Search Results (126)

Stepped bonded repair is widely used to restore load-carrying capacity in damaged composite structures, yet conventional circular-patch configurations require repair footprints that are frequently prohibited by spatial and geometric constraints in service environments. This study proposes an elliptical stepped repair strategy in which the patch axes are independently sized to accommodate directional space restrictions while preserving effective load transfer. A parametric three-dimensional finite element framework incorporating a Hashin-based progressive damage model and a cohesive-zone traction–separation law is developed and validated against both in-house lap-joint tests and an independent stepped-repair benchmark from the literature (discrepancy < 10%). Systematic variation in the elliptical geometry reveals that the major axis—oriented along the loading direction—is the dominant geometric parameter controlling strength recovery and failure mode: insufficient major-axis length results in premature adhesive debonding, whereas an appropriately sized major axis shifts failure to parent-laminate fracture and raises the ultimate load by up to 20% relative to a circular repair of equal minor-axis dimension. The minor axis plays a secondary but non-trivial role, and a synergistic optimum is identified at the 40–90 mm (minor–major) configuration. Regarding step partitioning, a four-step arrangement consistently maximizes ultimate load across all tested geometries due to the competition between transition-gradient smoothness and step-edge stress concentration density. Finally, an external woven overlay is shown to both improve and equalize strength across geometrically distinct repairs by suppressing interfacial stress concentration and engaging a global cooperative failure mode. These findings establish design guidelines for elliptical stepped repairs under engineering space constraints. 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

To address the low efficiency of finite element modeling and the reliance on manual measurements in electric/magnetic field analysis of complex overhead transmission line structures, this paper develops an IronPython-based automated computational platform within ANSYS Maxwell for 3-D modeling and electric/magnetic field analysis. First, by parsing transmission line data from the Grid Information Model (GIM), a unified coordinate transformation method is proposed to convert geographical coordinates into three-dimensional (3-D) Cartesian coordinates for finite element analysis. Based on the extracted line parameters, conductor sag is calculated and catenary modeling is implemented. An equivalent radius method is also introduced to simplify multi-bundle conductor modeling, enabling fast parametric construction of complex 3-D transmission line models. Second, by combining the IronPython scripting language with the .NET Windows Forms control library, a visualized finite element modeling and computation platform is developed. Finally, a typical double-circuit transmission line on the same tower is taken as a case study to calculate the spatial distribution of electric/magnetic fields. The influence of solution domain size on electric/magnetic field computation results is investigated, and optimal solution domain parameters are determined. The finite element results generated by the developed platform are further validated through comparison with measured data. The results demonstrate good agreement between calculated and measured values, confirming the accuracy and engineering applicability of the developed platform for electric/magnetic environment analysis of overhead transmission lines. Full article

A vulnerability surface modeling method based on dual intensity metrics is proposed to assess the impact of typhoons and heavy rainfall disasters on the distribution pole-tower conductor system. A three-dimensional finite-element model is developed for a typical “three-pole four-conductor” distribution line, considering the uncertainties in both load-side and structural-side parameters. A spatially coherent turbulent wind field is generated using the Davenport spectrum and harmonic superposition method, while an equivalent rain load is derived based on raindrop spectrum integration. Nonlinear dynamic time-history analysis is then conducted under multiple combinations of basic wind speeds and rainfall intensities, extracting engineering demand parameters such as conductor axial tension and pole-base bending moments. Based on probabilistic demand analysis, the relationship between engineering demand parameters and dual intensity measures is regressed in the logarithmic domain to construct bivariate fragility surfaces for both the conductors and the poles. Critical failure curves are obtained by intersecting the fragility surfaces with the 10% exceedance probability level, enabling rapid classification of structural risk under the joint effects of wind and rain. The results show that the regression model provides a high fit, effectively revealing that wind speed is the dominant control factor, while rainfall intensity serves as a secondary amplifying factor. The resulting critical failure curves can be directly used as operation and maintenance warning thresholds and can be coupled with observed and forecast meteorological data for time-varying risk assessment. These findings provide methodological support and engineering guidance for risk assessment, operation and maintenance decision-making, and resilience enhancement of distribution networks under multi-hazard coupling. Full article

During the extraction of shale oil from the Longmaxi Formation in the Sichuan Basin, it is found that the core samples contain natural fractures cemented by various minerals. However, the core extraction process is complex and expensive. In order to further investigate how cracks propagate and initiate in samples containing cementing layers under compression conditions, this study developed an experimental method involving plug cutting and mineral cementation reconstruction for the preparation of representative semi-artificial core samples. Through comprehensive analysis using computed tomography (CT), stereomicroscopy, and mechanical testing, we have demonstrated a high degree of consistency between artificial cemented cracks and natural cemented cracks. Through triaxial compression and Brazilian splitting experiments on artificially cemented samples, we found that low and high confining pressures significantly affect crack morphology. By using Abaqus finite element simulation to add crack propagation modes during the compression process of cement layers, we showed that different mineral cements (quartz, clay, and calcite) have secondary effects on crack morphology on the basis of confining pressure. Full article

Progressive collapse is characterized by disproportionate structural failure triggered by localized damage, such as column loss under extreme loading conditions. The objective of this study is to develop a simplified analytical model that is applicable in engineering practice without the need for high-fidelity nonlinear finite element analysis. Although current design guidelines (GSA and DoD) provide analytical procedures and acceptance criteria, they do not explicitly address the tensile resistance of girders after the acceptance criteria are satisfied, particularly under large deformation and connection failure. To address this limitation, this study proposes a simplified theoretical load–displacement model for a fixed-end girder subjected to three concentrated loads, considering the effects of secondary beams and focusing on the local girder response under a column-removal scenario. The proposed model incorporates moment–axial force interactions at plastic sections in the large-deformation range. Based on one-dimensional finite element analysis results, an early-developed axial force of 0.15F_p at the onset of the transition stage and a residual bending moment of 0.3M_p during the catenary action stage are explicitly introduced to better represent actual structural behavior. The girder response is idealized using five characteristic points: yielding (Y), full plasticity (P), transition initiation (T), pure catenary action initiation (C), and collapse governed by connection failure (F_conn). Stress distributions at plastic sections are analyzed using three-dimensional finite element models to establish stress-based formulations and a rational procedure for estimating axial force at collapse. The validity of the proposed model is verified through comparisons with finite element analysis results for girders with different span-to-depth ratios. The results demonstrate reasonable agreement in terms of collapse load and displacement, particularly for slender girders, confirming the applicability of the proposed model for progressive collapse assessment. Full article

For arch dam seismic safety evaluation, the finite element equivalent stress method has been widely used, and existing studies have realized mature equivalent stress calculation along the foundation surface path. However, from the scientific research perspective, there is a lack of a full dam surface equivalent stress characterization method for arch dams under seismic action; from the engineering practice perspective, the traditional path method cannot fully reflect the overall stress distribution of the dam, leading to insufficient comprehensive safety evaluation. To accurately assess the impact of seismic action on the overall structural safety of arch dams and address the above limitations, this study develops a methodology for calculating equivalent stress across the entire dam surface of arch dams under seismic action. Taking a concrete arch dam as the research object, a seismic wave input method based on viscoelastic artificial boundaries is employed. Three-dimensional finite element analysis of the arch dam is performed using ABAQUS, integrated with Python-based secondary development to extract stress along the integration path of each arch ring layer and calculate sectional internal forces. The equivalent stress of each arch ring layer integration path is then processed using the material mechanics method to obtain the equivalent stress distribution across the entire dam surface. A comparative analysis is conducted between the equivalent stress on the entire dam surface and that along paths on the foundation surface regarding the seismic dynamic response and behavioral patterns of the dam. The results demonstrate that the full dam surface equivalent stress approach not only accurately captures the extreme tensile and compressive stress values in the downstream foundation area but also identifies stress extrema in the upstream dam crest region, thereby achieving comprehensive characterization of the dam stress field under seismic action and enhancing both the efficiency and accuracy of equivalent stress calculations for arch dams. This method provides more comprehensive and reliable data support for seismic design optimization and reinforcement of arch dams. Compared with the traditional foundation surface path method, the proposed method achieves 100% identification of the whole dam surface stress extremum areas, with a maximum relative error of only 1.62% in the overlapping calculation area. Full article

Electrical Discharge Machining (EDM) enables precision post-weld finishing of AISI 304 stainless steel, but stochastic spark overlaps make the fatigue-critical maximum peak-to-valley height (R_max) difficult to predict. This study develops a validated physics-based framework quantifying how crater overlap governs R_max evolution. Experiments on unwelded AISI 304 cylinders—proxying weld metal while excluding heat-affected zone (HAZ) effects—used Central Composite Design (20 trials, 900–9380 μJ discharge energies). Profilometry and scanning electron microscopy (SEM) correlated the crater size, overlap intensity, micro-cracking, and R_max escalation from 18 to 85 μm. Primary and secondary crater formation under minimum and maximum overlap configurations were simulated using a 2D axisymmetric finite element model with Gaussian heat flux and temperature-dependent thermophysical properties. The predictive metric R_max,num = (d_initial + d_secondary)/2 achieved 11–19% average error against the experimental R_max,exp, with complementary valley depth (R_v) validation at 13% error. The Specimen 7 outlier (~50% error) reveals the limitations of deterministic modelling under stochastic debris accumulation and plasma instability at intermediate energies. Crater overlap generates secondary dimples, sharp inter-crater peaks, and rim micro-crack networks, driving the 4.7-fold R_max increase—approaching International Institute of Welding (IIW) fatigue thresholds (<25 μm for high-cycle categories). The framework explicitly links the discharge energy, plasma channel radius (R_pc), and overlap geometry to surface topography, enabling process optimization (I·t_on < 60 A·s maintains R_max < 25 μm). Mesh independence (<2.5% convergence) and six centre-point replicates (CV = 4.2%) confirm robustness. This validated upper-bound R_max predictor supports the digital co-optimization of welding and EDM parameters for aerospace/energy applications, with planned extensions to stochastic 3D models incorporating adaptive remeshing and real weld topographies. Full article

As a critical aerospace structural material, the fatigue crack propagation behavior and fatigue life of the nickel-based GH4169 superalloy are directly related to the service safety of engineering components. The crack closure effect is one of the key factors influencing the fatigue life of metallic materials. At present, the finite element method (FEM) is widely used to investigate fatigue crack propagation in metals. However, the commercial software ABAQUS 2021b employs the conventional Paris law for crack growth simulation, which neglects the influence of crack closure. In addition, ABAQUS cannot simultaneously perform fatigue life prediction and crack path prediction within a single numerical model. To overcome these limitations, the bi-prism-based single-lens (BSL) three-dimensional digital image correlation (3D DIC) technique was employed to experimentally investigate the crack closure behavior during fatigue crack propagation in GH4169 compact tension (CT) specimens. A new parameter, termed the crack opening ratio (COR), was introduced to quantitatively characterize the crack closure effect. Furthermore, a self-developed plugin was implemented on the ABAQUS platform through secondary development, enabling the numerical model to incorporate the influence of crack closure during fatigue crack propagation. The plugin automatically records the crack tip coordinates at each propagation step, calculates the stress intensity factors near the crack tip, and predicts the corresponding fatigue life, thereby integrating crack path prediction and fatigue life prediction within a unified framework. The results demonstrate that the COR effectively characterizes the crack closure effect in the numerical model, and the predicted fatigue life agrees with experimental results within an 11% deviation once the crack reaches a certain length. Full article

Springback control in Multi-Point Stretch Forming (MPSF) is significantly hindered by the computational intensity of Finite Element Analysis (FEA) and the limited predictive robustness of traditional regression methods. This study develops a hybrid GWO-CatBoost model acting as a data-driven surrogate for MPSF simulations by integrating the Grey Wolf Optimizer (GWO) with the CatBoost algorithm for high-precision springback forecasting. An FEA model of the MPSF process was initially validated through experimental comparison under a representative working condition to assess modeling accuracy. A comprehensive dataset comprising 1200 scenarios was generated via a full factorial design, incorporating key variables: curvature radius, sheet thickness, cushion thickness, and pre-stretching rate. In this study, the GWO was employed to perform automated hyperparameter tuning for CatBoost by optimizing the learning rate, tree depth, and number of iterations, thereby enabling accurate modeling of the complex nonlinear relationship between process inputs and numerical springback values. Numerical evaluations demonstrate that the GWO-CatBoost model outperforms GWO-XGBoost and GWO-Random Forest benchmarks, achieving a Coefficient of Determination (R²) of 0.9293, a root mean square error (RMSE) of 0.0274 mm and mean absolute error (MAE) of 0.0189 mm. Sensitivity analysis identifies sheet thickness as the dominant factor (46% contribution), with cushion thickness as the secondary driver (23%). This predictive framework serves as a computationally efficient auxiliary surrogate, designed to assist iterative finite element analyses and support process optimization in the manufacture of complex-curved panels. Full article

Underground coal gasification (UCG) is an emerging energy technology that involves the in situ conversion of coal into syngas through controlled combustion within a subsurface excavation. The geomechanical processes associated with UCG can lead to significant overburden caving and surface subsidence, posing risks to surface infrastructure and groundwater systems. To accurately predict the size of overburden caving zones and associated surface subsidence, a prediction model was developed based on simulation results using discrete element method (DEM) numerical models. The main purpose of developing such a model is to establish a systematic and computationally efficient method for the rapid prediction of the height of overburden caving and its associated surface subsidence induced by underground excavation. The model is broadly applicable to different types of underground excavations, and UCG is used in this study as a representative application scenario to demonstrate the relevance and performance of the model. Sensitivity analysis indicates that excavation span, tensile strength, and burial depth are the primary controls on the height of the caving zone within the ranges of parameters investigated. Rock density is retained as a secondary background parameter to represent gravitational loading and its contribution to the in situ stress level. The derived model was validated using published numerical, experimental, and field measurement data, showing good agreement within practical ranges. To further demonstrate the application of the model developed, the predicted caving geometries were incorporated into finite element method (FEM) models to simulate surface subsidence under different geological conditions. The results highlight that the arch structure formed by overburden caving can help redistribute stresses and thereby reduce surface deformation. The proposed model provides a practical, parameter-driven tool to assist in underground excavation design, environmental risk evaluation, and ground stability management. Full article

Considering the complexity and diversity of water-rich soft soil strata, indoor triaxial shear tests and creep tests were conducted on soft soil to explore its deformation law and creep characteristics. To address the nonlinear characteristics of soft soil creep, a nonlinear pot element was proposed and substituted for the two linear pot elements in the Burgers model, thus establishing an unsteady parametric Burgers model. The one-dimensional creep equation of the unsteady Burgers model was derived, theoretically determining that the unsteady model can describe three stages of creep. Based on this, the creep equation of the unsteady Burgers model was extended to a three-dimensional stress state, and the triaxial compression creep test curves of Ningbo soft soil were fitted and parameters identified. The above model was derived from a three-dimensional finite difference scheme suitable for numerical solution in FLAC3D. A custom constitutive creep model was developed in FLAC3D, and the non-accelerated creep stage and accelerated creep stage of the improved model were analyzed to verify the accuracy and reliability of the constitutive model. The results show that the numerical simulation results and the indoor creep test results are in good agreement in terms of strain increment and the creep change curve, which confirms the effectiveness and applicability of the proposed unsteady Burgers creep constitutive model and its secondary development application. Full article

Pile foundations are extensively employed in large-diameter silos owing to their superior stability. However, conventional equal-stiffness designs often require thicker pile caps and higher reinforcement ratios, leading to increased construction costs. It promotes the study of this paper, which optimized the design of pile foundations for large-diameter silos to reduce construction costs. A three-dimensional (3D) finite element (FE) numerical model, incorporating superstructure–foundation–soil interaction, was developed using ANSYS to analyze the effects of pile cap thickness (PCT), pile length (PL), and pile diameter (PD) on maximum differential settlement (MDS). Sensitivity analysis quantified the influence of each parameter. Additionally, improvements to the automatic grouping genetic algorithm (AGGA) were proposed and implemented in Matlab to enhance design optimization. Results show that PCT has the greatest impact on MDS, followed by PL and PD. Optimal ranges are 1.7–2.3 m for PCT, 11.8–19.3 m for PL, and 0.6–1.2 m for PD. Using long-slender piles instead of short-thick piles reduces concrete consumption by 39.16% and decreases MDS by 73.5%, effectively mitigating secondary internal forces in the superstructure and pile cap. This approach enhances structural safety and overall system stability, offering a cost-effective solution for large-diameter silo foundations. Full article

Pre-tensioned T-beams with polygonal tendons offer high load-bearing capacity and suitability for large spans, demonstrating broad application potential in bridge engineering. The cracking state of a prestressed beam is a crucial indicator for assessing its service state, while the ultimate bearing capacity is a key metric for structural safety. In this study, we designed a novel 30 m pre-tensioned T-beam with polygonal tendons and investigated its shear cracking performance and ultimate bearing capacity under a shear-span ratio of 2.5 through a full-scale test. A graded loading protocol was employed. The results indicate that during the initial loading stage, the shear cracking load of the inclined section was 1766 kN. A distinct inflection point appeared on the load–displacement curve, accompanied by a significant reduction in stiffness. Cracks initially developed at the junctions between the web and the top flange, as well as the diaphragm, and subsequently propagated towards the shear–flexural region, exhibiting typical shear–compression failure characteristics. During the secondary loading to the ultimate state, the beam demonstrated good ductility and stress redistribution capability. The ultimate shear capacity reached 3868 kN. Failure occurred by crushing of the concrete in the compression zone after the critical inclined crack penetrated the web, with the member ultimately reaching its ultimate capacity through a plastic hinge mechanism. Strain analysis revealed that the polygonal tendons effectively restrained the premature development of inclined cracks, thereby enhancing the overall shear performance and deformation capacity. This study verifies the mechanical performance of the new T-beam under a shear span-to-depth ratio of 2.5 through calculations based on different codes and finite element numerical analysis, providing experimental evidence and theoretical references for its engineering application. Full article

As an essential highway safety facility, roadside W-beam guardrails effectively prevent errant vehicles from entering hazardous zones or causing secondary collisions by blocking and redirecting them, thereby reducing accident severity. With the rapid development of the automotive industry, the front bumper height of small passenger cars generally ranges between 405 mm and 485 mm. However, the lower edge height of the current Chinese Class A W-beam guardrail is 444 mm above the ground, which leads to a high risk of “underride” during collisions, resulting in elevated occupant injury risks. To address this issue, this paper proposes an optimized guardrail structure composed of a double W-beam and a C-type beam, aiming to reduce the underride risk for small passenger cars while accommodating multi-vehicle protection needs. In this design, the double W-beam is installed at a height of 560 mm and the C-type beam at 850 mm, connected to circular posts using a regular hexagonal anti-obstruction block. The beam thickness is uniformly 3 mm, while the thickness of other components is 4 mm. To systematically evaluate the impact of material strength on both safety performance and cost, two material configurations are proposed: Scheme 1 uses Q235 carbon steel for all components; Scheme 2 reduces the thickness of the C-type beam to 2.5 mm and employs Q355 high-strength low-alloy steel, with the thickness of the connected anti-obstruction block reduced to 3.5 mm, while the other components retain Q235 steel and unchanged structural dimensions. Using finite element simulation, collisions involving small passenger cars, medium trucks, and buses are simulated, and performance comparisons are conducted based on vehicle trajectory and guardrail deformation. For the small passenger car scenario, risk quantification indicators—Acceleration Severity Index (ASI), Theoretical Head Impact Velocity (THIV), and Post-impact Head Deceleration (PHD)—are introduced to assess occupant injury. The results demonstrate that Scheme 2 not only meets the required protection level but also significantly reduces occupant risk for small passenger cars, lowering the injury rating from Class C to Class B. Moreover, the overall structural mass is reduced by approximately 1407 kg per kilometer, with material costs decreased by about RMB 10,129, demonstrating favorable economic efficiency. The proposed structural optimization not only effectively mitigates small car underride and improves multi-vehicle protection performance but also provides the industry with a novel guardrail geometric design directly applicable to engineering practice. The technical approach of enhancing material strength and reducing component thickness also offers a feasible reference for lightweight design, material savings, and cost optimization of guardrail systems, contributing significantly to improving the safety and sustainability of road transportation infrastructure. Full article