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Keywords = wrinkling prediction

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25 pages, 3359 KiB  
Article
In Vitro and In Silico Evaluation of the Anti-Aging Potential of Eugenia uniflora UAE Extracts
by Desy Muliana Wenas, Berna Elya, Sutriyo Sutriyo, Heri Setiawan, Rozana Othman, Syamsu Nur, Nita Triadisti, Fenny Yunita and Erwi Putri Setyaningsih
Molecules 2025, 30(15), 3168; https://doi.org/10.3390/molecules30153168 - 29 Jul 2025
Viewed by 229
Abstract
Skin aging is a natural biological process that can be accelerated by free radical induction, leading to a reduction in skin elasticity and the formation of wrinkles due to the depletion of elastin. Eugenia uniflora (dewandaru) is a promising plant believed to possess [...] Read more.
Skin aging is a natural biological process that can be accelerated by free radical induction, leading to a reduction in skin elasticity and the formation of wrinkles due to the depletion of elastin. Eugenia uniflora (dewandaru) is a promising plant believed to possess anti-aging properties, primarily attributed to its major constituents, myricitrin and quercetin. This study aimed to investigate the anti-elastase and antioxidant properties of Eugenia uniflora stem bark, ripe fruit, and seed extracts. Extracts were obtained using an ultrasound-assisted extraction (UAE) method with 70% ethanol. Quantitative phytochemical analysis involved measuring the total phenolic content (TPC), total flavonoid content (TFC), and antioxidant activity. Bioactive constituents were identified using LC-MS analysis, and their interactions with target enzymes were further evaluated through in silico molecular docking. The results demonstrated that the E. uniflora seed extract exhibited the highest antioxidant activity, with an IC50 of 5.23 µg/mL (DPPH assay) and a FRAP value of 3233.32 µmol FeSO4/g. Furthermore, the ethanolic seed extract showed significant anti-elastase activity with an IC50 of 114.14 µg/mL. Molecular docking predicted strong potential for several compounds as pancreatic elastase inhibitors, including 5-phenylvaleric acid, 2-(3-phenylpropyl)phenol, n-amylbenzene, 2-aminoadipic acid, and traumatin, each showing a prediction activity (PA) value exceeding 0.6. Notably, these compounds also exhibited inhibitory activity against tyrosinase. These findings collectively underscore the significant promise of E. uniflora seed extract as a novel and natural candidate for pharmacocosmeceutical product development, particularly for anti-aging applications. Full article
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23 pages, 4015 KiB  
Article
Predicting Electromagnetic Performance Under Wrinkling in Thin-Film Phased Arrays
by Xiaotao Zhou, Jianfei Yang, Lei Zhang, Huanxiao Li, Xin Jin, Yesen Fan, Yan Xu and Xiaofei Ma
Aerospace 2025, 12(7), 630; https://doi.org/10.3390/aerospace12070630 - 14 Jul 2025
Viewed by 246
Abstract
Deployable thin-film antennas deliver large aperture gains and high stowage efficiency for spaceborne phased arrays but suffer wrinkling-induced planarity loss and radiation distortion. To bridge the lack of electromechanical coupling models for tensioned thin-film patch antennas, we present a unified framework combining structural [...] Read more.
Deployable thin-film antennas deliver large aperture gains and high stowage efficiency for spaceborne phased arrays but suffer wrinkling-induced planarity loss and radiation distortion. To bridge the lack of electromechanical coupling models for tensioned thin-film patch antennas, we present a unified framework combining structural deformation and electromagnetic simulation. We derive a coupling model capturing the increased bending stiffness of stepped-thickness membranes, formulate a wrinkling analysis algorithm to compute tension-induced displacements, and fit representative unit-cell deformations to a dual-domain displacement model. Parametric studies across stiffness ratios confirm the framework’s ability to predict shifts in pattern, gain, and impedance due to wrinkling. This tool supports the optimized design of wrinkle-resistant thin-film phased arrays for reliable, high-performance space communications. Full article
(This article belongs to the Special Issue Space Mechanisms and Robots)
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19 pages, 4790 KiB  
Article
A Comprehensive Investigation on Shell Hydroforming of AA5052 Through Numerical Modeling and Experimental Analysis
by Arun Achuthankutty, Karthik Narayanan, Ajith Ramesh and Ratna Kishore Velamati
Symmetry 2025, 17(7), 989; https://doi.org/10.3390/sym17070989 - 23 Jun 2025
Viewed by 272
Abstract
This study investigates the shell hydroforming of 1.2 mm-thick AA5052 aluminum alloy sheets to produce hemispherical domes which possess inherent spatial symmetry about their central axis. Shell hydroforming is widely used in fabricating lightweight, high-strength components for aerospace, automotive, and energy applications. The [...] Read more.
This study investigates the shell hydroforming of 1.2 mm-thick AA5052 aluminum alloy sheets to produce hemispherical domes which possess inherent spatial symmetry about their central axis. Shell hydroforming is widely used in fabricating lightweight, high-strength components for aerospace, automotive, and energy applications. The forming process was driven by a spatially symmetrical internal pressure distribution applied uniformly across the blank to maintain balanced deformation and minimize geometrical distortion. Experimental trials aimed at achieving a dome depth of 50 mm revealed wrinkle formation at the blank periphery caused by circumferential compressive stresses symmetrical in nature with respect to the dome’s central axis. To better understand the forming behavior, a validated 3D finite element (FE) model was developed, capturing key phenomena such as material flow, strain rate evolution, hydrostatic stress distribution, and wrinkle development under symmetric boundary conditions. The effects of the internal pressure (IP), blank holding force (BHF), coefficient of friction (CoF), and flange radius (FR) were systematically studied. A strain rate of 0.1 s−1 in the final stage improved material flow, while a symmetric tensile hydrostatic stress of 160 MPa facilitated dome expansion. Although tensile stresses can induce void growth, the elevated strain rate helped suppress it. An optimized parameter set of IP = 5.43 MPa, BHF = 140 kN, CoF = 0.04, and FR = 5.42 mm led to successful formation of the 50 mm dome with 19.38% thinning at the apex. Internal pressure was identified as the most critical factor influencing symmetric formability. A process window was established to predict symmetric failure modes such as wrinkling and bursting. Full article
(This article belongs to the Section Engineering and Materials)
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17 pages, 9597 KiB  
Article
Finite Element Model of the Effect of Optic Nerve Sheath Anisotropy on Ocular Loading During Horizontal Duction
by Somaye Jafari, Shengqiang Cai and Joseph L. Demer
Bioengineering 2025, 12(6), 587; https://doi.org/10.3390/bioengineering12060587 - 29 May 2025
Viewed by 558
Abstract
Previous models of extraocular mechanics have often assumed isotropic properties for ocular tissues, despite evidence indicating anisotropy in the optic nerve sheath (ONS). To investigate this further, we developed a finite element model (FEM) of horizontal eye rotation using MRI data from a [...] Read more.
Previous models of extraocular mechanics have often assumed isotropic properties for ocular tissues, despite evidence indicating anisotropy in the optic nerve sheath (ONS). To investigate this further, we developed a finite element model (FEM) of horizontal eye rotation using MRI data from a living subject with normal tension glaucoma. Mechanical properties were derived from tensile tests on 17 post-mortem human eyes, revealing previously unrecognized anisotropic characteristics in the ONS. We simulated ±32° horizontal eye rotations and compared isotropic versus anisotropic ONS properties using the Holzapfel model. Strain distributions in the optic nerve (ON) were analyzed using ABAQUS 2024 software. During 32° adduction, stress and strain were concentrated at the ONS-sclera junction, reaching 8 MPa and 40% with isotropic properties, and 15 MPa and 30% with anisotropic properties. In contrast, during 32° abduction, stress was lower and strain was higher in the isotropic case (6 MPa and 30%) compared to the anisotropic case (12 MPa and 25%). Increased intraocular and intracranial pressures had minimal impact on the mechanical responses. These findings suggest that the anisotropic properties of the ONS increase stress concentration at the optic disc while reducing strain during eye movements, offering new insights into ocular biomechanics. A novel phenomenon emerged from the simulations: during larger ductions, the peripapillary Bruch’s membrane is predicted to wrinkle, forming undulations with an approximately 20 μm amplitude and 100 μm wavelength at its interface with the retina and choroid. Full article
(This article belongs to the Special Issue Biomechanics Studies in Ophthalmology)
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19 pages, 10897 KiB  
Article
Enhancing Product Performance via a Modified Double-Diaphragm Forming (mDDF) Preform Method for Prepreg Compression Molding of Fiber-Reinforced Polymer Composites
by Shin Kim, Honchung Shin, Kilsung Lee and Sungkyu Ha
Polymers 2025, 17(11), 1489; https://doi.org/10.3390/polym17111489 - 27 May 2025
Viewed by 377
Abstract
An enhanced process for shaping thermoset fiber-reinforced composites using Modified Double-Diaphragm Forming (mDDF) in Prepreg Compression Molding (PCM) is proposed to address limitations in conventional forming quality. To minimize surface defects, prepregs were pre-cut to reduce wrinkle formation and trimmed after preforming. Complex [...] Read more.
An enhanced process for shaping thermoset fiber-reinforced composites using Modified Double-Diaphragm Forming (mDDF) in Prepreg Compression Molding (PCM) is proposed to address limitations in conventional forming quality. To minimize surface defects, prepregs were pre-cut to reduce wrinkle formation and trimmed after preforming. Complex geometries were managed through draping analysis, which enabled identification and mitigation of wrinkle-prone regions. A challenging layup configuration (±45/0/90/0/90/0/±45) was selected, and temperature-dependent behavior of the prepreg—such as resin fluidity and wrinkle characteristics—was evaluated from room temperature to 80 °C. Material characterization included tensile, bias extension, bending, friction, and density tests. Forming simulations using AniForm Suite 3.0 incorporated fitted material parameters for predictive analysis. Experimental validation confirmed that the mDDF process significantly improved fiber alignment and eliminated wrinkle defects, especially in 16 previously identified critical zones. The final parts exhibited superior surface quality and dimensional accuracy compared to conventional PCM, highlighting the potential of mDDF for precision manufacturing of complex thermoset composite structures. Full article
(This article belongs to the Section Polymer Fibers)
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24 pages, 7910 KiB  
Article
Optimization of Magnetic Finishing Process and Surface Quality Research for Inner Wall of MP35N Cobalt–Chromium Alloy Vascular Stent Tubing Based on Plasma-Fused Al2O3 Magnetic Abrasives
by Yusheng Zhang, Yugang Zhao, Qilong Fan, Shimin Yang, Shuo Meng, Yu Tang, Guiguan Zhang and Haiyun Zhang
Micromachines 2025, 16(5), 591; https://doi.org/10.3390/mi16050591 - 18 May 2025
Viewed by 662
Abstract
To solve the manufacturing problem of the efficient removal of multi-scale surface defects (wrinkles, cracks, scratches, etc.) on the inner wall of MP35N cobalt–chromium alloy vascular stents, this study proposes a collaborative optimization strategy of magnetic abrasive polishing (MAF) based on a new [...] Read more.
To solve the manufacturing problem of the efficient removal of multi-scale surface defects (wrinkles, cracks, scratches, etc.) on the inner wall of MP35N cobalt–chromium alloy vascular stents, this study proposes a collaborative optimization strategy of magnetic abrasive polishing (MAF) based on a new type of magnetic abrasive. In response to the unique requirements for the inner wall processing of high aspect ratio microtubes, metal-based Al2O3 magnetic abrasives with superior performance were prepared by the plasma melt powder spraying method. A special MAF system for the inner wall of the bracket was designed and constructed. The four-factor and three-level Box–Behnken response surface method was adopted to analyze the influences and interactions of tube rotational speed, magnetic pole feed rate, abrasive filling amount, and processing clearance on surface roughness (Ra). The significance order of each parameter for Ra is determined as follows: processing clearance > tube rotational speed > abrasive filling amount > magnetic pole feed rate. Using the established model and multiple regression equations, the optimal parameters were determined as follows: a tube rotational speed of 600 r/min, a magnetic pole feed rate of 150 mm/min, an abrasive filling amount of 0.50 g, and a processing clearance of 0.50 mm. The optimized model predicted an Ra value of 0.104 μm, while the average Ra value verified experimentally was 0.107 μm, with the minimum error being 2.9%. Compared with the initial Ra of 0.486 μm, directly measured by the ultra-depth-of-field 3D microscope of model DSX1000, the surface roughness was reduced by 77.98%. MAF effectively eliminates the surface defects and deteriorated layers on the inner wall of MP35N tubes, significantly improving the surface quality, which is of great significance for the subsequent preparation of high-quality vascular stents and their clinical applications. Full article
(This article belongs to the Special Issue Advanced Manufacturing Technology and Systems, 3rd Edition)
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18 pages, 2889 KiB  
Article
Experimental Study of Flame Dynamics in a Triple-Injector Swirling Nonpremixed Combustor Under Different Thermoacoustic Self-Excited Instability Modes
by Xiang Zhang, Suofang Wang and Yong Liu
Sensors 2025, 25(3), 850; https://doi.org/10.3390/s25030850 - 30 Jan 2025
Viewed by 899
Abstract
Combustion instability is one of the prominent and unavoidable problems in the design of high-performance propulsion systems. This study investigates the heat release rate (HRR) responses in a triple-nozzle swirling nonpremixed combustor under various thermoacoustic self-excited instability modes. Dynamic pressure sensors and high-speed [...] Read more.
Combustion instability is one of the prominent and unavoidable problems in the design of high-performance propulsion systems. This study investigates the heat release rate (HRR) responses in a triple-nozzle swirling nonpremixed combustor under various thermoacoustic self-excited instability modes. Dynamic pressure sensors and high-speed imaging were employed to capture the pressure oscillations within the combustion chamber and the characteristics of flame dynamics, respectively. The results reveal nonlinear bifurcations in the self-excited thermoacoustic instabilities at different equivalence ratios. Significant differences in flame dynamics were observed across the instability modes. In lower frequency modes, the fluctuations in flame length contribute to the driving force of thermoacoustic instability. In relatively high-frequency modes, HRR fluctuations are dominated by the rolling up and convective processes of wrinkles on the flame surface. Alternating regions of gain and damping are observed on the flame surface. At even higher frequencies, both aforementioned HRR fluctuation patterns are simultaneously observed. These findings provide a deeper understanding of the complex interactions between flame dynamics and thermoacoustic instabilities, offering new insights into the design and optimization of nonpremixed combustion systems. The study underscores the importance of considering the spatial and temporal variations in flame behavior to effectively predict and control thermoacoustic instabilities. Full article
(This article belongs to the Special Issue Sensors Technologies for Measurements and Signal Processing)
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18 pages, 8651 KiB  
Article
Interlaminar Fracture Toughness Analysis for Reliability Improvement of Wind Turbine Blade Spar Elements Based on Pultruded Carbon Fiber-Reinforced Polymer Plate Manufacturing Method
by Hakgeun Kim, Yunjung Jang, Sejin Lee, Chanwoong Choi and Kiweon Kang
Materials 2025, 18(2), 357; https://doi.org/10.3390/ma18020357 - 14 Jan 2025
Viewed by 989
Abstract
The key structural components of a wind turbine blade, such as the skin, spar cap, and shear web, are fabricated from fiber-reinforced composite materials. The spar, predominantly manufactured via resin infusion—a process of resin injection and curing in carbon fibers—is prone to initial [...] Read more.
The key structural components of a wind turbine blade, such as the skin, spar cap, and shear web, are fabricated from fiber-reinforced composite materials. The spar, predominantly manufactured via resin infusion—a process of resin injection and curing in carbon fibers—is prone to initial defects, such as pores, wrinkles, and delamination. This study suggests employing the pultrusion technique for spar production to consistently obtain a uniform cross-section and augment the reliability of both the manufacturing process and the design. In this context, this study introduces carbon fiber-reinforced polymer (CFRP/CFRP) and glass fiber-reinforced polymer (GFRP/CFRP) test specimens, which mimic the bonding structure of the spar cap, utilizing pultruded CFRP in accordance with ASTM standards to analyze the delamination traits of the spar. Delamination tests—covering Mode I (double cantilever beam), Mode II (end-notched flexure), and mixed mode (mixed-mode bending)—were performed to gauge displacement, load, and crack growth length. Through this crack growth mechanism, the interlaminar fracture toughness derived was examined, and the stiffness and strength changes compared to CFRP based on the existing prepreg manufacturing method were analyzed. In addition, the interlaminar fracture toughness for GFRP, which is a material in contact with the spar structure, was analyzed, and through this, it was confirmed that the crack behavior has less deviation compared to a single CFRP material depending on the stiffness difference between the materials when joining dissimilar materials. This means that the higher the elasticity of the high-stiffness material, the higher the initial crack resistance, but the crack growth behavior shows non-uniform characteristics thereafter. This comparison provides information for predicting interlaminar delamination damage within the interior and bonding area of the spar and skin and provides insight for securing the reliability of the design life. Full article
(This article belongs to the Section Advanced Composites)
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15 pages, 4457 KiB  
Article
The Real-Time Prediction of Cracks and Wrinkles in Sheet Metal Forming According to Changes in Shape and Position of Drawbeads Based on a Digital Twin
by Sarang Yi, Daeil Hyun and Seokmoo Hong
Appl. Sci. 2025, 15(2), 700; https://doi.org/10.3390/app15020700 - 12 Jan 2025
Cited by 1 | Viewed by 1904
Abstract
In the automotive industry, extensive research has been conducted to eliminate factors negatively impacting product quality, such as wrinkles, cracks, and thickness distribution in components. The application of drawbeads often relies on the experience of field workers, leading to considerable trial and error [...] Read more.
In the automotive industry, extensive research has been conducted to eliminate factors negatively impacting product quality, such as wrinkles, cracks, and thickness distribution in components. The application of drawbeads often relies on the experience of field workers, leading to considerable trial and error before stabilizing the production process. Therefore, to efficiently transform these inefficiencies related to time and cost, there is a need for real-time predictive technology for forming quality based on the position of drawbeads and the bead force. This study proposes a method for predicting formability in real-time, based on a digital twin framework that considers the position of drawbeads and holder force. A digital twin was developed to predict the sheet metal forming process using Support Vector Machine, Random Forest, Gradient Boosting Machine, and Artificial Neural Networks. The machine learning models were trained using finite element analysis data corresponding to the position and bead force of drawbeads, enabling the real-time prediction of wrinkles and crack occurrences. The accuracy of the machine learning models was demonstrated, achieving 100% accuracy in determining crack occurrence, with a mean squared error (MSE) of 0.141 for wrinkle prediction and 0.038 for crack prediction, thereby ensuring the accuracy of the forming prediction model based on drawbead applications. Based on these predictive models, a user-friendly GUI has been developed, which is expected to reduce design time and costs while facilitating real-time predictions of forming quality, such as wrinkles and cracks, on-site. Full article
(This article belongs to the Special Issue Smart Manufacturing and Industry 4.0, 2nd Edition)
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16 pages, 6188 KiB  
Article
Optimization of Stamping Process Parameters for Sustainable Manufacturing: Numerical Simulation Based on AutoForm
by Huiju Zhang, Wenbo Wei, Sifang Long, Manyi Zhou and Chunhui Li
Sustainability 2025, 17(1), 341; https://doi.org/10.3390/su17010341 - 5 Jan 2025
Cited by 2 | Viewed by 1413
Abstract
To address the increasing demand for sustainable manufacturing in the automotive industry, this study focuses on the optimization of stamping process parameters for heavy truck seat reinforcement plates. Finite element analysis software and AutoForm R7 were utilized to develop a numerical simulation model [...] Read more.
To address the increasing demand for sustainable manufacturing in the automotive industry, this study focuses on the optimization of stamping process parameters for heavy truck seat reinforcement plates. Finite element analysis software and AutoForm R7 were utilized to develop a numerical simulation model for the stamping process, aiming to enhance material utilization and reduce waste. The research aimed to predict forming defects and explore the effects of blank holder force, friction coefficient, and drawbead resistance coefficient on springback, wrinkles, and strain, with an emphasis on improving production efficiency and minimizing resource consumption. The forming quality was optimized through adjustments in blank holder force, friction coefficient, and drawbead resistance coefficient, demonstrating the potential for eco-friendly manufacturing. Multi-objective optimization was performed to identify the optimal parameter combination, achieving sustainable outcomes with improved forming precision and reduced material waste. Results revealed that the optimal parameter combination (A4B4C2) included a blank holder force of 500 kN, a friction coefficient of 0.18, and a drawbead resistance coefficient of 0.25. These settings minimized material thinning (11.6%), excessive thickening (7.4%), and springback (0.905 mm), aligning with sustainable production standards. Full article
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12 pages, 5100 KiB  
Article
Inter-Ply Slipping Behaviors and Kinetic Equation of Carbon Fiber-Reinforced Epoxy Prepregs for Hot Diaphragm Preforming
by Haoxuan Zhang, Jintong Liu, Congfa Zhang, Hongfu Li, Guangquan Yue, Baozhong Sun and Boyan He
Materials 2024, 17(22), 5592; https://doi.org/10.3390/ma17225592 - 15 Nov 2024
Cited by 2 | Viewed by 941
Abstract
Wrinkles are urgent problems to be solved in the process of hot diaphragm preforming. Inter-ply slipping resistance is one of the causes of wrinkles. In this paper, based on the vertical inter-ply slipping test system, the inter-ply slipping behaviors of carbon fiber-reinforced epoxy [...] Read more.
Wrinkles are urgent problems to be solved in the process of hot diaphragm preforming. Inter-ply slipping resistance is one of the causes of wrinkles. In this paper, based on the vertical inter-ply slipping test system, the inter-ply slipping behaviors of carbon fiber-reinforced epoxy resin composite prepregs were characterized. The mechanism of wrinkles caused by inter-ply slipping resistance was analyzed. According to the different characteristics expressed by the fiber and resin during the slip process, the inter-ply slipping behaviors of the prepregs were divided into three stages. The effect of temperature on the inter-ply slipping stresses was shown. The temperature will affect the viscosity of the prepregs. When the viscosity of the prepregs is low, the inter-ply slipping resistance will decrease. Based on the Coulomb friction law and the hydrodynamic equation, the inter-ply slipping kinetic equation of the prepregs was established. The inter-ply slipping kinetic equation was introduced into the ABAQUS main program by the ‘vfriction’ subroutine. The introduction of inter-ply slipping dynamics improved the accuracy of predicting the shape and position of wrinkles. Full article
(This article belongs to the Special Issue Carbon Nanomaterials for Multifunctional Applications)
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14 pages, 4843 KiB  
Article
Enhanced Multi-Scale Attention-Driven 3D Human Reconstruction from Single Image
by Yong Ren, Mingquan Zhou, Pengbo Zhou, Shibo Wang, Yangyang Liu, Guohua Geng, Kang Li and Xin Cao
Electronics 2024, 13(21), 4264; https://doi.org/10.3390/electronics13214264 - 30 Oct 2024
Cited by 1 | Viewed by 1787
Abstract
Due to the inherent limitations of a single viewpoint, reconstructing 3D human meshes from a single image has long been a challenging task. While deep learning networks enable us to approximate the shape of unseen sides, capturing the texture details of the non-visible [...] Read more.
Due to the inherent limitations of a single viewpoint, reconstructing 3D human meshes from a single image has long been a challenging task. While deep learning networks enable us to approximate the shape of unseen sides, capturing the texture details of the non-visible side remains difficult with just one image. Traditional methods utilize Generative Adversarial Networks (GANs) to predict the normal maps of the non-visible side, thereby inferring detailed textures and wrinkles on the model’s surface. However, we have identified challenges with existing normal prediction networks when dealing with complex scenes, such as a lack of focus on local features and insufficient modeling of spatial relationships.To address these challenges, we introduce EMAR—Enhanced Multi-scale Attention-Driven Single-Image 3D Human Reconstruction. This approach incorporates a novel Enhanced Multi-Scale Attention (EMSA) mechanism, which excels at capturing intricate features and global relationships in complex scenes. EMSA surpasses traditional single-scale attention mechanisms by adaptively adjusting the weights between features, enabling the network to more effectively leverage information across various scales. Furthermore, we have improved the feature fusion method to better integrate representations from different scales. This enhanced feature fusion allows the network to more comprehensively understand both fine details and global structures within the image. Finally, we have designed a hybrid loss function tailored to the introduced attention mechanism and feature fusion method, optimizing the network’s training process and enhancing the quality of reconstruction results. Our network demonstrates significant improvements in performance for 3D human model reconstruction. Experimental results show that our method exhibits greater robustness to challenging poses compared to traditional single-scale approaches. Full article
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15 pages, 6728 KiB  
Article
Flexural Analysis of Additively Manufactured Continuous Fiber-Reinforced Honeycomb Sandwich Structures
by Rafael Guerra Silva, Esteban Gonzalez, Andres Inostroza and Gustavo Morales Pavez
J. Manuf. Mater. Process. 2024, 8(5), 226; https://doi.org/10.3390/jmmp8050226 - 10 Oct 2024
Cited by 1 | Viewed by 1726
Abstract
This study explores the flexural behavior of continuous fiber-reinforced composite sandwich structures built entirely using material extrusion additive manufacturing. The continuous fiber additive manufacturing system used in this study works sequentially, thus enabling the addition of fiber reinforcement just in the face sheets, [...] Read more.
This study explores the flexural behavior of continuous fiber-reinforced composite sandwich structures built entirely using material extrusion additive manufacturing. The continuous fiber additive manufacturing system used in this study works sequentially, thus enabling the addition of fiber reinforcement just in the face sheets, where it is most effective. Three-point bending tests were carried out on sandwich panel specimens built using thermoplastic reinforced with continuous glass fiber to quantify the effect of fiber reinforcement and infill density in the flexural properties and failure mode. Sandwich structures containing continuous fiber reinforcement had higher flexural strength and rigidity than unreinforced sandwiches. On the other hand, an increase in the lattice core density did not improve the flexural strength and rigidity. The elastic modulus of fiber-reinforced 3D-printed sandwich panels exceeded the predictions of the analytical models; the equivalent homogeneous model had the best performance, with a 15% relative error. However, analytical models could not correctly predict the failure mode: wrinkle failure occurs at 75% and 30% of the critical load in fiber-reinforced sandwiches with low- and high-density cores, respectively. Furthermore, no model is currently available to predict interlayer debonding between the matrix and the thermoplastic coating of fiber layers. Divergences between analytical models and experimental results could be attributed to the simplifications in the models that do not consider defects inherent to additive manufacturing, such as air gaps and poor interlaminar bonding. Full article
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28 pages, 16140 KiB  
Article
A Modeling Framework for the Thermoforming of Carbon Fiber Reinforced Thermoplastic Composites
by Long Bin Tan, Wern Sze Teo, Yi Wen Cheah and Sridhar Narayanaswamy
Polymers 2024, 16(15), 2186; https://doi.org/10.3390/polym16152186 - 31 Jul 2024
Cited by 3 | Viewed by 2467
Abstract
A comprehensive modeling framework for the thermoforming of polymer matrix woven laminate composite was developed. Two numerical indicators, the slip path length and traction magnitude, have been identified to be positively correlated to matrix smearing and wrinkling defects. The material model has been [...] Read more.
A comprehensive modeling framework for the thermoforming of polymer matrix woven laminate composite was developed. Two numerical indicators, the slip path length and traction magnitude, have been identified to be positively correlated to matrix smearing and wrinkling defects. The material model has been calibrated with picture-frame experimental results, and the prediction accuracy for intra-ply shear and thickness distribution was examined with measurements of the physically formed parts. Specifically, thickness prediction for most locations on the formed parts was accurate within an 11.6% error margin. However, at two points with significant intra-ply shear, the prediction errors increased to around 20%. Finally, a parametric study was conducted to determine the relationship between various process parameters and the quality of the formed part. For the trapezoidal part, orienting the laminate at 45 degrees to the mold axis reduces the likelihood of matrix smear and wrinkling defects. Although this laminate orientation yielded a greater spatial variation in part thickness, the thickness deviation is lower than that for the 0-degree orientation case. Two forming analyses were conducted with ramp rates of 25 mm/s and 80 mm/s to match the equipment’s operational limits. It was observed that higher forming rates led to a greater likelihood of defects, as evidenced by a 15% and 10% increase in the formed part areas with longer slip paths and higher traction magnitudes, respectively. It was discovered that shallower molds benefit from faster ramp rates, while deeper molds require slower rates to manage extensive shearing, stretching and bending. Faster forming rates lead to smaller thickness increases at high intra-ply shear regions, indicating a shift from intra-ply shear to out-of-plane bending due to the visco-plastic effect of the molten laminate and can negatively impact part quality. Lastly, it was shown that a well-conceived strategy using darts could improve the part quality by reducing the magnitude of the defect indicators. Full article
(This article belongs to the Collection State-of-the-Art Polymer Science and Technology in Singapore)
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26 pages, 15835 KiB  
Article
Numerical Optimization of Variable Blank Holder Force Trajectories in Stamping Process for Multi-Defect Reduction
by Feng Guo, Hoyoung Jeong, Donghwi Park, Geunho Kim, Booyong Sung and Naksoo Kim
Materials 2024, 17(11), 2578; https://doi.org/10.3390/ma17112578 - 27 May 2024
Cited by 1 | Viewed by 1737
Abstract
An intelligent optimization technology was proposed to mitigate prevalent multi-defects, particularly failure, wrinkling, and springback in sheet metal forming. This method combined deep neural networks (DNNs), genetic algorithms (GAs), and Monte Carlo simulation (MCS), collectively as DNN-GA-MCS. Our primary aim was to determine [...] Read more.
An intelligent optimization technology was proposed to mitigate prevalent multi-defects, particularly failure, wrinkling, and springback in sheet metal forming. This method combined deep neural networks (DNNs), genetic algorithms (GAs), and Monte Carlo simulation (MCS), collectively as DNN-GA-MCS. Our primary aim was to determine intricate process parameters while elucidating the intricate relationship between processing methodologies and material properties. To achieve this goal, variable blank holder force (VBHF) trajectories were implemented into five sub-stroke steps, facilitating adjustments to the blank holder force via numerical simulations with an oil pan model. The Forming Limit Diagram (FLD) predicted by machine learning algorithms based on the Generalized Incremental Stress State Dependent Damage (GISSMO) model provided a robust framework for evaluating sheet failure dynamics during the stamping process. Numerical results confirmed significant improvements in formed quality: compared with the average value of training sets, the improvements of 18.89%, 13.59%, and 14.26% are achieved in failure, wrinkling, and springback; in the purposed two-segmented mode VBHF case application, the average value of three defects is improved by 12.62%, and the total summation of VBHF is reduced by 14.07%. Statistical methodologies grounded in material flow analysis were applied, accompanied by the proposal of distinctive optimization strategies for the die structure aimed at enhancing material flow efficiency. In conclusion, our advanced methodology exhibits considerable potential to improve sheet metal forming processes, highlighting its significant effect on defect reduction. Full article
(This article belongs to the Special Issue Structure and Mechanical Properties of Alloys, Volume III)
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