduli, Poisson’s ratios, shear modulus, and orthotropy system orientation, in agreement with independent mechanical tests. This combined approach offers a practical and efficient solution for determining the elastic properties of complex materials, particularly in cases where traditional homogenization techniques are impractical or inadequate. Furthermore, this method can be a versatile tool for evaluating the damaging and aging effects on materials subjected to cyclic loading or those with irregular and complex internal structures. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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13 pages, 4536 KiB  
Proceeding Paper
Numerical Thermo-Structural Simulations for the Design of the Havar Beam Window of a Beryllium Target for Neutron Beam Production
by Roberta Dattilo
Eng. Proc. 2025, 85(1), 28; https://doi.org/10.3390/engproc2025085028 - 26 Feb 2025
Viewed by 159
Abstract
The present work was carried out as part of the PRIN 2022JCS2CN project “CoolGal”, which aims to design and manufacture a beryllium target cooled by Galinstan (a liquid metal alloy at room temperature) for the production of neutrons using energetic protons. The objective [...] Read more.
The present work was carried out as part of the PRIN 2022JCS2CN project “CoolGal”, which aims to design and manufacture a beryllium target cooled by Galinstan (a liquid metal alloy at room temperature) for the production of neutrons using energetic protons. The objective of the present work is to thermo-structurally design a beam window that encloses the environment in which the target is housed. The window consists of a Havar disk, the thickness of which must be minimized to absorb the least amount of proton beam power, while its diameter must be sufficient to avoid excessive beam loss. The window will then be embedded around its perimeter and will have to withstand two load conditions, applied individually: A mechanical load, due to the atmospheric pressure of 0.11 MPa during vacuuming, and a thermal load, due to heating during irradiation with the proton beam. Once a first-version window geometry was defined, a static structural finite element analysis (FEA) was carried out by activating geometric nonlinearities to assess the structural integrity of the window under mechanical loading. After that, a static thermal–mechanical FEA analysis was carried out to assess the structural integrity of the window under thermal loading. Given the compressive stress state induced by thermal loading and the slenderness of the window itself, a nonlinear buckling structural FEA analysis was also performed. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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14 pages, 5142 KiB  
Proceeding Paper
Numerical and Experimental Analysis of the Structural Behavior of an EPP Component
by Carlo Sabbatini, Gianluca Chiappini, Veronica Ilari, Giacomo Zandri and Marco Sasso
Eng. Proc. 2025, 85(1), 29; https://doi.org/10.3390/engproc2025085029 - 27 Feb 2025
Viewed by 189
Abstract
The use of expanded polymeric materials is becoming increasingly widespread in the industrial sector, not only for energy absorption purposes but also for structural applications. The most widely used approach to model the large strain elastic response of polymer foams in a finite [...] Read more.
The use of expanded polymeric materials is becoming increasingly widespread in the industrial sector, not only for energy absorption purposes but also for structural applications. The most widely used approach to model the large strain elastic response of polymer foams in a finite element (FE) solution is the use of the Ogden–Hill hyperelastic material model. We performed a uniaxial and simple shear test to calibrate the model’s parameters. In this work, a compression test was performed on a component, entirely made of expanded polypropylene, from a commercial machine. The experimental results, measured through 3D image analysis, were then compared with the simulation ones. This study aims to verify whether the Ogden foam model accurately describes the material’s behavior when the component has a complex geometry and large dimensions. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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12 pages, 2460 KiB  
Proceeding Paper
Model Order Reduction Applied to Replicate Blast Wave Interaction with Structure
by Edison Shehu, Giovanni Marchesi, Luca Lomazzi, Marco Giglio and Andrea Manes
Eng. Proc. 2025, 85(1), 30; https://doi.org/10.3390/engproc2025085030 - 27 Feb 2025
Viewed by 181
Abstract
This research explores the application of model order reduction (MOR) techniques for blast wave propagation and mitigation. Blast waves, with their rapid pressure changes and highly nonlinear behavior, pose significant challenges for predictive modeling. MOR, a mathematical dimensionality reduction technique, offers a solution [...] Read more.
This research explores the application of model order reduction (MOR) techniques for blast wave propagation and mitigation. Blast waves, with their rapid pressure changes and highly nonlinear behavior, pose significant challenges for predictive modeling. MOR, a mathematical dimensionality reduction technique, offers a solution by simplifying the complexity of large-scale dynamical systems described by differential equations. These systems can be computationally expensive to solve through conventional numerical schemes. MOR creates a reduced-order model (ROM) that retains the essential features and behavior of the original system but with fewer degrees of freedom. Unlike traditional high-fidelity simulations that are accurate but computationally expensive, MOR allows for multi-query scenarios. This approach significantly reduces computational demands without sacrificing accuracy, making it a valuable tool for engineers and professionals in safety engineering and defense planning. The study also enables the creation of reduced-order models based on high-fidelity simulations of blast wave interactions with structures, promoting their broader adoption in safety planning and structural assessments. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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9 pages, 2876 KiB  
Proceeding Paper
Fatigue Strength Determination of AISI 316L Steel and Welded Specimens Using Energy Methods
by Danilo D’Andrea, Giacomo Risitano, Pasqualino Corigliano and Davide D’Andrea
Eng. Proc. 2025, 85(1), 31; https://doi.org/10.3390/engproc2025085031 - 1 Mar 2025
Viewed by 423
Abstract
AISI 316 is a stainless steel known for its exceptional corrosion resistance and excellent mechanical properties. It is used in the chemical and pharmaceutical industries, food processing equipment, and medical devices. This alloy’s wide range of applications underscores its importance in industries requiring [...] Read more.
AISI 316 is a stainless steel known for its exceptional corrosion resistance and excellent mechanical properties. It is used in the chemical and pharmaceutical industries, food processing equipment, and medical devices. This alloy’s wide range of applications underscores its importance in industries requiring materials that can withstand extreme conditions while maintaining structural integrity and performance. Additionally, the excellent weldability and formability of AISI 316 allow for versatile design and production processes, ensuring durable and reliable performance in marine environments. This work aims to examine the behavior of AISI 316L and its welded joints under high-cycle fatigue loadings using infrared thermography (IR). Two kinds of experimental tests are performed on specimens with the same geometry: static tests and stepwise succession tests. The results of the static tests are in accordance with the stepwise succession test results in predicting the fatigue properties. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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8 pages, 2226 KiB  
Proceeding Paper
Development of a Numerical Prediction Method for the Strain Energy Density of Welded Joints Using Structural Stresses Derived from Nodal Forces
by Simone Lucertini, Giulia Morettini and Filippo Cianetti
Eng. Proc. 2025, 85(1), 32; https://doi.org/10.3390/engproc2025085032 - 4 Mar 2025
Viewed by 224
Abstract
This paper describes the numerical prediction of the fatigue strength at the toe of steel fillet-welded joints in conditions of HCF, comparing and integrating results from an energy-based approach based on the Average Strain Energy Density (A-SED) and structural stresses derived using the [...] Read more.
This paper describes the numerical prediction of the fatigue strength at the toe of steel fillet-welded joints in conditions of HCF, comparing and integrating results from an energy-based approach based on the Average Strain Energy Density (A-SED) and structural stresses derived using the nodal forces approach (Mesh-Insensitive) on shell FE models. The analysis considers plates of different thicknesses and weld sizes. The proposed method combines the two mentioned approaches to exploit the advantages of both, allowing a fast preliminary investigation of numerous and complex welded joints within a simplified model, with a coarse mesh and no geometric pre-processing required, while keeping a good adherence to the precision benefits given by local energy evaluations. This activity demonstrates a strong correlation between the numerical values obtained from the proposed innovative approach and the results from predictions made using a standard energy-based approach, with significantly lower computational and setup costs. Data processing and calculations are performed using the open-source software Python 3.10 (Software Foundation, Wilmington, DE, USA) to demonstrate the applicability of this method as a quick and ready-to-use “post-process” tool for industrial applications. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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11 pages, 6787 KiB  
Proceeding Paper
On the Compressive Behavior of Platonic- and Pacioli-Inspired Lattice Structures via FEA
by Carmine Martino, Chiara Bertolin, Francesco Penta and Chao Gao
Eng. Proc. 2025, 85(1), 33; https://doi.org/10.3390/engproc2025085033 - 4 Mar 2025
Viewed by 235
Abstract
Shapes and topologies of lattice materials have been extensively studied, yet very few studies have dealt with shapes inspired by ancient mathematicians, such as the Platonic solids discovered by Plato in 360 BC or the mathematical behavior of the unexplored “semi-regular” solids of [...] Read more.
Shapes and topologies of lattice materials have been extensively studied, yet very few studies have dealt with shapes inspired by ancient mathematicians, such as the Platonic solids discovered by Plato in 360 BC or the mathematical behavior of the unexplored “semi-regular” solids of Pacioli (1445–1517). Using the finite element analysis method, the buckling and post-buckling behavior of Platonic and Paciolian cells subjected to a compressive load were analyzed. In these solids, the energy absorbed per unit mass is an increasing function with the number of faces, similar to porosity, which reaches a maximum value for solids comprised of 90–100 surfaces. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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10 pages, 3033 KiB  
Proceeding Paper
Analysis of Gearbox Losses for High-Performance Electric Motorcycle Applications
by Adelmo Niccolai, Lorenzo Berzi and Niccolò Baldanzini
Eng. Proc. 2025, 85(1), 34; https://doi.org/10.3390/engproc2025085034 - 4 Mar 2025
Viewed by 264
Abstract
Finding an architectural solution that satisfies electric motorcycles’ performance and riding range is challenging due to the electric powertrain constraints, such as low battery energy density. This paper analyzes the gearbox and powertrain efficiency for battery electric motorcycles (BEMs) based on the drivetrain [...] Read more.
Finding an architectural solution that satisfies electric motorcycles’ performance and riding range is challenging due to the electric powertrain constraints, such as low battery energy density. This paper analyzes the gearbox and powertrain efficiency for battery electric motorcycles (BEMs) based on the drivetrain architecture and under various vehicle use scenarios. The impact on the consumption of a constant-speed gearbox is investigated, focusing mainly on load-independent losses. The analysis is performed using an analytic approach and experimental data. Two different gearbox and powertrain solutions are characterized through test bench experiments, running them under free-driving conditions and no-load tests. A comparison of these powertrain solutions in terms of consumption for the same motorcycle model under different speed profiles (WMTC, LA-4) is conducted. The results show the energy losses and provide information for defining drivetrain components and architectures. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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9 pages, 2511 KiB  
Proceeding Paper
Surface, Microstructure, and Wear Characterization of Annealed Cold-Sprayed HEA Coatings
by Nazanin Sheibanian, Raffaella Sesana, Mohsen Dehghanpour Abyaneh, Sedat Özbilen and Rocco Lupoi
Eng. Proc. 2025, 85(1), 35; https://doi.org/10.3390/engproc2025085035 - 6 Mar 2025
Viewed by 231
Abstract
Surface coatings are essential for enhancing the mechanical and functional properties of materials. Among these, annealed high-entropy alloy (HEA) coatings have gained attention for improving wear resistance and durability. This study comprehensively analyzes HEA-annealed coatings, focusing on their surface roughness and wear behavior. [...] Read more.
Surface coatings are essential for enhancing the mechanical and functional properties of materials. Among these, annealed high-entropy alloy (HEA) coatings have gained attention for improving wear resistance and durability. This study comprehensively analyzes HEA-annealed coatings, focusing on their surface roughness and wear behavior. A systematic and thorough approach is employed to examine the impact of annealing on coating characteristics. The research involves depositing Al 0.1–0.5 CoCrCuFeNi and MnCoCrCuFeNi coatings using the cold spray (CS) method, followed by a controlled annealing process. Surface roughness is evaluated through profilometry and microscopy techniques to assess modifications due to annealing. Tribological tests are conducted to investigate the wear performance of the coatings, and the findings are correlated with roughness measurements, offering insights into the relationship between surface texture and wear resistance. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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10 pages, 7244 KiB  
Proceeding Paper
A Multibody Mathematical Model to Simulate the Dynamic Behavior of Aerial Work Platforms Using Python
by Giacomo Cangi, Alessandro Angeletti, Massimiliano Palmieri and Filippo Cianetti
Eng. Proc. 2025, 85(1), 36; https://doi.org/10.3390/engproc2025085036 - 6 Mar 2025
Viewed by 208
Abstract
Understanding and knowing the extent of dynamic loads (forces and moments) acting on critical points of structures from the early stages of new product design allows companies to reduce product time-to-market and cut costs associated with physical validation tests. This is made possible [...] Read more.
Understanding and knowing the extent of dynamic loads (forces and moments) acting on critical points of structures from the early stages of new product design allows companies to reduce product time-to-market and cut costs associated with physical validation tests. This is made possible through the use of commercial software that enables the simulation of the dynamic behavior of a wide range of mechanical systems, and beyond. However, the use of such software is not straightforward and often requires a specialist within the company to have in-depth knowledge of both simulations and the software itself. Consequently, many companies give up the use of these tools, compromising the whole product development process, falling into the design and testing iterative loop. The multibody mathematical model developed in this study, simulated using python programming language, allows easy retrieval of all the necessary information without requiring the user to be a specialist in multibody dynamics simulations. This model is intended as a tool specifically designed for the type of product (aerial work platform) that serves, during the conceptual and preliminary design phases, to predict dynamic loads through calculations. The balance between the simplicity of such a tool and the accuracy of the results is the key point for the success of this work. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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12 pages, 14337 KiB  
Proceeding Paper
The Payload Design of the CUbesat Solar Polarimeter (CUSP), for Space Weather and Solar Flares X-Ray Polarimetry
by Giovanni Lombardi, Sergio Fabiani, Ettore Del Monte, Emanuele Di Meo, Andrea Lopez, Marco Camponeschi, Marco E. Biancolini, Daniele Brienza, Immacolata Donnarumma, Silvia Natalucci, Andrea Terracciano and Emanuele Zaccagnino
Eng. Proc. 2025, 85(1), 37; https://doi.org/10.3390/engproc2025085037 - 11 Mar 2025
Viewed by 302
Abstract
The CUbesat Solar Polarimeter (CUSP) project is a CubeSat mission orbiting the Earth aimed to measure the linear polarization of solar flares in the hard X-ray band by means of a Compton scattering polarimeter. CUSP is a project in the framework of the [...] Read more.
The CUbesat Solar Polarimeter (CUSP) project is a CubeSat mission orbiting the Earth aimed to measure the linear polarization of solar flares in the hard X-ray band by means of a Compton scattering polarimeter. CUSP is a project in the framework of the Alcor Program of the Italian Space Agency aimed to develop new CubeSat missions. It is approved for a Phase B study. In this work we describe some design solutions adopted for the most important design drivers of the payload. In particular, we report on the payload preliminary multi-physical design, including an orbital thermal environment preliminary assessment and a implementation of the static/dynamic finite element analysis. Moreover, a method for topology optimization of relevant components is discussed. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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12 pages, 5845 KiB  
Proceeding Paper
Development, Testing, and Validation of ADAS L2/L3 Systems: A KPI-Based Methodology
by Leandro Ronchi, Claudio Annicchiarico and Renzo Capitani
Eng. Proc. 2025, 85(1), 38; https://doi.org/10.3390/engproc2025085038 - 19 Mar 2025
Viewed by 199
Abstract
In recent years, advanced driver assistance systems (ADAS) have become increasingly popular, with the aim of significantly reducing road accidents and achieving the European Union’s goal of zero road fatalities by 2050. Level 2 and 3 ADAS systems, actively controlling vehicles rather than [...] Read more.
In recent years, advanced driver assistance systems (ADAS) have become increasingly popular, with the aim of significantly reducing road accidents and achieving the European Union’s goal of zero road fatalities by 2050. Level 2 and 3 ADAS systems, actively controlling vehicles rather than responding only in emergencies, are more crucial in reducing road accidents but increase system complexity and require greater investment in hardware, software development and calibration. This study proposes a consistent methodology that identifies specific KPIs to streamline the development and testing phases, both virtual and on-road. The proposed approach will be able to rapidly classify and evaluate the performance of Level 2 and Level 3 systems by reducing validation time and cost and minimizing the need for road tests. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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9 pages, 2737 KiB  
Proceeding Paper
Modal Shapes Selection Criterion for Modal Reconstruction Aimed at Structural Health Monitoring
by Gabriele Liuzzo, Miriam Parisi and Pierluigi Fanelli
Eng. Proc. 2025, 85(1), 39; https://doi.org/10.3390/engproc2025085039 - 21 Mar 2025
Viewed by 99
Abstract
This paper aims to demonstrate the applicability of a modal selection criterion based on strain energy potential for describing static deformations in a commonly used engineering geometry, specifically a circular plate. The analytical model relies on the definition of internal strain potential energy, [...] Read more.
This paper aims to demonstrate the applicability of a modal selection criterion based on strain energy potential for describing static deformations in a commonly used engineering geometry, specifically a circular plate. The analytical model relies on the definition of internal strain potential energy, enabling the calculation of the energy contribution of each mode derived from a modal analysis to the actual static deformation of the structure. The modal selection is designed to reconstruct the displacement and strain fields under linear elastic conditions, assuming small displacements and strains. This represents the initial phase of a research effort concerning structural health monitoring, where evaluating the displacement, strain, and stress fields is critical for assessing the integrity of mechanical systems. The study examines two loading conditions: axisymmetric and non-axisymmetric bending, which are prevalent in mechanical applications involving circular plates. Modal selection is performed using results from all nodes in the finite element model, as well as from a subset of nodes, demonstrating the feasibility of applying the selection method while reducing the number of equations in the problem. The results indicate a robust comparison between the finite element solution and the modal reconstruction, showcasing the flexibility of the proposed method for the given geometry. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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9 pages, 2759 KiB  
Proceeding Paper
Modelling and Mechanical Characterization of a Metamaterial Inspired by the Spinodal Decomposition
by Barbara Mandolesi, Christian Iandiorio, Valerio G. Belardi and Francesco Vivio
Eng. Proc. 2025, 85(1), 40; https://doi.org/10.3390/engproc2025085040 - 21 Mar 2025
Viewed by 145
Abstract
The increasing interest in metamaterials stems from the ability to expand the design space for material properties by tailoring the material architecture. Spinodal decomposition-inspired topologies are an emerging class of minimal surface-based metamaterials with promising properties. The diffusion process of the binary mixture [...] Read more.
The increasing interest in metamaterials stems from the ability to expand the design space for material properties by tailoring the material architecture. Spinodal decomposition-inspired topologies are an emerging class of minimal surface-based metamaterials with promising properties. The diffusion process of the binary mixture is modeled using the Cahn–Hilliard equation, which is typically approached with a statistical method (superimposition of Gaussian random fields) that is well founded only for its initial stages. In this work, a fast and efficient computational method based on the finite difference method is employed to simulate the entire 2D dynamic evolution. Next, the solution field is converted into a CAD model forming the metamaterial. The elastic properties are assessed using a computational homogenization in which both homogeneous displacement and periodic boundary conditions have been applied for comparison. Finally, results from experimental testing confirm the accuracy of the FE homogenization procedure developed here. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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17 pages, 8549 KiB  
Proceeding Paper
Experimental Analysis of an Autonomous Driving Strategy for a Four-Wheel Differential Drive Agricultural Rover
by Salvatore Martelli and Francesco Mocera
Eng. Proc. 2025, 85(1), 41; https://doi.org/10.3390/engproc2025085041 - 21 Mar 2025
Viewed by 154
Abstract
Currently, the entire agricultural sector is under significant pressure. The causes that may explain this are different, such as climate change, market instability, and the decline in the population of agricultural workers. As a result, the agricultural tractor and machinery field is at [...] Read more.
Currently, the entire agricultural sector is under significant pressure. The causes that may explain this are different, such as climate change, market instability, and the decline in the population of agricultural workers. As a result, the agricultural tractor and machinery field is at the center of an intense technological revolution. One of the possible solutions to the aforementioned problems can be represented by agricultural vehicles equipped with autonomous driving systems. The key pillar of an autonomous driven vehicle is its autonomous driving algorithm which represents the link between the information coming from the vehicle’s sensor systems and the success of the vehicle’s operative mission. In this paper, an experimental assessment of the motion strategy for a four-wheel differential drive agricultural rover was conducted. This work is structured in three parts. First, the description of the working principles of the autonomous driving algorithm is proposed. Then, the case study and the scaled prototype designed for this purpose are described. In the end, the result obtained by the virtual model, which acts as reference case, is compared with the results that came out of the field test campaign. The outcomes show the overlap between the virtual and real results. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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9 pages, 1278 KiB  
Proceeding Paper
Numerical Finite Element Modelling and Simplified Analytical Methodology for the Structural Analysis of Wound Rotors in Electric Motors
by Saverio Giulio Barbieri, Sara Mantovani and Valerio Mangeruga
Eng. Proc. 2025, 85(1), 42; https://doi.org/10.3390/engproc2025085042 - 21 Mar 2025
Viewed by 221
Abstract
Wound rotor electric motors offer low production costs and environmental sustainability, making them preferable over rare-earth-based motors, particularly at low speeds. However, in automotive applications, the demand for higher specific powers and rotational speeds increases the structural challenges for wound rotors. While commercial [...] Read more.
Wound rotor electric motors offer low production costs and environmental sustainability, making them preferable over rare-earth-based motors, particularly at low speeds. However, in automotive applications, the demand for higher specific powers and rotational speeds increases the structural challenges for wound rotors. While commercial Finite Element simulations integrate structural and electromagnetic needs, they could not immediately highlight the influence of single parameters on rotor stress. This paper introduces a simplified analytical methodology for the structural analysis of wound rotors, validated against Finite Element simulations, showing strong agreement. This approach is particularly useful during the early design stages for guiding preliminary geometry definitions. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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10 pages, 5873 KiB  
Proceeding Paper
Effect of Weight Distribution on Knee Joint Temperature Pattern Under Fatigue Condition
by Marta Spataro, Davide Crisafulli, Cristiano De Marchis, Giacomo Risitano and Dario Milone
Eng. Proc. 2025, 85(1), 43; https://doi.org/10.3390/engproc2025085043 - 22 Mar 2025
Viewed by 216
Abstract
Musculoskeletal diseases of the knee joint affect a large percentage of the population, particularly athletes at the competitive level where stress on the joints is higher. These conditions can be diagnosed and monitored using various imaging techniques, such as radiography, computed tomography, and [...] Read more.
Musculoskeletal diseases of the knee joint affect a large percentage of the population, particularly athletes at the competitive level where stress on the joints is higher. These conditions can be diagnosed and monitored using various imaging techniques, such as radiography, computed tomography, and magnetic resonance imaging. Additionally, digital infrared thermal imaging is gaining popularity for screening, diagnosis, and disease progression monitoring. This method measures the heat radiating from the superficial dermal microcirculation located 1–2 mm below the epidermal surface. Numerous pathological processes, such as inflammatory, metabolic, and toxic conditions, manifest as local changes in heat production, making infrared thermal imaging a valuable clinical tool. In the present study, the temperature of the knee area in 22 participants was monitored using an infrared camera while performing sit-to-stand cycles. The change in temperature correlated with weight distribution between the legs during exercise, measured using a Wii Balance Board. The results of this new trial protocol are promising and suggest that further investigations should be conducted with more patients. Infrared thermal imaging demonstrated consistency in repeated knee measurements and showed potential for evaluating the relationship between regional knee temperatures and pathological conditions. Its strengths lie in its simplicity, accuracy, non-invasive nature, radiation-free nature, and patient specificity, which can improve clinical management. In combination with other diagnostic techniques, thermography provides a comprehensive overview of patients’ clinical conditions. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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18 pages, 11906 KiB  
Proceeding Paper
Shape Optimization of Frame Structures Through a Hybrid Two-Dimensional Analytical and Three-Dimensional Numerical Approach
by Andrea Lopez, Christian Iandiorio, Daniele Milani, Pietro Salvini and Marco E. Biancolini
Eng. Proc. 2025, 85(1), 44; https://doi.org/10.3390/engproc2025085044 - 21 Mar 2025
Viewed by 80
Abstract
In this work, we propose a method for the shape optimization of frame structures using a mixed analytical–numerical approach. The goal is to achieve a uniform-strength frame structure, ensuring optimal material utilization and weight minimization. The optimization is performed in two calculation steps. [...] Read more.
In this work, we propose a method for the shape optimization of frame structures using a mixed analytical–numerical approach. The goal is to achieve a uniform-strength frame structure, ensuring optimal material utilization and weight minimization. The optimization is performed in two calculation steps. The first step uses an analytical model based on the Timoshenko beam theory, where appropriate mathematical steps give a uniform-strength shape of the entire structure. Depending on the type of cross-section analyzed, the exact uniform-strength profile of each element is derived by solving for three parameters related to the forces and moments acting on the element. These parameters are obtained by solving a nonlinear system of equations, which includes the external and internal kinematic constraints of the structure, as well as equilibrium equations for each element. However, the solution obtained using the one-dimensional theory is limited in areas affected by boundary effects, such as the interconnection regions between elements and those near the supports, for a decay distance at least equal to the characteristic diameter of the section. To address this limitation, the second optimization step involves incorporating solutions that account for a triaxial stress field. This is typically carried out by discretizing the structure using the finite element method. The frame geometry obtained from the previous analytical solution is constructed, and the regions affected by boundary effects are optimized using the Biological Growth Method (BGM). This is an iterative, bio-inspired method modeled on the growth of trees, which increases trunk diameter in proportion to the loads experienced. The method is applied simultaneously to all regions where three-dimensional effects are significant, with the aim of achieving uniform strength in areas influenced by boundary effects. An important aspect of applying the BGM is maintaining the topology of the initial mesh, which is ensured through the use of mesh morphing techniques. The results of the two-step optimization process are shown on simple geometries involving few elements, and on more complex geometries of mechanical interest. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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10 pages, 1657 KiB  
Proceeding Paper
Design Challenges in the Development of a Hydrogen-Fueled Micro Gas Turbine Unit for Energy Generation
by Uma Nataraj Gottipati, Angelo Minotti, Vincenzo La Battaglia and Alessandro Giorgetti
Eng. Proc. 2025, 85(1), 45; https://doi.org/10.3390/engproc2025085045 - 21 Mar 2025
Viewed by 194
Abstract
Environmental and social governance targets, as well as the global transition to cleaner renewable energy sources, push for advancements in hydrogen-based solutions for energy generators due to their high energy per unit mass (energy density) and lightweight nature. Hydrogen’s energy density and lightweight [...] Read more.
Environmental and social governance targets, as well as the global transition to cleaner renewable energy sources, push for advancements in hydrogen-based solutions for energy generators due to their high energy per unit mass (energy density) and lightweight nature. Hydrogen’s energy density and lightweight nature allow it to provide an extended range of uses without adding significant weight, potentially revolutionizing many applications. Moreover, a variety of sources, including renewable energy, can produce hydrogen, making it a potentially more sustainable option for energy storage despite its main limitations in production and transportation costs. In this framework we are proposing an innovative energy generator that might merge the benefits of batteries and hydrogen. The energy generator is based on a worldwide patented solution introduced by MIEEG s.r.l. regarding the shape of the chambers. This innovative solution can be used to design a 100% H2-fed microturbine with a high power/weight/volume ratio that works as a range extender of battery packs for a comprehensive, high-efficiency hybrid powertrain. In fact, it runs at 100,000 rpm and is designed to deliver about 100 kW in about 15 L of volume and 15 kg of weight (alternator excluded). The system is highly complex due to high firing temperatures, long life requirements, corrosion protection, mechanical and vibrational stresses, sealing, couplings, bearings, and the realization of tiny blades. This paper analyzes the main design challenges to face in the development of such complex generators, focusing on the hot gas path components, which are the most critical part of gas turbines. The contribution of additive manufacturing techniques, the adoption of special materials, and coatings have been evaluated for system improvement. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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13 pages, 4778 KiB  
Proceeding Paper
Fatigue Analysis of Draw Gears in Freight Trains
by Edoardo Risaliti, Francesco Del Pero, Alessandro Giorgetti, Luciano Cantone and Gabriele Arcidiacono
Eng. Proc. 2025, 85(1), 46; https://doi.org/10.3390/engproc2025085046 - 27 Feb 2025
Viewed by 93
Abstract
The majority of freight trains are characterized by a braking system that does not guarantee synchronous braking between different wagons. This results in the generation of considerable in-train forces during emergency braking operations, which are sometimes imposed by the railway infrastructure due to [...] Read more.
The majority of freight trains are characterized by a braking system that does not guarantee synchronous braking between different wagons. This results in the generation of considerable in-train forces during emergency braking operations, which are sometimes imposed by the railway infrastructure due to certain running speeds being exceeded. The magnitude of in-train forces is contingent upon a number of factors, the most significant ones being the length, mass and load composition of the trainset, in addition to the specific braking imposed. The application of excessive compressive in-train forces has the potential to cause the wagon to derail, particularly if the wagon is lightweight and traversing a small radius curve. Similarly, excessive tensile in-train forces applied to the screw couplers can cause them to fail, typically through fatigue, resulting in train disruption and necessitating the recovery of both portions of the trainset. The objective of this study is to perform a preliminary analysis of the UIC (International Union of Railways) unified screw couplers fatigue phenomenon, employing load spectra computed by the UIC 1.4.6 software TrainDy. A possible future development is developing a maintenance model functional to predict the extent of damage in freight wagon screw couplers during their service life. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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8 pages, 405 KiB  
Proceeding Paper
Rapid Assessment of the Fatigue Limit Using an Iterative Algorithm Applied to Intrinsic Dissipation
by Luca Santoro, Raffaella Sesana and Francesca Maria Curà
Eng. Proc. 2025, 85(1), 47; https://doi.org/10.3390/engproc2025085047 - 26 Mar 2025
Viewed by 124
Abstract
The aim of this paper is to introduce and validate an iterative algorithm for the rapid assessment of the fatigue limit. The algorithm is based on the analysis of intrinsic dissipation and offers a more efficient alternative to traditional fatigue testing methods. An [...] Read more.
The aim of this paper is to introduce and validate an iterative algorithm for the rapid assessment of the fatigue limit. The algorithm is based on the analysis of intrinsic dissipation and offers a more efficient alternative to traditional fatigue testing methods. An iterative method is applied to thermal data and dissipative data collected during cyclic loading tests. Passive thermography is used to monitor surface temperature increments, which are indicative of microstructural damage. The dataset is iteratively divided into regions above and below a hypothesized fatigue limit, and curve fitting is performed on each subset. The algorithm seeks to minimize the error between experimental data and the fitted curves, ensuring continuity at the estimated fatigue limit. The proposed iterative method provides a reliable and rapid estimate of the fatigue limit, significantly reducing the number of tests needed compared to conventional methods. The results demonstrate good agreement between predicted and experimental fatigue limits, particularly in additively manufactured materials with complex microstructures. This method offers a cost-effective and time-efficient solution for evaluating the fatigue performance of materials produced via additive manufacturing. It is especially useful in applications where rapid material characterization is required. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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14 pages, 4724 KiB  
Proceeding Paper
Mechanical Multiscale Lithium-Ion Battery Modeling for Optimized Battery Pack Design
by Davide Clerici, Francesca Pistorio, Salvatore Scalzo, Salvatore Martelli, Francesco Mocera and Aurelio Somà
Eng. Proc. 2025, 85(1), 48; https://doi.org/10.3390/engproc2025085048 - 27 Mar 2025
Viewed by 154
Abstract
In the automotive and working vehicle industry, lithium-ion batteries are a strategic component affecting the design, cost, and performance of vehicles. The electrochemical processes which allow the battery to deliver or store electrical energy involve the interaction of lithium ions with the electrode [...] Read more.
In the automotive and working vehicle industry, lithium-ion batteries are a strategic component affecting the design, cost, and performance of vehicles. The electrochemical processes which allow the battery to deliver or store electrical energy involve the interaction of lithium ions with the electrode microstructure, causing the mechanical deformation of the electrode. The deformation of the electrode microstructure has two effects: mechanical degradation and the resulting overall performance decay of the battery, and macroscopic battery deformation. In this work, macroscopic battery deformation originating at the atomic scale is investigated with a multi-physics homogenized model in two steps: first, the composite electrode is modeled with a representative volume element; secondly, the battery is modeled by homogenizing the contribution of the hundreds of composite electrode layers. Then, the impact of the deformation of the single battery on the whole battery module is numerically investigated. The deformation of the single battery computed with the model is validated with experimental measurements quantifying the macroscopic battery deformation during operation. Then, different design solutions for the battery module are investigated to optimize its energetic and volumetric efficiency while maintaining safe levels of battery module deformation. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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8 pages, 1852 KiB  
Proceeding Paper
Mechanical Characterization of Metal–Polymer Joints Fabricated via Thermal Direct Bonding Technique
by Chiara Morano, Andrea Morabito, Luigi Bruno, Marco Alfano and Leonardo Pagnotta
Eng. Proc. 2025, 85(1), 49; https://doi.org/10.3390/engproc2025085049 - 16 Apr 2025
Viewed by 152
Abstract
In recent years, thermoplastic polymers and composites have seen increasing application across various industrial sectors to develop lightweight structures. These materials have gained popularity in the market due to advancements in additive manufacturing. Thermal direct joining serves as an effective solution for integrating [...] Read more.
In recent years, thermoplastic polymers and composites have seen increasing application across various industrial sectors to develop lightweight structures. These materials have gained popularity in the market due to advancements in additive manufacturing. Thermal direct joining serves as an effective solution for integrating such thermoplastic materials into existing or de-novo metal structures. This method enables the creation of lightweight and virtually reversible joints, which foster end-of-life recyclability, thus aligning with the principles of a circular economy. However, these joints are still affected by a low strength, which is mostly related to the poor polymer–metal interaction. The use of surface treatments that promote mechanical interlocking of the polymer within surface asperities in the mating metallic adherend can be an effective strategy to enhance the strength, as well as to improve the toughness and damage tolerance of the joints. In this work, a laser treatment was used to modify the surface texture of an aluminum sheet prior to thermal bonding with 3D-printed polylactic acid (PLA). Different surface textures were analyzed by modifying the main process parameters. Roughness and wettability measurements were performed to identify the most effective processing condition. Finally, mechanical tests were performed to verify the improvement in joint resistance obtained by interface modification. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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25 pages, 12702 KiB  
Proceeding Paper
Nonlinear Elastoplastic Response and Damage Modeling in Power Electronics Packages Under Thermal Cycling
by Giuseppe Mirone, Raffaele Barbagallo, Luca Corallo, Giuseppe Bua, Guido La Rosa, Giovanna Fargione and Fabio Giudice
Eng. Proc. 2025, 85(1), 50; https://doi.org/10.3390/engproc2025085050 - 16 Apr 2025
Viewed by 95
Abstract
One of the common reliability tests performed on power modules for automotive applications is passive thermal cycling, which is conventionally representative of the highly demanding thermomechanical loads typical of steady-state operating conditions. The mechanical response of the electronics devices subjected to such testing [...] Read more.
One of the common reliability tests performed on power modules for automotive applications is passive thermal cycling, which is conventionally representative of the highly demanding thermomechanical loads typical of steady-state operating conditions. The mechanical response of the electronics devices subjected to such testing procedures, in terms of stress-strain response and of damage, is usually predicted by finite elements analyses where the remarkable nonlinearities intrinsic in the phenomena need to be properly addressed. This work regards the FEM modeling of the thermomechanical behavior of a power electronics package subjected to thermal cycles, focusing on the critical importance of modeling the complete elastoplastic behavior of materials, in contrast to the conventional elastic approach. By incorporating the full elastoplastic properties, the study aims to accurately evaluate the actual irreversible deformations and resulting stresses that develop within the package subjected to a representative passive thermal cycle and to compare the outcomes to those from purely elastic simulations. Additionally, damage models are compared for predicting the local detachment of the encapsulating resin from other layers. The predictions of the cohesive zone model (CZM) applied to a conventional interface layer are compared to those of a modified Tresca (MT) stress-dependent damage model applied to the resin bulk material. In addition, the estimate of linear-nonlinear evolutions of plastic strain and of damage at increasing numbers of cycles is investigated in the attempt to identify procedures for guessing the long-term mechanical response from short-term simulations. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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13 pages, 8489 KiB  
Proceeding Paper
Development of a Post-Processing Procedure to Characterize Damage in Hybrid Natural Woven Composites Subjected to Low-Velocity Impact by Means of Thermography Techniques
by Tiziana Matarrese, Claudia Sergi, Davide Palumbo, Fabrizio Sarasini and Umberto Galietti
Eng. Proc. 2025, 85(1), 51; https://doi.org/10.3390/engproc2025085051 - 16 Apr 2025
Viewed by 148
Abstract
The active thermographic techniques are well-established for controlling composite components subjected to low-velocity impact damage. However, in recent years, the main works on thermographic techniques have focused on processing the raw data with the aim of increasing the signal-to-noise ratio and the probability [...] Read more.
The active thermographic techniques are well-established for controlling composite components subjected to low-velocity impact damage. However, in recent years, the main works on thermographic techniques have focused on processing the raw data with the aim of increasing the signal-to-noise ratio and the probability of damage detection. It is well-known that assessing the residual strength of the material is crucial for quantifying the damage extension. In this regard, the aim of this work is to quantify the damage produced by impacted tests on hybrid woven composites by means of thermographic techniques. In particular, a novel procedure based on applying two filters frame by frame on the thermographic data obtained after applying the pulse thermographic technique was proposed, and information about the damage extension was provided. The results showed the possibility of quantitively estimating the damage and the effect of momentum in hybrid natural fiber composites. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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21 pages, 12749 KiB  
Proceeding Paper
Investigating the Friction Coefficient of Titanium Bolts with Vegetable Oils as Lubricants
by Dario Croccolo, Massimiliano De Agostinis, Stefano Fini, Muhammad Yasir Khan, Mattia Mele, Giorgio Olmi, Chiara Scapecchi and Muhammad Hassaan Bin Tariq
Eng. Proc. 2025, 85(1), 52; https://doi.org/10.3390/engproc2025085052 - 18 Apr 2025
Viewed by 160
Abstract
Threaded fasteners are one of the most important joining techniques, especially due to their ease of mounting and dismounting. These are essentially friction joints; therefore, friction coefficients between the surfaces play a critical role in the correct mounting of the threaded fasteners. Materials [...] Read more.
Threaded fasteners are one of the most important joining techniques, especially due to their ease of mounting and dismounting. These are essentially friction joints; therefore, friction coefficients between the surfaces play a critical role in the correct mounting of the threaded fasteners. Materials and lubrication conditions are the major factors that can affect the correct preload of the threaded fasteners. Particularly, when shifting from steel to titanium fasteners to achieve a high strength-to-weight ratio, the friction shift is very significant. Researchers have studied varying levels of lubrication to achieve optimum friction conditions. VG46 has been used most in the literature; however, its non-renewable nature necessitates the use of another alternative that is good for the environment and can cause a reduction in pollution in the environment. For this reason, in the present study, castor oil and fractionated coconut oil have been used for Ti bolts to achieve low friction coefficients. Torque tension tests have been performed on the Ti bolts using the different lubricants mentioned above and friction coefficients at the underhead and the threaded portions are compared with the commercial VG46 lubricant. Castor oil shows good performance compared to the other lubricants tested in terms of underhead friction coefficients, whereas the thread friction coefficients remain almost the same in all the lubrication conditions. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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11 pages, 5675 KiB  
Proceeding Paper
Integrated Framework for Manufacturing, Design, and Monitoring of Composite-Bonded Joints: An Overview of the Results of the IDEA Project (MOST)
by Marino Quaresimin, Paolo Andrea Carraro, Federico Lamon, Silvia Giovanna Avataneo, Matteo Basso, Andrea Merulla, Umberto Galietti, Ester D’Accardi, Davide Palumbo, Massimiliano De Agostinis, Mattia Mele, Monica Ferraris, Alessandro Benelli and Koshika Pandey
Eng. Proc. 2025, 85(1), 53; https://doi.org/10.3390/engproc2025085053 - 22 Apr 2025
Viewed by 88
Abstract
The IDEA project, developed in the frame of MOST—National Centre for Sustainable Mobility—addressed the growing need for reliable bonded joints in fibre-reinforced polymer composite structures used in transportation. Purely bonded joints are preferred for their lightweight and cost-efficient properties, but contamination and defect [...] Read more.
The IDEA project, developed in the frame of MOST—National Centre for Sustainable Mobility—addressed the growing need for reliable bonded joints in fibre-reinforced polymer composite structures used in transportation. Purely bonded joints are preferred for their lightweight and cost-efficient properties, but contamination and defect detection issues often make them unreliable. To solve this, the project developed innovative surface treatments, a methodology for the safe, optimized design of bonded joints, and structural health monitoring solutions, viable for real-time assessment. These advancements aim to increase the reliability and safety of bonded connections, helping industries adopt lighter, purely bonded joints over heavier, hybrid bonded/bolted options. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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20 pages, 10024 KiB  
Proceeding Paper
Evaluation of Seismic Effects on Atmospheric Pressure Liquid Storage Tanks
by Luca Chiappelloni, Francesco Serraino, Valerio Belardi, Simone Trupiano, Luca Gaetani and Francesco Vivio
Eng. Proc. 2025, 85(1), 54; https://doi.org/10.3390/engproc2025085054 - 27 Apr 2025
Viewed by 100
Abstract
As part of the seismic capacity assessment of thin-walled tanks containing liquid fuels, the appropriate modeling of hydrodynamic loads is required. The theory adopted in existing work requires the modeling of the hydrodynamic pressure contribution due to tank deformability, which, however, cannot be [...] Read more.
As part of the seismic capacity assessment of thin-walled tanks containing liquid fuels, the appropriate modeling of hydrodynamic loads is required. The theory adopted in existing work requires the modeling of the hydrodynamic pressure contribution due to tank deformability, which, however, cannot be calculated in closed form. The approach adopted in this work uses acoustic–structural modal analysis to obtain the deformation and response period required to calculate this contribution. The use of the proposed method, on a finite element model, allows the implementation of thickness variability and more geometric detail in the modal analysis. On the other hand, using the obtained load distributions, in non-linear static analyses, reduces the computational time compared to dynamic simulations. In addition, analyses can be performed by importing a pre-deformed surface derived from a three-dimensional scan of the real tank into the final model, thus including the effect of geometric imperfections. As a case study, an existing tank model was produced and analyzed, and the same damage patterns documented in real cases following seismic events were obtained. Therefore, due to the low computational cost, this method is appropriate to be reproduced for a statistically significant number of load cases. Full article
(This article belongs to the Proceedings of The 53rd Conference of the Italian Scientific Society of Mechanical Engineering Design)
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