Search Results (119)

The electrification of urban buses under forthcoming Euro 7 regulations requires new structural solutions ensuring both safety and efficient mass distribution. This study proposes a novel conceptual electric bus body structure with battery-integrated inter-window pillars, in which energy storage systems are embedded. The concept was evaluated using finite element analysis in ANSYS under UNECE R66 rollover conditions by comparing an original diesel configuration (O-model) with a battery-integrated electric (B-model) one. Despite a substantial increase in body mass (from 1947 to 5464 kg), the B-model demonstrated improved structural performance. The maximum deformation decreased from 1489.5 to 1319.7 mm, while the difference between the control point displacements decreased from 32.21 to 12.68 mm. The average relative deformation of pillars decreased from 8.48% to 3.59%, and the intrusion amplitude was reduced from approximately 566 to 167 mm. Analysis showed comparable peak von Mises stresses (414.62 MPa vs. 439.19 MPa), but the B-model exhibited a 6.7% reduction in critical regions and a 16.9% decrease in average stress levels. The B-model remained within the elastic regime at the end of the simulation, whereas the O-model showed residual plastic deformation. The results indicate that integrating battery systems into load-bearing pillars leads to improved structural stiffness and deformation behaviour under rollover conditions, while full certification-level verification of UNECE R66 compliance is beyond the scope of the present study. Full article

Two-dimensional (2D) materials are promising candidates for nanoscale wear-protective coatings. The mechanisms governing their tribological behaviour (i.e., friction and wear) are material-dependent. In this work, we use atomistic molecular dynamics simulations to investigate nanoscale sliding, friction, and lithographic tracks in two 2D materials, graphene and MoS₂, both placed on a SiO₂ substrate. Our results reveal fundamentally different deformation mechanisms in the two materials, where deformation comes as a consequence of applied normal load. MoS₂ deforms via the formation of a stable out-of-plane pucker beneath the contact, enabling efficient absorption and elastic redistribution of mechanical energy within the coating as well as simultaneous reduction of plastic deformation of the underlying material. Wear prevention in the substrate comes at the cost of localised damage to the MoS₂ layer along the sliding path once it reaches the rupture point. On the contrary, graphene exhibits strongly localised deformation due to its high in-plane stiffness and atomic thickness, leading to plastic deformation of the underlying material and mitigating layer damage. These findings provide clear design guidelines for 2D coatings in nanotribological applications, and highlight layered materials, such as MoS₂, as particularly effective for wear protection. Full article

Three-dimensional printed polymers produced using Fused Deposition Modelling (FDM) exhibit directional microstructures resulting from filament paths, layer interfaces, and cellular infill, leading to mechanical and tribological responses distinct from those of homogeneous bulk materials. This study presents a comparative tribomechanical evaluation of polypropylene (PP) bulk inserts and 3D-printed polyethylene terephthalate glycol (PETG) inserts with a 30% hexagonal infill, relevant for robotic gripping applications. Progressive scratch tests were performed under loads from 5 to 100 N (150 N for PP), and profilometry was applied to quantify groove morphology, ridge formation, and displaced-volume ratios. An elasto-plastic conical indentation model was used to derive indentation pressures and elastic–plastic transition radii from groove geometry. The PETG inserts exhibited heterogeneous groove depth, intermittent ridge tearing, and friction fluctuations associated with the internal infill structure, consistent with previous findings on anisotropy and architecture-dependent behaviour in additively manufactured polymers. In contrast, bulk PP demonstrated smoother friction profiles and more stable plastic flow under increasing loads. Two functional indices—specific frictional work and ridge-to-trace volumetric ratio—are introduced to support material selection for robotic gripping systems. The results show that local contact mechanics in 3D-printed inserts are governed by print-induced structural features and can be effectively evaluated through a scratch-based elasto-plastic analysis. The methods and results presented in this work support the rational selection and design of polymer inserts for robotic gripper fingertips. The proposed scratch-based elasto-plastic evaluation framework enables manufacturers and automation engineers to compare 3D-printed and conventional materials based on friction stability, wear response, and deformation resistance. This approach can be directly applied to optimise gripping performance in industrial handling, packaging, and collaborative robotics. Full article

This study investigates the pullout behaviour of hooked-end superelastic shape memory alloy (SMA) fibres embedded in concrete with the aim to develop an analytical model. Single fibre pullout experiments were performed to evaluate the mechanical response of SMA fibres with various hook geometries. A mathematical model based on the friction pulley method was then developed to predict the experimental pullout load versus displacement plots. The model integrates the tensile stress–strain response and the elastic–plastic constitutive behaviour of superelastic SMA materials, while also accounting for fibre slip and superelastic deformation during the pullout process. The pullout process is modelled through staged mechanisms including elastic response and debonding, progressive mechanical anchorage, and frictional pullout. The contribution of mechanical anchorage is governed by the elastic–superelastic strain distribution within the hook bends. The proposed model reasonably reproduces the overall load-slip response, peak pullout load, slip at peak load, and pullout energy for the three different fibre geometries extracted from normal strength and high-performance concrete matrix. The proposed mathematical model offers a transferable and predictive tool for assessing the pullout performance of hooked-end SMA fibres and supports their integration into design of SMA fibre-reinforced cementitious composites. Full article

This study explores the use of spectral methods for fatigue life assessment, considering the effects of material plasticity. While these methods are widely used for high-cycle fatigue in the linear elastic regime, their application to low-cycle fatigue remains more complex due to nonlinear material behaviour. By incorporating models such as Neuber’s rule and the Ramberg-Osgood formulation, this work examines how spectral methods can be adapted to account for elastic-plastic effects. A comparison is made between fatigue life estimations obtained with spectral approaches and results from time-domain nonlinear simulations. The study provides insights into the applicability of strain-based spectral methods, contributing to a better understanding of their potential and limitations in fatigue assessment. Full article

The geometry of ballasted railway tracks is crucial for ensuring railway safety and efficiency. This paper introduces the use of innovative steady-state algorithms designed to compute plastic strains in linear geotechnical structures like railway ballast layers, within Finite Element Methods (FEMs). Facing the specificities of moving loads, traditional step-by-step algorithms, while simple and adaptable, are computationally expensive and time-consuming. In contrast, the proposed steady-state algorithms leverage an Eulerian approach to describe the movement of loads significantly reducing computational time while maintaining accuracy. This paper proposes these algorithms as a methodological improvement and demonstrates the applicability and efficiency of the method for non-periodic structures, as well as for periodic structures, such as railway tracks with evenly spaced sleepers. This paper demonstrates the applicability and efficiency of theses algorithms through comparative studies with traditional methods on typical railway structures. The results show that the presented algorithm not only matches the accuracy of step-by-step methods but also drastically reduces computation time and data storage requirements. This advancement has practical applications for railway infrastructure managers, enabling more efficient and accurate predictions of track geometry evolution and preventing incidents through improved maintenance strategies. Full article

The implementation of Australia’s 2024 waste export ban has increased pressure on domestic recycling systems, resulting in an additional 650,000 tonnes of waste annually. This emphasises the urgent need for high volume landfill waste material recovery, especially in sustainable construction materials such as geopolymer concrete (GPC). Geopolymer concrete is recognised as a sustainable construction material; however, the scientific understanding of the compatibility between landfill waste and the geopolymer matrix, particularly under harsh environments, remains unknown. This paper presents an experimental investigation on five types of geopolymer concrete (GPC) mixes. The study included a control mix with natural stone chips and four additional mixes in which stone chips were 100% replaced with waste materials including shredded plastic, cardboard, crushed glass, and granular crumb rubber as fine aggregates. The mechanical performance, durability behaviour and stress-strain characteristics of these mixes were evaluated. Concrete samples were exposed to normal air, a saline environment with 10% salinity, and a hygrothermal environment at 60 °C and 98% humidity for four months to assess durability performance. The results demonstrate that GPC is compatible with landfill waste aggregates and enables the production of a workable mixture. As a result of saline environments, waste aggregate-based geopolymer concrete reduces compressive strength by 15%, while natural stone chips-based geopolymer concrete decreases strength by 45% during the same period, indicating that waste aggregates are more appropriate than natural aggregates in marine environments. Although the inclusion of waste aggregates reduces the strength and stiffness of the GPC, the materials continue to meet the mechanical property requirements for non-structural applications. A theoretical model considering the elastic modulus, ultimate strength and corresponding strain has been developed to predict compressive stress–strain behaviour of waste-based GPC. High modulus aggregates, typically ranging from approximately 10.0 GPa to 85.0 GPa such as stone chips and glass sand demonstrate parabolic stress–strain behaviour. In contrast low modulus aggregates, generally ranging from 1.0 GPa to 5.0 GPa including plastic, cardboard, and crumb rubber, exhibit a bilinear stress–strain response. Full article

This study investigates the finite element analysis (FEA) of beam-to-column bolted extended end-plate moment connections, with a focus on accurately reproducing plastic rotational stiffness. Existing FEA results for six experimentally tested connections from the literature show substantial discrepancies in the plastic range, despite acceptable elastic stiffness. These discrepancies are traced to conventional material modelling practices, where only yield and ultimate stresses are specified, engineering stress–strain data are used directly, and the minimum elongation is taken as the strain at ultimate stress. To address these limitations, the connections are re-modelled in ABAQUS using (i) a multi-linear approximation for the plastic stress–strain behaviour of mild steel plates, and (ii) a proposed bi-linear approximation that requires only measured yield and ultimate strengths but preserves the area under the reference curve. In both cases, true stress–strain values are supplied to the software for plastic analysis. These strategies reduce the average error in plastic rotational stiffness from 46–48% in the existing FEA to about 18% across all specimens, while maintaining good agreement in the elastic range. The results demonstrate that carefully constructed stress–strain approximations, combined with appropriate data formatting in ABAQUS, enable reliable validation of extended end-plate moment connection models and provide a practical basis for future parametric and design studies. Full article

Background: The compaction of formulation blends is a critical stage in pharmaceutical tablet manufacturing, particularly when drug substances or functional excipients exhibit limited flowability and tabletability. Objectives: This study systematically examined the mechanical behaviour of viscoelastic microcrystalline cellulose (MCC) and brittle anhydrous dibasic calcium phosphate (DCPA), as well as their mixtures, to check how deformation mechanisms influence powder handling and tablet performance. Methods: A compaction simulator, mimicking a small rotary tablet press, was used to evaluate tablet weight variability, densification profiles, die-filling height, force–displacement behaviour, and in-die Heckel analysis. Additional assessments included compression times, breaking force, tensile strength, elastic recovery, as well as in-die and out-of-die tablet thickness across various compositions and compaction pressures. Results/Conclusions: Bulk density values from the simulator showed strong correlation with pharmacopeial measurements (R² ≥ 0.997). Measurable differences in true density and cohesiveness led to poor flowability for MCC and good flow for DCPA, with mixtures containing higher DCPA concentration displaying markedly improved flow characteristic. Compaction analyses confirmed extensive plastic deformation for MCC and fragmentation for DCPA. Increasing MCC content elevated die-fill height, compaction energy, and tablet weight variability, whereas higher DCPA fractions decreased apparent density of tablets and reduced energy demand. Tabletability and compressibility profiles reflected that MCC generated hard tablets but exhibited higher elastic recovery, while DCPA formed softer tablets with closer to linear strength–pressure relationships. Energy profiling demonstrated that MCC stored more elastic energy and required higher overall compression work, whereas DCPA reduced elastic accumulation. Overall, blending viscoelastic and brittle excipients offers a robust strategy for optimizing manufacturability, mechanical strength, and energy efficiency in tablet production. Full article

This paper presents the results of experimental tests and numerical analyses of the behaviour of brackets used in substructures of ventilated facades. Two representative solutions were compared: a traditional aluminium bracket and an innovative passive bracket with a composite interlayer. The aim was to assess their load-bearing capacity, deformation and failure mechanisms, and the suitability of the calculation methods used. Laboratory tests were carried out at ITB’s accredited Laboratory of Building Elements in accordance with the European Assessment Document (EAD 090034-00-0404). The aluminium bracket was tested under standard environmental conditions. In parallel, finite element (FE) analyses were performed, including elastic–plastic modelling for metallic systems and material and geometric nonlinear analyses for the passive bracket. The results revealed fundamental differences in the behaviour of the two solutions. The aluminium bracket exhibited a predictable plasticisation mechanism, the ability to redistribute stresses, and a gradual loss of capacity. Linear analyses proved sufficient in this case and were consistent with the tests. The passive bracket, by contrast, showed quasi-brittle behaviour, strong temperature sensitivity, and no plastic reserve, resulting in a sudden failure mechanism. For this case, the use of classical linear models leads to unsafe simplifications and underestimated results. The study demonstrates that the development of passive facade bracket technology requires a nonlinear approach and extended long-term testing covering the rheology of composite materials and environmental effects. The findings also reveal a normative gap: current design guidelines and EAD documents focus on metallic solutions while overlooking the specific behaviour of passive brackets. The results constitute an important contribution to knowledge on the safety and durability of ventilated facades and may serve as a basis for developing dedicated design procedures and for updating normative documents. Full article

This paper concerns the issue of selecting appropriate stress field parameters for predicting the stability of headings driven under the geological and mining conditions of Polish underground copper mines. The problem is of key importance due to strict safety requirements in mine workings that serve ventilation and transport functions. Numerical analyses were carried out for four stress field variants: the stress state determined based on Bulin’s formulas (variant 1), the hydrostatic stress state (variant 2), and stress states determined from in situ measurements conducted in the Rudna mine (variant 3 and variant 4). Numerical simulations were performed for a group of four headings, supported with fully grouted rock bolts, in the geological and mining conditions of the Rudna mine. Stability assessment was performed using the finite element method (FEM). Rock mass input parameters for the modeling were obtained with RocLab 1.0, applying the Hoek–Brown classification, while numerical analyses employed the Mohr–Coulomb failure criterion. The elastic–plastic model with softening was used to describe the rock mass behaviour. Numerical calculations were conducted in the RS2 computer program in a triaxial stress state and in a plane strain state. The range of the yielded rock mass zone in the roof of the headings was assumed as the optimal measure of the headings stability. The obtained simulation results provided a basis for recommending suitable rock bolting systems to protect the stability of headings developed under various initial stress field conditions. Full article

The accurate prediction of the mechanical behaviour of silica–epoxy nanocomposites is essential for advancing their application in high-performance industries, including aerospace, automotive, and structural engineering. Conventional experimental characterization methods are often time-consuming and costly, highlighting the need for efficrelianceient computational alternatives. This study proposes a machine learning based on Random Forest Regression to predict the stress–strain behaviour of silica–epoxy nanocomposites with high accuracy. The model employs two independent and physically meaningful input parameters—SiO₂ nanoparticle concentration (wt%) and strain—to predict stress, thereby capturing the true constitutive relationship of the material. The model was trained and validated on an extensive experimental dataset of 7422 observations across five compositions (0–4 wt% SiO₂), obtained from systematic tensile testing following the ASTM D638 standard. Rigorous stratified 10-fold cross-validation confirmed excellent generalization (mean R² = 0.9977 ± 0.0023) with minimal overfitting (training–validation gap < 0.005). The performance of the test set (R² = 0.9948, mean absolute error (MAE) = 0.0404 MPa) surpasses recent literature benchmarks by nearly 5%, establishing state-of-the-art accuracy in nanocomposite property prediction. Error analysis revealed stable prediction accuracy throughout the elastic and plastic regimes (error variance < 0.004 MPa² for strain), with a physically consistent increase in error near failure due to complex damage mechanisms. Feature importance analysis indicated that strain and SiO₂ concentration contributed 78.4% and 21.6%, respectively, to predictive accuracy. This is consistent with constitutive modelling principles, in which deformation state primarily determines stress magnitude, while composition modulates the functional relationship. Mechanical property extraction from experimental curves showed optimal performance at 2–3 wt% SiO₂, yielding balanced enhancements in tensile strength (+1–2%) and failure strain (+36–64%) relative to neat epoxy. The validated framework reduces material development time by 65–80% and cost by 60–75% compared with conventional trial-and-error methods, offering a robust, data-driven tool for the efficient design and optimization of silica–epoxy nanocomposites. A comprehensive discussion of limitations and applicability boundaries ensures the framework’s responsible and reliable deployment in engineering practice. Full article

This work examines the mechanical behaviour of 3D-printed stochastic lattice structures fabricated using a semi-controlled design. A primary goal is to predict and optimize the mechanical response of these Acrylic Styrene Acrylonitrile (ASA) filament structures when subjected to compressive stress. By transitioning from a purely stochastic method to a semi-controlled tessellation approach within Rhinoceros 7 software, we effectively generated the proposed design models. This methodology results in mechanical responses that are both predictable and reliable. The design parameters, including nodal formation, strut thickness, and lattice generation based on a predefined geometric routine, are associated with the regulation of the relative density. This approach aims to minimize the effect of relative density on the actual stiffness and strength evaluation. Our findings are cantered on the compressive testing of structures, which were generated using a Voronoi population distributed along a parabolic curve. We analyzed their mechanical response to the point of failure by examining stress–strain fluctuations. Three distinct behaviour stages are observed: elastic range, plastic range, and collapse without densification. The influence of crosslink geometry on the elastic responses was highlighted, with parabolic configurations affecting the peak stresses and elastic line slopes. The structures exhibited purely brittle behaviour, characterized by abrupt local cracking and oscillatory plateau formation in the plastic stage. Full article

Aramid fibre has become a critical material for individual soft body armour due to its lightweight nature and exceptional impact resistance. To investigate its energy absorption mechanism, quasi-static and dynamic tensile experiments were conducted on Kevlar^® 29 plain-woven fabric using a universal material testing machine and a Split Hopkinson Tensile Bar (SHTB) apparatus. Tensile mechanical responses were obtained under various strain rates. Fracture morphology was characterised using scanning electron microscopy (SEM) and ultra-depth three-dimensional microscopy, followed by an analysis of microstructural damage patterns. Considering the strain rate effect, a viscoelastic constitutive model was developed. The results indicate that the tensile mechanical properties of Kevlar^® 29 plain-woven fabric are strain-rate dependent. Tensile strength, elastic modulus, and toughness increase with strain rate, whereas fracture strain decreases. Under quasi-static loading, the fracture surface exhibits plastic flow, with slight axial splitting and tapered fibre ends, indicating ductile failure. In contrast, dynamic loading leads to pronounced axial splitting with reduced split depth, simultaneous rupture of fibre skin and core layers, and fibrillation phenomena, suggesting brittle fracture characteristics. The modified three-element viscoelastic constitutive model effectively captures the strain-rate effect and accurately describes the tensile behaviour of the plain-woven fabric across different strain rates. These findings provide valuable data support for research on ballistic mechanisms and the performance optimisation of protective materials. Full article

Recycling polyethylene terephthalate (rPET) from packaging materials consumes a vast amount of energy and incurs significant economic and environmental costs. This study proposes directly recycling rPET into woven fabrics to eliminate reprocessing while still preserving the mechanical performance of the material. The mechanical properties of rPET were tested along two orthogonal directions, and the resulting test data were used to calibrate an elasto-plastic model in order to capture the constitutive behaviour of the material. Additionally, the virtual weaving of rPET fibres into fabrics was modelled using finite element analysis (FEA) to replicate the actual manufacturing process. The results show that rPET that is directly recycled into woven fabrics exhibits superior performance to the same material derived from reprocessing. A strong anisotropy of rPET materials was observed, with distinct elastic and ductile behaviours. The FEA simulation also revealed the critical role of the ductility of rPET fibres when used as warp yarns. The process parameters to achieve a successful weaving operation for different yarn configurations, taking into account the motion and tension of the fibres during manufacture, were also identified. A further sensitivity study highlights the influence of friction between the fibres on the tension force of warp yarns. The virtual manufacture-by-weaving model suggests that utilising rPET with a simplified recycling approach can lead to the sustainable manufacture of fabrics with broad industrial applications. Full article