Search Results (40)

Material extrusion additive manufacturing (MEAM) has emerged as a versatile and widely adopted 3D printing technology due to its cost-effectiveness and ability to process a diverse range of materials. However, achieving consistent part quality and repeatability remains a challenge, mainly due to variations in process parameters and material behavior during fabrication. In-situ monitoring and advanced process control systems have been increasingly integrated into MEAM to address these issues, enabling real-time detection of defects, optimization of printing conditions, reliability of fabricated parts, and enhanced control over mechanical properties. This review examines the state-of-the-art in-situ monitoring techniques, including thermal imaging, vibrational sensing, rheological monitoring, printhead positioning, acoustic sensing, image recognition, and optical scanning, and their integration with process control strategies, such as closed-loop feedback systems and machine learning algorithms. Key challenges, including sensor accuracy, data processing complexity, and scalability, are discussed alongside recent advancements and their implications for industrial applications. By synthesizing current research, this work highlights the critical role of in-situ monitoring and process control in advancing the reliability and precision of MEAM, paving the way for its broader adoption in high-performance manufacturing. Full article

Renewable fuels produced from animal- and plant-based edible oils have emerged as an alternative to oil and natural gas. Burgeoning interest in renewables can be attributed to the rapid depletion of fossil fuels caused by the global energy demand and the environmental advantages of renewables, specifically reduced emissions of greenhouse gases. An important property of the feedstock that is crucial for the conversion of edible oils to renewable fuels is the total acid number (TAN), as even a small increase in TAN for the feedstock can lead to corrosion of the catalyst in the refining process. Currently, the TAN is determined by potentiometric titration, which is time-consuming, expensive, and requires the preparation of reagents. As part of an effort to promote the use of renewable fuels, a partial least squares regression method with orthogonal signal correction to remove spectral information related to the sample background was developed to determine the TAN from the mid-infrared (IR) spectra of the feedstock. Digitally blended mid-IR spectral data were generated to fill in regions of the PLS calibration where there were very few samples. By combining experimental and digitally blended mid-IR spectral data to ensure adequate sample representation in all regions of the spectra–property calibration and better understand the spectra–property relationship through the identification of sample outliers in the original data that can be difficult to detect because of swamping, a PLS regression model for TAN (R² = 0.992, cross-validated root mean square error = 0.468, and bias = 0.0036) has been developed from 118 experimental and digitally blended mid-IR spectra of commercial feedstock. Thus, feedstock whose TAN value is too high for refining can be flagged using the proposed mid-IR method, which is faster and easier to use than the current titrimetric method. Full article

Mining by-products present both an environmental challenge and a resource opportunity. This review investigates their potential application in road pavement construction, focusing on materials such as fly ash, slag, sulphur, red mud, tailings, and silica fume. Drawing from laboratory and field studies, the review examines their roles across pavement layers—subgrade, base, subbase, asphalt mixtures, and rigid pavements—emphasising mechanical properties, durability, moisture resistance, and ageing performance. When properly processed or stabilised, many of these wastes meet or exceed conventional performance standards, contributing to reduced use of virgin materials and greenhouse gas emissions. However, issues such as variability in composition, leaching risks, and a lack of standardised design protocols remain barriers to adoption. This review aims to consolidate current research, evaluate practical feasibility, and identify directions for future studies that would enable the responsible and effective reuse of mining waste in transportation infrastructure. Full article

While extensive research has addressed electromechanical systems interacting with power electronic converters, most studies lack a unified modeling framework that simultaneously captures converter switching behavior, nonlinear dynamics, and linearized control-oriented representations. In particular, the dynamic interaction between two-level full-bridge converters and angular-motion electromechanical switching devices (EMDs) is often simplified or abstracted, thereby limiting control system design and frequency-domain analysis. This work presents a comprehensive dynamic modeling methodology for an angular-motion EMD driven by a full-bridge dc-dc converter. The modeling framework includes (i) a detailed nonlinear switching model, (ii) an averaged nonlinear model suitable for control design, and (iii) a small-signal linearized model for deriving transfer functions and evaluating system stability. The proposed models are rigorously validated through time-domain simulations and Bode frequency analysis, confirming both theoretical equilibrium points and dynamic characteristics such as resonant frequencies and phase margins. The results demonstrate strong consistency across the modeling hierarchy and reveal critical features—such as ripple-induced resonance and low-frequency coupling—that are essential for robust controller design. This framework established a foundational tool for advancing the control and optimization of electromechanical switching systems in high-performance applications. Full article

In this paper, we introduce the Levy Flight-enhanced Whale Optimization Algorithm with Tabu Search elements (LWOATS), an innovative hybrid optimization approach that enhances the standard Whale Optimization Algorithm (WOA) with advanced local search techniques and elite solution management to improve performance on global optimization problems. Techniques from the Tabu Search algorithm are adopted to balance the exploration and exploitation phases, while an elite reintroduction strategy is implemented to retain and refine the best solutions. The efficient optimization of LWOATS is further aided by the utilization of Levy flights and local search based on the Nelder–Mead simplex method. An Orthogonal Experimental Design (OED) analysis was employed to fine-tune the algorithm’s parameters. LWOATS was tested against three different algorithm sets: fundamental algorithms, advanced Differential Evolution (DE) variants, and improved WOA variants. Wilcoxon tests demonstrate the promising performance of LWOATS, showing improvements in convergence speed, accuracy, and robustness compared to traditional WOA and other metaheuristic algorithms. After extensive testing against a challenging set of benchmark functions and engineering optimization problems, we conclude that our proposed method is well suited for tackling high-dimensional optimization tasks and constrained optimization problems, providing substantial computational efficiency gains and improved overall solution quality. Full article

Springback represents the deflection of a workpiece after releasing the forming tools or dies, which influences the quality and precision of the final products. It is basically governed by the elastic strain recovery of the material after unloading. Most approaches only implement reverse bending to determine the final shape of the formed product. However, stretch plays significant role whe the blank is held by a blank holder. In this paper, an algorithm is presented to calculate the contributions of both stretch loads and bending moments to elastic deformation during springback for each element, and to combine them mathematically and geometrically to achieve the final shape of the product. Comparing the results of this algorithm for different sheet metal forming processes with experimental measurements demonstrates that this technique successfully predicts a wide range of springback with reasonable accuracy. The advantage of this approach is its accuracy, which is not sensitive to hardening and softening mechanisms, the magnitude of plastic deformation during the forming process, or the size of the object. The application of the proposed formulation is limited to long profiles (plane-strain cases). However, it can be extended to more general applications by adding the effect of torsion and developing equations in 3D space. Due to the explicit nature of the calculations, data-processing time would be reduced significantly compared to the sophisticated algorithms used in commercial software. Full article

This study introduced a systematic framework to develop practical design guidelines specifically for filament-based material extrusion of metals (MEX/M), an additive manufacturing (AM) process defined by ISO/ASTM 52900. MEX/M provides a cost-efficient alternative to conventional manufacturing methods, which is particularly valuable for rapid prototyping. Although AM offers significant design flexibility, the MEX/M process imposes distinct geometric and process constraints requiring targeted optimization. The research formulates and validates design guidelines tailored for the MEX/M using an austenitic steel 316L (1.4404) alloy filament. The feedstock consists of a uniform blend of 316L stainless steel powder and polymeric binder embedded within a thermoplastic matrix, extruded and deposited layer by layer. Benchmark parts were fabricated to examine geometric feasibility, such as minimum printable wall thickness, feature inclination angles, borehole precision, overhang stability, and achievable resolution of horizontal and vertical gaps. After fabrication, the as-built (green-state) components undergo a two-step thermal post-processing treatment involving binder removal (debinding), followed by sintering at elevated temperatures to reach densification. Geometric accuracy was quantitatively assessed through a 3D scan by comparing the manufactured parts to their original CAD models, allowing the identification of deformation patterns and shrinkage rates. Finally, the practical utility of the developed guidelines was demonstrated by successfully manufacturing an impeller designed according to the established geometric constraints. These design guidelines apply specifically to the machine and filament type utilized in this study. Full article

Hydrostatic transmissions are essential in applications demanding variable torque and speed, such as mining and agricultural machinery, due to their compact design, high power-to-weight ratio, and efficient variable speed control. Despite these advantages, their inherent nonlinearities and susceptibility to parametric uncertainties pose significant challenges for precise motion control. This study presents a comparative analysis of classical PID and robust H-infinity controllers for regulating the speed of hydraulic motors under varying torsional loads. A linearized uncertain system model is developed using upper Linear Fractional Transformations (LFTs) to capture key parametric uncertainties. A simplified H-infinity controller is designed to robustly manage system dynamics, particularly addressing phase lags induced by uncertain loads. Simulation results demonstrate that the H-infinity controller offers superior performance over the PID controller in terms of stability, disturbance rejection, and robustness to load fluctuations. This work contributes a practically viable robust control solution for improving the reliability and precision of electro-hydraulic systems, particularly in demanding, real-world environments. Full article

The Dynamic Stiffness Matrix (DSM) of a structure is a frequency-dependent stiffness matrix relating the actions (forces and moments) and displacements (translations and rotations) when the structure vibrates at a given frequency. The DSM may be used to find the natural frequencies, modes, and structural response. For many structures, including skeletal frames of prismatic members, exact transcendental expressions for the DSM are readily available. This paper presents a mathematical proof of a linear determinantal relationship between the DSM of a skeletal frame when it is undamaged, cracked, and hinged at the crack location. The rotational stiffness or flexibility of the crack also appears as a linear term. This relationship gives, for the first time, an explicit equation to directly calculate the stiffness of the rotational spring representing a crack from measured natural frequencies for any potential crack location. Numerical examples demonstrate that computing the DSM of the intact and hinged structures gives an efficient solution method for the inverse problem of identifying crack location and severity. This paper also shows that an approximate DSM based on a finite element model can be used in the same way, making this procedure more versatile. Furthermore, new approximate expressions for the natural frequencies of structures with very small or very severe cracks are derived. An interesting relationship between the square of the bending moment in an undamaged beam and the determinant of the DSM of a hinged beam is also derived. This relationship, which can also be inferred from previous work, leads to a better understanding of the effect of crack location in specific vibration modes. Full article

Additive manufacturing (AM) technologies have witnessed remarkable advancements, offering opportunities to produce complex components across various industries. This paper explores the potential of AM for fabricating bipolar plates (BPPs) in fuel cell or electrolysis cell applications. BPPs play a critical role in the performance and efficiency of such cells, and conventional manufacturing methods often face limitations, particularly concerning the complexity and customization of geometries. The focus here lies in two specific AM methods: the laser powder bed fusion of metals (PBF-LB/M) and material extrusion of metals (MEX/M). PBF-LB/M, tailored for high-performance applications, enables the creation of highly complex geometries, albeit at increased costs. On the other hand, MEX/M excels in rapid prototyping, facilitating the swift production of diverse geometries for real-world testing. This approach can facilitate the evaluation of geometries suitable for mass production via sinter-based manufacturing processes. The geometric deviations of different BPPs were identified by evaluating 3D scans. The PBF-LB/M method is more suitable for small features, while the MEX/M method has lower deviations for geometrically less complex BPPs. Through this investigation, the limits of the capabilities of these AM methods became clear, knowledge that can potentially enhance the design and production of BPPs, revolutionizing the energy conversion and storage landscape and contributing to the design of additive manufacturing technologies. Full article

This paper presents a new computational library for pneumatic circuits, written in the specialized circuit-oriented language “Modelica”, and executed within an open-source IDE, “OpenModelica”, freely available for downloading on the Internet. The library focuses on the problem of energy efficiency and energy savings (two different concepts, that we intend to clarify in the text). The idea is to use the Modelica scripts to simulate typical circuits, known by their energy-efficient designs. We reason that air throttling within valves is one of the great challenges when it comes to energy losses. Also, we argue that compressed air reuse can be seen as a means of increasing efficiency, basically through replacing air throttling with counter-pressure velocity control. A simplified version of the developed Modelica library is made available to the reader in the ^{Appendix A}, to be used with new scripts and adapted to different realities. In our view, in many situations, open-code Modelica programs may constitute an alternative to proprietary software, where the mathematical models of components are mostly hidden from the end user. Theoretical experiments are carried out, focusing on energy management. The results show that the Modelica library hereby presented is solid, with great prospects of future development. They also show that energy efficiency in pneumatic circuits, at times, comes with the cost of poorly controlled velocity and pressure at the actuator, which requires a careful analysis by the designer, before an actual implementation. Full article

Pillar-to-pillar dashboards have become common in modern electric vehicles. These dashboards are made of liquid crystal displays (LCDs), of which backlight units (BLUs) are an integral part. Particulate contamination inside BLUs can lead to either an aesthetic or functional failure and is in consequence a part of quality control. Automatic optical inspection (AOI) was used to detect particulate matter to enable a process chain analysis to be carried out. The investigation showed that a high percentage of all contaminants originated from the assembly of the edge/side lightguide. The implementation of an additional cleaning process was the favored countermeasure to reduce the contaminants. The objective (cleanliness requirement) was to remove all contaminants larger than 100 µm from the lightguide with contactless (non-destructive) cleaning methods. The preferred cleaning methods of choice were compressed air and CO₂ snow jet cleaning. This work investigates the cleaning efficacy of both cleaning methods under consideration of the following impact factors: distance, orientation (inclination) and speed. The central question of this paper was as follows: would cleaning with compressed air be sufficient to meet the cleanliness requirements? In order to answer this question, a cleaning validation was carried out, based on a Box–Behnken design of experiments (DoE). To do so, representative test contaminants had to be selected in step one, followed by the selection of an appropriate measurement technology to be able to count the contaminants on the lightguide. In the third step, a test rig had to be designed and built to finally carry out the experiments. The data revealed that CO₂ was able to achieve a cleaning efficacy of 100% in five of the experiments, while the best cleaning efficacy of compressed air was 89.87%. The cleaning efficacy of compressed air could be improved by a parameter optimization to 94.19%. In contrast, a 100% cleaning efficacy is achievable with CO₂ after parameter optimization, which is what is needed to meet the cleanliness requirements. Full article

The vibration response of a component, particularly the frequency response of the component, can be used in the determination of the loss factor damping, η, due to energy dissipation and the elastic modulus (E). The ASTM E756-04 standard provides the methodology and the guidance for the determination of the loss factor damping and elastic modulus experimentally. This standard specifically calls for the use of a beam with a rectangular cross-section. Also, the theoretical formulation developed there is based on such a beam cross-section. Here, in this paper, the theoretical formulation and numerical simulation for determining the loss factor damping and elastic modulus are a derivation of the methodology used in the ASTM standard and other R&D work, but for a circular plate configuration. The delta change derivation, both theoretically and numerically, is proven to be accurate and validated here. This method is useful in the characterization of materials that have applications in structural vibration, aerospace subcomponents, micro and mini sensory devices, medical devices, and many other areas. Similar to the ASTM standard, the materials could include metals, ceramics, rubbers, plastics, reinforced epoxy matrices, composites, and woods. This paper mainly formulates the technique via numerical and computational methods. It is the intention of the author to also, as a future research agenda, experimentally produce data that can be correlated with this theoretical and numerical methodology. Full article

Precise flow measurement is crucial in fluid power systems. Especially in combination with pressure, hydraulic power can be particularly beneficial for predictive maintenance and control applications. However, conventional flow sensors in fluid power systems are often invasive, thus disrupting the flow and yielding unreliable measurements, especially under transient conditions. A common alternative is to estimate the flow rate using pressure differentials along a pipe and the Hagen–Poiseuille law, which is limited to steady, laminar, and incompressible flows. This study advances a previously introduced analytical soft sensor, demonstrating its ability to accurately determine the transient pipe flow beyond laminar conditions, without requiring a dedicated flow rate sensor. This method provides a robust and computationally efficient solution for real-world hydraulic systems by applying two pressure transducers. A key contribution of this work is the investigation of signal filtering, revealing that even a simple first-order low-pass filter with a 100 Hz cutoff frequency significantly improves accuracy, which is demonstrated for pulsation frequencies of 5, 10, and 15 Hz, where the filtered results closely match experimental data from a test rig. These findings underscore the soft sensor’s potential as a reliable alternative to traditional flow sensors, offering high accuracy with minimal computational overhead for a wide range of flow conditions. Full article