Appl. Sci. 2026, 16(7), 3146; https://doi.org/10.3390/app16073146 (registering DOI) - 24 Mar 2026
Abstract
Scalability of the original test design for the box assembly with removable component (BARC) structure is of interest in the field of experimental structural analysis. As complex structures become increasingly difficult to test experimentally the larger they become, it is a common test
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Scalability of the original test design for the box assembly with removable component (BARC) structure is of interest in the field of experimental structural analysis. As complex structures become increasingly difficult to test experimentally the larger they become, it is a common test practice to use a scaled-down representative model to understand the characteristics of these systems. For complex structures with non-rigid boundary conditions, there exists a gap in understanding the effects of scalability and welding. To gain a better understanding of the outcomes of this phenomenon, the dynamical effects of upscaling the dimensions of the BARC structure are analyzed. Three variations of the BARC are investigated experimentally and computationally, namely, the original BARC system, the BARC system upscaled at 1.5 times the size of the original model, and the BARC system upscaled at two times the size of the original model. The original BARC is tested to investigate the properties of the predetermined boundary conditions. Because the upscaled BARC systems are manufactured using welding, an investigation of the variability of results due to welding imperfections is conducted to evaluate its effects on the vibrational properties of the systems. The dominant resonant frequencies of the three systems are identified through an impact hammer test. The results are then compared to those obtained through finite element analysis, in which both datasets show agreement. In general, as the BARC system is upscaled, the resonant frequencies decrease without inducing mode switching for the selected boundary conditions, indicating that the larger systems are less rigid. To understand the trends of nonlinear softening/hardening and nonlinear damping, forced vibration experiments conducted in the form of true random and controlled stepped-sine excitations are performed. The results show that, in general, as the BARC system is upscaled, changes in the nonlinear properties of the system are induced. With regard to the effects of using welding to manufacture BARC systems, the results prove that variations in welding can lead to non-negligible variations in the vibratory responses of the BARC system. Additionally, several types of harmonic vibrational testing are investigated to understand the physics behind their varied responses. Overall, this work shows that upscaling the BARC system can be beneficial to researchers who require a less rigid system for investigations and that manufacturing of BARC systems by welding can be a cost-effective alternative to subtractive manufacturing.
Full article
(This article belongs to the Special Issue Nonlinear Dynamics in Mechanical Engineering and Thermal Engineering)
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