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Computational and Experimental Modeling of Interfaces and Joints in Advanced Materials

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Materials Simulation and Design".

Deadline for manuscript submissions: 20 October 2025 | Viewed by 2071

Special Issue Editor

Dr. Rafał Grzejda

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering and Mechatronics, West Pomeranian University of Technology in Szczecin, 70-310 Szczecin, Poland
Interests: mechanics of materials; finite element method; joints in mechanical engineering; stiffness of mechanical systems; composite joints
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In addition to experimental research, mechanical engineering is now also focusing on assessing the behavior of various engineering structures using computational methods such as, but not limited to, the finite element method. This Special Issue of Materials will focus on critical findings, advances and applications of numerical and experimental methods in all mechanical engineering fields related to structural connections of advanced materials. Papers dealing with new developments in relation to theoretical, computational, experimental and modeling techniques and their applications in science and technology will be considered. Papers that cover a wide range of issues are welcome, including (but not limited to) the following topics:

  1. Finite element analysis;
  2. Computational and experimental modeling;
  3. Structural health monitoring;
  4. Interfaces and their connections;
  5. Connections in mechanical engineering;
  6. Deformation analysis;
  7. Geometric modeling.

Dr. Rafał Grzejda
Guest Editor

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. Materials 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 2600 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

  • finite element analysis
  • computational and experimental modeling
  • structural health monitoring
  • interfaces and their connections
  • connections in mechanical engineering
  • deformation analysis
  • geometric modeling

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Published Papers (5 papers)

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Research

17 pages, 2870 KiB  
Article
Influence of Magnetorheological Finishing on Surface Topography and Functional Performance of Shoulder Joint Cap Surface
by Manpreet Singh, Gagandeep Singh, Riyad Abu-Malouh, Sumika Chauhan and Govind Vashishtha
Materials 2025, 18(14), 3397; https://doi.org/10.3390/ma18143397 - 20 Jul 2025
Viewed by 191
Abstract
The surface quality of biomedical implants, such as shoulder joint caps, plays a critical role in their performance, longevity, and biocompatibility. Most biomedical shoulder joints fail to reach their optimal functionality when finished through conventional techniques like grinding and lapping due to their [...] Read more.
The surface quality of biomedical implants, such as shoulder joint caps, plays a critical role in their performance, longevity, and biocompatibility. Most biomedical shoulder joints fail to reach their optimal functionality when finished through conventional techniques like grinding and lapping due to their inability to achieve nanometer-grade smoothness, which results in greater wear and friction along with potential failure. The advanced magnetorheological finishing (MRF) approach provides enhanced surface quality through specific dimensional control material removal. This research evaluates how MRF treatment affects the surface roughness performance and microhardness properties and wear resistance behavior of cobalt–chromium alloy shoulder joint caps which have biocompatible qualities. The study implements a magnetorheological finishing system built with an electromagnetic tool to achieve the surface roughness improvements from 0.35 µm to 0.03 µm. The microhardness measurements show that MRF applications lead to a rise from HV 510 to HV 560 which boosts the wear protection of samples. After MRF finishing, the coefficient of friction demonstrates a decrease from 0.12 to 0.06 which proves improved tribological properties of these implants. The results show that MRF technology delivers superior benefits for biomedical use as it extends implant life span and decreases medical complications leading to better patient health outcomes. The purposeful evaluation of finishing techniques and their effects on implant functionality demonstrates MRF is an advanced technology for upcoming orthopedic implants while yielding high precision and enhanced durability and functional output. Full article
(This article belongs to the Special Issue Computational and Experimental Modeling of Interfaces and Joints in Advanced Materials)
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18 pages, 3602 KiB  
Article
Modeling and Analysis of Torsional Stiffness in Rehabilitation Robot Joints Using Fractal Theory
by Shuaidong Zou, Wenjie Yan, Guanghui Xie, Renqiang Yang, Huachao Xu and Fanwei Sun
Materials 2025, 18(12), 2866; https://doi.org/10.3390/ma18122866 - 17 Jun 2025
Viewed by 281
Abstract
The torsional stiffness of rehabilitation robot joints is a critical performance determinant, significantly affecting motion accuracy, stability, and user comfort. This paper introduces an innovative traction drive mechanism that transmits torque through friction forces, overcoming mechanical impact issues of traditional gear transmissions, though [...] Read more.
The torsional stiffness of rehabilitation robot joints is a critical performance determinant, significantly affecting motion accuracy, stability, and user comfort. This paper introduces an innovative traction drive mechanism that transmits torque through friction forces, overcoming mechanical impact issues of traditional gear transmissions, though accurately modeling surface roughness effects remains challenging. Based on fractal theory, this study presents a comprehensive torsional stiffness analysis for advanced traction drive joints. Surface topography is characterized using the Weierstrass–Mandelbrot function, and a contact mechanics model accounting for elastic–plastic deformation of micro-asperities is developed to derive the tangential stiffness of individual contact pairs. Static force analysis determines load distribution, and overall joint torsional stiffness is calculated through the integration of individual contact contributions. Parametric analyses reveal that contact stiffness increases with normal load, contact length, and radius, while decreasing with the tangential load and roughness parameter. Stiffness exhibits a non-monotonic relationship with fractal dimension, reaching a maximum at intermediate values. Overall system stiffness demonstrates similar parameter dependencies, with a slight decrease under increasing output load when sufficient preload is applied. This fractal-based model enables more accurate stiffness prediction and offers valuable theoretical guidance for design optimization and performance improvement in rehabilitation robot joints. Full article
(This article belongs to the Special Issue Computational and Experimental Modeling of Interfaces and Joints in Advanced Materials)
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27 pages, 3753 KiB  
Article
A Surrogate Artificial Neural Network Model for Estimating the Fatigue Life of Steel Components Based on Finite Element Simulations
by Ela Marković, Tea Marohnić and Robert Basan
Materials 2025, 18(12), 2756; https://doi.org/10.3390/ma18122756 - 12 Jun 2025
Viewed by 434
Abstract
A surrogate artificial neural network (ANN) model trained on the data generated from a computational finite element-based (FE-based) model is developed. The developed ANN model enables the estimation of the fatigue life (number of load cycles to failure) of component-like specimens with stress [...] Read more.
A surrogate artificial neural network (ANN) model trained on the data generated from a computational finite element-based (FE-based) model is developed. The developed ANN model enables the estimation of the fatigue life (number of load cycles to failure) of component-like specimens with stress concentrators. Using the developed model, the component-specific S-N curves can be generated with an accuracy comparable to that of the computational FE-based model. The investigation covered through- and surface-hardened steel components with different numbers and types of stress concentrators. The basis for data generation is the parametrized computational FE-based model, which enables the determination of the stress–strain response and the calculation of the fatigue life of examined components under cyclic loading conditions. The computational FE-based model can be adjusted to include components with different geometries and heat treatment conditions. The computational FE-based model incorporates nonlinear material behavior to provide a more accurate representation of the component’s behavior, which results in higher computational costs. In contrast, the developed ANN model provides a quicker and more efficient way to assess the fatigue life of both through- and surface-hardened components, overcoming these limitations. Full article
(This article belongs to the Special Issue Computational and Experimental Modeling of Interfaces and Joints in Advanced Materials)
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20 pages, 3859 KiB  
Article
Symmetric and Asymmetric Semi-Metallic Gasket Cores and Their Effect on the Tightness Level of the Bolted Flange Joint
by Przemysław Jaszak and Rafał Grzejda
Materials 2025, 18(11), 2624; https://doi.org/10.3390/ma18112624 - 4 Jun 2025
Viewed by 425
Abstract
The paper presents the effect of the symmetric and asymmetric semi-metallic gasket core shape on the tightness level in bolted flange joints. Experimental tests, as well as numerical calculations based on the finite element method, revealed that the asymmetric gasket core provides a [...] Read more.
The paper presents the effect of the symmetric and asymmetric semi-metallic gasket core shape on the tightness level in bolted flange joints. Experimental tests, as well as numerical calculations based on the finite element method, revealed that the asymmetric gasket core provides a higher strain on the sealing graphite layer and leads to a more uniform distribution of strain on the particular ridges of the core. Furthermore, the leakage rate of the asymmetric gasket was reduced by approximately 60% compared to the symmetric gasket. It was also observed that the uniformity of pressure and strain distribution in a gasket with an asymmetric core occurs over about 80% of the gasket width. The leakage reduction effect in a flange joint sealed with a gasket with an asymmetric core was theoretically explained. As shown, the main leakage flows through the porous structure of the graphite layer, while the leakage path at the interface between the metal rough profile and the graphite layer is several orders of magnitude smaller. Full article
(This article belongs to the Special Issue Computational and Experimental Modeling of Interfaces and Joints in Advanced Materials)
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13 pages, 5749 KiB  
Article
Rolling Contact Fatigue Behavior of Pitch Bearing Raceway in Offshore Wind Turbines
by Haifeng He, Yiming Chen, Yang Liu, YongChao Zhu and Xin Jin
Materials 2025, 18(8), 1816; https://doi.org/10.3390/ma18081816 - 15 Apr 2025
Viewed by 438
Abstract
As critical components in offshore wind turbine (OWT) systems, pitch bearings require exceptional fatigue resistance to ensure the extended operational lifespan and structural reliability demanded by marine environments. Failure of these bearings due to rolling contact fatigue (RCF) can severely affect the economic [...] Read more.
As critical components in offshore wind turbine (OWT) systems, pitch bearings require exceptional fatigue resistance to ensure the extended operational lifespan and structural reliability demanded by marine environments. Failure of these bearings due to rolling contact fatigue (RCF) can severely affect the economic efficiency of offshore wind turbines and potentially lead to safety accidents involving both humans and machinery. A simulation model for pitch bearings used in a 3 MW OWT is established to study the RCF behavior under operational conditions based on continuum damage mechanics. Both the elastic and plastic damage are considered in the damage process through a Python script. A user subroutine UMAT is programmed to depict the gradual deterioration of mechanical properties. The results indicate that the fatigue damage of the raceway exhibits significant nonlinear characteristics, with elastic damage playing a predominant role in determining its fatigue life under operational conditions. Full article
(This article belongs to the Special Issue Computational and Experimental Modeling of Interfaces and Joints in Advanced Materials)
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