Search Results (151)

An optimized extrusion process is desired for both an environmentally friendly and economically sustainable recycling process. The aim of this study is to simulate the melt conveying zone of a single-screw extruder when using contaminated polymers instead of commonly used pure materials, to optimize a mechanical recycling process, and to reduce the number of measurements needed for rheological input data by using mixing rules. Polypropylene (PP) is blended with a polyamide 12 (PA 12) grade and another PP grade to introduce polymer impurities into the material. The blends are subjected to extrusion experiments in a lab-scale single-screw extruder with pressure and temperature sensors along the barrel. An isothermal analytical simulation model is proposed using representative shear rate values and rheological mixing rules to calculate the pressure distribution along the screw channel throughout the melt conveying zone. The rheological input data for the simulation is taken from high-pressure capillary rheometric measurements, but also substituted with values derived from mixing rules. The results show that the application of the shear viscosity through mixing models yields simulated pressure values similar to those measured in the experiments. With the introduction of representative viscosity into the model, relative deviations of around 5% at certain screw speeds can be achieved. Full article

In view of the lack of research on the extrusion of pineapple caused by the overall stress response of pineapple at the present stage of pineapple automatic harvesting, the finite element model of pineapples can be studied by constructing such a model. At present, there is still a lack of research on the mechanical properties of the pineapple stem. In this research, the mechanical properties of a pineapple stem were determined by a three-point bending test, a compression test, and a theoretical calculation. Based on the cohesive zone model (CZM), the relevant parameters of the pineapple fruit–stem junction were determined by the fracture test. The overall finite element model of pineapple was established, and then the verification test of the finite element model was carried out. In the validation test, the correlation between sample size parameters and results was analyzed, and the validity of the test sample selection was demonstrated. By substituting the simulation results into the derivation formula, the maximum traction strength and maximum displacement error values were calculated to be 4.3% and 2.9%, respectively, which verified the accuracy of the cohesive zone model parameters. By comparing the maximum load force and load displacement of the load point in the test and simulation, the error of the load force at the fracture point relative to the average value was 3.6%, and the error of the load displacement relative to the average value was 1.4%. The numerical results showed that the model reflected the accuracy of the process of pineapple plant fracture. This study provides a reliable finite element model for future research on pineapple automatic harvesting. Full article

Biodegradable packaging based on starch–polycaprolactone (PCL) composites is a promising route to reduce reliance on petroleum-derived plastics. Here, wheat starches with A- and B-type crystallinity—sourced from Kazakhstani varieties—were dual-modified by electron-beam irradiation followed by acetylation and incorporated into PCL (30–50 wt%) via melt extrusion and compression molding. The resulting films were characterized for morphology, mechanical performance, water-vapor permeability (WVP), thermal behavior, antibacterial activity, and biodegradation under soil and composting conditions. Acetylated A-type starch dispersed more uniformly within the PCL matrix, yielding smoother surfaces, higher tensile strength, and moderate WVP. In contrast, B-type starch produced a more porous microstructure with increased WVP and accelerated mass loss during composting (up to ~45% within 10 days at higher starch loadings). Incorporation of starch slightly decreased thermal stability relative to neat PCL, while agar-diffusion assays against Escherichia coli and Staphylococcus aureus showed loading-dependent inhibition zones, with A-type composites generally outperforming B-type at equivalent contents. Taken together, A-type starch–PCL films are better suited for applications requiring mechanical integrity and controlled moisture transfer, whereas B-type systems favor breathable packaging and rapid compostability. These results clarify how starch crystalline type governs structure–property–degradation relationships in PCL composites and support the targeted design of sustainable packaging materials using regionally available starch resources. Full article

Understanding the microstructure–property relationship in aluminum extrusions is crucial to leverage their potential in automotive lightweighting. The sensitivity of the processing history to the microstructure and through-thickness variations poses a major challenge since it leads to strong directionality in plasticity and fracture. Reliable characterization of the mechanical response under relevant stress states is crucial for the development of modeling strategies and performance ranking in alloy design. To this end, tensile and 3-point bend tests were performed for an aluminum extrusion produced on a laboratory-scale extrusion press at Rio Tinto Aluminium. Direct measurements of surface strains during bending using stereoscopic digital image correlation revealed that a larger bend angle in the VDA238-100 test does not necessarily imply a higher fracture strain. The T4 sample tested in the extrusion direction sustained a bend angle of 104° compared to 68° in T6 for the same nominal bend severity (ratio of sheet thickness to punch radius), despite comparable major fracture strains of 0.60 and 0.58, respectively. It is proposed that the work-hardening behavior governs the strain distribution on the outer bend surface. The higher hardening rate in the T4 condition helped distribute deformation in the bend zone more uniformly. This delayed fracture to larger bend angles since strain is accumulated at a lower rate. To assess whether the effect of the hardening behavior is manifest at a microstructural lengthscale, microcomputed tomography (μ-CT) scans were conducted on interrupted bend samples. The distribution and severity of damage in the form of cracks on the outer bend surface were distinct to the temper and thus the hardening rate. Full article

Tunnel construction in weak and fractured strata often faces risks such as tunnel face instability and large deformation of surrounding rock, which are difficult to effectively control using conventional support methods. Based on the engineering background of the No. 8# TA Tunnel in the F3 section of Georgia’s E60 Highway, this study employed ADECO-RS and developed a 3D numerical model with finite difference software to simulate full-face tunnel excavation process. The influence of advanced reinforcement measures on the stability of the surrounding rock was systematically investigated. The control effectiveness of different advanced reinforcement schemes was evaluated by comparing the displacement field, stress field, and plastic zone distribution of the surrounding rock under three conditions: no support, advanced pipe roof support, and a combination of pipe roof and glass fiber bolts. A comprehensive quantitative analysis of the synergistic effect of the combined reinforcement was also performed. The results indicated that significant extrusion deformation of the tunnel face and vault settlement occurred after excavation. The pressure arch developed within a range of 17.5 to 22 m above the tunnel vault. The surrounding rock of this tunnel was classified as type B (short-term stable). Deformation primarily occurred within one tunnel diameter ahead of the face, with the deformation rate significantly reduced after support. Advanced pipe roof support effectively restrained surrounding rock deformation, while the combination of advanced pipe roof and glass fiber bolts delivered better performance: reducing final convergence by 73.10%, pre-convergence by 82.69%, and face extrusion by 87.66%. The combined support also contracted the pressure arch boundaries from 17.5 to 22 m to 6–12.5 m, reduced the extent of major principal stress deflection, and significantly shrinks the plastic zone. Glass fiber bolts played a key role in controlling plastic zone expansion and ensuring stability. This study provides theoretical and numerical references for safe construction and advanced support design in tunnels under complex geological conditions. Full article

This study presents a newly developed program that seamlessly converts G-code into formats compatible with Abaqus, enabling precise finite element simulations for FDM 3D printing. The tool operates on a two-pronged framework: a mathematical model incorporating key print parameters (layer thickness, extrusion temperature, print speed, and raster width) and a shape generator managing geometric parameters (fill density, pattern, and raster orientation). Initially, a predefined virtual section, based on predetermined dimensions, enhanced the correlation between experimental results and simulations. Subsequently, a corrected virtual section, derived from the mathematical model using the Box–Behnken methodology, improves accuracy, achieving a virtual thickness error of 1.06% and a width error of 8%. The model is validated through tensile testing of ASTM D638 specimens at 0°, 45°, and 90° orientations, using adaptive C3D4 mesh elements (0.35–0.6 mm). Results demonstrate that the corrected cross-section significantly improved simulation accuracy, reaching correlations above 95% in the elastic zone and 90% in the elastoplastic zone across all orientations. By optimizing the workflow from design to manufacturing, this program offers substantial benefits for the aerospace, medical, and automotive sectors, enhancing both the efficiency of the printing process and the reliability of simulations. Full article

In this study, we examined how printing temperature affects the microstructure and mechanical properties of polylactic acid (PLA) composite reinforced with iron oxide i.e., magnetite manufactured using a material extrusion technique. The composite was printed at temperatures from 185 °C to 215 °C. Microstructure analysis via synchrotron radiation X-ray microtomography revealed changes in both iron oxide and porosity contents within the printed structures. Mechanical testing results demonstrated a limited effect of the printing temperature on tensile performance. Finite element computation is considered to predict the elasticity behavior of the printed composite by converting 3D images into 3D structural meshes. When implementing a two-phase model, the predictions show a leading role of the iron oxide content, and an overestimation of the stiffness of the composite. A three-phase model demonstrates a better matching of the experimental results suggesting a limited load transfer across the PLA-iron oxide interface with Young’s moduli in the interphase zone as small as 10% of PLA Young’s modulus. Magnetic actuation demonstrates that experiments on PLA-iron oxide plates reveal a pronounced thickness-dependent limitation, with the maximum deflection observed in thin strips of 0.4 mm. Full article

In the context of polymer-based composites, the knowledge of the correlations between the processing conditions, the microstructure, and the final properties is essential to tailor polymeric systems for specific applications. Specifically concerning the extrusion process, an accurate design of the screw profile allows for achieving composites with modulable microstructures, according to the specific properties required by the intended application. In this work, films of polylactic acid-based composites with 5 wt.% of talc were obtained by means of a single-screw extruder equipped with a flat die and a calender unit. Three different screw profiles, namely a general-purpose compression screw, a screw with a reverse flow zone, and a barrier screw, were employed for the production of films. The ability of the screw profile in varying the degree of filler dispersion and distribution was assessed through morphological and rheological analyses, demonstrating that the barrier screw is more able in disaggregating the talc lamellae. Due to the achieved microstructures, films produced using this screw profile exhibited superior barrier properties, with a decrease of about 27% in the oxygen permeability as compared to unfilled PLA. However, a concurrent decrease in material ductility as compared to the other films was observed. Finally, the thermoformability of the composites was assessed; also in this case, trays with more precise edges and corners were obtained for the film formulated through the barrier screw. Full article

The layered composite roof of a coal mine roadway exhibits heterogeneity, with pronounced variations in layer thickness and strength. Fully grouted rock bolts installed in such layered roofs usually penetrate two or more strata and bond with them to form an integrated anchorage system. Roof failure typically initiates in the shallow strata and progressively propagates to deeper layers; thus, the mechanical properties of the rock at the free surface critically influence the overall stability of the layered roof and the load-transfer behavior of the bolts. In this study, a layered rock mass model was developed using three-dimensional particle flow code (PFC3D), and a triaxial loading scheme with a single free surface was applied to investigate the effects of free-surface rock properties, support parameters, and confining pressure on the load-bearing performance of the layered rock mass. The main findings are as follows: (1) Without support, the ultimate bearing capacity of a hard-rock-free-surface specimen is about 1.2 times that of a soft-rock-free-surface specimen. Applying support strengths of 0.2 MPa and 0.4 MPa enhanced the bearing capacity by 29–38% and 46–75%, respectively. (2) The evolution of axial stress in the bolts reflects the migration of the load-bearing core of the anchored body. Enhancing support strength improves the stress state of bolts and effectively mitigates the effects of high-stress conditions. (3) Under loading, soft rock layers exhibit greater deformation than hard layers. A hard-rock free surface effectively resists extrusion deformation from deeper soft rocks and provides higher bearing capacity. Shallow free-surface failure is significantly suppressed in anchored bodies, and “compression arch” zones are formed within multiple layers due to bolt support. Full article

Following the trend of food waste valorization to produce innovative bio-based materials, this study proposes the conversion of brewer’s spent grain (BSG) into added value edible, high oxygen barrier, flexible, active packaging films via an extrusion molding compression method. Gelatin (Gel) was used as both a reinforcement and barrier agent and glycerol (Gl) as a plasticizer. Eugenol was nanoencapsulated on natural zeolite (EG@NZ), and pure clove powder (ClP) was used as an active agent to obtain BSG/Gel/Gl/xEG@NZ and BSG/Gel/Gl/xClP (x = 5, 10, and 15 %wt.) active films. Both BSG/Gel/Gl/xEG@NZ and BSG/Gel/Gl/xClP films show enhanced tensile, oxygen barrier, antioxidant, and antibacterial properties, and low toxicity and genotoxicity values. All BSG/Gel/Gl/xEG@NZ films presented a higher oxygen barrier, higher total phenolic content (TPC) values, higher antioxidant activity according to a 2,2-diphenyl-1-picrylhydrazyl (DPPH) assay, higher inhibition zones against Staphylococcus aureus and Escherichia coli, and lower toxicity and genotoxicity than all BSG/Gel/Gl/xClP films. Thus, the superiority of the nanoencapsulated EG in NZ as compared to the physical encapsulated EG in ClP is proved. Briefly, BSG/Gel/Gl/15EG@NZ active film exhibited ~218% higher tensile strength, ~93% higher TPC value, and ~90% lower effective concentration for a 60% antioxidant activity value (EC₆₀) as compared to the pure BSG/Gel/Gl film. The zones against S. aureus and E. coli were 45 and 30 mm, respectively, and the oxygen barrier was zero. The use of this film extended the shelf life of fresh minced meat by two days and exhibited the high potential to be used as active packaging material. Full article

High-strength steel has high strength and low thermal conductivity, and its thin-walled parts are very susceptible to residual stress and deformation caused by cutting heat during the drilling process, which affects the machining accuracy and quality. High-strength steel thin-walled components are widely used in aerospace and other high-end sectors; however, systematic investigations into their temperature fields during drilling remain scarce, particularly regarding the evolution characteristics of the temperature field in thin-wall drilling and the quantitative relationship between drilling parameters and these temperature variations. This paper takes the thin-walled parts of AF1410 high-strength steel as the research object, designs a special fixture, and applies infrared thermography to measure the bottom surface temperature in the thin-walled drilling process in real time; this is carried out in order to study the characteristics of the temperature field during the thin-walled drilling process of high-strength steel, as well as the influence of the drilling dosage on the temperature field of the bottom surface. The experimental findings are as follows: in the process of thin-wall drilling of high-strength steel, the temperature field of the bottom surface of the workpiece shows an obvious temperature gradient distribution; before the formation of the drill cap, the highest temperature of the bottom surface of the workpiece is distributed in the central circular area corresponding to the extrusion of the transverse edge during the drilling process, and the highest temperature of the bottom surface can be approximated as the temperature of the extrusion friction zone between the top edge of the drill and the workpiece when the top edge of the drill bit drills to a position close to the bottom surface of the workpiece and increases with the increase in the drilling speed and the feed volume; during the process of drilling, the highest temperature of the bottom surface of the workpiece is approximated as the temperature of the top edge of the drill bit and the workpiece. The maximum temperature of the bottom surface of the workpiece in the drilling process increases nearly linearly with the drilling of the drill, and the slope of the maximum temperature increases nearly linearly with the increase in the drilling speed and feed, in which the influence of the feed on the slope of the maximum temperature increases is larger than that of the drilling speed. Full article

The Southern Lhasa Terrane, as the southernmost tectonic unit of the Eurasian continent, has long been a focal area in global geoscientific research due to its complex evolutionary history. The Yeba Formation exposed in this terrane comprises an Early–Middle Jurassic volcanic–sedimentary sequence that records multiphase tectonic deformation. This study applies structural analysis to identify three distinct phases of tectonic deformation in the Yeba Formation of the Southern Lhasa Terrane. The D₁ deformation is characterized by brittle–ductile shearing, as evidenced by the development of E-W-trending regional shear foliation (S₁). S₁ planes dip northward at angles of 27–87°, accompanied by steeply plunging stretching lineations (85–105°). Both south- and north-directed shear-rotated porphyroclasts are observed in the hanging wall. ⁴⁰Ar-³⁹Ar dating results suggest that the D₁ deformation occurred at ~79 Ma and may represent an extrusion-related structure formed under a back-arc compressional regime induced by the low-angle subduction of the Neo-Tethys Ocean plate. The D₂ deformation is marked by the folding of the pre-existing shear foliation (S₁), generating an axial planar cleavage (S₂). S₂ planes dip north or south with angles of 40–70° and fold hinges plunge westward or NWW. Based on regional tectonic evolution, it is inferred that the deformation may have resulted from sustained north–south compressional stress during the Late Cretaceous (79–70 Ma), which caused the overall upward extrusion of the southern Gangdese back-arc basin, leading to upper crustal shortening and thickening and subsequently initiating folding. The D₃ deformation is dominated by E-W-striking ductile shear zones. The regional shear foliation (S₃) exhibits a preferred orientation of 347°∠75°. Outcrop-scale ductile deformation indicators reveal a top-to-the-NW shear sense. Combined with regional tectonic evolution, the third-phase (D3) deformation is interpreted as a combined product of the transition from compression to lateral extension within the Lhasa terrane, associated with the activation of the Gangdese Central Thrust (GCT) and the uplift of the Gangdese batholith since ~25 Ma. Full article

The Sidi Aissa Pb-Zn-(Ag) District, located within the Nappe Zone of northern Tunisia, has been reinterpreted as a typical intermediate-sulfidation (IS) epithermal mineralization system based on field observations and lithogeochemical analyses. Previously described as vein-style Pb-Zn deposits, the local geological framework is dominated by extensional normal faults forming half-grabens. These faults facilitated the exhumation of deep Triassic autochthonous rocks and the extrusion of 8-Ma rhyodacites and Messinian basalts. These structures, functioning as pathways for magmatic-hydrothermal fluids, facilitated the upward migration of acidic fluids, which interacted with the surrounding wall rocks, forming a subsurface alteration zone. The mineralization, shaped by Miocene extensional tectonics and magmatic activity, occurred in three stages: early quartz-dominated veins, an intermediate barite-rich phase, and late-stage supergene oxidation. Hydrothermal alteration, characterized by silicification, argillic, and propylitic zones, is closely associated with the deposition of base metals (Pb, Zn) and silver. The mineral assemblage, including barite, galena, sphalerite, and quartz, reflects dynamic processes such as fluid boiling, mixing, and pressure changes. Full article

Polymer co-extrusion experiments are described simulating the dynamics of two different magmas (e.g., silicic and mafic having different viscosities) flowing simultaneously in a vertical volcanic pipe or conduit which results in the effusion of composite lava domes on the surface. These experiments, involving geologically realistic conduit length-to-diameter aspect ratios of 130:1 or 380:1, demonstrate that co-extrusion of magmas having different viscosities can explain not only the observed normal zoning observed in planar dikes and the pipelike conduits that evolve from dikes but also the compositional layering of effused lava domes. The new results support earlier predictions, based on observations of induced core-annular flow (CAF), that dike and conduit zoning along with dome layering are found to depend on the viscosity contrast of the non-Newtonian (shear-thinning) magmas. Any magma properties creating viscosity differences, such as crystal content, bubble content, water content and temperature may also give rise to the CAF regime. Additionally, codependent flow behavior involving the silicic and mafic magmas may play a significant role in modifying the nature of volcanic eruptions. For example, lubrication of the flow by an annulus of a more mafic, lower-viscosity component allows a more viscous but more volatile-charged magma to be injected rapidly to greater vertical distances along a dike into a lower pressure regime that initiates exsolving of a gas phase, further assisting ascent to the surface. The rapid ascent of magmas exsolving volatiles in a dike or conduit is associated with explosive silicic eruptions. Full article

This study investigates strategies to enhance the structural integrity of 3D-printed orthopedic transtibial exoskeleton sockets by integrating non-planar reinforcement with structured prepreg rods composed of continuous carbon fibers, leveraging multi-axis additive manufacturing techniques. A prototype of a cylindrical polyamide 3D-printed exoskeleton socket is examined. Numerical modeling using progressive failure analysis, incorporating material property degradation models, successfully simulated damage accumulation in the studied 3D-printed structures. Numerical simulations revealed that crack formation initiates in the socket’s distal section, aligning with physical test observations. Targeted localized reinforcement with carbon rods effectively strengthened the high-load regions of the prosthetic devices. A method to improve product strength by optimization of the internal architecture of the embedded reinforcements in the local stress concentrator zones is proposed. The results demonstrate a reduction in stress concentrations within prostheses when using carbon fiber reinforcements. Multi-axis dual extrusion non-planar additive manufacturing techniques were used to produce the developed prototypes. Surface morphology was examined, and optimal process parameters were determined to enhance printing quality. The developed approach enables precise reinforcement of custom-shaped sockets with complex geometries. Full article