Search Results (3,446)

This study explores an integrated multi-physics design approach for a high-speed Interior Permanent Magnet Synchronous Motor (IPMSM) optimized for marine diesel engine Exhaust Gas Recirculation (EGR) blower systems. To satisfy the rigorous operational demands of marine environments, an IPMSM with a rated output of 150 kW and a base speed of 9000 rpm was developed. The design validity was rigorously verified through a comprehensive multi-physics framework using the Finite Element Method (FEM), ensuring a balance between electromagnetic, thermal, and mechanical performance. The investigation established a mathematical model for the IPMSM driven by a Space Vector Pulse-Width Modulation (SVPWM) inverter, facilitating a detailed analysis of steady-state characteristics within the EGR system. To guarantee long-term reliability at high rotational speeds, the study performed an integrated thermal analysis based on precise electrical loss separation and a rotor-dynamic evaluation focusing on unbalanced vibration responses of the shaft. Finally, the proposed design was validated by integrating the IPMSM into a full-scale EGR blower system. Experimental evaluations across the entire operating range confirm that the integrated design successfully achieves the high power density and mechanical robustness required for marine diesel applications. Full article

The development of next-generation terahertz (THz) transmitters and receivers based on 3D stacked packaging technology relies heavily on the integration of high-performance waveguide directional couplers. This paper presents an accurate and efficient method based on the mode-matching method (MMM) for the rapid analysis of a branch waveguide coupler fabricated through a silicon-based 3D stacking process. In contrast to the traditional method using the finite-element method (FEM) in HFSS, which is cumbersome and time-consuming, the proposed method offers orders-of-magnitude speed improvement. It is especially well-suited for large-scale uncertainty error analysis and statistical evaluation of THz waveguide couplers and related components. This theoretical MMM is validated through an experiment by characterizing a deep reactive ion etching (DRIE) fabricated and 3D stacked 220 GHz waveguide coupler. Full article

This study investigates the non-uniformity (NU%) of copper deposition in a three-dimensional panel electroplating cell using COMSOL Multiphysics^® 6.1 (COMSOL Inc., Burlington, MA, USA). To ensure the accuracy of the simulated current efficiency, the modeling was initially conducted on the electrodeposition of nanoscale metal wires (Nanowires, NWs) using the Finite Element Method (FEM) in COMSOL. After verifying that the simulation accurately reflected the current efficiency at the nanoscale, the model was scaled up to simulate full-sized panel-level electroplating. Various simulation conditions were explored, including two dimensional and three dimensional, electrode kinetics equations, electrolyte compositions, and current densities. The effects of these parameters on current efficiency and deposition uniformity were analyzed to develop a highly accurate COMSOL model. In terms of electrode kinetics, the study compares the advantages and limitations of secondary current distribution and tertiary current distribution models found in the previous literature, and evaluates their simulation results. Furthermore, to reflect the experimental condition where a pre-deposited copper seed layer was applied to reduce internal cathode resistance, the electrode shell physics module in COMSOL was implemented to simulate the potential distribution across the cathode surface. The results confirm that the numerical model using the tertiary current distribution provides more accurate predictions compared to the conventional secondary current distribution approach. Full article

This study explores the structural safety, mechanical response and optimal construction parameters of the Horizontal Directional Drilling (HDD) technology applied in airport rigid pavements novelly for navigation lighting renovation. This study adopts a combined research method of three-dimensional finite element modeling (FEM) and field tests (full-scale 4C and 4E class airport runway sections). The reliability of the model is verified by the measured data using a Heavy Weight Deflectometer (HWD). The effects of drilling depth, drilling position and typical aircraft loads on the stress and deformation at the bottom of the pavement slab are systematically analyzed. Then, drilling, grouting and non-destructive testing are carried out in the field full-scale test section to investigate the change in pavement bearing capacities. The results show that minimized influence on the mechanical properties of the pavement can be achieved by using 15 cm drilling depths at either slab center or joints. The pavement stiffness slightly decreases by a maximum of 18.9% after drilling. According to the field grouting test, the Impulse Stiffness Modulus (ISM) of most measuring points can be recovered to the original level before drilling. The use of a 10 cm diameter HDD driller meets the structural safety requirements of airport pavements. The HDD technology induces minimized pavement damage and influence on the bearing capacity of the airport runway structure compared with traditional construction technologies, highlighting its advantages in airfield navigation lighting renovations. Full article

In the vehicle electrification sector, the precise and reliable control of e-motors is of the utmost importance for ensuring the efficient and safe operation of the whole electric vehicle drivetrain. Specifically, the assessment of the absolute rotor position of the permanent magnet-based synchronous motors is necessary for precise e-motor control, which is strongly determined by the precision of the sensing device used for the absolute rotor position assessment. Magnetic rotational position sensing devices/encoders are predominantly used in the automotive sector. The accuracy of a magnetic-based rotational position sensing device can be affected by defects/errors which may occur during its manufacturing and/or assembly process. These defects may in turn affect the accuracy of the e-motor’s control and operation. The primary objective of this study was to numerically and experimentally design and investigate the accuracy of a magnetic-based off-axis rotational position sensing device intended for the control of a new permanent magnet e-motor, which was developed for a two-wheeler electric vehicle drivetrain. First, a 3D parametric numerical model of a magnetic rotational position sensing device mounted on the motor shaft was built by virtue of the finite element method (FEM). Based on numerical simulations, the appropriate dimensions of the magnetic ring were determined and the possible errors which may have occurred during its manufacturing process have been numerically imposed and analyzed. Second, the rotor position sensing device was prototyped based on the recommendations obtained with the 3D FEM model. Finally, the accuracy of the designed rotational position device was then experimentally assessed by comparing it to a standardized end-of-shaft rotational position encoder. To evaluate the influence of the possible errors on the e-motor rotor position measurement, the output characteristics of the motor torque as a function of its rotational speed of a real permanent magnet e-motor were experimentally assessed using two different rotational position devices. Based on the numerical end experimental results, we identified the manufacturing errors of the magnetic ring and analyzed their influence on the resulting output characteristics of the e-motor. The results revealed that the magnetic ring eccentricity and its magnetization process could affect the accuracy of the e-motor’s output torque characteristics. Full article

With the shift of oil and gas exploitation to deep seas, the 35 kV high-voltage electric slip ring in Single-Point Mooring (SPM) systems faces critical challenges of insulation failure and thermal failure, threatening operational safety. This study aims to investigate its insulation strength and temperature rise characteristics. A three-dimensional electric field model and a magnetic–thermal coupling model considering the skin effect were established using the finite element method (FEM). Simulations were conducted under four high-voltage configurations and various high-current operating conditions, followed by AC breakdown tests and high-current temperature rise experiments for validation. The results show that the maximum electric field (up to 19.53 kV/mm) concentrates at the inlet polytetrafluoroethylene (PTFE) bushing, which is the insulation weak point. The maximum temperature rise at the center ring can be predicted by a power-law model. Moreover, simulation results agree well with experimental data, confirming the reliability of the computational studies. This work provides a theoretical and experimental basis for the optimal design and safe operation of high-voltage slip rings in offshore SPM systems. Full article

This paper presents a computational study of wave–bathymetry and wave–structure interaction problems using advanced numerical techniques based on high-fidelity, two-phase Navier–Stokes (TpNS) flow and reduced-order, fully nonlinear potential flow models. For high-fidelity simulations, the TpNS equations are discretized using the finite-element method, with free-surface evolution captured through a hybrid level-set (LS) and volume-of-fluid (VOF) formulation. A monolithic, phase-conservative LS equation is introduced to mitigate mass loss and interface smearing, combined with a semi-implicit projection scheme. Hydrodynamic forces are resolved using a high-order, phase-resolving cut finite-element method (CutFEM), which enables the representation of complex solid geometries within a fixed background mesh. An equivalent polynomial of Heaviside and Dirac distributions ensures accurate evaluation of surface and volume integrals. Hence, no explicit generation of cut cell meshes, adaptive quadrature, or local refinement is required. For reduced-order modeling, a fast regularized boundary integral method (RBIM) is employed to solve the fully nonlinear potential flow. Singular and near-singular integrals are treated using a subtract-and-addition technique based on auxiliary functions derived from Stokes’ theorem, allowing direct application of high-order quadrature without conventional boundary element discretization. An arbitrary Lagrangian–Eulerian (ALE) formulation is adopted to enforce free-surface boundary conditions while avoiding excessive mesh distortion. The proposed approaches are applied to investigate highly nonlinear wave transformation over complex bathymetry and wave-induced dynamics of floating structures, including eddy-making damping effects. Numerical results are validated against experimental measurements. These two modeling approaches represent complementary levels of physical fidelity and computational efficiency, and their systematic comparison clarifies the trade-offs between computational accuracy, efficiency, and cost for practical marine problems. Full article

The present study investigates the thermo-mechanical behaviour and fatigue life associated with the shrink-fit process of shrink-fit tool holders. These holders are an indispensable component of high-precision and high-speed machining processes in modern manufacturing industries. Shrink-fit holders are subjected to elevated levels of stress as a consequence of repeated heating and cooling cycles, which can result in clamping fatigue over time. In this study, a three-dimensional finite element model (FEM) of a holder manufactured from H13 tool steel in accordance with BT40 standards was created using ANSYS software. The numerical analyses included transient thermal and structural analyses, consisting of a 4.5-s induction heating stage at 10 kW power, followed by a 1200-s cooling process. The analysis yielded results that were corroborated by the experimental data. It was established that, upon the conclusion of the heating process, the temperature in the conical region of the holder attained a range of approximately 388–417 °C. Furthermore, it was ascertained that a radial expansion of approximately 17.2–22 µm, which is required for the successful insertion of the cutting tool into the inner bore, was achieved. The fatigue life prediction, which constitutes the main focus of the study, applied the Soderberg criterion and evaluated two basic loading scenarios: the first tool assembly and repeated tool assembly cycles. The calculations yielded a life estimate of approximately 12,407 cycles for the first tool assembly cycle and approximately 19,400 cycles for the repeated tool assembly cycle. Accordingly, the repeated tool assembly condition exhibited a longer fatigue life than the first tool assembly condition. The enhanced longevity observed in the repeated tool assembly scenario is attributed to the stress cycle not fully reaching zero during this process, resulting in a lower stress amplitude. Full article

Polymer nanocomposites offer significant potential for improving the strength-to-weight ratio and dynamic behavior of drone blades. This study examines the vibration characteristics of tapered aramid (Kevlar)/epoxy composite blades reinforced with nanocarbon fillers—graphene (2D), multi-walled carbon nanotubes (MWCNTs, 1D), and fullerene (0D)—to determine the most effective filler for enhancing stiffness and operational stability. The laminated blades (300 mm length, 200 mm width, root thickness 13 mm, tip thickness 8 mm) incorporate ply drop-offs and a central honeycomb core. Modeling was performed using classical laminate plate theory integrated with the finite element method (FEM) in MATLAB (R2016a). Under clamped–free–free–free boundary conditions, the study considered rotational speeds of 750–2250 rpm, setting angles of 30–60°, various fiber orientations, and nanofiller contents of 0–10 wt.%. The results indicate that while the setting angle minimally affects natural frequency, it significantly influences damping in modes (1,2) and (2,1). Increasing nanofiller content improves stiffness, with optimal performance observed near 5 wt.%. At 1500 rpm in mode (1,1), MWCNTs provided the greatest enhancement. Overall, MWCNTs exhibited superior stiffness improvement and rotational stability compared to other fillers. Full article

To ensure the safety and structural integrity of composite flexible blades under strong winds, this study investigates the extreme aeroelastic responses of the IEA 15 MW wind turbine blade during an emergency shutdown with pitch system faults. Existing studies often rely on simplified models or one-way coupling; we adopt a bidirectional computational fluid dynamics–finite element method (CFD–FEM) fluid–structure interaction (FSI) framework to examine how wind speed and pitch system faults affect aerodynamic loads, displacement responses, and structural stresses when the blade is shut down in a parked-upwind condition. The results reveal that, under the no-pitch condition, the blade experiences extreme loading, with thrust being approximately 15 times higher and the peak stress being 8.6 times that of the pitch condition. Furthermore, a high frequency of 1.969 Hz emerges, significantly increasing the risk of aeroelastic instability as the wind speed increases or under the no-pitch condition. A stress analysis identified that high stress is mainly located in the main spar region, with the peak stress location shifting closer to the blade root under the no-pitch condition. This study highlights the potential risks of composite flexible blades during shutdowns and provides a reference for structural safety design and targeted monitoring. Full article

Accurate and fast junction-temperature estimation in Silicon Carbide (SiC) power modules is crucial for reliable operation, health monitoring and predictive control of power electronic converters in different applications. However, direct temperature measurement inside the module is difficult and high-fidelity thermal models are often very computationally expensive for real-time implementation. This paper proposes a digital twin development approach for fast and accurate temperature estimation in all three dimensions of a SiC MOSFET power module by a combination of finite element method (FEM) modelling and neural networks. The work is especially relevant in thermal monitoring and managing power electronics converters such as renewable energy systems, energy storage systems, Electric Vehicles (EV), etc. The model incorporates a neural network trained on data generated from an FEM model built in COMSOL Multiphysics. The developed digital twin can estimate the temperature distribution, including the ten junction temperatures of the Wolfspeed EAB450M12XM3 module, with an average estimation time of 0.063 s, enabling predictive control. In order to improve practical applicability and model synchronization with the physical system, NTC-based feedback techniques are discussed (single-Temperature Coefficient (NTC) and double-NTC approaches). The proposed framework is investigated in terms of prediction accuracy and computational performance related to the FEM-generated reference data. The approach improves model reliability by adjusting the parameters of the critical digital and physical modules. The combination of FEM-based modelling and machine learning can provide a foundation for accurate, real-time thermal monitoring in power electronic modules. Full article

The current study offers a deeper understanding of the thermal behavior of AISI 420 stainless-steel drill bits during titanium alloy machining. It utilizes non-linear simulations with the finite element method (FEM) to analyze heat generation, accumulation, and dissipation. The FEM formulation displays the time-dependent temperatures for the tool and hole during the drilling process. The simulation was examined during drilling and subsequent stages, up to room temperature. The study explored a wide range of drill bit lengths (60–160 mm) and tool diameters (2–10 mm). Significant convergence of 4.1% was achieved when compared to infrared thermography data. Furthermore, increasing the tool length beyond 120 mm did not significantly increase the thermal effect. Moreover, increasing the tool diameter up to 10 mm also did not significantly increase the thermal efficiency compared to tool diameters between 2 and 5 mm based on a constant tool length. An exploratory data analysis (EDA) heatmap correlation matrix was used to examine the most efficient variables and the optimum tool geometry. The results obtained provide a clear understanding of the optimal geometry choice for steel drilling tools when used in drilling titanium alloys. Full article

Quantifying river surface flow velocity is essential for hydrodynamic modelling, flood forecasting, and water resource management. Traditional in situ methods provide accurate point measurements but are costly and limited in spatial coverage. Unmanned aerial vehicles (UAVs) offer a flexible, non-contact alternative for high-resolution monitoring. Optical flow is a tracer-independent technique for deriving velocity fields from RGB video, making it well suited to UAV-based surveys. However, its operational use is hindered by the limited availability of annotated datasets and by instability under low-texture or noisy conditions. This study combines a Finite element method (FEM)-based physical flow model with UAV video to generate reference datasets and introduces a modified Recurrent All-Pairs Field Transforms (RAFT) architecture based on multiframe sequences. A Gated Recurrent Unit fusion module (Fuse-GRU) is incorporated prior to correlation computation, improving robustness to illumination changes and surface homogeneity while maintaining computational efficiency. The proposed model delivers stable, physically consistent velocity estimates across multiple rivers and flow conditions. Accuracy improves with higher spatial resolution and moderate temporal spacing. Compared to field measurements, the average angular difference ranged from 8 to 15°. The high error values were mainly caused by inaccuracies in the physical model and by complex river features. These findings confirm that multiframe optical flow can reproduce realistic river flow patterns with accuracy comparable to physically-based simulations, thereby supporting UAV-based hydrometric monitoring and model validation. Full article

To reduce the computational burden of 3D finite element analysis for hybrid-flux high-speed switched reluctance motors (HFHSRMs), a quasi-3D parameterized equivalent magnetic network (EMN) is proposed. A parameterized radial–circumferential cross-grid is used to discretize the stator, air-gap, and rotor regions, and axial coupling branches are introduced to represent key 3D flux paths. Rotor rotation and rotor dislocation are implemented through a circumferential node-shift mapping, thereby avoiding topology reconstruction at different rotor positions. Core nonlinearity is incorporated using a piecewise fit of measured B–H data, and sparse-matrix assembly is adopted to improve solution efficiency. Based on the proposed EMN, key electromagnetic quantities are evaluated, including air-gap flux density, static characteristics, and dynamic characteristics. The results are validated against 3D finite element method (FEM) and prototype experiments. In the prototype experiments, the EMN prediction errors of key quantities are within 6%. In addition, computational efficiency is significantly improved compared with the 3D FEM, enabling rapid parameter iteration and early-stage design evaluation for HFHSRMs. Full article

The restricted availability of raw materials underscores the significance of recycling asphalt materials that have reached the end of their service life, facilitating their reuse with additives for economic and sustainability benefits. The study includes both empirical investigations and numerical analyses. Empirical studies were conducted in four stages to evaluate the binder and mixture. First, the rheological properties of binders obtained from various sources were assessed in both unmodified and modified states. Second, the binders were subjected to different levels of aging. Third, the presence of additives in the binders was investigated. In the final stage, the analysis of asphalt pavement layers was conducted using the finite element method (FEM) for both modified and unmodified binders. Performance tests were carried out to evaluate the binder’s properties, and physical examinations were conducted to compare these properties. The binders were tested under both unaged and aged conditions using linear amplitude sweep (LAS), frequency sweep (FS), multiple stress creep recovery (MSCR), and bending beam rheometer (BBR) tests. The results indicated that aging increased the stiffness of the binders, regardless of their source. Additionally, the introduction of a rejuvenator reduced the binder’s stiffness, particularly at low temperatures. Findings showed that the growth rate (GR) and rutting parameters increased with binder aging, while the frequency decreased. The R² value of 0.92 demonstrates a strong correlation between the parameters. Polymer-modified binders demonstrated superior deformation resistance and higher stiffness stability. Overall, aging reduced asphalt flexibility, whereas modified binders improved long-term pavement deformation performance. Full article