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Applied Sciences
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Mechanical Structures: Fatigue Behavior, FEM Modeling and Design Best Practices
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Mechanical Structures: Fatigue Behavior, FEM Modeling and Design Best Practices

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Mechanical Engineering".

Deadline for manuscript submissions: 30 June 2025 | Viewed by 3385

Special Issue Editors

Dr. Valerio Mangeruga

E-Mail Website
Guest Editor
Engineering Department “Enzo Ferrari”, University of Modena and Reggio Emilia, 41125 Modena, Italy
Interests: FEM modeling; mechanical design; powertrain design; hybrid power unit; ICE and electric motor structural analysis; fatigue analysis; experimental tests
Prof. Dr. Matteo Giacopini

E-Mail Website
Guest Editor
Engineering Department “Enzo Ferrari”, University of Modena and Reggio Emilia, 41125 Modena, Italy
Interests: FEM structural analysis; FEM thermostructural analysis; fatigue; low-cycle thermal fatigue; engine components; EHD lubrication
Dr. Saverio Giulio Barbieri

E-Mail Website
Guest Editor
Engineering Department “Enzo Ferrari”, University of Modena and Reggio Emilia, 41125 Modena, Italy
Interests: structural analysis; analytical calculations and FE simulations; thermo-structural analyses of engine components and electric motor components

Special Issue Information

Dear Colleagues,

The study of mechanical structures plays a crucial role in advancing engineering solutions across industries. As materials and structures are increasingly subjected to complex loading conditions, understanding their fatigue behavior and strain-rate properties is essential for ensuring long-term reliability and safety. Innovations in design practices and computational modeling, such as finite element modeling (FEM), have further highlighted the need for interdisciplinary research in this field. By integrating experimental data with advanced simulation techniques, engineers can optimize structural designs and develop innovative materials and production technologies for a wide range of applications.

In this context, we are pleased to announce a Special Issue on Mechanical Structures: Fatigue Behavior, FEM Modeling and Design Best Practices. This Special Issue will explore the latest advancements in research on innovative materials (such as functionally graded materials and metamaterials), design procedures, and numerical and analytical methodologies.

In this Special Issue, original research articles and reviews are welcome. Research areas may include (but are not limited to) the following:

  • Fatigue behavior.
  • Thermal fatigue behavior.
  • Strain-rate-dependent properties of engineering materials.
  • Best practices in mechanical design.
  • FEM modeling techniques.
  • Experimental studies of materials.

This Special Issue provides a platform for pioneering research that merges theoretical, experimental, and computational approaches, contributing to the development of more reliable and efficient mechanical systems.

We look forward to your valuable contributions.

Dr. Valerio Mangeruga
Prof. Dr. Matteo Giacopini
Dr. Saverio Giulio Barbieri
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • fatigue behavior
  • strain-rate properties
  • finite element modeling (FEM)
  • multi-axial loading
  • functionally graded materials
  • metamaterials
  • smart materials
  • additive manufacturing design

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (4 papers)

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Research

24 pages, 10207 KiB  
Article
Integrating Stamping-Induced Material Property Variations into FEM Models for Structural Performance Simulation of Sheet-Metal Components
by Burello Elia, Hamed Rezvanpour, Dario Cimolino, Francesco Capaccioli and Alberto Vergnano
Appl. Sci. 2025, 15(5), 2480; https://doi.org/10.3390/app15052480 - 25 Feb 2025
Viewed by 518
Abstract
The accurate prediction of structural performance in sheet-metal components is critical for optimizing design and ensuring reliability in engineering applications. This study emphasizes the necessity of incorporating non-uniformities induced by stamping processes, such as thickness variation and work-hardening effects, into Finite Element Method [...] Read more.
The accurate prediction of structural performance in sheet-metal components is critical for optimizing design and ensuring reliability in engineering applications. This study emphasizes the necessity of incorporating non-uniformities induced by stamping processes, such as thickness variation and work-hardening effects, into Finite Element Method (FEM) simulations. Experimental and computational analyses reveal that neglecting these variations results in significant discrepancies, particularly in displacement predictions, where deviations exceeding 50% were observed at specific points. While elastic behavior showed reasonable agreement with experimental results, plastic deformation predictions were notably less accurate due to the inherent inhomogeneities of the real work-hardening model compared to the uniform assumptions in standard FEM models. These findings underscore the need for improved methodologies in mapping stamping-induced material properties and validating simulation results. Further refinement of mapping accuracy and validation techniques is essential for enhancing the predictive capabilities of FEM simulations for complex sheet-metal components. Full article
(This article belongs to the Special Issue Mechanical Structures: Fatigue Behavior, FEM Modeling and Design Best Practices)
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18 pages, 3401 KiB  
Article
Numerical Analysis of Fatigue Life of Wind Turbine Blades Reinforced with Graphene Platelets
by Hyeong Jin Kim and Jin-Rae Cho
Appl. Sci. 2025, 15(4), 1866; https://doi.org/10.3390/app15041866 - 11 Feb 2025
Viewed by 981
Abstract
The rapid growth of wind energy has necessitated the development of advanced materials to address the increasing structural demands of wind turbine blades. Graphene platelets (GPLs) have garnered attention as a promising reinforcement material due to their outstanding mechanical properties, such as high [...] Read more.
The rapid growth of wind energy has necessitated the development of advanced materials to address the increasing structural demands of wind turbine blades. Graphene platelets (GPLs) have garnered attention as a promising reinforcement material due to their outstanding mechanical properties, such as high strength and low density. This study investigates the fatigue life of wind turbine blades reinforced with GPLs, benchmarking their performance against conventional fiberglass blades. A finite element model of a 5 MW wind turbine blade was developed to evaluate stresses within the blade structure. The traditional fiberglass blade was modeled based on the SNL 61.5 m design by Sandia National Laboratories, while the GPL-reinforced composite (GPLRC) blade was designed by substituting fiberglass with GPLRCs. Material properties of the GPLRCs were determined using the rule of mixtures and the Halpin–Tsai micromechanics model. Wind speed data were randomly sampled following the probability distribution observed at European wind farms, and corresponding aerodynamic loads were computed using blade element momentum theory. Finite element analyses were performed to derive stress time histories, and fatigue life was predicted using the S-N curve approach, incorporating the Goodman diagram and the Palmgren–Miner rule. The results reveal that while GPLRC-reinforced blades exhibit some limitations in fatigue performance compared to traditional fiberglass blades, potential solutions for improving their durability are proposed, highlighting avenues for further research and optimization in the application of GPLRCs to wind turbine blades. Full article
(This article belongs to the Special Issue Mechanical Structures: Fatigue Behavior, FEM Modeling and Design Best Practices)
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18 pages, 10071 KiB  
Article
Crack Propagation in Axial-Flow Fan Blades Under Complex Loading Conditions: A FRANC3D and ABAQUS Co-Simulation Approach
by Mariem Ben Hassen, Slim Ben-Elechi and Hatem Mrad
Appl. Sci. 2025, 15(3), 1597; https://doi.org/10.3390/app15031597 - 5 Feb 2025
Viewed by 699
Abstract
Since fan blades are exposed to fatigue, and in some cases harsh loading conditions, they may exhibit fracture failures due to crack propagation, resulting in significant losses. Previous studies of crack propagation in blades are mainly confined to either simplified blade geometry or [...] Read more.
Since fan blades are exposed to fatigue, and in some cases harsh loading conditions, they may exhibit fracture failures due to crack propagation, resulting in significant losses. Previous studies of crack propagation in blades are mainly confined to either simplified blade geometry or loads, resulting in a significant discrepancy between the simulated crack propagation and the real blade propagation behavior, while it is lacking for challenging shapes and loads. A co-simulation approach of FRANC3D and ABAQUS was developed to study the crack propagation of an axial-flow fan blade subjected to centrifugal, aerodynamic, and combined loads. The projected approach is validated with results obtained from analytical calculations and experiments. Meanwhile, making use of benchmarks, the Stress Intensity Factor (SIF) and the prediction of mixed-mode crack growth path are validated. Considering various loads, the crack propagation path response for the fan blade is computed for different growth steps. The results pinpoint that the crack propagation length of the crack tip center is maximum under centrifugal loading. However, the aerodynamic load led to a maximum propagation length of the crack tip endpoints. In addition, the combined force of centrifugal and aerodynamic loads limits the crack from growing. Full article
(This article belongs to the Special Issue Mechanical Structures: Fatigue Behavior, FEM Modeling and Design Best Practices)
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33 pages, 13471 KiB  
Article
Challenges and Constraints in the Application of Rule-Based Hull Girder Load Adjustments: Insights with Future Directions
by Chang Hwan Jang and Do Kyun Kim
Appl. Sci. 2025, 15(3), 1480; https://doi.org/10.3390/app15031480 - 31 Jan 2025
Cited by 3 | Viewed by 790
Abstract
The International Association of Classification Societies (IACS) has introduced the concept of the Equivalent Design Wave (EDW) for the calculation of dynamic loads for structural analysis in the Common Structural Rule (CSR) for the design of bulk carriers and oil tankers. An EDW [...] Read more.
The International Association of Classification Societies (IACS) has introduced the concept of the Equivalent Design Wave (EDW) for the calculation of dynamic loads for structural analysis in the Common Structural Rule (CSR) for the design of bulk carriers and oil tankers. An EDW is a set of loads representing a design wave whose response is equivalent to the required design value at a given probability level. Classification societies are applying the EDW concept by implementing design loading equations for LNG carriers, bulk carriers, and oil tankers. According to the EDW loads, dozens of load cases are generated using the design load formula, and the hull girder loads calculated from them are adjusted to the target values. In this short communication, the hull girder load is adjusted according to the method described in the DNV rule for a cargo hold model of an LNG carrier. The adjusted load is distributed as a nodal force by shear flow and simple beam theory. An alternative method is introduced by comparing existing methods with regard to adjustment methods and load distribution. After discussing existing methods, a method for adjusting all hull girder load components in three steps and a load distribution method using the stress field were derived. The limitation of the current technique and insights summarised in this short communication may support readers in understanding the rule-based hull girder load adjustment technique. In addition, this limitation may clearly motivate the demand for alternative technology development for hull girder load adjustment. Full article
(This article belongs to the Special Issue Mechanical Structures: Fatigue Behavior, FEM Modeling and Design Best Practices)
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