Search Results (46)

Wind turbine blades face significant challenges from stochastic wind loads, impacting structural integrity. Traditional analysis often isolates Computational Fluid Dynamics (CFD) from Building Information Modeling (BIM) in the design process. This study bridges this gap by integrating BIM forward design with CFD simulation. A universal BIM modeling framework is developed for rapid blade modeling, which is compatible with ANSYS Workbench 2022 R1 through intermediate format conversion. The influence of wind load on the blades under various wind speed conditions is analyzed, and the results indicate a significant correlation between wind load intensity and blade structural response. The maximum windward pressure reaches 4.96 kPa, while the leeward suction peaks at −6.28 kPa. The displacement at the tip and middle part of the blades significantly increases with the increase in wind speed. The growth rate of displacement between adjacent speeds rises from 1.20 to 1.94, and the overall increase rate within the entire range rises from 1.02 to 4.16. These results demonstrate the feasibility of using BIM forward design in accurate performance analysis, and also extends the value of BIM in wind energy. Furthermore, a bidirectional information flow is established, where BIM provides geometry for CFD, and simulation results will inform BIM design refinement. Full article

Accurate path tracking is crucial for greenhouse robots operating in complex environments. However, traditional curve tracking algorithms suffer from low tracking accuracy and large tracking errors. This study aim to develop a high precision greenhouse autonomous following robot, use ANSYS Workbench 19.2 to perform stress and deformation analysis on the robot, then propose a path tracking method based on Linear Quadratic Regulator (LQR) to optimize the pure tracking to ensure high precision curved path tracking for curved tracking, finally perform a comparative simulation analysis in MATLAB R2024a. The structural analysis shows that the maximum equivalent stress is 196 MPa and the maximum deformation is 1.73 mm under a load of 600 kg, which are within the yield limit of 45 steel. Simulation results demonstrate that at a speed of 2 m/s, the conventional Pure Pursuit algorithm incurs a maximum lateral error of 0.3418 m and a heading error of 0.2669 rad under high curvature conditions. By contrast, the LQR–Pure Pursuit algorithm reduces the peak lateral error to 0.0904 m and confines the heading error to approximately 0.0217 rad. Experimental validation yielded an RMSE of 0.018 m for lateral error and 0.016 m for heading error. These findings confirm that the designed robot can sustain its payload under most operating scenarios and that the proposed tracking strategy effectively suppresses deviations and improves path-following accuracy. Full article

This study presents a numerical model for analyzing fatigue crack growth in 42CrMo4 steel pivot bolts under different heat treatments and service loads. The finite element method (FEM) in the ANSYS Workbench environment (version 2019R1) (SMART Crack Growth), along with algorithms based on Paris’s law implemented in MATLAB (version R2016a), was used. The results highlight the significant influence of heat treatment on fatigue resistance and serve as a basis for optimizing design parameters and improving the durability of the structural components. Full article

With the increasing environmental pollution and resource consumption caused by automobiles, a lightweight design of automobiles is the best solution at present. In this paper, the load-bearing frame of pure electric SUVs is taken as the research object. The finite element analysis method is used to analyze the strength, stiffness and modal performance of the load-bearing frame, and the material selection of the frame is optimized according to the analysis results to achieve a lightweight design. First, a three-dimensional model of the pure electric SUV frame is established using SolidWorks software 2019 and then imported into ANSYS 2024 R1 Workbench for meshing and material property definition. Then, through finite element static analysis, the various force conditions of the frame under three typical working conditions of full-load bending, full-load braking and full-load turning are simulated; the stress distribution and deformation of the frame under different working conditions are confirmed; and the strength and stiffness performance of the frame are evaluated. After the above analysis, a modal analysis of the frame is carried out, and the natural frequency and vibration mode of the frame are finally obtained. According to the analysis results, the material replacement method is selected to optimize the lightweight design of the frame. The results show that the weight of the frame is significantly reduced after material optimization, while still meeting the strength, stiffness and modal performance requirements. This article provides a certain reference value for the lightweight design of pure electric SUV frames in the future. Full article

Background/Objectives: Dental cavity preparation is a critical procedure in restorative dentistry that involves the removal of decayed tissue while preserving a healthy tooth structure. Excessive stress during tooth preparation leads to enamel cracking, dentin damage, and long term compressive pulp health. This study employed finite element analysis (FEA) to investigate the stress distribution in dental structures during cavity preparation using round diamond burs of varying diameters and depths of cut (DOC). Methods: A three-dimensional human maxillary first molar was generated from computed tomography (CT) scan data using 3D Slicer, Fusion 360, and ANSYS Space Claim 2024 R-2. Finite element analysis (FEA) was conducted using ANSYS Workbench 2024. Round diamond burs with diameters of 1, 2, and 3 mm were modeled. Cutting simulations were performed for DOC of 1 mm and 2 mm. The burs were treated as rigid bodies, whereas the dental structures were modeled as deformable bodies using the Cowper–Symonds model. Results: The simulations revealed that larger bur diameters and deeper cuts led to higher stress magnitudes, particularly in the enamel and dentin. The maximum von Mises stress was reached at 136.98 MPa, and dentin 140.33 MPa. Smaller burs (≤2 mm) and lower depths of cut (≤1 mm) produced lower stress values and were optimal for minimizing dental structural damage. Pulpal stress remained low but showed an increasing trend with increased DOC and bur size. Conclusions: This study provides clinically relevant guidance for reducing mechanical damage during cavity preparation by recommending the use of smaller burs and controlled cutting depths. The originality of this study lies in its integration of CT-based anatomy with dynamic FEA modeling, enabling a realistic simulation of tool–tissue interaction in dentistry. These insights can inform bur selection, cutting protocols, and future experimental validations. Full article

End milling is a process that is widely used for producing components in aerospace applications, automobile applications, and many other fields. It is crucial to forecast a workpiece’s deformation behaviour during the machining process to choose the best process settings and maximize the part’s overall quality. Understanding the behaviour of each workpiece during the end-milling process through physical experiments is critical, but expensive. Hence, it is inevitable that a numerical study will be developed to estimate workpiece deformation with higher accuracy and less computational cost. The end-milling process on AISI 1045 is simulated in this work using a 3D finite element modelling technique. The ANSYS Workbench 2020 R1 is used to conduct an explicit dynamic analysis in the suggested model. The workpiece’s stress and deformation values throughout the machining process are estimated and examined. Full article

Hydrodynamic journal bearings play a vital role in high-speed, heavy-load machinery. Their performance directly affects system efficiency and reliability. Supercritical carbon dioxide (S-CO₂), with its favorable thermophysical properties, is a promising lubricant. This study focused on a four-oil-cavity hydrodynamic journal bearing using S-CO₂ as the working fluid. A numerical model was established in ANSYS Workbench 2024 R1 using a fluid–structure interaction (FSI) method. The model was validated through comparison with literature data. Parametric studies were conducted by varying radial clearance, eccentricity, inlet diameter, and oil cavity size. Results showed that reducing the oil cavity wrap angle enhanced load capacity. Larger inlet diameters improved lubrication but could increase deformation. An appropriate combination of inlet diameter and eccentricity effectively reduced shell deformation. These findings offer design guidance for S-CO₂-lubricated bearings in high-speed applications. Full article

This study investigates the structural integrity and dynamic behavior of symmetry-optimized battery pack systems for new energy vehicles through advanced finite element analysis. It examines symmetry-optimized battery pack systems with mechanically stable and thermally adaptive potentials. Leveraging geometric symmetry principles, a high-fidelity three-dimensional (3D) model was constructed in SolidWorks 2023 and subjected to symmetry-constrained static analysis on ANSYS Workbench 2021 R1 platform. The structural performance was systematically evaluated under three critical asymmetric loading scenarios: emergency left/right turns and braking conditions, with particular attention to symmetric stress distribution patterns. The numerical results confirmed the initial design’s compliance with mechanical requirements while revealing symmetric deformation characteristics in dominant mode shapes. Building upon symmetry-enhanced topology configuration, a novel lightweight strategy was implemented by substituting Q235 steel with ZL104 aluminum alloy. While mechanical symmetry has been widely studied, thermal gradients in battery packs can induce asymmetric expansions. For example, uneven cooling may cause localized warping in aluminum alloy shells. This multiphysics effect must be integrated into symmetry constraints to ensure true stability. Symmetric material distribution optimization reduced the mass by 19% while maintaining structural stability, as validated through comparative static and modal analyses. Notably, the symmetric eigenfrequency arrangement in optimized modules effectively avoids common vehicle excitation bands (8–12 Hz/25–35 Hz), demonstrating significant resonance risk reduction through frequency redistribution. This research establishes a symmetry-driven design paradigm that systematically coordinates structural efficiency with dynamic reliability, providing critical insights for developing next-generation battery systems with balanced performance characteristics. Full article

Fuel cells, propulsion systems, and reaction control systems (RCSs) are just a few of the space applications that depend on pressure vessels (PVs) to safely hold high-pressure fluids while enduring extreme environmental conditions both during launch and in orbit. Under these challenging circumstances, PVs must be lightweight while retaining structural integrity in order to increase the efficiency and lower the launch costs. PVs have significant challenges in space conditions, such as extreme vibrations during launch, the complete vacuum of space, and sudden temperature changes based on their location within the satellite and orbit types. Determining the operational temperature limits and endurance of PVs in space applications requires assessing the combined effects of these factors. As the main propellant for satellites and rockets, hydrogen has great promise for use in future space missions. This study aimed to assess the structural integrity and determine the thermal operating limits of different types of hydrogen pressure vessels using finite element analysis (FEA) with Ansys 2019 R3 Workbench. The impact of extreme space conditions on the performances of various kinds of hydrogen pressure vessels was analyzed numerically in this work. This study determined the safe operating temperature ranges for Type 4, Type 3, and Type 1 PVs at an operating hydrogen storage pressure of 35 MPa in an absolute vacuum. Additionally, the dynamic performance was assessed through modal and random vibration analyses. Various aspects of Ansys Workbench were explored, including the influence of the mesh element size, composite modeling methods, and their combined impact on the result accuracy. In terms of the survival temperature limits, the Type 4 PVs, which consisted of a Nylon 6 liner and a carbon fiber-reinforced epoxy (CFRE) prepreg composite shell, offered the optimal balance between the weight (56.2 kg) and a relatively narrow operating temperature range of 10–100 °C. The Type 3 PVs, which featured an Aluminum 6061-T6 liner, provided a broader operational temperature range of 0–145 °C but at a higher weight of 63.7 kg. Meanwhile, the Type 1 PVs demonstrated a superior cryogenic performance, with an operating range of −55–54 °C, though they were nearly twice as heavy as the Type 4 PVs, with a weight of 106 kg. The absolute vacuum environment had a negligible effect on the mechanical performance of all the PVs. Additionally, all the analyzed PV types maintained structural integrity and safety under launch-induced vibration loads. This study provided critical insights for selecting the most suitable pressure vessel type for space applications by considering operational temperature constraints and weight limitations, thereby ensuring an optimal mechanical–thermal performance and structural efficiency. Full article

This paper presents an experimental and numerical investigation of the axial compression behavior of perforated cold-formed steel upright profiles commonly used in pallet racking systems. The primary objective is to examine how slenderness influences the failure modes and load-bearing capacity of these structural elements. Three column lengths, representative of typical vertical spacing in industrial rack systems, were tested under pin-ended boundary conditions. All specimens were fabricated from 2 mm thick S355 steel sheets, incorporating web perforations and a central longitudinal stiffener. Experimental results highlighted three distinct failure mechanisms dependent on slenderness: local buckling for short columns (SS-340), combined distortional–flexural buckling for medium-length columns (MS-990), and global flexural buckling for slender columns (TS-1990). Finite Element Method (FEM) models developed using ANSYS Workbench 2021 R1 software accurately replicated the observed deformation patterns, stress concentrations, and load–displacement curves, with numerical results differing by less than 5% from experimental peak loads. Analytical evaluations performed using the Effective Width Method (EWM) and Direct Strength Method (DSM), following EN 1993-1-3 and AISI S100 specifications, indicated that EWM tends to underestimate the ultimate strength by up to 15%, whereas DSM provided results within 2–7% of experimental values, especially when the entire net cross-sectional area was considered fully effective. The originality of the study is the comprehensive evaluation of full-scale, perforated, stiffened cold-formed steel uprights, supported by robust experimental validation and detailed comparative analyses between FEM, EWM, and DSM methodologies. Findings demonstrate that DSM can be reliably applied to perforated sections with moderate slenderness and adequate web stiffening, without requiring further local reduction in the net cross-sectional area. Full article

Effective thermal management is essential for the safe and efficient operation of lithium-ion battery packs, particularly in compact, airflow-sensitive applications such as drones. This study presents a comprehensive thermal analysis of a 16-cell lithium-ion battery pack by exploring seven geometric configurations under airflow speeds ranging from 0 to 15 m/s and integrating nano-carbon-based phase change materials (PCMs) to enhance heat dissipation. A Computational Fluid Dynamics (CFD) approach was employed using Ansys Discovery and Workbench 2024 R1 to simulate airflow and heat transfer processes with high spatial resolution. Using high-fidelity 3D simulations, we found that the trapezoidal wide-base configuration, combined with a 5-inlet and 1-outlet airflow design, achieved the most balanced cooling performance across all speed regimes. This configuration maintained battery temperatures within the optimal operating range (∼45 °C) in both low- and high-speed airflow conditions, with a maximum temperature reduction of up to 8.3 °C compared to the standard square configuration. Additionally, PCM integration extended the thermal regulation duration to approximately 12.5 min, effectively buffering thermal spikes during peak loads. These findings underscore the critical role of CFD-driven geometric optimization and advanced material integration in designing high-efficiency, compact cooling systems for energy-dense battery applications in drones and portable electronics. Full article

This research outlines the design of capacitive pressure sensors fabricated from three biocompatible materials, featuring both circular and square geometries. The sensors were structured with a dielectric layer positioned between gold-plated electrodes at the top and bottom. Their performance was assessed through simulations conducted with ANSYS Workbench. Of the various sensor configurations tested, the circular design that included two crescent-shaped slots and a 20 µm thick PDMS dielectric material demonstrated the highest sensitivity of 10.68 fF/mmHg. This study further investigated the relationship between resonant frequency shifts and arterial blood pressure, revealing an exceptionally linear response, as evidenced by a Pearson’s correlation coefficient of −0.99986 and an R-squared value of 0.99972. This confirmed the sensor’s applicability for obtaining precise blood pressure measurements. Additionally, a 3 × 30 mm cobalt–chromium (Co-Cr) stent was obtained, and its inductance was measured using an impedance analyzer. Full article

Due to the complex operating environment of combine harvesters, uneven terrain, multiple vibration sources, and complex transmission systems, failures easily occur in critical working components, especially the bolted connections of the vibrating screen. To address these issues, this study first established a bolt-tightening mechanical model. Secondly, a finite element simulation of the preload force was performed using Ansys Workbench software (2023R2). The simulation results showed that the bolt head area exhibits a ring-shaped strain distribution. To determine the critical state of bolt loosening, a single-bolt loosening test was conducted. The experimental results indicated that when the bolt pressure decreased to 78.4 N and the torque decreased to 0.5 N·m, bolt loosening intensified, and the pressure value showed a sharp decreasing trend. These pressure and torque values can be defined as the bolt loosening threshold, providing an important reference basis for subsequent monitoring and early warning. Finally, to more realistically simulate actual working conditions, a combine harvester field vibration test was conducted. By arranging triaxial acceleration sensors on the bolted connections of the vibrating screen, acceleration signals were collected under both low-speed and high-speed field operating conditions. Time–frequency analysis was performed on the signals to extract characteristic values for each measurement point. The field vibration test results showed that the characteristic values of the transmission shaft bolt structure of the vibrating screen were at a relatively high level, indicating that this part is subjected to a large vibration load. Furthermore, frequency domain feature analysis revealed that the vibration frequency components in this area are complex, which further increases the risk of bolt loosening. This study provides an in-depth analysis of the loosening characteristics and vibration characteristics of the vibrating screen’s bolted connections in combine harvesters. The results provide an important theoretical basis and technical support for the online monitoring of failures in the vibrating screen’s bolt structure. Full article

The majority of engineering structures are subjected to intricate loading scenarios or possess intricate geometries, resulting in a mixed-mode stress within the component. This study aims to investigate the fracture behavior of these components under mixed-mode loading conditions by examining the relationship among the fatigue stress ratio (R), loading angle, and geometry thicknesses in compact tension shear (CTS) specimens. Using advanced ANSYS simulation techniques, this research explores how these factors affect the fatigue life cycles of engineering materials. To simulate real-world loading scenarios and study various mixed-mode configurations, compact tension shear (CTS) specimens were subjected to three specific loading angles: 30°, 45°, and 60°. These angles were applied in combination with various stress ratios (0.1–0.5) to capture a wide range of loading conditions. This study employed ANSYS Workbench 19.2, featuring cutting-edge technologies such as separating, morphing, and adaptive remeshing (SMART), to precisely model crack growth, calculate fatigue life, and analyze stress distribution. A comparative analysis with experimental data revealed that the loading angle has a profound effect on both the trajectory of fatigue crack growth (FCG) and the number of fatigue life cycles. The results demonstrate that the loading angle significantly influences the trajectory of FCG and the number of fatigue life cycles. Specifically, a loading angle of 45 degrees resulted in the maximum principal and shear stresses, indicating a state of pure shear loading. The findings reveal critical insights into the interaction between stress ratios, geometry thicknesses, fatigue life cycles, and loading angles, enhancing the understanding of engineering components’ behavior under mixed-mode stress situations. Full article

To reduce harvest losses of a pepper harvester with a drum of elastic tooth type picking mechanism, this paper proposes an optimization method using AHP (Analytic Hierarchy Process) and RSM (Response Surface Methodology), thereby identifying the optimal harvesting parameters. Based on Hertz’s contact theory and projectile motion theory, dynamic and kinematic models were established for the picking and casting stage. Key parameters influencing harvest loss were identified as drum rotational speed, operating speed, and tooth spacing. A simulation model was constructed, and solved within LS-DYNA of ANSYS Workbench. A Box–Behnken design in RSM was employed to investigate the effects of drum rotational speed, operating speed, and tooth spacing on the picking rate, breakage rate, and loss rate. The optimal parameters, obtained through RSM optimization after AHP weighting, were determined to be a drum rotational speed of 182 r/min, an operating speed of 0.42 m/s, and a tooth spacing of 40 mm. A test bench was designed for validation, with simulation results deviating from experimental results by less than 5%. With optimized parameters, the picking rate increases from 89.73% to 95.13%, the breakage rate decreases from 3.21% to 2.66%, and the loss rate decreases from 5.16% to 3.95%. This study provides a theoretical foundation and practical reference for optimizing the drum with elastic tooth type picking mechanism in pepper harvesters. Full article