Search Results (4,089)

This study presents the first investigation into the application of ultrasonic vibration-assisted electrical discharge machining (UV-EDM) using graphite electrodes for external cylindrical surface machining—an essential surface in the production of tablet punches and sheet metal-forming dies. A custom ultrasonic horn was designed and fabricated using 90CrSi material to operate effectively at a resonant frequency of 20 kHz, ensuring stable vibration transmission throughout the machining process. A Box–Behnken experimental design was employed to explore the effects of five process parameters—vibration amplitude (A), pulse-on time (Ton), pulse-off time (Toff), discharge current (Ip), and servo voltage (SV)—on two key performance indicators: material removal rate (MRR) and surface roughness (Ra). The optimization process was conducted in two stages: single-objective analysis to maximize MRR while ensuring Ra < 4 µm, followed by a hybrid multi-objective approach combining NSGA-II and the Analytic Hierarchy Process (AHP). The optimal solution achieved a high MRR of 9.28 g/h while maintaining Ra below the critical surface finish threshold, thus meeting the practical requirements for punch surface quality. The findings confirm the effectiveness of the proposed horn design and hybrid optimization strategy, offering a new direction for enhancing productivity and surface integrity in cylindrical EDM applications using graphite electrodes. Full article

The aim of this paper is to tailor the geometry and material parameters of a three-layer railway track model to achieve favorable properties for the circulation of high-speed trains at very high velocities. The three layers imply that the model should have three critical velocities for resonance. However, in many cases, some of these values are missing and must be replaced by pseudo-critical values. Since no resonance occurs at pseudo-critical velocities, even in the absence of damping, deflections never reach infinity. By using optimization techniques, it is possible to adjust the model’s parameters, so that the increase in vibrations remains minimal and does not pose a real danger. In this way, circulation velocities could be extended beyond the critical value, thereby increasing the network capacity and, consequently, improving the competitiveness of rail transport compared to other modes of transportation, thus contributing to decarbonization. The presented results are preliminary and require further analysis and validation. Several optimization techniques are implemented, leading to the establishment of designs that already have rather high pseudo-critical velocities. Further research will show how these theoretical findings can be utilized in practice.  Full article

The current paper presents a comprehensive intelligent system designed to optimize the performance of a barrier eddy current separator (BECS), comprising a conveyor belt, a vibration feeder, and a magnetic drum. This system was trained and validated on real-world industrial data gathered directly from the working separator under 81 different operational scenarios. The intelligent models were used to recommend optimal settings for drum speed, belt speed, vibration intensity, and drum angle, thereby maximizing separation quality and minimizing energy consumption. the smart separation module utilizes YOLOv11n-seg and achieves a mean average precision (mAP) of 0.838 across 7163 industrial instances from aluminum, copper, and plastic materials. For shape classification (sharp vs. smooth), the model reached 91.8% accuracy across 1105 annotated samples. Furthermore, the thermal monitoring unit can detect iron contamination by analyzing temperature anomalies. Scenarios with iron showed a maximum temperature increase of over 20 °C compared to clean materials, with a detection response time of under 2.5 s. The architecture integrates a Digital Twin using Azure Digital Twins to virtually mirror the system, enabling real-time tracking, behavior simulation, and remote updates. A full connection with the PLC has been implemented, allowing the AI-driven system to adjust physical parameters autonomously. This combination of AI, IoT, and digital twin technologies delivers a reliable and scalable solution for enhanced separation quality, improved operational safety, and predictive maintenance in industrial recycling environments. Full article

This study presents a detailed experimental comparison of the rotordynamic and thermal performance of automotive turbochargers supported by two distinct hydrodynamic bearing configurations: fully floating ring bearings (FFRBs) and semi-floating ring bearings (SFRBs). While both designs are widely used in commercial turbochargers, they exhibit significantly different dynamic behaviors due to differences in ring motion and fluid film interaction. A cold air-driven test rig was employed to assess vibration and temperature characteristics across a range of controlled lubricant conditions. The test matrix included oil supply pressures from 2 bar (g) to 4 bar (g) and temperatures between 30 °C and 70 °C. Rotor speeds reached up to 200 krpm (thousands of revolutions per minute), and data were collected using a high-speed data acquisition system, triaxial accelerometers, and infrared (IR) thermal imaging. Rotor vibration was characterized through waterfall and Bode plots, while jump speeds and thermal profiles were analyzed to evaluate the onset and severity of instability. The results demonstrate that the FFRB configuration is highly sensitive to oil supply parameters, exhibiting strong subsynchronous instabilities and hysteresis during acceleration–deceleration cycles. In contrast, the SFRB configuration consistently provided superior vibrational stability and reduced sensitivity to lubricant conditions. Changes in lubricant supply conditions induced a jump speed variation in floating ring bearing (FRB) turbochargers that was approximately 3.47 times larger than that experienced by semi-floating ring bearing (SFRB) turbochargers. Furthermore, IR images and oil outlet temperature data confirm that the FFRB system experiences greater heat generation and thermal gradients, consistent with higher energy dissipation through viscous shear. This study provides a comprehensive assessment of both bearing types under realistic high-speed conditions and highlights the advantages of the SFRB configuration in improving turbocharger reliability, thermal performance, and noise suppression. The findings support the application of SFRBs in high-performance automotive systems where mechanical stability and reduced frictional losses are critical. Full article

The Furuta pendulum is a well-known benchmark in the field of underactuated mechanical systems due to its reduced number of control inputs compared to its degrees of freedom, and richly nonlinear behavior. This work addresses the challenge of accurately modeling and controlling such a system without relying on traditional linearization techniques. In contrast to the common approach based on Lagrangian analytical modeling and state–space linearization, we propose a methodology that integrates a high-fidelity multibody model developed in Simscape Multibody (MATLAB), capturing the complete nonlinear dynamics of the system. The multibody model includes all geometric, inertial, and joint parameters of the physical hardware and interfaces directly with Simulink, enabling realistic simulation and control integration. To validate the physical fidelity of the multibody model, we perform a frequency-domain analysis of the pendulum’s natural free response. The dominant vibration frequency extracted from the simulation is compared with the theoretical prediction, demonstrating accurate capture of the system’s inertial and dynamic properties. This validation strategy strengthens the reliability of the model as a digital twin. The classical analytical formulation is provided to validate the simulation model and serve as a comparative framework. This dual modeling strategy allows for benchmarking control strategies against a trustworthy nonlinear digital twin of the Furuta pendulum. Preliminary experimental results using a physical prototype validate the feasibility of the proposed approach and set the foundation for future work in advanced nonlinear control design using the multibody representation as a digital validation tool. Full article

Repairing veneer defects is the key to ensuring the quality of plywood. In order to improve the maintenance quality and material utilization efficiency during the maintenance process, this paper proposes a bidirectional maintenance method based on gear rack transmission and its related equipment. Based on the working principle, a geometric relationship model was established, which combines the structural parameters of the mold, punch, and gear system. Simultaneously, it solves the problem of motion attitude analysis of conjugate tooth profiles under non-standard meshing conditions, aiming to establish a constraint relationship between stamping motion and structural design parameters. On this basis, a constrained optimization model was developed by integrating multi-objective optimization theory to maximize maintenance efficiency. The NSGA-III algorithm is used to solve the model and obtain the Pareto front solution set. Subsequently, three optimal parameter configurations were selected for simulation analysis and experimental platform construction. The simulation and experimental results indicate that the veneer repair time ranges from 0.6 to 1.8 seconds, depending on the stamping speed. A reduction of 28 mm in die height decreases the repair time by approximately 0.1 seconds, resulting in an efficiency improvement of about 14%. The experimental results confirm the effectiveness of the proposed method in repairing veneer defects. Vibration measurements further verify the system’s stable operation under parametric modeling and optimization design. The main vibration response occurs during the meshing and disengagement phases between the gear and rack. Full article

In this paper, an uncertainty optimization method based on the adaptive hybrid correlation Kriging surrogate model is proposed to optimize the ply angles of laminated spherical-conical shells. First, equations of motion of laminated spherical-conical shells are constructed to calculate the vibration characteristics. Then, this paper proposes a Kriging surrogate model with adaptive weight hybrid correlation functions and validates its accuracy. Based on this framework, the weight distribution of the surrogate model for uncertain parameters in laminated spherical-conical shells under different ply angles is analyzed. To address the uncertainty optimization problem in laminated spherical-conical shell structures, an Improved Multi-objective Salp Swarm Algorithm is developed, and its optimization efficacy is systematically validated. Furthermore, an adaptive hybrid correlation Kriging surrogate model is reconstructed, incorporating both uncertainty parameters and design variables as inputs, with the peak vibration displacement and fundamental frequency serving as the output responses. The uncertainty optimization results confirm that the proposed methodology, along with the enhanced Kriging modeling strategy, exhibits both applicability and computational efficiency for such engineering applications. Full article

To address the issue of low accuracy in identifying the transition states of rolling bearing performance degradation when relying solely on vibration signals, this study proposed a vibration–temperature fusion-based adaptive method for bearing performance degradation assessments. First, a multidimensional time–frequency feature set was constructed by integrating vibration acceleration and temperature signals. Second, a novel composite sensitivity index (CSI) was introduced, incorporating the trend persistence, monotonicity, and signal complexity to perform preliminary feature screening. Mutual information clustering and regularized entropy weight optimization were then combined to reselect highly sensitive parameters from the initially screened features. Subsequently, an adaptive feature fusion method based on auto-associative kernel regression (AFF-AAKR) was introduced to compress the data in the spatial dimension while enhancing the degradation trend characterization capability of the health indicator (HI) through a temporal residual analysis. Furthermore, the entropy weight method was employed to quantify the information entropy differences between the vibration and temperature signals, enabling dynamic weight allocation to construct a comprehensive HI. Finally, a dual-criteria adaptive bottom-up merging algorithm (DC-ABUM) was proposed, which achieves bearing life-stage identification through error threshold constraints and the adaptive optimization of segmentation quantities. The experimental results demonstrated that the proposed method outperformed traditional vibration-based life-stage identification approaches. Full article

This study proposes a vibration-based approach for detecting and quantifying sub-slab corner voids in airport cement concrete pavement. Scaled down slab models were constructed and subjected to controlled moving load simulations. Acceleration signals were collected and analyzed to extract time–frequency domain features, including power spectral density (PSD), skewness, and frequency center. A finite element model incorporating contact and nonlinear constitutive relationships was established to simulate structural response under different void conditions. Based on the simulated dataset, a random forest (RF) model was developed to estimate void size using selected spectral energy indicators and geometric parameters. The results revealed that the RF model achieved strong predictive performance, with a high correlation between key features and void characteristics. This work demonstrates the feasibility of integrating simulation analysis, signal feature extraction, and machine learning to support intelligent diagnostics of concrete pavement health. Full article

This study employs a force element analysis to investigate vortex-induced vibrations (VIV) of three side-by-side circular cylinders at Reynolds number Re = 100, mass ratio m* = 10, spacing ratios S/D = 3–6, and reduced velocities Ur = 2–14. The lift and drag forces are decomposed into three physical components: volume vorticity force, surface vorticity force, and surface acceleration force. The present work systematically examines varying S/D and Ur effects on vibration amplitudes, frequencies, phase relationships, and transitions between distinct vortex-shedding patterns. By quantitative force decomposition, underlying physical mechanisms governing VIV in the triple-cylinder system are elucidated, including vortex dynamics, inter-cylinder interference, and flow structures. Results indicate that when S/D < 4, cylinders exhibit “multi-frequency” vibration responses. When S/D > 4, the “lock-in” region broadens, and the wake structure approaches the patterns of an isolated single cylinder; in addition, the trajectories of cylinders become more regularized. The forces acting on the central cylinder present characteristics of stochastic synchronization, significantly different from those observed in two-cylinder systems. The results can advance the understanding of complex interactions between hydrodynamic and structural dynamic forces under different geometric parameters that govern VIV response characteristics of marine structures. Full article

The aim of this paper is the investigation of changes in modal parameters of composite pressure vessel structures with different prestress states realized by varying fiber tension. Two series of vessels was manufactured and examined with different wound tensions, the first—3 N and second—80 N, respectively. Other technological factors, such as the type and weight of carbon fiber used, as well as liner type, were kept constant. The vessels were examined with internal pressure equal to atmospheric and without pressure fittings. The modal tests were performed on storage tanks suspended on an elastic cord in the horizontal orientation to prevent the structure from being disturbed by vibrations. The examinations were focused only on the cylindrical part of the vessels. Based on modal analysis, parameters such as natural frequencies, dampings and modal shapes were determined. Research results indicate clear changes in natural frequencies and damping coefficients between the two investigated prestress states. It is interesting that natural frequencies for bending modes are higher in the case of structures with high fiber tension, while in the case of other vibration forms, the natural frequencies have smaller values in comparison with the first series. Full article

The dynamics of the vibrational mode of motion of the driving member of a nonideal system, a mixing–whipping device based on a simple slide-crank mechanism, was studied. The highly nonlinear differential equations of motion were solved numerically by the Runge–Kutta method. The interaction of the mixing–whipping device with the nonideal excitation source causes the rotational speed of the engine shaft and the rotation angle of the driving member to fluctuate, accomplishing a damped process. The parameters of the device and the nonideal energy source have an effect on the kinematic, vibrational and energy characteristics of the system. An increase in the engine’s torque, crank length, number and radius of piston holes, and piston mass, as well as a decrease in the fluid’s density, leads to a reduction in the oscillation range of the crank angle, amplitude and period of angular velocity oscillations of the engine shaft and the mixing–whipping force power. The effects of a nonideal energy source may be used in designing a mixing–whipping device based on a slider-crank mechanism to select effective system parameters and an energy-saving motor in accordance with the requirements of technological processes and products. Full article

Material extrusion additive manufacturing (MEAM) has emerged as a versatile and widely adopted 3D printing technology due to its cost-effectiveness and ability to process a diverse range of materials. However, achieving consistent part quality and repeatability remains a challenge, mainly due to variations in process parameters and material behavior during fabrication. In-situ monitoring and advanced process control systems have been increasingly integrated into MEAM to address these issues, enabling real-time detection of defects, optimization of printing conditions, reliability of fabricated parts, and enhanced control over mechanical properties. This review examines the state-of-the-art in-situ monitoring techniques, including thermal imaging, vibrational sensing, rheological monitoring, printhead positioning, acoustic sensing, image recognition, and optical scanning, and their integration with process control strategies, such as closed-loop feedback systems and machine learning algorithms. Key challenges, including sensor accuracy, data processing complexity, and scalability, are discussed alongside recent advancements and their implications for industrial applications. By synthesizing current research, this work highlights the critical role of in-situ monitoring and process control in advancing the reliability and precision of MEAM, paving the way for its broader adoption in high-performance manufacturing. Full article

This paper investigates the vibration suppression of cantilevered beams using nonlinear shunted piezoelectric circuits. The beam’s inertia and geometric nonlinearities are considered. A quadratic nonlinear piezoelectric capacitance is used such that there exists a two-to-one internal resonance between the mechanical and electrical modes. The internal resonance coupling is exploited to trigger the saturation phenomenon such that the beam’s vibration reaches a limit beyond an excitation amplitude threshold. The equations governing the nonlinear vibration of the beam coupled with the shunt circuit are derived, and modal analysis is used to obtain a system of two nonlinearly coupled modal equations. The equations are then numerically integrated to obtain the results. A parametric study is performed to assess the significance of system parameters, such as the location of the piezoelectric patch, its size, circuit resistance, and nonlinear gain, on the effectiveness of vibration suppression. The results show that the proposed design effectively suppresses the linear and nonlinear vibrations of the beam. The proposed absorber is space-efficient and does not add mass to the primary system, and hence, it has the potential in systems where the weight matters, such as aerospace applications. Full article

Background: Off-label nebulization of tranexamic acid (TXA) solution is common practice for the treatment of hemoptysis. However, data regarding nebulization protocols, resulting aerodynamic parameters of the generated aerosol, and corresponding biopharmaceutical parameters are missing. The aim of this in vitro study was to investigate the aerosol characteristics of nebulized sterile, aqueous TXA solution. Methods: TXA solution 100 mg/mL was nebulized for 2 min by a multi-dose vibrating mesh nebulizer using 15 L/min and 30 L/min air flow rates. The generated aerosol was analyzed by a Next Generation Cascade Impactor. For each air flow rate, the mean Fine Particle Dose (FPD), Fine Particle Fraction (FPF), the Mass Median Aerodynamic Diameter (MMAD), and Geometric Standard Deviation (GSD) were quantified. Results: Nebulization at 15 L/min air flow rate resulted in a MMAD of 6.68 ± 0.23 µm and GSD of 2.02 ± 0.16. The FPD < 5 µm was 16.56 ± 0.45 mg, the FPF < 5 µm 28.91 ± 3.40%. Nebulization at 30 L/min air flow rate revealed a MMAD of 5.18 ± 0.12 µm and GSD of 2.14 ± 0.10. The FPD < 5 µm was 16.30 ± 1.38 mg, the FPF < 5 µm 35.43 ± 0.59%. Conclusions: Nebulization of TXA 100 mg/mL solution by a specified vibrating mesh nebulizer generated an aerosol particle distribution and deposition pattern suitable for the treatment of hemoptysis with bronchial origin. Full article