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11 pages, 9905 KiB

Open AccessProceeding Paper

Production Parameters and Thermo-Mechanical Performance of Twisted and Coiled Artificial Muscles (TCAMs)

by Salvatore Garofalo, Chiara Morano, Leonardo Pagnotta and Luigi Bruno

Eng. Proc. 2025, 85(1), 1; https://doi.org/10.3390/engproc2025085001 - 13 Feb 2025

Viewed by 188

High-strength polymer fibers such as nylon 6, nylon 6,6, and polyethylene are utilized to produce Twisted and Coiled Artificial Muscles (TCAMs) through the twisting of low-cost fibers. These artificial muscles exhibit high displacement and specific power, particularly under electrothermal actuation, which requires conductive [...] Read more.

High-strength polymer fibers such as nylon 6, nylon 6,6, and polyethylene are utilized to produce Twisted and Coiled Artificial Muscles (TCAMs) through the twisting of low-cost fibers. These artificial muscles exhibit high displacement and specific power, particularly under electrothermal actuation, which requires conductive elements. An experimental setup was developed to produce, thermally treat, and characterize commercially available nylon 6,6 fibers coated with silver. The results demonstrate that TCAMs can contract by over 15% and generate forces up to 2.5 N with minimal energy input. Key factors such as motor speed, applied load, and fiber geometry affect the overall performance. Full article

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7 pages, 6129 KiB

Open AccessProceeding Paper

Lock-in Thermography for Surface Treatment Characterization in Gears

by Francesca Maria Curà, Luca Corsaro and Ludovica Tromba

Eng. Proc. 2025, 85(1), 2; https://doi.org/10.3390/engproc2025085002 - 13 Feb 2025

Viewed by 152

Abstract

Mechanical gears are essential in power transmission systems across various industrial applications. Their performance is critically influenced by residual stresses from manufacturing processes like induction hardening, case hardening, and shot peening. Surface compressive residual stresses enhance resistance to pitting fatigue, bending fatigue and [...] Read more.

Mechanical gears are essential in power transmission systems across various industrial applications. Their performance is critically influenced by residual stresses from manufacturing processes like induction hardening, case hardening, and shot peening. Surface compressive residual stresses enhance resistance to pitting fatigue, bending fatigue and crack propagation, improving overall hardness. In the present work, a Non-Destructive Thermographic method (Active thermography), based on measurement of the thermal diffusivity parameter, is presented to characterize the surface treatments applied to gears. Surface hardness was measured using a micro-hardness tester, and residual stresses were determined with an X-Ray diffractometer, showing variations due to surface treatments. The variation in the thermal diffusivity parameter, obtained using the Slope Method, was found to be an indicator of the surface treatments’ effectiveness. Full article

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10 pages, 4818 KiB

Open AccessProceeding Paper

Analytical and Numerical Methods for the Identification of Torsional Oscillations and Forcing in Internal Combustion Engines

by Dario Santonocito and Sebastian Brusca

Eng. Proc. 2025, 85(1), 3; https://doi.org/10.3390/engproc2025085003 - 13 Feb 2025

Viewed by 192

Abstract

Crankshafts, present in internal combustion engines, are mechanical parts subject to torsion and bending that vary over time and, if the forcing is close to one of the natural frequencies of the system, they can encounter problems of torsional oscillations. These vibrations can [...] Read more.

Crankshafts, present in internal combustion engines, are mechanical parts subject to torsion and bending that vary over time and, if the forcing is close to one of the natural frequencies of the system, they can encounter problems of torsional oscillations. These vibrations can lead to maximum oscillation amplitudes, with consequent fatigue stresses that would compromise the resistance and correct functioning of the shaft. The aim of this work is to indicate a methodology for identifying the natural frequencies of the crankshaft and the decomposition of the torques, due to gases and inertia, to identify the different harmonics; in fact, if one of these harmonics is close to the natural frequency of the crankshaft, the system will go into resonance. Full article

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8 pages, 5067 KiB

Open AccessProceeding Paper

An Efficient Criterion for Evaluating Fatigue Strength Improvement Through the Stop-Hole Technique

by Bruno Atzori, Luca Vecchiato and Giovanni Meneghetti

Eng. Proc. 2025, 85(1), 4; https://doi.org/10.3390/engproc2025085004 - 13 Feb 2025

Viewed by 167

Abstract

This study investigates the effect of a non-zero fillet radius, ρ, on the fatigue behaviour of notched components under uniaxial loading. A new diagram is introduced, which discusses the relationship between the notch tip radius and the fatigue limit. It also identifies [...] Read more.

This study investigates the effect of a non-zero fillet radius, ρ, on the fatigue behaviour of notched components under uniaxial loading. A new diagram is introduced, which discusses the relationship between the notch tip radius and the fatigue limit. It also identifies a critical radius, ρ**, precisely marking the transition from sharp to blunt notch behaviour. Additionally, its application to the “stop-hole” technique is considered, where both material properties and geometric characteristics are analysed, demonstrating that introducing a fillet radius can improve fatigue resistance. Full article

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10 pages, 5624 KiB

Open AccessProceeding Paper

Fatigue Life Analysis of Traditional and Annealed AISI 304L Specimens by Thermographic Methods

by Davide Crisafulli, Michal Jambor, Miroslav Šmíd, Dario Santonocito and Giacomo Risitano

Eng. Proc. 2025, 85(1), 5; https://doi.org/10.3390/engproc2025085005 - 13 Feb 2025

Viewed by 141

Abstract

AISI 304L is a low-carbon austenitic stainless steel widely used in common engineering applications, according to its good mechanical properties such as high ductility, corrosion resistance, and easy weldability. This material is adopted in various environmental conditions, such as pressure vessels or in [...] Read more.

AISI 304L is a low-carbon austenitic stainless steel widely used in common engineering applications, according to its good mechanical properties such as high ductility, corrosion resistance, and easy weldability. This material is adopted in various environmental conditions, such as pressure vessels or in pipelines where fluid temperature variations occur and affect its mechanical behavior. Nowadays, the applications of advanced investigation methodologies, such as infrared thermography, are widely adopted for the rapid analysis of the fatigue properties of common materials, especially metals. In this work, fatigue properties were evaluated on AISI304L specimens having two different microstructural states, one in the as-received condition and the other one after solution annealing. Fatigue test campaigns were performed with the application of the Risitano Thermographic Method. The microscopic analysis highlights the differences in the microstructure before and after the heat treatment. The characteristics of the microstructures are the main ones responsible for the different fatigue behavior obtained with experimental tests. The Thermographic Method proved to be a valid rapid approach for the fatigue analysis, confirming that the annealing process led to an improvement in the fatigue strength of the material. Full article

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13 pages, 2066 KiB

Open AccessProceeding Paper

Development of Procedures for Disassembly of Industrial Products in Python Environment

by Maurizio Guadagno, Eleonora Innocenti, Lorenzo Berzi, Saverio Corsi and Massimo Delogu

Eng. Proc. 2025, 85(1), 6; https://doi.org/10.3390/engproc2025085006 - 13 Feb 2025

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Abstract

Circular Design methodology is essential for sustainable industrial practices. This study provides a methodology with a Python-based computational tool that optimizes industrial products’ disassembly sequences, focusing on Design for End of Life (DfEoL) and Design for Disassembly (DfD) to promote Circular Design. The [...] Read more.

Circular Design methodology is essential for sustainable industrial practices. This study provides a methodology with a Python-based computational tool that optimizes industrial products’ disassembly sequences, focusing on Design for End of Life (DfEoL) and Design for Disassembly (DfD) to promote Circular Design. The tool creates disassembly precedence graphs and shows the best disassembly path for target components, facilitating material recovery and environmental sustainability. The tool was applied to a case study on an Axial Flux Permanent Magnet (AFPM) electric motor. The approach provides a flexible and open access solution for optimizing product design within a Circular Design framework. Full article

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12 pages, 2784 KiB

Open AccessProceeding Paper

On the Exploration of the Influence of Seabed Reflected Waves on Naval Structures

by Jacopo Bardiani, Marco Giglio, Claudio Sbarufatti and Andrea Manes

Eng. Proc. 2025, 85(1), 7; https://doi.org/10.3390/engproc2025085007 - 13 Feb 2025

Viewed by 191

Abstract

The interaction between naval structures and underwater shock waves generated by explosions is critical in marine engineering. Numerical analysis is pivotal in investigating the effects of reflected waves from the free surface and the seabed on submerged or floating structures. This topic still [...] Read more.

The interaction between naval structures and underwater shock waves generated by explosions is critical in marine engineering. Numerical analysis is pivotal in investigating the effects of reflected waves from the free surface and the seabed on submerged or floating structures. This topic still needs to be explored in the marine engineering literature despite its significance. Understanding the complex dynamics of shock wave reflections is paramount for ensuring marine installations’ structural integrity and safety, including submarines, offshore platforms, and surface vessels. This paper aims to fill this gap by presenting a preliminary numerical study focused on analyzing the influence of reflected waves caused by the seabed on a simple ship-like structure, where the free-surface effects are negligible. A Coupled Eulerian–Lagrangian approach based on the suite MSC Dytran was used to investigate the interaction between shock waves and the seabed, considering a structure represented by an underwater cylinder and several seabed compositions. A deeper understanding of this phenomenon is crucial for enhancing the resilience and safety of marine installations, thereby mitigating potential risks and ensuring sustainable maritime operations. The simulations presented in this work represent the starting point for the creation of datasets to be used in Machine Learning applications. Full article

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12 pages, 1824 KiB

Open AccessProceeding Paper

Investigation of Damage Caused by Chlorine-Contaminated Fuel in Standard Vehicle Components

by Vincenzo La Battaglia, Valerio Mussi, Stefano Marini and Alessandro Giorgetti

Eng. Proc. 2025, 85(1), 8; https://doi.org/10.3390/engproc2025085008 - 13 Feb 2025

Viewed by 364

Abstract

Several car manufacturers have encountered corrosion in certain mechanical components caused by chlorine in fuel. The current regulations governing the quality of fuel allowed for trade are briefly described. Next, this paper analyzes the possible origin of chlorine in damaged components. In particular, [...] Read more.

Several car manufacturers have encountered corrosion in certain mechanical components caused by chlorine in fuel. The current regulations governing the quality of fuel allowed for trade are briefly described. Next, this paper analyzes the possible origin of chlorine in damaged components. In particular, the phenomenon of corrosion found in EGR valves and EGR coolers is analyzed. The analyses conducted to determine the nature of the corrosion and its origin are illustrated. Finally, the effects of the phenomenon on engine operation are analyzed, depending on the type of damaged component. Full article

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9 pages, 3579 KiB

Open AccessProceeding Paper

Lightening the Scissor Lift Platform Using Composite Material

by Luigi Solazzi

Eng. Proc. 2025, 85(1), 9; https://doi.org/10.3390/engproc2025085009 - 13 Feb 2025

Viewed by 145

Abstract

This research presents the main results related to the lightweighting of a specific scissor lift platform with the following key specifications: a working load limit of 3000 N and a platform height of 5.5 m. The design (for both steel and innovative materials) [...] Read more.

This research presents the main results related to the lightweighting of a specific scissor lift platform with the following key specifications: a working load limit of 3000 N and a platform height of 5.5 m. The design (for both steel and innovative materials) was conducted by evaluating the load conditions, some of which were derived from relevant standards. The new solution, which uses aluminum and composite materials instead of structural steel, reduces the overall weight from approximately 24.7 kN to 13.1 kN (a 53.1% reduction). Additionally, the lifting and travel power required for the new design is about half that of the original solution. Full article

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15 pages, 1191 KiB

Open AccessProceeding Paper

A Review of Computational Methods and Tools for Life Cycle Assessment of Traction Battery Systems

by Eleonora Innocenti, Maurizio Guadagno, Lorenzo Berzi, Marco Pierini and Massimo Delogu

Eng. Proc. 2025, 85(1), 10; https://doi.org/10.3390/engproc2025085010 - 13 Feb 2025

Viewed by 209

Abstract

Life Cycle Assessment (LCA) is crucial for evaluating the environmental impact of products, but challenges such as uncertainties and data limitations hinder its effective use in design. This paper reviews LCA computational tools, focusing on traction batteries, and examines aspects such as software [...] Read more.

Life Cycle Assessment (LCA) is crucial for evaluating the environmental impact of products, but challenges such as uncertainties and data limitations hinder its effective use in design. This paper reviews LCA computational tools, focusing on traction batteries, and examines aspects such as software architecture, database integration, and uncertainty analysis. It highlights how these platforms enhance usability for designers by enabling interaction with complex models and integrating multidisciplinary features. By analyzing system boundaries, inventory criteria, and impact assessment, this review offers valuable insights for researchers, practitioners, and policymakers in LCA, addressing the implementation challenges and best practices for sustainable battery design. Full article

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11 pages, 948 KiB

Open AccessProceeding Paper

A Generalized Model to Describe Electromagnetic Shock Absorbers

by Gennaro Sorrentino, Renato Galluzzi, Andrea Tonoli and Nicola Amati

Eng. Proc. 2025, 85(1), 11; https://doi.org/10.3390/engproc2025085011 - 14 Feb 2025

Viewed by 199

Abstract

The development of chassis technologies has pushed significant focus towards electrification for enhanced vehicle efficiency, flexibility, safety, and performance. In this context, the suspension represents a key system, as it strongly influences both vehicle dynamics and comfort. The trend is to replace the [...] Read more.

The development of chassis technologies has pushed significant focus towards electrification for enhanced vehicle efficiency, flexibility, safety, and performance. In this context, the suspension represents a key system, as it strongly influences both vehicle dynamics and comfort. The trend is to replace the usual hydraulic damper with mechatronic actuators. Rotary electromagnetic shock absorbers are among these solutions, featuring a rotary electric machine and a proper rotary-to-linear transmission stage. Far from being ideal force sources, these actuators may introduce inertial, compliance, and friction phenomena to the suspension. This paper proposes a generalized equivalent model to reproduce the mechanical behavior of electromagnetic shock absorbers. The formulation of this tool helps compare different shock absorber technologies in terms of their dynamic response. Furthermore, it can be used to synthesize control strategies that account for intrinsic limitations of chassis actuators. Full article

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9 pages, 2476 KiB

Open AccessProceeding Paper

A Finite Element Analysis of a Lithium-Ion Battery Cell Under Abuse Conditions

by Aljon Kociu, Daniele Barbani, Luca Pugi, Lorenzo Berzi, Niccolò Baldanzini and Massimo Delogu

Eng. Proc. 2025, 85(1), 12; https://doi.org/10.3390/engproc2025085012 - 14 Feb 2025

Viewed by 231

Abstract

Lithium-ion battery cells are the fundamental components of all Energy Storage Systems (ESSs) used in electric vehicles (EVs). Increasing concerns about safety issues, particularly the response of battery cells to mechanical crushes that can lead to internal short circuits (ISCs) and potential thermal [...] Read more.

Lithium-ion battery cells are the fundamental components of all Energy Storage Systems (ESSs) used in electric vehicles (EVs). Increasing concerns about safety issues, particularly the response of battery cells to mechanical crushes that can lead to internal short circuits (ISCs) and potential thermal runaway (TR), necessitate detailed investigation. To evaluate the response of a battery under abuse conditions, a homogeneous finite element (FE) model of a battery cell was developed. This model employs a simplified representation of a battery cell where the internal properties are assumed to be uniform throughout the entire cell. A full factorial approach was utilized to determine the homogenized jellyroll material characteristics. A detailed FEM serves as a benchmark for validating the homogeneous battery model. While requiring less computational effort, the homogeneous model maintains sufficient accuracy, making it suitable for modelling entire battery packs, thanks to the reduced number of elements. Full article

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10 pages, 3122 KiB

Open AccessProceeding Paper

A Computational Multiphysics Study of a Satellite Thruster

by Marcello A. Lepore, Marzio Piller, Mario Guagliano and Angelo R. Maligno

Eng. Proc. 2025, 85(1), 14; https://doi.org/10.3390/engproc2025085014 - 14 Feb 2025

Viewed by 124

Abstract

This work concerns a study of the thermomechanical behaviour of a commercial thruster for aerospace use. The thruster, operated using a bipropellant liquid mixture, is used for the motion and in-orbit altitude control of small telecommunications satellites. The mixture used in the combustion [...] Read more.

This work concerns a study of the thermomechanical behaviour of a commercial thruster for aerospace use. The thruster, operated using a bipropellant liquid mixture, is used for the motion and in-orbit altitude control of small telecommunications satellites. The mixture used in the combustion process is composed of propylene and nitrous oxide, while the wall of the thruster is made of PH15-5 stainless steel. A computational fluid dynamics analysis of conjugate heat transfer determines the spatial–temporal distribution of temperature within the thruster wall. This information is passed to a finite element mechanical model that simulates the stress and the equivalent plastic strain distribution within the thruster wall. Full article

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11 pages, 3638 KiB

Open AccessProceeding Paper

Infrared Thermography for Non-Destructive Testing of Cooling Hole Integrity and Flow Evaluation in Specimens Made with Innovative Technologies

by Ester D’Accardi, Luca Ammannato, Alessandra Giannasi, Marco Pieri, Giuseppe Masciopinto, Francesco Ancona, Giovanni Santonicola, Davide Palumbo and Umberto Galietti

Eng. Proc. 2025, 85(1), 15; https://doi.org/10.3390/engproc2025085015 - 14 Feb 2025

Viewed by 108

Abstract

This study developed a non-destructive testing (NDT) method using infrared thermography to inspect tubes with holes and slots made by electro-erosion and additive manufacturing. CO₂ was used as a tracer gas to verify the opening and evaluate the flow shape from the [...] Read more.

This study developed a non-destructive testing (NDT) method using infrared thermography to inspect tubes with holes and slots made by electro-erosion and additive manufacturing. CO₂ was used as a tracer gas to verify the opening and evaluate the flow shape from the holes and slots. To improve the signal contrast, a controlled hot background was used as a reference, and infrared cameras monitored the thermal response to detect flow variations caused by different geometries. The tests included different diameters, pitches, and aspect ratios, comparing results between additive manufacturing and electro-erosion under various conditions. Moreover, a preliminary setup using compressed air and inductive heating was developed to assess hole openings by cooling the piece, aiming to eliminate CO₂ use. The comparison of results, the post-processing analysis of quantitative indices, and specific thermal features enabled a non-destructive evaluation of the holes by using different technologies, providing an assessment of the opening conditions, outlet, geometry, and flow shape. Full article

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10 pages, 2887 KiB

Open AccessProceeding Paper

Study of Damage and Microplastic Release in Clear Aligners Under Cyclic Loads

by Claudia Barile, Caterina Casavola, Claudia Cianci, Domenico Ciavarella, Giovanni Pappalettera, Carmine Pappalettere and Vimalathithan Paramsamy Kannan

Eng. Proc. 2025, 85(1), 16; https://doi.org/10.3390/engproc2025085016 - 18 Feb 2025

Viewed by 171

Abstract

In this research work, the mechanical performance of a thermoformed clear dental aligner is studied. Its performance is evaluated under the cyclic compression test, which is designed to simulate the occlusal forces applied on the aligner during swallowing operations for its entire usage [...] Read more.

In this research work, the mechanical performance of a thermoformed clear dental aligner is studied. Its performance is evaluated under the cyclic compression test, which is designed to simulate the occlusal forces applied on the aligner during swallowing operations for its entire usage period. The mechanical results show that the aligner exhibit stable energy absorption and stiffness behaviour throughout its use period and thus can potentially be used for clinical applications. The microplastic released from the aligner due to the fatigue-like damage is analysed using optical microscopy. Most of the microplastics released have larger dimensions, which may be excreted from the gastrointestinal tracts and have less possibility to pass through the epithelium passively. Therefore, the use of aligner may not pose any cytotoxic health risks. Full article

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9 pages, 3854 KiB

Open AccessProceeding Paper

The Mechanical Characterization of a Gyroid-Based Metamaterial by Compression Testing

by Andrea Ciula, Gianluca Rubino and Pierluigi Fanelli

Eng. Proc. 2025, 85(1), 17; https://doi.org/10.3390/engproc2025085017 - 18 Feb 2025

Viewed by 141

Abstract

Gyroid-based mechanical metamaterials have garnered increasing attention for their unique mechanical properties, particularly in applications involving complex stress environments. This study focuses on the mechanical characterization of the gyroid cell, a member of the Triply Periodic Minimal Surfaces (TPMS) family, through both experimental [...] Read more.

Gyroid-based mechanical metamaterials have garnered increasing attention for their unique mechanical properties, particularly in applications involving complex stress environments. This study focuses on the mechanical characterization of the gyroid cell, a member of the Triply Periodic Minimal Surfaces (TPMS) family, through both experimental and numerical analyses. Three different gyroid morphologies were generated by varying a single parameter in the parametric equation of the gyroid surface. Specimens were fabricated by 3D printing based on Liquid Crystal Display (LCD) technology, and compression tests were conducted to measure the equivalent Young’s modulus. Numerical models developed using Finite Element Method (FEM) analysis were validated through the experimental findings. The results indicate a good correlation between the experimental and numerical data, particularly in the linear elastic region, confirming the suitability of FEM simulations in predicting the mechanical response of these cellular structures. The study serves as a foundational step towards a broader multi-physical characterization of TPMS-based metamaterials and paves the way for the future development of tailored metamaterials for specific applications, including sacrificial limiters in plasma-facing components of Tokamaks. Full article

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15 pages, 8399 KiB

Open AccessProceeding Paper

An Investigation of the Monotonic and Cyclic Behavior of Additively Manufactured TPU

by Sara Ricci, Alberto Pagano, Andrea Ceccacci, Gianluca Iannitti and Nicola Bonora

Eng. Proc. 2025, 85(1), 18; https://doi.org/10.3390/engproc2025085018 - 18 Feb 2025

Viewed by 94

Abstract

The mechanical properties of rubber-like materials, such as their high flexibility and durability, make them widely applicable across different industrial fields, from aerospace to healthcare and, most notably, the automotive sector. In operative conditions, these materials experience large deformations and repeated loadings, which [...] Read more.

The mechanical properties of rubber-like materials, such as their high flexibility and durability, make them widely applicable across different industrial fields, from aerospace to healthcare and, most notably, the automotive sector. In operative conditions, these materials experience large deformations and repeated loadings, which may result in inelastic and dissipative phenomena. The aim of this study is to investigate the mechanical properties of two thermoplastic elastomeric materials manufactured with the Fused Filament Fabrication (FFF) technique: unfilled thermoplastic polyurethane (TPU) and TPU reinforced with carbon nanotubes (CNTs). Several experimental tests were performed to assess the response of both materials under monotonic and cyclic loadings. The addition of CNTs led to improved stiffness and strength without compromising elasticity. Under repeated loadings, both materials were characterized by the Mullins and viscous effects. However, the presence of CNTs was found to slightly amplify these inelastic phenomena. The integration of additive manufacturing technologies, combined with the use of innovative fillers, can offer design and performance optimization to all those components that strongly rely on elastomers. Full article

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16 pages, 1813 KiB

Open AccessProceeding Paper

Scaling the Response of a Simplified Hull Girder Subjected to Underwater Explosions

by Giovanni Marchesi, Luca Lomazzi, Marco Giglio and Andrea Manes

Eng. Proc. 2025, 85(1), 19; https://doi.org/10.3390/engproc2025085019 - 19 Feb 2025

Viewed by 146

Abstract

Underwater explosions (UNDEXs) represent a significant threat to marine vessels, motivating the analysis of their resulting dynamic response and damage. Conducting experimental investigations on full-scale ships, while being the most consistent strategy, is not always feasible due to obvious economic constraints. Consequently, researchers [...] Read more.

Underwater explosions (UNDEXs) represent a significant threat to marine vessels, motivating the analysis of their resulting dynamic response and damage. Conducting experimental investigations on full-scale ships, while being the most consistent strategy, is not always feasible due to obvious economic constraints. Consequently, researchers usually rely on scaled models designed to replicate real-world scenarios in laboratory environments. Despite the widespread use of this approach, the scaling laws between prototypes and models are not yet satisfactory due to the complexity of the UNDEX phenomena and the variability in boundary conditions. To address this aspect, the present study focuses on the scalability of a simplified vessel, termed a simplified hull girder (SHG). This study is conducted numerically and originates from a comparison with experiments available in the literature. This work has two objectives: firstly, it provides a practical approach to simulating the behaviour of complex architectures that undergo severe deformation due to blast loads, a critical challenge for state-of-the-art computational methods. Secondly, this work aims to assess the reliability of the scaling laws commonly used in UNDEX scenarios and to highlight the importance of strain-rate effects. Full article

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13 pages, 727 KiB

Open AccessProceeding Paper

Innovative Model for Material Selection Within the Automotive Lightweight Eco-Design Field

by Edoardo Risaliti, Arcidiacono Gabriele, Francesco Del Pero and Paolo Citti

Eng. Proc. 2025, 85(1), 20; https://doi.org/10.3390/engproc2025085020 - 19 Feb 2025

Viewed by 61

Abstract

This paper presents an innovative integrated Ashby-VIKOR model for material selection when dealing with the re-design of automotive components under a wide-spectrum range of both sustainability and design aspects. The conceived approach combines the Ashby method, which assesses mechanical properties and costs, with [...] Read more.

This paper presents an innovative integrated Ashby-VIKOR model for material selection when dealing with the re-design of automotive components under a wide-spectrum range of both sustainability and design aspects. The conceived approach combines the Ashby method, which assesses mechanical properties and costs, with the VIKOR multi-criteria decision analysis, including a comprehensive model functional to assess the environmental impact of the considered automotive assets. This study also incorporates the implementation of the methodology to a literature case study (engine bracket for a C-class electric vehicle) to evaluate the robustness of the approach under varying different boundary conditions of the analysis. The results show the usefulness of the method in assessing new lightweight design solutions under an integrated structural integrity/sustainability point of view. In particular, the outcomes of the case study analysis show that significant improvements are offered by the lightweight alternative both in terms of component weight, cost efficiency and carbon footprint, identifying low-alloy steels and aluminum composites as optimal materials for this specific application. Full article

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13 pages, 3082 KiB

Open AccessProceeding Paper

Design of an Electromechanical Testing Machine for Elastomers’ Fatigue Characterization

by Gabriel Testa, Nicola Bonora, Luca Esposito and Gianluca Iannitti

Eng. Proc. 2025, 85(1), 21; https://doi.org/10.3390/engproc2025085021 - 19 Feb 2025

Viewed by 153

Abstract

The VITAL-E (Versatile Innovative Testing Low-Cycle Fatigue for Elastomers) project introduces a shift in low-cycle fatigue (LCF) testing by replacing traditional hydraulic systems with an electromechanical solution. Hydraulic machines, although widely used, present issues such as fluid leakage, environmental impact, high maintenance, and [...] Read more.

The VITAL-E (Versatile Innovative Testing Low-Cycle Fatigue for Elastomers) project introduces a shift in low-cycle fatigue (LCF) testing by replacing traditional hydraulic systems with an electromechanical solution. Hydraulic machines, although widely used, present issues such as fluid leakage, environmental impact, high maintenance, and complex feedback control. In contrast, VITAL-E incorporates a zero-backlash linear actuator, addressing a key challenge in electromechanical systems: backlash. This issue, caused by axial movement between the nut and screw during load reversals, can disrupt load application and compromise test accuracy. By eliminating backlash, the chosen actuator ensures continuous and precise load application, especially during critical cycle reversals, enhancing both the accuracy and reliability of LCF testing. Beyond technical improvements, the electromechanical system reduces component complexity, wear, and maintenance needs while offering easier upgrades and adaptability to evolving testing demands. Compared to conventional hydraulic systems, VITAL-E’s design offers an innovative industrial solution, promoting a new generation of LCF test machines that excel in accuracy, reliability, and operational efficiency. This innovation aligns with the growing demand for sustainable and adaptable testing solutions, particularly in the automotive industry, ensuring that LCF testing remains relevant for future research and industrial needs. Full article

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17 pages, 1297 KiB

Open AccessProceeding Paper

Survivability Approach to Increase the Resilience of Critical Systems

by Salvatore Annunziata, Luca Lomazzi, Marco Giglio and Andrea Manes

Eng. Proc. 2025, 85(1), 22; https://doi.org/10.3390/engproc2025085022 - 19 Feb 2025

Viewed by 123

Abstract

The survivability approach necessitates a vulnerability assessment, which quantifies the likelihood that a platform will be rendered inoperative when exposed to a threat—whether man-made or natural. This concept is closely tied to survivability, defined as the probability that a platform will complete its [...] Read more.

The survivability approach necessitates a vulnerability assessment, which quantifies the likelihood that a platform will be rendered inoperative when exposed to a threat—whether man-made or natural. This concept is closely tied to survivability, defined as the probability that a platform will complete its assigned mission. Detection and potential exposure to a threat can significantly reduce a system’s survivability. As a result, vulnerability evaluation has become a critical aspect of designing platforms that operate in high-risk environments. Numerous techniques have been developed for vulnerability assessment, with many studies aimed at achieving increasingly accurate evaluations to improve the reliability and safety of mechanical systems. Notably, in 1985, Ball introduced the concept of survivability, outlining various design solutions and techniques for fixed-wing and rotary-wing aircraft. Since then, several vulnerability assessment programs have been launched, leading to the creation of some of the most resilient platforms in use today. The assessment of vulnerability plays a key role in determining solutions to enhance the likelihood of a system successfully completing its mission. In this context, this paper presents the application of in-house software to analyze a fixed-wing Remotely Piloted Aircraft System (RPAS). The model used to validate the software’s capabilities was developed using publicly available data, enabling a practical demonstration of the software’s functionality. Applied to this case study, the software assesses the RPAS vulnerability against various impact threats. The software not only evaluates vulnerability but also suggests protective solutions to mitigate it. This application demonstrates how the software can enhance the reliability and safety of an existing operational system while also showcasing its potential for use during the preliminary design phase of a broader range of platforms. Full article

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13 pages, 6101 KiB

Open AccessProceeding Paper

Characterisation of Novel Self-Healing Composites Using Acousto-Ultrasonic Testing

by Claudia Barile, Vimalathithan Paramsamy Kannan, Giulia Derosa and Giovanni Pappalettera

Eng. Proc. 2025, 85(1), 23; https://doi.org/10.3390/engproc2025085023 - 19 Feb 2025

Viewed by 91

Abstract

Self-healing composites are designed based on natural healing processes such as bone regeneration and blood coagulation. These composites have polymeric material containing covalent adaptable networks that rearrange their molecular structure when heated, thereby serving as a healing agent. The inclusion of the healing [...] Read more.

Self-healing composites are designed based on natural healing processes such as bone regeneration and blood coagulation. These composites have polymeric material containing covalent adaptable networks that rearrange their molecular structure when heated, thereby serving as a healing agent. The inclusion of the healing polymers into the principal matrix of the fiber-reinforced composites alters their off-axis properties. In addition, the healing agents tend to bleed out of the composite structures upon heating. It is, therefore, essential to characterize the extent of the changes in the off-axis properties of the self-healing composites. In this research work, three different configurations of self-healing composites are subjected to three-point bending tests, and their healing characteristics are studied using Acousto-Ultrasonic tests. Frequencies of the propagating stress waves in the AU tests are used to analyze the different conditions of the self-healing composites, such as virgin, damaged, damaged-partially healed, and damaged-fully healed. The results show that the AU test could potentially be used to evaluate the healing behavior of these fiber-reinforced self-healable composites. Full article

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14 pages, 11264 KiB

Open AccessProceeding Paper

Analytical, Numerical, and Experimental Analysis of Tangential Attraction and Repulsion Forces Between Parallel Magnets in an Automotive Mechanical System

by Carmelo Serraino, Tommaso Carditello, Luca Dusini, Alberto Nicoletta, Dario Santonocito and Giacomo Risitano

Eng. Proc. 2025, 85(1), 24; https://doi.org/10.3390/engproc2025085024 - 18 Feb 2025

Viewed by 61

Abstract

This study highlights the importance of magnets in the advancement of automotive technology, focusing on the forces of attraction and repulsion between two magnets in relative tangential motion. The magnets were tested using a tensile machine developed by KnoWow and adapted to measure [...] Read more.

This study highlights the importance of magnets in the advancement of automotive technology, focusing on the forces of attraction and repulsion between two magnets in relative tangential motion. The magnets were tested using a tensile machine developed by KnoWow and adapted to measure attraction forces as a function of longitudinal and transversal distances. The data collected made it possible to create a detailed map of the interactions of the forces. To validate the experimental results, a finite element analysis (FEA) was performed. The high correspondence between the experimental and simulated data confirmed the reliability of the method, making it usable for future automotive designs requiring optimization of magnetic forces. Full article

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14 pages, 20965 KiB

Open AccessProceeding Paper

Innovative Design and Prototyping of Reconfigurable Run-Flat Tire

by Gabriel Testa, Luca Esposito, Andrea Ceccacci, Gianluca Iannitti and Nicola Bonora

Eng. Proc. 2025, 85(1), 25; https://doi.org/10.3390/engproc2025085025 - 21 Feb 2025

Viewed by 81

Abstract

Tire puncturing is one of the main causes of accidents and/or traffic interruptions, leading to unsafe and unsustainable mobility scenarios. Insert-supporting Run-Flat systems can be a strategic technology to improve tire performance, but further developments are needed to improve system reliability, modularity, and [...] Read more.

Tire puncturing is one of the main causes of accidents and/or traffic interruptions, leading to unsafe and unsustainable mobility scenarios. Insert-supporting Run-Flat systems can be a strategic technology to improve tire performance, but further developments are needed to improve system reliability, modularity, and efficiency. A novel Run-Flat system was proposed in the present study to address specific features. The concept was developed by exploiting numerical simulation tools, enabling a comprehensive system assessment. In addition, a technological demonstrator was manufactured employing rapid prototyping techniques based on 3D printing processes. Full article

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9 pages, 870 KiB

Open AccessProceeding Paper

Sensitivity Analysis of Integrated Sensors Created Through Additive Manufacturing for Monitoring Components Subject to Dynamic Loads

by Agnese Staffa, Massimiliano Palmieri, Giulia Morettini and Filippo Cianetti

Eng. Proc. 2025, 85(1), 26; https://doi.org/10.3390/engproc2025085026 - 23 Feb 2025

Viewed by 88

Abstract

The progress in the development of sensors made using additive manufacturing (AM) techniques has opened up new possibilities for their integration into more complex structures, such as CubeSats. In this study, preliminary tests were conducted on printed sensors by FDM embedded in simple [...] Read more.

The progress in the development of sensors made using additive manufacturing (AM) techniques has opened up new possibilities for their integration into more complex structures, such as CubeSats. In this study, preliminary tests were conducted on printed sensors by FDM embedded in simple structures to evaluate their feasibility under simulated operational conditions, including temperature variations and dynamic loads. The results obtained represent a preliminary step toward the full integration of embedded sensors in 3D-printed structures. With further development, 3D-printed embedded sensors could be used to monitor dynamic loads and vibrations during service, which is essential for structural health monitoring and determining fatigue life. Full article

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16 pages, 4655 KiB

Open AccessProceeding Paper

A Combined Approach of Experimental Testing and Inverse FE Modelling for Determining Homogenized Elastic Properties of Membranes and Plates

by Christian Iandiorio, Riccardo Serenella and Pietro Salvini

Eng. Proc. 2025, 85(1), 27; https://doi.org/10.3390/engproc2025085027 - 23 Feb 2025

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Abstract

Accurately determining the mechanical properties of complex materials is a key challenge in structural analysis, especially when using the finite element method (FEM). While homogeneous materials can be modeled with relative ease, heterogeneous materials such as composites or biological tissues with multiphase compositions [...] Read more.

Accurately determining the mechanical properties of complex materials is a key challenge in structural analysis, especially when using the finite element method (FEM). While homogeneous materials can be modeled with relative ease, heterogeneous materials such as composites or biological tissues with multiphase compositions pose significant difficulties due to the variability in their internal structures. The most used approach is numerical homogenization, which allows for the estimation of effective material properties by combining the characteristics of individual phases; however, this technique may not always be feasible, especially for materials with irregular or unknown phase distributions. This paper proposes an original methodology that combines non-destructive experimental testing with an inverse finite element modeling to extract the anisotropic elastic properties of quasi two-dimensional structures such as membranes and plates. The method involves modeling the component using membrane or plate finite elements, but managing a global stiffness matrix expressed analytically. While geometric information is incorporated in the global stiffness matrix, the material properties, specifically the components of the anisotropic elasticity matrix, remain unknown. The experimental data, comprising force and displacement measurements, are used to solve a nonlinear system, allowing for the identification of the material’s constitutive properties via numerical computation. To validate this approach, two experimental setups were conducted. The first involved a hyperelastic neoprene membrane, subjected to various biaxial preloading conditions, while the second focused on PLA plates produced through additive manufacturing including both homogeneous and reinforced variants. In both cases, the method successfully captured the full anisotropic elastic response, yielding accurate estimates of Young’s moduli, Poisson’s ratios, shear modulus, and orthotropy system orientation, in agreement with independent mechanical tests. This combined approach offers a practical and efficient solution for determining the elastic properties of complex materials, particularly in cases where traditional homogenization techniques are impractical or inadequate. Furthermore, this method can be a versatile tool for evaluating the damaging and aging effects on materials subjected to cyclic loading or those with irregular and complex internal structures. Full article

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13 pages, 4536 KiB

Open AccessProceeding Paper

Numerical Thermo-Structural Simulations for the Design of the Havar Beam Window of a Beryllium Target for Neutron Beam Production

by Roberta Dattilo

Eng. Proc. 2025, 85(1), 28; https://doi.org/10.3390/engproc2025085028 - 26 Feb 2025

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Abstract

The present work was carried out as part of the PRIN 2022JCS2CN project “CoolGal”, which aims to design and manufacture a beryllium target cooled by Galinstan (a liquid metal alloy at room temperature) for the production of neutrons using energetic protons. The objective [...] Read more.

The present work was carried out as part of the PRIN 2022JCS2CN project “CoolGal”, which aims to design and manufacture a beryllium target cooled by Galinstan (a liquid metal alloy at room temperature) for the production of neutrons using energetic protons. The objective of the present work is to thermo-structurally design a beam window that encloses the environment in which the target is housed. The window consists of a Havar disk, the thickness of which must be minimized to absorb the least amount of proton beam power, while its diameter must be sufficient to avoid excessive beam loss. The window will then be embedded around its perimeter and will have to withstand two load conditions, applied individually: A mechanical load, due to the atmospheric pressure of 0.11 MPa during vacuuming, and a thermal load, due to heating during irradiation with the proton beam. Once a first-version window geometry was defined, a static structural finite element analysis (FEA) was carried out by activating geometric nonlinearities to assess the structural integrity of the window under mechanical loading. After that, a static thermal–mechanical FEA analysis was carried out to assess the structural integrity of the window under thermal loading. Given the compressive stress state induced by thermal loading and the slenderness of the window itself, a nonlinear buckling structural FEA analysis was also performed. Full article

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14 pages, 5142 KiB

Open AccessProceeding Paper

Numerical and Experimental Analysis of the Structural Behavior of an EPP Component

by Carlo Sabbatini, Gianluca Chiappini, Veronica Ilari, Giacomo Zandri and Marco Sasso

Eng. Proc. 2025, 85(1), 29; https://doi.org/10.3390/engproc2025085029 - 27 Feb 2025

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Abstract

The use of expanded polymeric materials is becoming increasingly widespread in the industrial sector, not only for energy absorption purposes but also for structural applications. The most widely used approach to model the large strain elastic response of polymer foams in a finite [...] Read more.

The use of expanded polymeric materials is becoming increasingly widespread in the industrial sector, not only for energy absorption purposes but also for structural applications. The most widely used approach to model the large strain elastic response of polymer foams in a finite element (FE) solution is the use of the Ogden–Hill hyperelastic material model. We performed a uniaxial and simple shear test to calibrate the model’s parameters. In this work, a compression test was performed on a component, entirely made of expanded polypropylene, from a commercial machine. The experimental results, measured through 3D image analysis, were then compared with the simulation ones. This study aims to verify whether the Ogden foam model accurately describes the material’s behavior when the component has a complex geometry and large dimensions. Full article

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12 pages, 2460 KiB

Open AccessProceeding Paper

Model Order Reduction Applied to Replicate Blast Wave Interaction with Structure

by Edison Shehu, Giovanni Marchesi, Luca Lomazzi, Marco Giglio and Andrea Manes

Eng. Proc. 2025, 85(1), 30; https://doi.org/10.3390/engproc2025085030 - 27 Feb 2025

Viewed by 53

Abstract

This research explores the application of model order reduction (MOR) techniques for blast wave propagation and mitigation. Blast waves, with their rapid pressure changes and highly nonlinear behavior, pose significant challenges for predictive modeling. MOR, a mathematical dimensionality reduction technique, offers a solution [...] Read more.

This research explores the application of model order reduction (MOR) techniques for blast wave propagation and mitigation. Blast waves, with their rapid pressure changes and highly nonlinear behavior, pose significant challenges for predictive modeling. MOR, a mathematical dimensionality reduction technique, offers a solution by simplifying the complexity of large-scale dynamical systems described by differential equations. These systems can be computationally expensive to solve through conventional numerical schemes. MOR creates a reduced-order model (ROM) that retains the essential features and behavior of the original system but with fewer degrees of freedom. Unlike traditional high-fidelity simulations that are accurate but computationally expensive, MOR allows for multi-query scenarios. This approach significantly reduces computational demands without sacrificing accuracy, making it a valuable tool for engineers and professionals in safety engineering and defense planning. The study also enables the creation of reduced-order models based on high-fidelity simulations of blast wave interactions with structures, promoting their broader adoption in safety planning and structural assessments. Full article

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9 pages, 2876 KiB

Open AccessProceeding Paper

Fatigue Strength Determination of AISI 316L Steel and Welded Specimens Using Energy Methods

by Danilo D’Andrea, Giacomo Risitano, Pasqualino Corigliano and Davide D’Andrea

Eng. Proc. 2025, 85(1), 31; https://doi.org/10.3390/engproc2025085031 - 1 Mar 2025

Viewed by 10

Abstract

AISI 316 is a stainless steel known for its exceptional corrosion resistance and excellent mechanical properties. It is used in the chemical and pharmaceutical industries, food processing equipment, and medical devices. This alloy’s wide range of applications underscores its importance in industries requiring [...] Read more.

AISI 316 is a stainless steel known for its exceptional corrosion resistance and excellent mechanical properties. It is used in the chemical and pharmaceutical industries, food processing equipment, and medical devices. This alloy’s wide range of applications underscores its importance in industries requiring materials that can withstand extreme conditions while maintaining structural integrity and performance. Additionally, the excellent weldability and formability of AISI 316 allow for versatile design and production processes, ensuring durable and reliable performance in marine environments. This work aims to examine the behavior of AISI 316L and its welded joints under high-cycle fatigue loadings using infrared thermography (IR). Two kinds of experimental tests are performed on specimens with the same geometry: static tests and stepwise succession tests. The results of the static tests are in accordance with the stepwise succession test results in predicting the fatigue properties. Full article

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13 pages, 5159 KiB

Open AccessProceeding Paper

The Design Enhancement of a Pneumatic Cylinder for Valve Actuators by Integrating the “Design-by-Formulas” and “Design-by-Analysis” Approaches with Multiple Integrative Advanced Simulations

by Giovanni Maiocchi, Francesco Fornasari and Luca Collini

Eng. Proc. 2025, 85(1), 5013; https://doi.org/10.3390/engproc2025085013 - 17 Feb 2025

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Abstract

The authors would like to make a meaningful contribution to product development strategies by introducing an original holistic design methodology for pressure-containing equipment. A case study is presented, focusing on the design enhancement of a pneumatic cylinder for valve actuators. The purpose of [...] Read more.

The authors would like to make a meaningful contribution to product development strategies by introducing an original holistic design methodology for pressure-containing equipment. A case study is presented, focusing on the design enhancement of a pneumatic cylinder for valve actuators. The purpose of the discussed methodology is supplying designers with a full picture of the product, usually not directly available, thanks to the extensive use of advanced Finite Element Analysis (FEA) to increase confidence in the safety and reliability of the design at the virtual prototype stage while providing useful insights that can be used during product life in occasions such as root cause analyses. The new design approach is applied to the cylinder by analyzing it in special conditions like during a pressure burst test using an FEA. A comparison with the experimental results confirms that the proposed methodology can potentially contribute to introducing renewed, safe, reliable, and lighter components, reducing the cost and time of development. Full article

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