Search Results (161)

This study analyzes the impact of geometric variations induced by the manufacturing process on the aerodynamic efficiency of an airfoil used in the design of a 3 kW wind turbine blade. For this purpose, a computational fluid dynamics (CFD) analysis was implemented, and the results were compared with those obtained using QBlade software. After blade fabrication, experimental evaluation was performed using the laser triangulation technique, enabling the reconstruction of the deformed airfoils and their comparison with the original geometry. Additional CFD simulations were carried out on the manufactured airfoil to quantify the loss of aerodynamic efficiency due to geometrical deformations. The results show that the geometric deviations significantly affect the aerodynamic coefficients, generating a decrease in the lift coefficient and an increase in the drag coefficient, which negatively impacts the airfoil aerodynamic efficiency. A 14.9% reduction in the rotor power coefficient was observed with the deformed airfoils compared to the original design. This study emphasizes the importance of quality control in wind turbine blade manufacturing processes and its impact on turbine power performance. In addition, the findings can contribute to the development of design compensation strategies to mitigate the adverse effects of geometric imperfections on the aerodynamic performance of wind turbines. Full article

Creating high-fidelity digital twins (DTs) for Industry 4.0 applications, it is fundamentally reliant on the accurate 3D modeling of physical assets, a task complicated by the inherent imperfections of real-world point cloud data. This paper addresses the challenge of reconstructing accurate, watertight, and topologically sound 3D meshes from sparse, noisy, and incomplete point clouds acquired in complex industrial environments. We introduce a robust two-stage completion-to-reconstruction framework, C2R3D-Net, that systematically tackles this problem. The methodology first employs a pretrained, self-supervised point cloud completion network to infer a dense and structurally coherent geometric representation from degraded inputs. Subsequently, a novel adaptive surface reconstruction network generates the final high-fidelity mesh. This network features a hybrid encoder (FKAConv-LSA-DC), which integrates fixed-kernel and deformable convolutions with local self-attention to robustly capture both coarse geometry and fine details, and a boundary-aware multi-head interpolation decoder, which explicitly models sharp edges and thin structures to preserve geometric fidelity. Comprehensive experiments on the large-scale synthetic ShapeNet benchmark demonstrate state-of-the-art performance across all standard metrics. Crucially, we validate the framework’s strong zero-shot generalization capability by deploying the model—trained exclusively on synthetic data—to reconstruct complex assets from a custom-collected industrial dataset without any additional fine-tuning. The results confirm the method’s suitability as a robust and scalable approach for 3D asset modeling, a critical enabling step for creating high-fidelity DTs in demanding, unseen industrial settings. Full article

In recent years, there has been an increasing transition from 1D point-based to 3D point-cloud-based data acquisition for monitoring applications and deformation analysis tasks. Previously, many studies relied on point-to-point measurements using total stations to assess structural deformation. However, the introduction of terrestrial laser scanning (TLS) has commenced a new era in data capture with a high level of efficiency and flexibility for data collection and post processing. Thus, a robust understanding of both data acquisition and processing techniques is required to guarantee high-quality deliverables to geometrically separate the measurement uncertainty and movements. TLS is highly demanding in capturing detailed 3D point coordinates of a scene within either short- or long-range scanning. Although various studies have examined scanner misalignments under controlled conditions within the short range of observation (scanner calibration), there remains a knowledge gap in understanding and characterizing errors related to long-range scanning (scanning calibration). Furthermore, limited information on manufacturer-oriented calibration tests highlights the motivation for designing a user-oriented calibration test. This research focused on investigating four primary sources of error in the generic error model of TLS. These were categorized into four geometries: instrumental imperfections related to the scanner itself, atmospheric effects that impact the laser beam, scanning geometry concerning the setup and varying incidence angles during scanning, and object and surface characteristics affecting the overall data accuracy. This study presents previous findings of TLS calibration relevant to the four error sources and mitigation strategies and identified current challenges that can be implemented as potential research directions. Full article

This study systematically investigates the axial compression capacity calculation method for 7075-T6 aluminum alloy rectangular hollow section (RHS) members based on the Continuous Strength Method (CSM). Axial compression tests were conducted on nine RHS specimens using a YAW-500 electro-hydraulic servo testing machine, and nonlinear finite element models considering material plasticity and geometric imperfections were established using ABAQUS/CAE. The numerical results showed good agreement with experimental data, verifying the model’s reliability. Parametric analysis was then performed on RHS members, leading to the development of a CSM-based capacity calculation method and a modified curve for predicting the stability reduction factors of square hollow section members. The approach combining this modified curve with Chinese codes is termed the Modified Chinese Code Method. The axial capacities calculated by the CSM-based method, Modified Chinese Code Method, EN 1999-1-1, and AASTM were compared for accuracy evaluation. The conclusions indicate that the proposed modified curve provides more accurate predictions of stability coefficients for square tubes, and the CSM-based method yields more precise capacity predictions than existing international design codes, though it may overestimate the capacity for Class 4 cross-section members and thus requires further refinement. Full article

Near-unstable cavities hold promise for reducing thermal noise in next-generation gravitational wave detectors and for enhancing light–matter interactions in quantum electrodynamics. However, operating close to the edge of geometrical stability presents significant challenges, including increased coupling to higher-order modes and heightened sensitivity to small cavity length changes and mirror imperfections. This study employs Finesse v3 simulations to systematically investigate the modal behavior of a plano-concave cavity as it approaches instability, incorporating measured mirror surface defects and anisotropic curvature to replicate realistic conditions. The simulations highlight the degradation of beam purity and control signals as the cavity approaches instability. By validating the simulations against experimental data, we confirm Finesse’s reliability for modeling cavities while identifying critical limitations in regimes close to the edge of stability. These findings provide essential guidance for optimizing cavity designs in future gravitational wave detectors, balancing performance gains against the challenges of operating at the stability edge. Full article

This study delves into the delamination-driven nonlinear buckling characteristics of metal–composite cylindrical shells with different interfacial strengths. Although surface treatments are known to affect bonding performance, their specific influences on the delamination buckling behavior of metal–composite cylindrical shells remain underexplored. Accordingly, sandblasting and polishing processes were employed to the fabrication of single-lap shear specimens. The topography of the treated surface was then characterized through scanning electron microscopy, optical profilometry, and contact angle measurements. For topography characterization and performance tests, sandblasted and polished metal–composite cylindrical shells were fabricated for hydrostatic tests. A cohesive zone model was used to analyze the influences of interfacial strength on the nonlinear buckling characteristics of metal–composite cylindrical shells, and the modeling results were validated by benchmarking them with experimental results. Subsequently, a detailed parametric study was conducted to investigate the effects of cohesive zone parameters and geometric imperfection on the load-bearing capacity of the shells. The new findings reveal that among the fabricated steel specimens, the specimens subjected to 80-mesh sandblasting exhibited the highest bond strength in single-lap shear tests, with the bond strength being 2.56 times higher than that of polished specimens. Moreover, sandblasted metal–composite cylindrical shells exhibited a 55.0% higher average collapse load than that of polished metal–composite cylindrical shells. Full article

The patch loading resistance of slender steel plate girders is a critical factor in the design of launched steel and composite steel–concrete bridges. Traditional design methods enhance patch loading resistance through various stiffening techniques, with contributions typically estimated via code expressions calibrated on experimental data that do not always reflect the complexities of full-scale bridge applications. Finite Element (FE) modeling offers a more realistic alternative, though its practical application is often hindered by modeling uncertainties and nonlinearities. To bridge this gap, this paper introduces an advanced FE modeling approach. It provides a comprehensive description of an FE model that accurately predicts both the load–displacement behavior and the patch loading resistance. The model is benchmarked against a broad set of experimental tests and systematically investigates the effects of key modeling parameters and their interactions—material stress–strain law, boundary condition representation, stiffness of the load introduction area, initial geometric imperfections, and solving algorithms. Key findings demonstrate that a bilinear elastoplastic material model with hardening is sufficient for estimating ultimate resistance, and kinematic constraints can effectively replace rigid transverse stiffeners. The stiffness of the load application zone significantly influences the response, especially in launched bridge scenarios. Initial imperfections notably affect both stiffness and strength, with standard fabrication tolerances offering suitable input values. The modified Riks algorithm is recommended for its efficiency and stability in nonlinear regimens. The proposed methodology advances the state of practice by providing a simple yet reliable FE modeling approach for predicting patch loading resistance in real-world bridge applications, leading to safer and more reliable structural designs. Full article

This study deals with the problem of uneven wear of brake pads of wagons caused by a set of structural, dynamic, technological and operational factors. It has been found that an uneven distribution of the brake pad pressure force leads to higher maintenance costs and lower braking efficiency. The main causes of uneven wear are worn kinetostatic units, differences in the geometric parameters of pads, and imperfections in the lever transmission design. A method for optimizing the distribution of the pressure force using weight coefficients and the Lagrange function has been developed; it reduces the uneven wear of brake pads to 8–10% compared to that of a typical wagon bogie brake system, which is 20–35%. The experiments conducted have shown that for a mileage of 74,400 km and with the air distributor in empty mode, the wear of the pads is 19.6–28 mm, while in the loaded mode it amounts to 27.53–38.04 mm. The stress state of brake pads was determined with consideration of the weight coefficients. It was found that for abnormal wear of brake pads, their strength is not observed. The strength of the wheel when interacting with an abnormally worn pad has also been assessed. The resulting stresses are 1.5% higher than those that occur when the wheel interacts with the pad with nominal dimensions. The results of the research will contribute to the database of developments to be used for designing of modern structures of tribotechnical pairs of rolling stock and increasing the efficiency of railway transport. Full article

Robotic positioning accuracy is critically affected by both geometric and non-geometric errors. To address this dual error issue comprehensively, this paper proposes a novel two-stage compensation framework. First, a Memory based red billed blue magpie optimizer (MRBMO) is employed to identify and compensate for geometric errors by optimizing the geometric parameters based on end-effector observations. This memory-guided evolutionary mechanism effectively enhances the convergence accuracy and stability of the geometric calibration process. Second, a tuned graph neural network (AMPSO-GNN) is developed to model and compensate for non-geometric errors, such as cable deformation, thermal drift, and control imperfections. The GNN architecture captures the topological structure of the robotic system, while the adaptive momentum PSO dynamically optimizes the network’s hyperparameters for improved generalization. Experimental results on a six-axis industrial robot demonstrate that the proposed method significantly reduces residual positioning errors, achieving higher accuracy compared to conventional calibration and compensation strategies. This dual-compensation approach offers a scalable and robust solution for precision-critical robotic applications. Full article

An analytical study of the nonlinear response of imperfect stiffened doubly curved shells made of functionally graded material (FGM) is presented. The formulation of the problem is based on the first-order shear deformation shell theory in conjunction with the von Kármán geometrical nonlinear strain–displacement relationships. The nonlinear equations of the motion of stiffened double-curved shells based on the extended Sanders’s theory were derived using Galerkin’s method. The material properties vary in the direction of thickness according to the linear rule of mixture. The effect of both longitudinal and transverse stiffeners was considered using Lekhnitsky’s technique. The fundamental frequencies of the stiffened shell are compared with the FE solutions obtained by using the ABAQUS 6.14 software. A stepwise approximation technique is applied to model the functionally graded shell. The resulting nonlinear ordinary differential equations were solved numerically by using the fourth-order Runge–Kutta method. Closed-form solutions for nonlinear frequency–amplitude responses were obtained using He’s energy method. The effect of power index, functionally graded stiffeners, geometrical parameters, and initial imperfection on the nonlinear response of the stiffened shell are considered and discussed. Full article

Despite significant progress, fabricating two-dimensional (2D) lithium niobate (LN)-based photonic crystal (PhC) cavities integrated with tapered and PhC waveguides remains challenging, due to structural imperfections. Notable, especially, are variations in hole radius (r) and inclination angle (°), which induce bandgap shifts and degrade quality factors (Q-factor). These fabrication errors underscore the critical need to address nanoscale tolerances. Here, we systematically investigate the impacts of key geometric parameters on optical performance and optimize a 2D LN-based cavity integrated with taper and PhC waveguide system. Using a 3D Finite-Difference Time-Domain (FDTD) and varFDTD simulations, we identify stringent fabrication thresholds. The a must exceed 0.72 µm to sustain Q > ${10}^7$; reducing a to 0.69 µm collapses Q-factors below ${10}^4$, due to under-coupled modes and bandgap misalignment, which necessitates ±0.005 µm precision. When an r < 0.22 µm weakens confinement, Q plummets to 2 × ${10}^4$ at r = 0.20 µm (±0.01 µm etching tolerance). Inclination angles < 70° induce 100× Q-factor losses, requiring ±2° alignment for symmetric modes. Air slot width (s) variations shift resonant wavelengths and require optimization in coordination with the inclination angle. By optimizing s and the inclination angle (at 70°), we achieve a record Q-factor of 6.21 ×${10}^6$, with, in addition, C-band compatibility (1502–1581 nm). This work establishes rigorous design–fabrication guidelines, demonstrating the potential for LN-based photonic devices with high nano-fabrication robustness. Full article

Stiffened panels are extensively used in aerospace applications, particularly in wing and fuselage sections, due to their favorable strength-to-weight ratio under in-plane loading conditions. This research employs the commercial finite element software Ansys-19 to analysis the critical buckling and ultimate collapse load of an aluminum stiffened panel having a dimension of 1244 mm (Length) × 957 mm (width) × 3.5 mm (thickness), with three stiffener blades located 280 mm away from each other. Both the critical buckling load and post-buckling ultimate failure load of the panel are validated against the experimental data found in the available literature, where the edges towards the length are clamped and simply supported, and the other two edges are free. For nonlinear buckling analysis, a plasticity power law is adopted with a small geometric imperfection of 0.4% at the middle of the panel. After the numerical validation, the investigation is further carried out considering four different lateral pressures, specifically 0.013 MPa, 0.065 MPa, 0.085 MPa, and 0.13 MPa, along with the compressive loading boundary conditions. It was found that even though the pressure application of 0.013 MPa did not significantly impact the critical buckling load of the panel, the ultimate collapse load was reduced by 18.5%. In general, the ultimate collapse load of the panel was severely affected by the presence of lateral pressure while edge compressing. Three opening shapes—namely, square, circular, and rectangular/hemispherical—were also investigated to understand the behavior of the panel with openings. It was found that the openings significantly affected the critical buckling load and ultimate collapse load of the stiffened panel, with the lateral pressure also contributing to this effect. Finally, in critical areas with higher lateral pressure load, a titanium panel can be a good alternative to the aluminum panel since it can provide almost twice to thrice better buckling stability and ultimate collapse load to the panels with a weight nearly 1.6 times higher than aluminum. These findings highlight the significance of precision manufacturing, particularly in improving and optimizing the structural efficiency of stiffened panels in aerospace industries. Full article

Bimetallic-clad pipes demonstrate exceptional advantages in transporting corrosive oil and gas through the combination of the load-carrying capacity of the base material and the anti-corrosive function of the thin layer of corrosion-resistant alloy. This study investigates the mechanical properties of 24-inch X65 + Alloy625 metallurgically clad pipes through experimental tests and finite element analysis. Uniaxial tensile testing with digital image correlation reveals uniform deformation between the base and clad layers until interfacial failure initiates at an average strain threshold of 34.17%. Microstructural characterization shows continuous metallurgical bonding, with the X65 layer exhibiting polygonal ferrite and bainitic phases, contrasting with the austenitic equiaxed grain structure of Alloy625. In terms of numerical modeling, finite element analyses that consider both initial geometric imperfections and manufacturing-induced residual stresses are performed to evaluate the bending response of the clad pipe. The effect of initial ovality and residual stresses on its bending capacity is also studied. Full article

As part of the seismic capacity assessment of thin-walled tanks containing liquid fuels, the appropriate modeling of hydrodynamic loads is required. The theory adopted in existing work requires the modeling of the hydrodynamic pressure contribution due to tank deformability, which, however, cannot be calculated in closed form. The approach adopted in this work uses acoustic–structural modal analysis to obtain the deformation and response period required to calculate this contribution. The use of the proposed method, on a finite element model, allows the implementation of thickness variability and more geometric detail in the modal analysis. On the other hand, using the obtained load distributions, in non-linear static analyses, reduces the computational time compared to dynamic simulations. In addition, analyses can be performed by importing a pre-deformed surface derived from a three-dimensional scan of the real tank into the final model, thus including the effect of geometric imperfections. As a case study, an existing tank model was produced and analyzed, and the same damage patterns documented in real cases following seismic events were obtained. Therefore, due to the low computational cost, this method is appropriate to be reproduced for a statistically significant number of load cases. Full article

This study experimentally and numerically investigated the overall buckling behavior of steel box column components. Two box section specimens were fabricated for axial compression tests. Prior to the tests, the material properties, initial geometric imperfections and residual stress were measured. In addition, an extended parameter analysis was conducted using a finite element model validated by experimental results to evaluate the impact of geometric defects and residual stresses on the bearing capacity of unstiffened and stiffened box section columns. A novel column curve was proposed based on massive datasets of parametric models. The short and long column specimens exhibited typical strength failure and buckling failure modes, respectively. The initial geometric imperfections and residual stresses slightly reduced the buckling strength from the models, with a maximum reduction in buckling strength owing to initial geometric imperfections of 5.2% and that owing to residual stresses of 6.52%. The unstiffened and stiffened box columns have the same stability coefficient when the slenderness ratio is the same. Additionally, the ultimate load capacity calculation formula for stiffened box columns proposed in this paper averages 2.20% higher than Class C curves in JTG D64-2015, lies between Japanese and U.S. codes, and demonstrates good accuracy. Full article