Search Results (403)

This study analyses the application of the Friction Stir Welding (FSW) process on polymeric materials manufactured by additive manufacturing (AM), specifically with polylactic acid (PLA). FSW is a solid-state welding process characterized by its low heat input and minimal distortion, which makes it ideal for the assembly of complex or large components made by additive manufacturing. To evaluate its effectiveness, a portable FSW device was developed for the purpose of joining PLA specimens made by AM using different filler densities (15% and 100%). Two tool geometries (a cylindrical and truncated cone) were utilized by varying the parameters of rotational speed, tilt angle, and feed rate. The results revealed two different process stages, transient and steady-state, and showed differences in weld quality depending on the material density, tool type, and material addition. The study confirms the viability of FSW for joining PLA parts made by AM and suggests potential applications in industries that require robust and precise joints in plastic parts, thereby helping hybrid manufacturing to progress. Full article

Fused Filament Fabrication (FFF) enables the manufacturing of complex polymer components. However, surface finish and dimensional accuracy remain key limitations for their integration into functional assemblies. This study explores the potential of conventional turning as a post-processing strategy to improve the geometric and surface quality of PLA reinforced with carbon fiber (CF) parts produced by FFF. Machinability was evaluated through the analysis of cutting forces, thermal behavior, energy consumption, and surface integrity under varying cutting speeds, feed rates, and specimen slenderness. The results indicate that feed is the most influential parameter across all performance metrics, with lower values leading to improved dimensional accuracy and surface finish, achieving the most significant reductions of 63% in surface roughness (Sa) and 62% in cylindricity deviation. Nevertheless, the surface roughness is higher than that of metals, and deviations in geometry along the length of the specimen have been observed. A critical shear stress of 0.237 MPa has been identified as the limit for interlayer failure, defining the boundary conditions for viable cutting operation. The incorporation of CNC turning as a post-processing step reduced the total fabrication time by approximately 83% compared with high-resolution FFF, while maintaining dimensional accuracy and enhancing surface quality. These findings support the use of machining operations as a viable and efficient post-processing method for improving the functionality of polymer-based components produced by additive manufacturing. Full article

An analysis of the working surfaces of cylindrical gears after scuffing shock tests allowed for the assessment of the effect of loading conditions on the form of damage to the tooth surfaces. Unlike the method of scuffing under severe conditions, where loading is applied gradually, the presented tests employed direct maximum loading—shock loading—without prior lapping of the gears under lower loads. This loading method significantly increases the vulnerability of the analyzed components to scuffing, enabling an evaluation of their limit in terms of operational properties. To identify the changes and the types of the teeth’s working surface damage, the following microscopy techniques were applied: scanning electron microscopy (FE-SEM) with EDS microanalyzer, optical interferential profilometry (WLI), atomic force microscope (AFM), and optical microscopy. The results allowed us to define the characteristic damage mechanisms and assess the efficiency of the applied DLC coatings when it comes to resistance to scuffing in shock scuffing conditions. Tribological tests were performed by means of an FZG T-12U gear test rig in a power circulating system to test cylindrical gear scuffing. The gears were made from 18CrNiMo7-6 steel and 35CrMnSiA nano-bainitic steel and coated with W-DLC/CrN. Full article

This study investigates the influence of die design parameters on forging forces and thermomechanical responses during near-solidus forging (NSF) of complex steel components. Finite element simulations using Forge NxT analyzed six die configurations varying geometry orientation, gating system design (conical, cylindrical, curvilinear), and draft angles (20° and 30°), with 42CrMo4E steel modeled at 1360 °C. Key responses including punch and lateral forces, temperature distribution, strain localization, and die stress were evaluated to assess design effects. Results showed that the gating system geometry critically controls material flow and load requirements. The conical gating design with a 30° draft angle yielded the lowest punch (141.54 t) and lateral (149.44 t) forces, alongside uniform temperature and strain distributions, which improve product quality by minimizing defects and incomplete filling. Lower lateral forces also reduce die opening risk, enhancing die life. In contrast, the base case with a 20° draft angle exhibited higher forces and uneven strain, increasing die stress and compromising part quality. These findings highlight the importance of selecting appropriate gating systems and draft angles to reduce forming loads, increase die life, and improve uniform material flow, contributing to better understanding of die design in NSF of complex steel components. Full article

The research investigated the influence of laser powder bed fusion (LPBF) parameters for NickelAlloy HX, a nickel-based superalloy, to achieve high-density components with superior mechanical properties. A systematic approach was employed, involving printing 40 cylindrical specimens with varying energy densities (50–240 J/mm³) to evaluate porosity, hardness, and anisotropy. Results revealed that energy density significantly influences relative density, with optimal parameters identified at 111 J/mm³ (900 mm/s scan speed, 120 W laser power). Microstructural examination revealed columnar grains aligned with the build direction in as-printed samples. The findings highlight the trade-offs between density, hardness, and microstructure in the additive manufacturing of nickel-based superalloys, providing actionable insights for industrial applications requiring specific property profiles. Full article

This study investigates the impact of thermal barrier coatings (TBCs) on the individual contributions of cooling components in impingement-jet combined cooling under low Reynolds number conditions. Using decoupled methods, numerical simulations were conducted for cylindrical, fan-shaped, and conical hole geometries. The results show that without TBCs, the conical hole provides the best cooling performance, while the fan-shaped hole performs the worst. After applying TBCs, the cooling effectiveness of the cylindrical and conical holes remains largely unchanged, but the fan-shaped hole shows significant improvement, with performance comparable to the conical hole. The cylindrical hole keeps a uniform shape, leading to increased velocity and preventing stable film formation. In contrast, the expanding flow passages of the fan-shaped and conical holes promote a gradual decrease in flow velocity, supporting stable film formation and effective thermal protection. Impingement cooling accounts for more than 75% of the overall cooling effectiveness for across hole types. For cylindrical and conical holes, the TBCs primarily enhance in-hole cooling, while for the fan-shaped hole, it increases in-hole cooling effectiveness and shifts film cooling effectiveness from negative to positive, significantly improving its overall contribution. Full article

Linear passive electrical devices/components are usually characterized in the frequency domain by their impedance, i.e., the ratio of the voltage and current phasors. The use of the impedance concept does not raise particular concerns in low-frequency regimes; however, things become more complicated when it comes to rapid time-varying phenomena, mainly because the voltage depends not only on the position of the points between which it is defined but also on the choice of the integration path that connects them. In this article, based on first principles (Maxwell equations and Poynting vector flow considerations), we discuss the concept of impedance and define it unequivocally for a class of electrical devices/components with rotational symmetry. Two application examples are presented and discussed. One simple example concerns the per-unit-length impedance of a homogeneous cylindrical wire subject to the skin effect. The other, which is more elaborate, concerns a heterogeneous structure that consists of a dielectric disk sandwiched between two metal plates. For the lossless situation, the high-frequency impedance of this device (circular parallel plate capacitor) reaches zero when the frequency reaches a certain critical frequency f_c; then, it becomes inductive and increases enormously when the frequency reaches another critical frequency at 1.6 f_c. The influence of losses on the impedance of the device is thoroughly investigated and evaluated. Impedance corrections due to dielectric losses are analyzed using a frequency-dependent Debye permittivity model. The impedance corrections due to plate losses are analyzed by considering radial current distributions on the outer and inner surfaces of the plates, the latter exhibiting significant variations near the critical frequencies of the device. Full article

The lead-cooled fast reactor (LFR), a Generation IV nuclear system candidate, presents unique neutronic characteristics distinct from pressurized water reactors. Its neutron spectrum spans wider energy ranges with fast neutron dominance, exhibiting resonance phenomena across energy regions. These features require a fine energy group structure for fuel lattice calculations, significantly increasing computational demands. To balance local heterogeneity modeling with computational efficiency, researchers across the world adopt fuel assembly equivalence methods using 1D cylindrical models through volume equivalence principles. This approach enables detailed energy group calculations in simplified geometries, followed by lattice homogenization for few-group parameter generation, effectively reducing whole-core computational loads. However, limitations emerge when handling strongly heterogeneous components like structural/control rods. This study investigates the 1D equivalence method’s accuracy in lead–bismuth fast reactors under various fuel assembly configurations. Through comprehensive analysis of material distributions and their equivalence impacts, the applicability of the one-dimensional equivalence approach to fuel assemblies of different geometries and material types is analyzed in this paper. The research further proposes corrective solutions for low-accuracy scenarios, enhancing computational method reliability. This paper is significant in its optimization of the physical calculation and analysis process of a new type of fast reactor component and has important engineering application value. Full article

This work explores the morphogenesis of the skeletal mineral component, with a specific emphasis on hydroxyapatite (HAp) crystal assembly. Bone is fundamentally a triphasic biomaterial, consisting of an inorganic mineral phase, an organic matrix, and an aqueous component. The inorganic phase (hydroxyapatite), is characterized by its hexagonal prismatic nanocrystalline structure. We leverage a cellular automata (CA) paradigm to computationally simulate the mineralization process, leading to the formation of the bone’s hydroxyapatite framework. This model exclusively considers the physicochemical aspects of bone formation, intentionally excluding the biological interactions that govern in vivo skeletal development. To optimize computational efficiency, a simplified anatomical segment of a long bone (e.g., the femur) is modeled. This geometric simplification encompasses an outer ellipsoidal cylindrical boundary (periosteal envelope), an inner ellipsoidal surface defining the interface between cortical and cancellous bone, and a central circular cylindrical lumen representing the medullary cavity, which accommodates the bone marrow and primary vasculature. The CA methodology is applied to generate the internal bone microarchitecture, while deliberately omitting the design of smaller, secondary vascular channels. Full article

To address the issues of high pod damage rate and unpicked pod rate in the picking device of peanut picking combine harvesters during the harvesting of sun-dried peanuts, a low-damage peanut picking device was developed. This device combines flat pin teeth with a two-stage round steel concave screen. Contact models between the picking components and peanut pods, as well as between pods and the concave screen, were analyzed to determine the optimal structural parameters of the picking components and the most suitable concave screen type. Using peanut plants that had been dug, windrowed, and naturally sun-dried in the field for 3–5 days as test material, bench tests were conducted with pod breakage rate and unpicked pod rate as evaluation indices. The installation direction of the picking elements and the combination form of the concave screen were used as experimental factors. The optimal configuration was determined to be flat pin teeth installed with parallel axial forward bending with a tip fillet radius of 6 mm, and a concave screen composed of right round steel + straight round steel with front sparse and rear dense type. Field comparative experiments with a conventional picking device—comprising cylindrical bar teeth and a straight round steel concave screen—showed that the pod breakage rate decreased from 1.92% to 1.17%, and the unpicked pod rate decreased from 1.14% to 0.62%. This study provides a theoretical basis for the structural optimization and performance enhancement of the threshing device in peanut picking combine harvesters. Full article

Cell membranes contain a variety of biomolecules, especially various kinds of lipids and proteins, which constantly change with fluidity and environmental stimuli. Though Helfrich curvature elastic energy has successfully explained many phenomena for single-component membranes, a new theoretical framework for multicomponent membranes is still a challenge. In this work, we propose a generalized Helfrich free-energy functional describe equilibrium shapes and phase behaviors related to membrane heterogeneity with via curvature-component coupling in a unified framework. For multicomponent membranes, a new but important Laplace–Beltrami operator is derived from the variational calculation on the integral of Gaussian curvature and applied to explain the spontaneous nanotube formation of an asymmetric glycolipid vesicle. Therefore, our general mathematical framework shows a predictive capabilities beyond the existing multicomponent membrane models. The set of new curvature-component coupling EL equations have been derived for global vesicle shapes associated with the composition redistribution of multicomponent membranes for the first time and specified into several typical geometric shape equations. The equilibrium radii of isotonic vesicles for both spherical and cylindrical geometries are calculated. The analytical solution for isotonic vesicles reveals that membrane stability requires distinct elastic moduli among components ($k_{\mathrm{A}}\ne k_{\mathrm{B}}$, ${\overline{k}}_{\mathrm{A}}\ne {\overline{k}}_{\mathrm{B}}$), which is consistent with experimental observations of coexisting lipid domains. Furthermore, we elucidate the biophysical implications of the derived shape equations, linking them to experimentally observed membrane remodeling processes. Our new free-energy framework provides a baseline for more detailed microscopic membrane models. Full article

Improving the reliability and durability of internal combustion engines in marine vessels is a complex issue. The vibrations generated in these engines significantly affect their proper operation. One of the current research challenges is identifying effective methods to reduce, among other things, torsional vibrations generated within the crank–piston system. To mitigate these vibrations, viscous dampers are commonly used. The selection of a viscous damper for a high-power multi-cylinder engine, such as those in marine power plants, requires a thorough understanding of the thermo-hydrodynamic properties of oil films formed in the spaces between the damper housing and the inertial mass. The description of the phenomena involved is complicated by the variable positioning of the inertial mass center relative to the housing during operation. Most previous studies assume a concentric alignment between these components. The main novelty of this work lies in highlighting the combined effect of the eccentric motion of the inertial ring on both hydrodynamic resistance and thermal characteristics, which has not been fully addressed in existing studies. This article defines the oil flow resistance coefficients and develops static characteristics of the dampers. Additionally, it evaluates the impact of the size of the frontal and cylindrical surfaces of the damper on its heat dissipation capacity. The presented characteristics can be utilized to assess the performance parameters of this type of damper. Full article

The application of double-layer shell structure is very common in some situations that require complex loads and vibrations, such as key components such as the shell and wings of aerospace engines, and the shell of underwater vehicles. Many authors have conducted research on the vibration and acoustic radiation characteristics of double-layer cylindrical shells. By adding reinforcement and ribs between the double-layer cylindrical shells and optimizing structural design, passive vibration control techniques can effectively solve high frequency vibration problems, but the impact on mid to low frequency vibrations is still limited. Therefore, this article conducts theoretical research on a novel active vibration control method that inserts an active actuator between a double-layer cylindrical shell to achieve better mid low frequency vibration control effects. Firstly, the substructure admittance method is applied to analytically and dynamically model a double-layer cylindrical thin shell structure with active support, and the vibration power flow of the system is theoretically derived to evaluate the vibration reduction effect. Then, numerical simulation analysis was conducted on the influence of different configurations of six feedback control parameters, time delays, and other factors on the vibration power flow. Finally, based on the image, the conclusion is drawn that all six feedback control parameters can improve the vibration control effect of the coupled system to a certain extent, but not every feedback control parameter has a prominent effect, and the effective range of some parameters is relatively narrow. Full article

Grinding, as the most crucial finishing process for bearing rings, influences the surface integrity of bearings through the roughness of the ground surface. In order to improve the surface roughness of bearing ring grinding under multiple working conditions, a prediction model of bearing ring surface roughness based on feature extraction was proposed. Firstly, the signal was decomposed using the Complete Ensemble Empirical Mode Decomposition with Adaptive Noise (CEEMDAN) algorithm, and the sensitive components were selected based on the correlation coefficient between Intrinsic Mode Functions (IMFs) and the original signal. The time-domain, frequency-domain, and entropy-domain features of the selected IMF components were extracted. Then, Principal Component Analysis (PCA) was employed for signal feature fusion, and a feature set was constructed in combination with grinding parameters. A prediction model based on Support Vector Regression (SVR) was established to achieve regression prediction of the grinding surface roughness. The proposed method for predicting the surface roughness of precision cylindrical grinding of bearings demonstrated that the determination coefficient (R²), mean absolute error (MAE), root mean square error (RMSE), and mean absolute percentage error (MAPE) were 0.9953, 0.0020, 0.0050, and 0.0187, respectively. The results indicate that the incorporation of entropy features and grinding parameters in the model provide more information pertinent to grinding surface roughness, thereby effectively enhancing the predictive accuracy. Full article

The application of CAD/CAM technologies in modern production has revolutionized manufacturing processes, leading to significant improvements in precision, efficiency, and flexibility. These technologies enable the design and manufacturing of complex geometries with high accuracy, reducing errors and material waste. CAD/CAM integration streamlines workflows, enhances productivity, and facilitates rapid prototyping, accelerating the time-to-market for new products. Additionally, it supports customization and scalability in production, allowing for cost-effective small-batch and large-scale manufacturing. Without a 3D model of the product, it is not possible to use the advantages of applying advanced CAD/CAM technologies. Recognizing 3D models from engineering drawings is essential for modern production, especially for outsourcing companies in fluctuating market conditions, where the production process is organized with 2D workshop drawings on paper. This paper proposes a novel methodology for reconstructing 3D models from 2D engineering drawings, specifically those in DXF file format, leveraging a genetic algorithm. A core component of this approach is the representation of the 2D drawing as a symmetric adjacency matrix. This matrix serves as the foundational data structure for the genetic algorithm, enabling the evolutionary process to effectively optimize the 3D reconstruction. The experimental evaluation, conducted on multiple engineering drawing test cases (including both polyhedral and cylindrical geometries), demonstrated consistent convergence of the proposed GA-based method toward topologically valid and geometrically accurate 3D wireframe models. The approach achieved successful reconstruction in all cases, with fitness scores ranging from 1.1 to 112.2 depending on model complexity, and average execution times from 2 to 100 s. These results confirm the method’s robustness, scalability, and applicability in real-world CAD environments, while establishing a new direction for topology-driven 3D reconstruction using evolutionary computation. Full article