Journal of Experimental and Theoretical Analyses — Advanced Methods for Science, Engineering, and Technology

In this work, the sintering behavior of tapes prepared via tape casting from stainless-steel and zirconia powders is investigated by optical—as well as push-rod—dilatometry. Both methods are compared in terms of sample preparation, measurement conditions, and advantages and disadvantages. The experimental work shows the advantages of optical dilatometry in the characterization of the sintering behavior of load-free sintering tapes and the possibility of simultaneously observing sample warpage and deformation. Push-rod dilatometry requires a constant load on the sample, which influences measurement in the case of tapes with lower mechanical stability due to their sensitivity to deformation, but it has advantages because of its higher accuracy in measuring dimensional changes. In the case of warpage, shrinkage due to the sintering of the sample is superimposed by an irregular deformation process that can be separated by analytical methods. No in-plane shrinkage anisotropy of the tapes is observed for either type of tape. In the case of the push-rod dilatometer, an additional peak in the shrinkage rate is observed in the early stage of compaction, along with a slight shift and an increased maximum in the compaction rate. This is most likely due to the effects of the contact pressure of the push-rod. Full article

Tangential turning produces an asymmetric cutting-force system that may cause tool and workpiece deflection, leading to cylindricity, coaxiality, and roundness deviations in practice. This study investigates the relationships between three cutting force components and form errors during tangential turning of 42CrMo4 steel. Tangential, axial, and radial forces were measured under systematically varied cutting speed, feed, and depth of cut, and the resulting cylindricity, coaxiality, and roundness parameters were obtained through precision form measurements. The depth of cut showed the strongest influence on cutting forces, with high correlations to all components (r = 0.709–0.870). Feed was most closely associated with coaxiality error (r = 0.730), while cutting speed was primarily related to cylindricity deviation (r = 0.766). The novelty of this work lies in the combined and quantitative analysis of full cutting-force components and multiple form–accuracy descriptors within a single experimental framework for tangential turning. The results directly link process load to geometric accuracy and provide guidance for selecting cutting parameters to improve dimensional precision in tangential turning of alloy steels. Full article

A vibration energy harvester (VEH) based on the principle of variable magnetic reluctance has been developed to enable wireless and maintenance-free power supply for condition monitoring sensors in vibrating machinery. Conventional battery or wired solutions are often impractical due to limited lifetime and high installation costs, motivating the use of vibration-based energy harvesting. The proposed VEH converts mechanical vibrations into electrical energy through the relative motion of a movable ferromagnetic core within a magnetic circuit. Unlike conventional VEH designs, where the magnet is the moving element, this concept utilizes a movable ferromagnetic core in combination with a stationary pole piece for voltage induction. This configuration enables a compact and easily adjustable proof mass, as neither the coil nor the magnet needs to be moved. The VEH is designed to operate effectively under excitation frequencies between $16 \mathrm{H}\mathrm{z}$ and $50 \mathrm{H}\mathrm{z}$ and acceleration levels from $9.81 {\displaystyle \frac{\mathrm{m}}{{\mathrm{s}}^2}}$ (equivalent to $1 \mathrm{g}$) up to $98.1 {\displaystyle \frac{\mathrm{m}}{{\mathrm{s}}^2}}$ (equivalent to $10 \mathrm{g}$). To ensure a reliable power supply, the VEH must deliver a minimum electrical output of $0.1 \mathrm{m}\mathrm{W}$ at the lowest excitation ($1 \mathrm{g}$) while maintaining structural integrity. Additionally, the maximum permissible displacement amplitude of the movable core is limited to $1.15 \mathrm{m}\mathrm{m}$ to avoid mechanical damage and ensure durability over long-term operation. Coupled magnetic-transient and mechanical finite element method (FEM) simulations were conducted to analyze the system’s dynamic behavior and electrical power output across varying excitation frequencies and accelerations. A laboratory prototype was developed and tested under controlled vibration conditions to validate the simulation results. The experimental measurements confirm that the VEH achieves an electrical output of $0.166 \mathrm{m}\mathrm{W}$ at $9.81 {\displaystyle \frac{\mathrm{m}}{{\mathrm{s}}^2}}$ and $16 \mathrm{H}\mathrm{z}$, while maintaining the maximum allowable displacement amplitude of $1.15 \mathrm{m}\mathrm{m}$, even at $98.1 {\displaystyle \frac{\mathrm{m}}{{\mathrm{s}}^2}}$ ($10 \mathrm{g}$) and $50 \mathrm{H}\mathrm{z}$. The strong agreement between simulation and experimental data demonstrates the reliability of the coupled FEM approach. Overall, the proposed VEH design meets the defined performance targets and provides a robust solution for powering wireless sensor systems under a wide range of vibration conditions. Full article

Multi-laser powder bed fusion is an emerging additive manufacturing technology that enables the production of high-performance components with intricate geometries and large aspect ratios. These tall, slender structures are highly susceptible to steep thermal gradients and residual stress, leading to deformation that compromises dimensional accuracy and structural integrity. This study investigates how geometric compensation, support structure design, and part scaling influence thermal deformation in Inconel 718 components fabricated via multi-laser powder bed fusion. Using pre-compensation, iterative support refinements, and scaled experimental builds, the deformation response across multiple geometries and print strategies is evaluated. Both compensated and original designs are printed on a commercial system equipped with three simultaneously operating lasers. Results show that printing high-angle surfaces without support structures is infeasible, as thermally induced warping and delamination lead to catastrophic failures. Conical support structures spanning critical regions reduce deformation by more than 50% compared to unsupported builds. Reduced-scale parts, however, do not reliably replicate full-scale deformation behavior due to altered boundary conditions and thermal pathways. These findings highlight the need for integrated design-for-AM workflows where compensation, support design, and scale effects are addressed jointly. The study demonstrates that deformation mechanisms do not scale linearly, emphasizing the limitations of small-scale proxies and the necessity of full-scale validation when developing reliable, deformation-aware design strategies for multi-laser powder bed fusion. Full article

This study explores the viability of ultra-high-performance concrete (UHPC) as a structural material for compressed air storage (CAES) systems, combining comprehensive experimental testing and numerical simulations. Scaled (1:20) CAES tanks were designed and tested experimentally under controlled pressure conditions up to 4 MPa (580 psi), employing strain gauges to measure strains in steel cylinders both with and without UHPC confinement. Finite element models (FEMs) developed using ANSYS Workbench 2024 simulated experimental conditions, enabling detailed analysis of strain distribution and structural behavior. Experimental and numerical results agreed closely, with hoop strain relative errors between 0.9% (UHPC-confined) and 1.9% (unconfined), confirming the numerical model’s accuracy. Additionally, the study investigated the role of a rubber interface layer integrated between the steel and UHPC, revealing its effectiveness in mitigating localized stress concentrations and enhancing strain distribution. Failure analyses conducted using the von Mises criterion for steel and the Drucker–Prager criterion for UHPC confirmed adequate safety factors, validating the structural integrity under anticipated operational pressures. Principal stresses from numerical analyses were scaled to real-world operational pressures. These thorough results highlight that incorporating rubber enhances the system’s structural performance. Full article

This paper presents a practical and cost-effective method for in-motion estimation of a vehicle’s CoG position in all three directions by measuring accelerations during two types of maneuvers: braking (longitudinal and vertical CoG estimation) and cornering (lateral and vertical CoG estimation). The proposed method’s main advantage is that it does not require knowledge of vehicle characteristics, such as mass distribution, suspension geometry, or inertia parameters. It relies solely on the known distances between the sensors and their positions relative to a defined reference point on the vehicle. To validate the developed method, experimental tests were conducted on a prototype vehicle, varying the load conditions for the proposed driving scenarios. The CoG position obtained from dynamic maneuvers was compared with reference values derived from static measurements. The results showed that the proposed method could estimate the CoG position with an average error of 3% in the longitudinal direction, a maximum error of 12% in the lateral direction, and a maximum error of 14% in the vertical direction. Full article

Simplified and scalable models of physical systems are extremely valuable in a variety of different engineering fields to test and diagnose particular modes of failure and optimize build conditions. In this work, we develop a practical method to prepare and analyze giant unilamellar vesicles (GUVs) for detailed biophysical interrogations. The method is rapid, scalable, and versatile, where characterization of lipid membrane conformational changes can be performed on multiplexed samples using tissue culture plates and a convenient, high-throughput fluorescence microscopy setup. The simplicity of the setup is enabled by an AI image recognition model that, when trained on the appearance of GUVs in the images, outperforms other image segmentation methods such as the watershed algorithm or the Hough transform. The method allows for the rapid quantification of entire 96-well plates containing in total O (1,000,000) GUVs and provides a potential testbed for the development of drugs. We highlight the power of our system by including large-scale data on the screening of lipophilic analogs of the small molecule antimetabolite carmofur. Full article

This study investigates the fatigue strength of a motor hanger used in high-speed electric multiple units (EMUs). Finite element analysis and field measurements revealed that reduced weld penetration significantly increases stresses in welded regions. Line tests demonstrated that a 100 Hz torque ripple induces elastic vibration of the hanger, serving as the primary driver of stress propagation, with stress and acceleration levels increasing proportionally with the torque ripple amplitude. This 100 Hz excitation lies close to the hanger’s constrained modal frequency of about 109 Hz, creating a near-resonance condition that amplifies dynamic deformation at the welded joints and accelerates fatigue crack initiation. Hangers with lower in situ modal frequencies exhibited higher equivalent stresses. Joint dynamic simulation further showed that increasing motor mass reduces the longitudinal acceleration of the hanger, while enhancing the radial stiffness of rubber nodes markedly decreases both longitudinal and vertical vibration accelerations as well as stress responses. Based on these insights, a structural improvement scheme was developed. Strength analysis and on-track tests confirmed substantial reductions in overall and weld stresses after modification. Fatigue bench tests indicated that the critical welds of the improved hanger achieved a service life of 15 million km, more than twice that of the original structure (7.08 million km), thereby satisfying operational safety requirements. Full article

Optimising the learning rate is essential for efficient neural network training, but static methods can cause overshooting or undershooting, while adaptive techniques like ADAM often struggle to balance exploration and exploitation. We introduce the Polling Method, an ensemble-based optimisation approach that dynamically selects the most effective learning rate at each step, improving convergence and mitigating issues inherent in traditional optimisation strategies. By evaluating base models with varying learning rates at each epoch, the method adaptively balances exploration and exploitation without being constrained by predefined functions or gradient noise. This study details the theoretical foundation, implementation, and integration of the Polling Method with the ADAM optimiser, demonstrating its effectiveness in Artificial Neural Networks and Bayesian variational inference. The results demonstrate that Polling Method-ADAM reduces absolute error by 50% compared to ADAM alone, while also accelerating convergence. In Bayesian optimisation, it reduces the mean gradient shift from 0.85 to 0.7835 over 500 iterations, indicating improved stability in high-dimensional problems. By introducing adaptive learning rate selection within training, the Polling Method enhances optimisation efficiency while mitigating noise accumulation. This framework provides a computationally efficient, flexible alternative for deep learning applications, offering significant improvements over traditional optimisers and a potential breakthrough in neural network training strategies. Full article

Ionic propulsion, where charged particles, ions, are produced between electrodes and accelerate towards the negative electrode, has practical applications as a propulsion system in the space industry; however, its adoption to in-atmosphere ionic propulsion is relatively new and faces different challenges. A high potential difference is required to achieve a corona discharge between a positive and negative electrode. In this work, we will explore the feasibility of ionic propulsion using CFD modelling to replicate the effect of the ions, with a future aim of improving efficiency. The ionization region is modelled for a 15 kV potential difference, which is replicated with a velocity inlet, based on experimental data. The output velocity from the numerical simulation shows the same trend as theoretical predictions but significantly underestimates the magnitude of the ionic wind when compared with theoretical estimates. Further modelling is highlighted to improve predictions and assess if the theoretical model overestimates the ionic wind. Full article

This paper presents three different approaches for generating points along the interaction diagram corresponding to design load effects—shear, bending moment, and axial force—to achieve optimal shear strength adequacy with the Australian bridge design standard AS 5100.5. The methodology targets the optimal shear condition by matching the design shear $V^{*}$ with the capacity $\varphi V_u$, which represents achieving a load rating factor of unity within the specified tolerance limits. The first typical approach for generating points for two load effects is by increasing the moment–shear ratio ${\eta }_m$ in small increments from zero to a large value (theoretically infinity), and for each increment, to goal-seek the condition. The other approaches investigated are the use of increasing factored moment $M^{*}$ and the use of Monte Carlo simulation. A pretensioned bridge I-girder section reported in the literature was used in the study. The Monte Carlo simulation method was found to be the simplest to program. It allows an interaction surface for the influence of three load effects for optimal shear adequacy to be obtained with minimal program coding and outperforms the goal–seeking approaches for multi-variable interactions. It can create 2-D interaction lines for various levels of shear adequacy for the interaction of $M^{*}$ and $V^{*}$, and 3-D interaction surfaces for $M^{*}$, $V^{*}$, and $N^{*}$. The potential use of interaction diagrams was explored, and the advantages and limitations of using each method are presented. The interaction curves of two typical pretensioned concrete sections of a plank girder, one next to an end support and the other close to mid-span, were created to show the distinguishing features resulting from their reinforcement. Full article

Aluminum light poles are essential components of modern infrastructure, providing illumination for highways, urban areas, and pedestrian pathways. Despite their importance, structural vulnerabilities in handholes—necessary for electrical access—can reduce fatigue life due to the structure’s response to wind. This study addresses a critical gap in translating laboratory-derived S–N data into field-applicable methods for assessing cumulative damage in these structures. A probabilistic cumulative damage analysis framework was developed to quantify the structural degradation of handholes due to variable wind velocities. Using a series of controlled cyclic fatigue tests and Miner’s Rule, the study establishes a methodology to convert stress ranges into equivalent wind velocities and correlate laboratory cycle counts with real-world loading conditions. The findings reveal a logarithmic progression of damage accumulation and highlight the utility of integrating standardized factors from ASCE-7 for scalable and geographically adaptable assessments. A proof-of-concept application demonstrates the model’s potential to predict failure risks during extreme wind events, such as hurricanes and tornadoes. This research provides a practical and predictive tool for engineers and contractors to evaluate the structural integrity of aluminum light poles, enabling proactive maintenance and reducing unplanned failures. Full article

This study addresses the critical challenge of variable image quality in deep learning-based automated pest identification. We propose a holistic pipeline that integrates systematic Image Quality Assessment (IQA) with tailored preprocessing to enhance the performance of a YOLOv5 object detection model. The methodology begins with a No-Reference IQA using BRISQUE, PIQE, and NIQE metrics to quantitatively diagnose image clarity, noise, and distortion. Based on this assessment, a tailored preprocessing stage employing six different filters (Wiener, Lucy–Richardson, etc.) is applied to rectify degradations. Enhanced images are then used to train a YOLOv5 model for detecting four common pest species. Experimental results demonstrate that our IQA-anchored pipeline significantly improves image quality, with average BRISQUE and PIQE scores reducing from 40.78 to 25.42 and 34.94 to 30.38, respectively. Consequently, the detection confidence for challenging pests increased, for instance, from 0.27 to 0.44 for Peach Borer after dataset enhancement. This work concludes that a methodical approach to image quality management is not an optional step but a critical prerequisite that directly dictates the performance ceiling of automated deep learning systems in agriculture, offering a reusable blueprint for robust visual recognition tasks. Full article

Roll-to-roll production of thin organic and large-area electronic (TOLAE) devices often involves a two-step process per functional layer: a continuous, un-pattered deposition of the film and subsequent structuring process, such as laser ablation. Thin-film organic devices should be protected using ultra-barrier films. To perform laser ablation of functional layers on top of such barrier films, in particular that of transparent electrodes, highly selective laser ablation is required to completely remove the layers without damaging the thin-film barrier layers underneath. When targeting highly selective laser ablation of indium tin oxide (ITO) on top of silicon nitride (SiN) barrier layers with a 1064 nm picosecond or 1030 nm femtosecond laser, we observed the emergence of visible large-scale patterns due to local variations in ablation quality. Our investigations using a very sensitive Raman spectroscopy setup show that the observed ablation variations stem from subtle differences in optical path length within the heat-stabilized plastic substrates. These variations are likely caused by minute, localized changes in the refractive index, introduced during the bi-axial stretching process used in film fabrication. Depending on the optical path length, these variations lead to either constructive or destructive interference between the incoming laser beam and the light reflected from the back surface of the substrate. By performing laser ablation under an angle such that the reflected and incoming laser beam do not spatially overlap, highly selective uniform laser ablation can be performed, even for two stacked optically transparent layers. Full article

In this paper, an integrated geometric and thermal-induced errors prediction approach for active error compensation in machine tools is proposed and evaluated. The proposed approach is based on a hybrid of physical and neural network predictive modeling to drive an adaptive position controller for real-time error compensation including geometric and thermal-induced errors. Error components are formulated as a three-dimensional error field in the time-space domain. This approach involves four key steps for its development and implementation: (i) simplified experimental procedure combining a multicomponent laser interferometer measurement system and sixteen thermal sensors for error components measurement, (ii) artificial neural network-based predictive modeling of both position-dependent and position-independent error components, (iii) tridimensional volumetric error mapping using rigid body kinematics, and finally (iv) implementation of the real-time error compensation. Assessed on a turning center, the proposed approach conducts a significant improvement of the machine accuracy. The maximum error is reduced from 30 µm to less than 3 µm under thermally varying conditions. Full article

Natural fiber-reinforced unidirectional composites are increasingly adopted in modern industries due to their superior mechanical performance and desirable properties from both material and engineering perspectives. Among various approaches, representative volume element (RVE) generation and analysis is considered one of the most suitable and convenient methods for predicting the elastic moduli of composites. The main aim of this study is to investigate and compare the elastic moduli of natural fiber–reinforced unidirectional composite RVEs using theoretical, numerical, and machine learning models. The numerical predictions in this study were generated using the ANSYS Material Designer tool (version ANSYS 19). A comparison was made between experimental results reported in the literature and different theoretical models, showing high accuracy in validating these numerical outcomes. A dataset comprising 1600 samples was generated from numerical models in combination with the well-known theory of RVE, namely rule of mixture (ROM), to train and test two machine learning algorithms: Random Forest and Linear Regression, with the goal of predicting three major elastic moduli—longitudinal Young’s modulus (E₁₁), in-plane shear modulus (G₁₂), and major Poisson’s ratio (V₁₂). To evaluate model performance, mean squared error (MSE), mean absolute error (MAE), mean absolute percentage error (MAPE), and coefficient of determination (R²) were calculated and compared against datasets with and without the theoretical values as input variables. The performance metrics revealed that with the theoretical values, both Linear Regression and Random Forest predict E₁₁, G₁₂, and V₁₂ well, with a maximum MSE of 0.033 for G₁₂ and an R² score of 0.99 for all cases, suggesting they can predict the mechanical properties with excellent accuracy. However, the Linear Regression model performs poorly when theoretical values are not included in the dataset, while Random Forest is consistent in accuracy with and without theoretical values. Full article

This research presents a detailed Life Cycle Assessment (LCA) of 26 mm Crown cork metal closures used in glass bottle packaging, with the objective of quantifying and comparing their environmental impacts across all life cycle stages. This study adheres to ISO 14040 and ISO 14044 standards and utilizes Microsoft Excel for structuring and documenting input–output data across each phase. The LCA encompasses three primary stages: raw material production (covering iron ore extraction and steel manufacturing), manufacturing processes (including metal sheet printing, forming, and packaging of closures), and the transport phase (distribution to bottling facilities). During the Life Cycle Inventory (LCI), steel production emerged as the most environmentally burdensome phase. It accounted for the highest emissions of carbon dioxide (CO₂), carbon monoxide (CO), nitrogen oxides (NO_x), and sulphur oxides (SO_x), while emissions of heavy metals and volatile organic compounds were found to be negligible. The Life Cycle Impact Assessment (LCIA) was carried out using the Eco-Indicator 99 methodology, which organizes emissions into impact categories related to human health, ecosystem quality, and resource depletion. Final weighting revealed that steel production is the dominant contributor to overall environmental impact, followed by the manufacturing stage. In contrast, transportation exhibited the lowest relative impact. The interpretation phase confirmed these findings and emphasized steel production as the critical stage for environmental optimization. This study highlights the potential for substantial environmental improvements through the adoption of low-emission steel production technologies, particularly Electric Arc Furnace (EAF) processes that incorporate high percentages of recycled steel. Implementing such technologies could reduce CO₂ emissions by up to 68%, positioning steel production as a strategic focus for sustainability initiatives within the packaging sector. Full article

We describe the problem of estimating the speaker’s head orientation from the asynchronous multi-channel waveforms observed by microphones distributed in a room. In particular, we address a novel problem of estimating head orientation from sound captured by fewer microphones than the number of distinct head orientations to be distinguished. This is because the head orientation is an important clue indicating the speaker’s intended conversational partners. Head orientation estimation technology is an essential technology within environmental intelligence technology, which uses sensors embedded in rooms to monitor and support people’s activities. We propose a head orientation estimation method that aims to achieve high angular resolution using a small number of microphones. The proposed method achieves high estimation accuracy by using the spatial radiation pattern of the sound source as clues and by integrating information from multiple frequency bands. We conducted an experiment to estimate head orientation with an angular resolution of $15\mathrm{degrees}$ under observation conditions using six microphones. Experimental results showed that higher estimation accuracy was obtained than the conventional method using distributed microphone arrays (Oriented Global Coherence Field method) and the conventional method using distributed microphones (Radiation Pattern Matching method). The proposed method utilizing multiple frequency bands achieved the best performance with a mean absolute error of $10.58\mathrm{degrees}$ in the task of classifying 24 distinct head orientations. Full article