Browse Topic: Finite element analysis

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Fatigue Damage Analysis of a Wheeled Vehicle2026-99-12079/4/2026
This article studies the fatigue damage problem of vehicles under air drop and off-road conditions. First, a multi-body dynamics model of the entire vehicle is established in ADAMS/View to obtain loads and center-of-gravity acceleration under off-road conditions. Subsequently, a finite element model of the vehicle air drop is created in HyperMesh and LS-DYNA to simulate the landing impact and extract loads on key components. By superimposing and spectrum processing the loads from the two conditions, a vehicle load spectrum is compiled and used as input for fatigue analysis. Based on the Miner linear cumulative damage criterion and the material S–N curve, fatigue life predictions are made for key areas of the frame and suspension. The results indicate that the front cross beam and auxiliary longitudinal beam at the bottom of the frame are the most vulnerable components, with the auxiliary longitudinal beam reaching failure under both conditions, but having a limited impact on the overall vehicle operation. Although the peak acceleration under air drop conditions is higher, the off-road conditions lead to more severe cumulative damage due to higher impact frequency and duration. This study provides references for vehicle structural optimization and service reliability enhancement.
Lin, Qingpeng, Zhang, Qiang, Fu, Lei, Huang, Jianbing, Qin, Weiwei, Sun, Xiaowang
A Computing Method of Splitting Factor for 3D Non-Compatible Generalised Mixed Hexahedral Element2026-99-12119/4/2026
With the rapid development of the aerospace industry, FEM has been widely applied as a key tool. However, the high complexity of aircraft and spacecraft geometries and structures often leads to unavoidable distorted meshes in FEM, which significantly degrades the accuracy of analysis results. Both the splitting factor and the mesh distortion significantly affect the accuracy of the generalised mixed elements. The coefficient matrix deviation between the distorted element and the standard element was quantified. Thus, the computing equation for a three-dimensional (3D) hexahedral distorted element’s splitting factor was constructed. Examples were used to validate the proposed method. For distorted meshes, the accuracy of NCGME has been improved.
Shen, Ao, Qing, Guanghui
Experimental Testing and Finite Element Simulation on Tensile Mechanical Behavior of Nickel-based Superalloys2026-99-12249/4/2026
The accurate prediction of high-temperature mechanical behavior of GH3230, as a core material for the new generation of combustion chambers in China, is a key technical prerequisite for promoting engineering applications. This article is the first to conduct a systematic study on the tensile properties of the alloy at three typical service temperatures of 200°C, 550°C, and 900°C, combining high- temperature tensile testing with numerical simulation. Through metallographic observation, the excellent microstructure characteristics of the alloy, including no grain boundary defects, inclusion phase size less than 5 μm, and uniform distribution, were clarified. Based on this, a multi-temperature adaptive tensile simulation model was established. Experimental verification showed that the model can accurately reproduce stress-strain tensile curves at different temperatures, with prediction errors controlled within a reasonable range, effectively breaking through the limitations of traditional single-temperature simulation. This study not only provides an efficient and accurate new method for the performance analysis and safety evaluation of GH3230 in a wide temperature range but also provides practical technical means to support the component-level engineering application of this material. At the same time, the research results also provide a reference technical path and research ideas for the multi-temperature mechanical performance prediction of other nickel-based high-temperature alloys.
Qiao, Yongle, Xie, Jiahui, Li, Lei, Zhou, Jie, Zhu, Yankun, Wang, Yifei
High-Precision Micro-Satellite Attitude Control: Design and Testing of an Ultrasonic Motor-Driven Control Moment Gyroscope2026-99-12919/4/2026
The issues associated with the traditional single-gimbal control moment gyroscope (SGCMG) driven by electromagnetic motors, such as complex structure, significant gear backlash, weak anti- interference capability, poor adaptability to space environments, and large volume and weight, make it difficult to meet the attitude control requirements of micro/nano satellites. To address these issues, this paper proposes an SGCMG design based on a rotary traveling wave ultrasonic motor (RTWUM) drive. Ultrasonic motors offer advantages including high torque, fast response, self-locking upon power-off, immunity to electromagnetic interference, and simple structure, making them suitable for spacecraft attitude control systems. This paper elaborates on the working principle and structural design of the ultrasonic motor, covering the entire process from stator modal optimization, flywheel and gimbal structural design to system integration and control system implementation. Through finite element analysis and experimental verification, the designed ultrasonic motor-driven SGCMG meets the requirements of micro/nano satellites in terms of output torque, speed control accuracy, and structural compactness, demonstrating the promising application prospects of ultrasonic motors in aerospace attitude control.
Wu, Jintao, Zhang, Jiyang, Li, Huafeng, Pan, Song
Aerodynamic Load Calculation and Prediction Method for Folded Wing Mechanism2026-99-12899/4/2026
The folding wing mechanism is widely used in aircraft design. Whether the folding wing surface can unfold smoothly determines whether the aircraft can fly normally. Therefore, studying the aerodynamic loads and structural deformations during the unfolding process of folded wing surfaces is very important. The motion process of a folded wing mechanism is a typical fluid-structure interaction (FSI) process. During deployment, the wing surface moves under the combined action of the actuator’s pull and the aerodynamic loads from the incoming flow, while the large deformation of the wing surface during its movement, in turn, affects the aerodynamic loads on the mechanism from the flow field. Considering the FSI effects during the unfolded motion process of the folded wing, simulation was conducted using the ALE algorithm in LS-DYNA to obtain the kinematic and dynamic parameters in the unfolded motion process, and also to get the aerodynamic torque on the wing under different angles and angular velocities. In practical engineering applications, the actuation force of the deployment mechanism can vary due to factors such as the amount and performance of the pyrotechnic material. Consequently, the final velocity and the whole motion process of the wing mechanism will also change. For the calculation of aerodynamic external loads under multiple operating conditions, using the ALE algorithm will consume a large amount of computational time and cost. Given the high computational cost and long computation time of finite element simulations, a BP neural network was established to calculate the aerodynamic loads on the wing surface under different actuation forces. This allows for a rapid assessment of whether significant deformation or damage will occur to the folding mechanism or nearby components during the deployment process.
Wei, Ting, Li, Naitian, Tong, Zongkai
The Flexibility Coefficient Fitting of Bolt in Metal-Composite Hybrid Joint Structures Based on L-M Method2026-99-12679/4/2026
This study used the L-M (Levenberg-Marquardt) algorithm to analyze the fitting of the flexibility coefficient of fasteners in the mixed connection structure of metal composite materials to address key challenges in aircraft structural design. Through parametric modeling and finite element simulation of single lap joints, the system evaluates eight key factors, including the direction of the composite material layer, the elastic modulus of the metal plate, the plate thickness ratio, the fastener diameter, the elastic modulus of the fastener, the Poisson’s ratio of the fastener, the magnitude of the preload force, and the type of bolt configuration, covering convex and countersunk variants. Advanced material modeling techniques are introduced in the study to accurately capture the anisotropic behavior of the composite material layer and its interaction with metal components under different load conditions. The results show that the higher modulus and thickness of the composite material plate and metal plate significantly reduce the flexibility of fasteners, and larger fastener diameters are associated with reinforcement. The elastic modulus further reduces flexibility. The flexibility of convex head bolts is significantly lower than that of countersunk head bolts, while Poisson’s ratio, preload force, and humidity have little effect. Based on these findings, a new flexible calculation formula containing nine undetermined parameters is proposed. The L-M algorithm is used for nonlinear regression to derive formulas with physical significance. The verification shows that the proposed formula is highly consistent with the finite element results, with a corrected coefficient of determination of 0.956. Among 864 test sample points, 73.61% have an error of less than 5%, and only 0.23% have a deviation of more than 15%. Comparative analysis with twelve existing methods, including the Delft University and Boeing formulas, confirms that the proposed method has better accuracy. This method effectively expands the applicability of traditional flexible formulas, provides solid theoretical support for advanced aircraft connection design, and realizes diverse mixing in aerospace engineering and accurate calculation of connection configuration.
Fan, Zhuotao, Wang, Xu, Wang, Tong, Li, Xianchao
An Experimental and Numerical Study on the Optimization of Quasi-static Energy Absorption Performance in Aluminum Alloy Thin-walled Tubes with Varied Notch Configurations2026-99-12559/4/2026
Aluminum alloy thin-walled tubular parts play an important role in the energy absorbing elements of automotive passive safety. The number of geometry-trigger based notches is a factor in alleviate the initial force peak and shift the progressive buckling mode. However, until now, only limited work has been reported considering multiple notches. It is hard to clearly understand the impacts of the number of triggers on the buckling behavior and thresholds. Here, a mixture of quasi-static axial compression testing with high-fidelity finite element simulations is used to explore the influence of elliptical perforation number on AA6061-T6 tube crushing behaviour. For the first time, it is demonstrated that increasing the perforations leads to non-monotonic buckling evolution: from symmetry increasing → asymmetrical instability → optimal re-symmetrization → excessive weakening. We observe this transition from isolated holes to a collective “weakening hoop” controlling symmetric buckling as the number of holes increases. Our results give optima for separate objectives; T6 offers the best overall crashworthiness (45.2% less maximum force), with the other measures showing T4 with the best stiffness. We determine quantitative relationships between the number of holes and corresponding performance metrics. This gives practical design criteria for the design of energy absorbers.
Guo, Zifa, Jin, Ming
Design and Analysis of Transmission Line Tower Erection Equipment2026-99-12409/4/2026
In response to the industry's problems of transportation difficulties, low efficiency, and high safety risks during the erection of high-voltage transmission line towers in mountainous areas, this paper proposes a light tower erection device that integrates connection, assembly, and fixing functions. The device adopts 180 mm Q345 equal-angle steel tower legs and is equipped with a hydraulic drive system. The tower body is raised through the coordinated work of the main and secondary hydraulic cylinders. In contrast, the vertical and horizontal hydraulic cylinders are used for auxiliary descent and precise fine adjustment. Its modular and lightweight structural design meets the transportation needs in narrow spaces in mountainous areas. The specifications of the hydraulic cylinder are determined by mechanical calculation, and the structural strength of the square tube and the main and secondary hydraulic cylinder connecting rods is verified by finite element analysis. Kinematic simulation confirms that the operating performance of the device is stable. This device provides an efficient and reliable piece of technical equipment for the construction of transmission lines in mountainous areas, which has important engineering application value and broad promotion and application prospects.
Li, Hailong, Chen, Zhen, He, Longping, Wang, Zhongpan, Li, Cheng
Extreme-Condition Analysis of Flow and Structural Strength in a Closed Space2026-99-12769/4/2026
This study investigates the transient Fluid-Solid-Thermal (F-S-T) multi-physics coupling behavior of a direct-acting reversible check valve under extreme working conditions in a closed environment. The valve operates within a military system, functioning for gas addition and resisting explosive reactions, where its internal chamber experiences rapid transitions to ultra-high temperature (2000°C) and ultra-high pressure (800 MPa). Given the threat posed by such transient impingement to the structural strength of the pressure-bearing components, a detailed study is essential. A coupled numerical simulation is employed, utilizing Ansys Fluent for Computational Fluid Dynamics (CFD) and Ansys Mechanical for Finite Element Analysis (FEA). A three-dimensional, compressible, Navier-Stokes model and F-S-T coupling governing equations are established to simulate the transient flow field and transient structural field. Results indicate that the Impinging Flow Field (IFF) exhibits a highly unsteady state due to fluid inertia and aggregation-recoil effects, with local pressure peaks reaching 1590 MPa. The temperature field shows marked hysteresis relative to pressure and develops pronounced thermal stratification. The equivalent stress distribution closely follows the transient fluid pressure in the Impinging Structure Field (ISF), confirming strong F-S-T coupling. Although localized areas, particularly near the outlet region and specific inner walls, experience stresses exceeding the yield strength and enter the plastic stage, the overall valve structure remains intact, with stress levels staying within the material's ultimate bearing capacity. This research demonstrates the viability of the adopted coupled simulation methodology for analyzing extreme transient events. The findings provide a valuable reference for the safety design and assessment of valves operating in similar extreme environments.
Lai, Fangye, Wang, Xuesheng
Stress-Strain Response Characteristics of Buried Gas Pipelines Under Landslide Action2026-99-12759/4/2026
Typically, triggered by geological hazards such as landslides, ground displacement acts as the main cause for the failure of buried pipelines. To maintain the structural integrity of these pipelines, an in-depth investigation is required to understand how these pipelines, subjected to landslide thrust, respond mechanically. During the research, a refined three-dimensional (3D) finite element model for soil-pipeline interaction was established, as evidenced by existing experimental data, which takes the elastoplastic behavior of the soil and complex contact conditions into consideration. According to a thorough parametric study, on the basis of the model, the effects of pipeline, landslide, and soil vary in their protection, detrimental, and complex trade-off levels. On the one hand, protective measures concerning wall thickness, steel grade, and other similar factors serve to improve resilience; on the other hand, detrimental factors such as burial depth and soil stiffness escalate the possibility of failure risk. Notably, the influences related to landslide extent and pipe diameter are not straightforward and monotonic. In other words, when one factor increases, risk may be reduced in one regime and amplified in another. Therefore, words like “wider” or “bigger” should not be equal to “safer” by default. To conclude, based on the results, train-based evaluation is supported, and some practical guidance can be provided for the design and risk assessment for pipelines in areas where geohazards may occur.
Zhang, Ruijia, Dong, Shaocan, Wang, Xinyu, Li, Yuxing, Hu, Qihui, Wang, Wuchang
Investigation into the Crashworthiness of Freight Vehicles under Frontal Impact2026-99-12869/4/2026
This paper investigates the crashworthiness of freight vehicles under frontal impact based on the C-NCAP (China New Car Assessment Program) standard. Explicit dynamics and finite element methods were employed to conduct simulation analyses of the impact event, with the aim of offering references for improving vehicle crashworthiness. The findings indicate that the vehicle cabin remains largely intact, providing sufficient survival space for occupants. However, increased load amplifies the impact impulse and reduces crashworthiness. Additionally, the use of an enhanced anti-collision beam helps distribute impact forces and lowers the peak impact load.
Liu, Zihan, Jiang, Yi, Wang, Pu
Research on Multi-Condition Topology Optimization of Transport Ship Pillar Structure2026-99-12289/4/2026
Structural optimization in shipbuilding represents a significant research focus within the fields of naval architecture and marine engineering. This study investigates multi-condition topological optimization for the deck pillar region of a transport ship's sectional structure. A mechanical model incorporating six typical load conditions was developed, and the Analytical Hierarchy Process (AHP) was employed to quantify the weighting coefficients for each condition. This enabled multi-condition collaborative topological optimization of the pillar layout. The optimized configuration underwent model reconstruction and finite element verification. Results demonstrate that the proposed multi-condition collaborative topology optimization method effectively balances structural performance and weight reduction requirements while satisfying strength specifications. This method yields optimal pillar layouts meeting multi-condition constraints, providing a reference for multi-condition topology optimization studies in ship structures.
Pei, Zihao, Wei, Yi, Feng, Ruge, Liu, Kun
An Energy Balanced Splitting Factor Calculation Method for Nonconforming Generalized Mixed Finite Elements with Distorted Meshes2026-99-12239/4/2026
This paper presents an Energy-Balanced Splitting Factor Method (EBSFM) for nonconforming generalized mixed finite elements to enhance accuracy and stability under mesh distortion. The splitting factor significantly influences the numerical solutions. Traditional approaches employ a uniform splitting factor for all elements, neglecting their distinct characteristics and boundary conditions. Wang's geometry-based Stiffness–Compliance Splitting Factor Method (SCSFM) is adopted to obtain element-wise initial values. Building upon SCSFM, the proposed EBSFM optimizes the splitting factor through an energy balance criterion that minimizes the deviation between mixed energy and generalized strain energy, thereby improving the physical consistency of the finite element model. The method establishes an approximate mapping relationship between unknown variables and splitting factors via matrix decomposition and reconstruction techniques, enabling element-wise adaptive optimization. The EBSFM demonstrates consistent superiority in terms of displacement accuracy, stress accuracy, and energy balance.
Shang, Zhongxin, Wang, Zhenyu
Johnson-Cook Model Calibration of 10# Steel and Dynamic Mechanical Behavior Analysis under High Strain Rates2026-99-12019/4/2026
As a typical material for fragmentation warheads, the mechanical behavior and ballistic penetration performance of 10# steel are critical for assessing warhead lethality. To characterize the dynamic response of 10# steel, systematic experiments were conducted, including quasi-static tensile tests, split-Hopkinson tensile bar tests, and thermal softening measurements. A = 505.46 MPa, B = 292.84 MPa, n = 0.335, C = 0.0343, and m = 1.213 are the calibrated Johnson–Cook parameters. Bridgman-corrected notched tensile tests determined damage parameters D1 to D4: 0.065, 0.746, −0.646, and 0.031). A study of its constitutive behavior shows that the strength of 10# steel increases with stress triaxiality and strain rate, whereas increasing temperature enhances ductility and reduces strength. Finite element software was updated to include the calibrated parameters to develop a material model for ballistic impact simulation. When compared with the ballistic penetration test results obtained using a 14.5 mm projectile, the simulated residual velocities show less than 5% deviation from the measured values. 3D scanning reveals that fragment sizes in experimental data differ by under 10% from simulation predictions. This work enables precise numerical simulations for warhead fragmentation prediction and lightweight armor design.
Tian, Yumo, Zhang, Longhui, An, Fengjiang, Feng, Bo
The Vacuum System of Arc Section Standard Cell for STCF Collider Rings2026-99-12389/4/2026
The Super Tau-Charm Facility (STCF) is a new-generation positron-electron collider planned in China. The core mission of STCF is to design a new generation of large-scale scientific facility featuring a center-of-mass energy between 2 and 7 GeV and a peak luminosity of more than 5×10^31 cm^–2s^–1. Given its high beam intensity and high luminosity characteristics. This will provide serious difficulties for the vacuum system’s design due to its high beam intensity and high luminosity features. The double-ring collider and the injector are the two primary components of the STCF. Each collider ring is divided into arcs, straight sections, and the interaction region. The arc sections adopt the same standard cell design. This paper primarily introduces the vacuum system of a standard cell for the arc section. This is related to the space simulation of aerospace on the ground, which requires a very high vacuum. By designing an overall scheme for the vacuum system, the structure and dimensions of the vacuum chamber are determined. The synchrotron radiation power and dynamic gas load distribution are calculated for the Arc Dipole Magnet. The placement scheme for vacuum components such as vacuum pumps, bellows, and BPMs is determined. At the same time, simulation analysis was conducted on the temperature, strength, and internal pressure of the vacuum chamber using finite element analysis software. Different vacuum chamber materials will have different calculation results, and the copper vacuum chamber is selected in this paper. The design specifications meet the technical requirements proposed by the physical system, providing a theoretical basis for the development of the next prototype and technical guidance for the design of vacuum systems in other sections.
Zhao, Lijuan, Zhang, Ruiyang, Sun, Kun, Gong, Hailiang, Jiao, Weijie, Zhang, Benfu, Mao, Mingyang
Finite Element Analysis of Mechanical Behavior of Steel Reinforced Concrete (SRC) Columns Designed by Different Methods2026-99-04158/28/2026
The design of integrated station-bridge structures is challenged by the coexistence of building codes based on Limit State Design (LSD) and railway codes using Allowable Stress Design (ASD). This study employs finite element analysis to compare the performance of Steel Reinforced Concrete (SRC) columns designed under these two philosophies. The results demonstrate the significant conservatism of the ASD method: When achieving the same safety margin, the ASD-designed column required 2.36 times the cross-sectional area, yielding an 89% higher axial capacity but a disproportionately small increase in shear strength, indicating material inefficiency. A subsequent parametric analysis identified steel strength as key to axial capacity and concrete strength as critical for shear capacity, with shear performance reaching its maximum at an axial compression ratio of 0.6. These findings quantify these behavioral differences, offering a basis for refining design methods and codes harmonization for such structural members.
Tang, Jia, Duan, Linli, Chen, Nan, Huang, Yunfei, Guo, Wei, Jiang, Lizhong, Yu, Yujie, Xu, Yongjia
Finite Element Simulation and Application of Ultrasonic TOFD Detection for Austenitic Stainless Steel Welds2026-99-04068/28/2026
Ultrasonic TOFD detection is one of the most important non-destructive testing techniques for welds. However, the complex beam deflection, scattering, and attenuation of ultrasonic waves in the heterogeneous weld structure lead to the weak signal of the defect diffraction wave received by the probe and the low signal-to-noise ratio, which has a negative impact on the engineering application of ultrasonic TOFD detection technology in austenitic stainless steel welds. In this study, a numerical model of the ultrasonic TOFD detection process for austenitic stainless steel welds was established based on the finite element method. Combined with the test method, the interaction mechanism between the ultrasonic wave and weld structure is analyzed, and the probe arrangement method to reduce the interference of weld scattering noise is proposed. The results show that the finite element model can simulate the anisotropic characteristics of ultrasonic waves in austenitic stainless steel welds, including sound field distortion, sound energy scattering, and attenuation. Combined with the detection test, it has been proven that the adverse effect of the weld structure on the TOFD detection signal can be reduced by changing the probe detection surface.
Hu, Lichen, Huang, Hui, Qian, Shengjie, Hu, Weiwei, Chen, Zhenhua
Numerical and Experimental Investigation of the Impact of Close-Range Construction of Large-Section Tunnels on Existing Subway2026-99-04258/28/2026
Large-section tunnel construction using the mining method can significantly affect the operational safety of existing metro lines and ground stability, while their non-uniform settlement remains challenging to monitor comprehensively. In this study, the post-station section of a metro project in Chengdu was investigated to elucidate the vertical displacement and ground settlement behavior induced by a large-section tunnel undercrossing an existing metro line. A displacement reconstruction method integrating sparse-point monitoring with a radial basis function neural network (RBFNN) was developed to fit the full-field settlement distribution of both the existing line and the ground surface. A finite element model incorporating the existing shield tunnels, station structures, and the newly constructed mined tunnel was established, and the construction process was simulated. The numerical results indicated maximum settlements of 4.42 mm for the existing line and 4.37 mm for the ground surface, with fitting errors below 5.8% and 6.1%, respectively. Physical model tests further validated the approach, yielding maximum settlements of 0.86 mm and 1.01 mm for the existing line and ground surface, respectively, and an average fitting error below 3.5%. Both numerical and experimental findings confirmed that the induced displacements were within a controllable range and that the surrounding strata remained stable. The proposed method enables accurate and intuitive reconstruction of displacement distribution during under-crossing tunnel construction, reducing the number of required monitoring points while maintaining high fitting accuracy.
Wang, Rui, Chen, Jian, Cheng, Tao, Du, Lin, Li, Ruixiao
Influence of Restraint System Angles on Impact Response and Protection of Child Occupants in Vertical Crash Conditions2026-99-04138/28/2026
Focusing on the protection needs of child occupants in the scenario of aircraft vertical crashes, a finite element calculation model based on the cabin structure of a certain type of small electric aircraft was established. The child seat restraint system was coupled with the THUMS 3YO human body model, and the vertical 15 g condition meeting the requirements of Article 23.562 of CCAR-23-R3 was simulated. The influence law of the safety belt restraint angles (formed by different safety belt routing positions) on the dynamic response and injury indicators of child occupants was explored. To verify the rationality of the simulation results, a physical impact experiment was conducted using a Hybrid III 3YO child dummy and the same type of child seat, with key indicators (e.g., head acceleration, lumbar load) measured and compared with simulation data. The analysis results show that the effect of the safety belt restraint angle on the overall protective performance is less pronounced under vertical conditions, but a clear trend is observed: when the angle is in the range of 76°~84°, the head acceleration is relatively low and the brain tissue injury indicators are in the optimal state, which can effectively reduce the risk of head and neck injuries; when the restraint angle increases to 92°, the lumbar axial load and lung strain increase significantly, indicating a detrimental effect. The results of this study clarify the differences in the protective performance of child seats under different restraint angles, and provide a theoretical basis and technical guidance for the layout of safety belt anchors of aircraft seats and the optimal design of child seats.
Wang, Yafeng, Guo, Pan, Li, Weiliang, Shi, Xiaopeng
Dynamic Response and Energy Absorption of a Novel Arc-Shaped Hourglass Re-Entrant Honeycomb under Impact Loading2026-99-04178/28/2026
This study introduces an arc-shaped hourglass re-entrant auxetic honeycomb (AHRH) and examines its impact-induced dynamic response and energy-absorption behavior via finite-element simulations. The conventional re-entrant honeycomb (RH) is adopted as the baseline, and side-by-side simulations are performed at impact speeds of 10, 20, and 30 m/s. The mechanical response of both lattices is assessed through force-displacement characteristics, absorbed-energy histories, and representative deformation modes. Results indicate that the AHRH significantly reduces the initial peak force, prolongs the plateau stage, and exhibits a distinct dual-plateau feature, thereby achieving the desirable crashworthiness mode of “low initial peak-extended plateau-high densification”. Compared with the RH, the AHRH achieves increases of approximately 42.9%-59.7% in total energy absorption and 42.8%-56.1% in specific energy absorption while maintaining nearly identical mass. The enhanced performance arises from the arc-edge geometry, which alleviates local stress concentrations, promotes progressive buckling, and generates multiple plastic hinges. These mechanisms lead to smoother load transfer, avoidance of excessively high initial impact loads, and more efficient crash energy management. Overall, the proposed AHRH structure demonstrates superior energy absorption capacity and deformation stability compared with the conventional RH, providing new insights and practical references for the lightweight design and optimization of advanced protective and crashworthy structures.
Jiang, Zhide, Chen, Long, Yu, Ping
Lightweight Research on CFRP Bumper Impact Beam2026-99-04118/28/2026
As a critical component in vehicular passive safety systems, the automotive bumper beam significantly influences overall crash safety performance and lightweight potential. This study presents a comprehensive investigation into the lightweight design of a carbon fiber reinforced polymer (CFRP) bumper beam, systematically substituting a conventional aluminum alloy component based on the principle of equivalent bending stiffness. The research methodology integrates finite element modeling, design of experiments, and multi-objective decision-making to optimize crashworthiness. Initial design replaced the 3 mm aluminum beam with a 2.4 mm CFRP configuration using a [0°, 45°, 90°, -45°] ply sequence, demonstrating maintained structural integrity with substantial mass reduction potential. Through Latin Hypercube Sampling, 50 design configurations incorporating variations in panel thicknesses (five distinct sections) and ply orientation sequences were generated and evaluated under an 8 km/h frontal impact simulation. Crashworthiness was assessed through four key indicators: mass, specific energy absorption (SEA), maximum intrusion distance (Dm), and peak impact force (Fm). The entropy weight method objectively determined indicator weights, revealing maximum intrusion (49.27%) as the most critical factor, followed by mass (32.75%), peak force (9.75%), and SEA (8.23%). Subsequently, the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) was employed to comprehensively evaluate and rank all design alternatives. The optimized CFRP configuration (Scheme #38) achieved remarkable performance: 69.1% mass reduction (from 4.505 kg to 1.392 kg), 379.6% improvement in specific energy absorption, 12.6% reduction in peak impact force, while maintaining intrusion within acceptable design limits. This research establishes a robust framework for CFRP bumper beam optimization, successfully balancing lightweight objectives with enhanced crashworthiness, providing valuable insights for automotive lightweight safety component development.
Wang, Yizhi, Zhong, Rong, Long, Jiangqi
Finite Element Analysis of New Energy Vehicle Chassis Using ANSYS2026-99-03438/14/2026
Amid the rapid development of the new energy vehicle industry, the vehicle frame, as the core load-bearing component of the entire vehicle, plays a direct role in the vehicle’s safety, lightweight design, and power performance through its design and performance. Although research on new energy vehicle frames has matured, issues related to the lightweighting of drive shaft-associated structures and the balance between weight reduction and strength/stiffness still require in-depth exploration. This study focuses on the chassis of new energy vehicles, utilizing Q295 low-alloy high-strength steel. Based on the vehicle’s dimensions and mass parameters, a simplified 3D model was constructed using SolidWorks. Static analysis under bending and torsion conditions, along with a 6th-order modal analysis, was conducted using ANSYS software. Based on the analysis results, optimizations were implemented at both structural and material levels: structurally, the central crossbeam was widened, holes were opened on the crossbeam’s vertical plane to reduce weight, and the longitudinal beam welding process was optimized; materially, Q295 steel was retained in high-stress zones, while aluminum alloy replaced it in low-stress zones. The optimized frame achieved a 15% reduction in torsional stress, a 16% decrease in bending stress, a 2% reduction in torsional deformation, and a 3% decrease in bending deformation. Total mass decreased by 12.7 kg, with both strength and stiffness meeting design requirements. This approach synergistically enhances frame lightweighting and performance, providing technical support for optimizing the overall performance of new energy vehicles.
Guo, Lihong, Wang, Yiyou, Yang, Zihao
Research on Wind-Induced Vibration Response of Heavy Cargo Ropeways for Power Transmission Lines2026-99-03308/14/2026
The construction of overhead power transmission lines in remote mountainous regions frequently relies on aerial ropeway systems, as conventional ground transportation is often impractical. However, complex terrain conditions combined with highly variable wind environments can significantly threaten the operational stability and structural safety of these cargo ropeway systems. To investigate these effects, a refined finite element model of a ropeway support was developed in ANSYS, and stochastic, time-varying wind fields were generated in MATLAB. The simulated wind time histories were applied to the numerical model to perform nonlinear transient dynamic analyses, enabling the evaluation of wind-induced displacement responses under different wind angles of attack. Based on the simulated response histories, critical stress- and displacement-sensitive regions of the support structure were identified, and the implications for structural detailing and design optimization of cargo ropeway supports were discussed.
Lv, Yanfeng, Yang, Zhonglv, Sun, Minggang, Jin, Hengdong
Strength and Rotor Dynamic Simulation Analysis of a Brake Testing Device2026-99-03278/14/2026
The brake test bench is an effective method for studying wheel-rail interaction by simulating the braking process of rail vehicles. To ensure the safe and reliable operation of the brake test bench, this article focuses on introducing a comprehensive single-wheel brake test device. A finite element model of the wheelset assembly and test bench was established, and the strength, mode, and dynamic performance of the wheelset assembly and braking system were analyzed by simulating the braking process. The analysis results indicate that the wheelset assembly and braking system meet the strength requirements of the braking test process, and the test speed is maintained below the critical speed of the test bench. This validates the rationality and safety of the brake testing device and provides a foundation for subsequent brake research.
Jing, Yuhang, He, Taixiong, Song, Ye
Stress Analysis and Simulation Study of Propane Spherical Tanks2026-99-03348/14/2026
As special pressure-bearing vessels, spherical tanks are widely used in chemical, oil refining, and other fields. However, their safe operation faces the dual challenges of structural failure and leakage diffusion. Meanwhile, due to its low lower explosive limit and the low ignition energy required, propane will evaporate rapidly after leakage to form an explosive mixed gas, which may further trigger severe accidents such as combustion and explosion. Therefore, this paper takes a 3000 m3 propane spherical tank as the research object, comprehensively applies the finite element analysis method, and systematically researches stress distribution, aiming to provide theoretical support for the safety design of spherical tanks and accident prevention and control.
Huang, Yuanxuan, Tao, Gang, Zhang, Lijing
Mechatronic Transfer Wheelchair Based on SLAM, A*/DWA Algorithms, and Finite Element Safety Assurance2026-99-03418/14/2026
With the acceleration of population aging, the number of disabled older people is increasing, and the demand for home care is also rising. In the case of a narrow space and no gap between the bed and the ground, the transfer of patients between the wheelchair and the bed has become a challenge. Current solutions suffer from bulky designs, require caregiver assistance, and pose potential safety risks. In order to solve the above problems, this paper proposes an intelligent transfer wheelchair with voice interaction and autonomous navigation function. The wheelchair innovatively adopts a cantilever transfer device, which can enable safe and stable transfer without requiring bed-floor clearance, and has the dual functions of a wheelchair and a transfer device, effectively saving family space. The stability of the structure is verified by finite element analysis. Under the action of a 500 N load, the maximum stress and maximum displacement are within the safety limit of the material. The wheelchair is also equipped with an advanced human-computer interaction system with voice interaction and autonomous navigation functions. Users can control the operation of the wheelchair through voice. The navigation module of SLAM and the hybrid A*/Dynamic Window Approach (DWA) path planner realizes the high-precision docking of the wheelchair and the bed. The results show that the design can realize the safe transfer of disabled people between wheelchair and bed, and provide a solution for home intelligent nursing.
Wang, Shunli, Peng, Li, Zhao, Liang
Research on Rigidity-Intensity Analysis and Structural Optimization of the Shuttle Vehicle Load-Bearing Plate2026-99-03068/14/2026
The shuttle vehicle is a critical piece of handling equipment in automated logistics warehouses. As its primary load-bearing component, the load plate is subject to spatial constraints, requiring both a compact structure and effective prevention of structural deformation that could compress the battery. For a shuttle vehicle load plate developed by a company—with a rated load of 1500 kg and a maximum allowable deformation of ≤ 2 mm—this study first adopts the finite element method (FEM) to analyze its structural characteristics and establish a hybrid mesh model consisting of 1D beam elements, 2D shell elements, and 3D solid elements. Symmetry constraints are applied to reduce the computational scale. The structural deformation and stress under two constraint schemes (fixed constraints and surface-to-surface contact constraints) are compared and analyzed. The results indicate that surface-to-surface contact constraints should be adopted under this working condition, and potential design risks are identified. During the analysis, mesh independence is verified to determine an appropriate mesh size, thereby avoiding errors induced by mesh dimensions. Finally, an optimization design is conducted with the goal of lightweighting. Taking the cross-sectional dimensions of the load plate’s stiffeners and the thickness of the load plate as variables, and deformation as the constraint condition, the overall structural weight is reduced from 32.7 kg to 29.6 kg through multiple gradient-based iterative optimizations, effectively achieving the lightweighting objective. Experimental results show good consistency with the computational predictions. Additionally, the manufacturing process requirements and cost impacts of the optimized scheme are analyzed, and a manufacturing solution that meets technical requirements while ensuring economic feasibility is proposed.
Liu, Rui, Shen, Jie, Chen, Meng
Analysis of the Influence of the Centroid Distribution of the Raft on the Shafting Alignment2026-99-03048/14/2026
Aiming at the problem of shaft alignment disturbed by the centroid distribution of the raft in the ship propulsion system, the quantitative influence of centroid offset on bearing load distribution and axis deformation is revealed. Based on the theory of an elastically supported continuous beam, the finite element model of the raft-shaft coupling system is established. By adjusting the position of the raft counterweight mass point (longitudinal offset range ±0.5 m) to simulate the centroid change, the static solution algorithm is used to analyze the key parameters, such as bearing load and axis alignment accuracy, under multiple groups of centroid offset conditions. It is concluded that when the centroid of the raft moves to the propeller end, the load of the 1# and 2# bearing near the propeller end increases, and the load of the 3# and 6# bearing near the thrust plate end decreases. The lateral offset of the center of mass increases, the axial offset at the stern bearing increases, the maximum deflection of the shafting increases, and the deformation of the raft structure increases. The centroid distribution of the raft is a disturbance source of the shafting alignment state, and its offset will reconstruct the bearing load distribution and cause the axis deformation. It is recommended to control the lateral offset of the center of mass at the design stage and reserve the dynamic compensation margin for the shafting alignment.
Yin, Hong, Jin, Yong, Wang, Jun, Tian, Jiabing
Structural Design and Mechanical Performance Analysis of Key Components of Deicing Robots for Transmission Lines2026-99-03468/14/2026
Extreme winter weather often leads to ice accretion on transmission lines. Manual removal is inefficient, costly, and poses safety risks. To address this issue, this paper presents the design of a de-icing robot to replace manual operations for transmission line de-icing. The main content focuses on the detailed structural design of the robot, including the mobile platform, de-icing mechanism, and adaptive adjustment module. Finite element simulations are conducted on key components to verify the structural rationality and the correctness of material selection. The proposed de-icing robot enhances the safety of the de-icing process, improves operational efficiency, and provides a valuable reference for transmission line de-icing methods, demonstrating significant practical value.
Chang, Hao, Zhen, Chen, Han, Fengmei, Li, Cheng
Design of a Biomimetic Spherical-End Tool Based on Gastropod-Shell Surface Microstructures and an Investigation of its Polishing Performance2026-99-10018/7/2026
To improve stress-distribution uniformity and reduce wear during polishing, a biomimetic flexible polishing tool was developed by incorporating microstructured surface features inspired by the gastropod shell. A biomimetic flexible polishing tool was first geometrically modeled, and then the tool–workpiece contact was analyzed in the elastic polishing regime using Preston’s material removal equation to elucidate stress transmission and contact deformation mechanisms. An Abaqus finite-element model of the elastic tool–workpiece contact was subsequently established to compute tool and workpiece stress fields and contact-area fraction during polishing. The biomimetic tools were fabricated by curing silicone rubber mixed with carbon nanotubes. Polishing validation was performed on a small CNC platform using quartz glass under the parameters α=15°, ap=2mm, and w=30r/s. Results indicate that the biomimetic tool incorporating gastropod-shell microstructures increases the machining contact area by up to 48.60% relative to a conventional tool, and after t=30 min of polishing the surface roughness Ra decreased from 1.019μm to 76nm. These outcomes demonstrate that the biomimetic microstructured flexible tool effectively improves contact stress uniformity and enhances surface- processing accuracy for quartz glass.
Song, Jintao, Hui, Jizhuang, Guo, Lei, Xu, Chen, Hei, Zhengqiang, Zhong, Taiyang, Wang, Jiawei, Liu, Jin
Analysis and Elimination of Transient Impact of Rollers in S-cam Brakes2026-01-50668/5/2026
S-cam brake is a drum-type foundation brake used in heavy commercial vehicles. It is a safety-critical device; hence, thorough validation of its performance by lab test rigs and field tests is essential. During prototype testing, an unusual impact was observed during dynamic braking at high pressure application, specifically when the brake drum is rotating, after a period of operation of about 10,000 cycles. This phenomenon was then observed even at static braking when the brake drum was at rest. From initial inspection, it is due to the cam roller, which rides on the web-slot provided at the shoe assembly, while the S-cam is rotating and falls back instantly. This phenomenon occurs repeatedly and creates an audible noise, which needs to be eliminated. The study aims to correlate the phenomenon using finite element analysis (FEA) as in a prototype test and to identify the root cause and optimize the design variables. Since the friction coefficient at the cam roller–web interface is unknown after a period of operation, different values of friction coefficient, ranging from 0.1 to 0.8, are iterated and simulated by rotating the S-cam until the braking effort is reached. The dynamic implicit analysis procedure in Abaqus standard is used to simulate this condition. Based on the results, design variables were improved to mitigate the issue. A quick solution, achieved by modifying a minor feature, successfully prevented the fallback behavior and was validated through physical testing. Furthermore, a permanent solution was developed to eliminate both the “ride-on” and “fallback” phenomena by optimizing component dimensions. This FEA methodology helps to validate the design in an initial concept phase itself for future variants. Using this method, even the structural and fatigue performance of braking parts can be validated at a system-level simulation with better accuracy.
Dinesh Kumar, J., Riyaz Mohamed, D., Vasanth Bharath, S., Rajkumar, S., Murugan, S.
Study on Penetration Damage Characteristics of Honeycomb Non-pneumatic Safety Tiree2026-99-01677/31/2026
To improve the mobility and reliability of special-purpose vehicles that are operated in extreme conditions and to minimize the influence of tire failure on the vehicle’s mobility, this paper investigates how the mechanical properties of honeycomb non-pneumatic tires are affected after high-speed impacts from external projectiles. A prototype of a network non-pneumatic honeycomb tire was initially developed, which was made of polyurethane material. The five parameter model of the Mooney-Rivlin model was selected as its constitutive relation and the experimental study was performed to validate three-dimensional stiffness simulation model for the tire. Secondly, a LS-DYNA-based finite element model was developed to describe the dynamic behaviors of the tire under an external impact at various locations (e.g. tread, single spoke plate and joints), and to investigate the influence of local damage and spoke plate fracture on the stiffness of the tire. The results indicate that the tire has better performance of resisting the impacts at small and medium levels, with the decrease of radial stiffness of the tire less than 4% after experiencing the ultrahigh load; after the spokes plate is broken, the radial stiffness of tire drops significantly by comparing with the intact tire, that is 24.17%, which has a great effect on the support performance of the tire. The findings of this work offer theoretical support and design guidelines for the structural optimization and properties improvement of NPTS.
Yao, Tuzao, Sun, Xiaowang, Zhang, Qiang, Fu, Lei, Huang, Jianbin
Static and Dynamic Performance Analysis and Parametric Optimization of Five-Axis Ultra-Precision Machine Tool via FEM2026-99-02207/31/2026
The static-dynamic behaviors of ultra-precision five-axis machine tools are the core factors to ensure sub-micron-level machining accuracy. This study establishes a detailed finite element model of an entire machine based on the ANSYS Workbench platform and conducts in-depth research on the static-dynamic characteristics of the entire machine of the ultra-precision five-axis machining center by using the finite element analysis(FEM) method and combining the principles of statics and dynamics. By constructing an accurate finite element model, the stress distribution, deformation, and modal vibration characteristics of the entire machine, especially the key parts, such as spindle box, crossbeam, column, and guide rails, under complex loads such as gravity and cutting force are simulated. The static analysis reveals a maximum deformation of 0.17 mm in the spindle box and the column, and the maximum stress is 58 MPa (at the Z-direction guide rail contact point), which is lower than the allowable stress of Q215 steel (195.5 MPa). The modal analysis extracts the first six natural frequencies (50.683 - 175.91 Hz), and the low-order vibration modes are mainly the Y/X-direction swing of the column, revealing the weak stiffness links. Based on the analysis results, a parametric optimization method was further adopted to optimize the structure of the weak components: the base, the column and the spindle box. This significantly enhanced the overall stiffness, reducing the maximum deformation to 0.039 mm and the maximum stress to 45MPa. The first six natural frequencies were all greatly increased (the first one reaching 85.548Hz). These findings provide valuable insights for machine tool structural enhancement and performance optimization.
Li, Shan, Sohi, Seyed Hamed Hashemi
Simulation Research on Non-Destructive Testing of Pipeline Based on Ultrasonic Guided Wave2026-99-01437/31/2026
Ultrasonic guided waves enable long-range, low-intrusion inspection of pipelines. This study examines how array topology and axial spacing influence the quality of defect echoes when the longitudinal axisymmetric mode L(0,2) is used. We build COMSOL finite-element models of a steel pipe and excite it with PZT-4 at 80 kHz; three practical layouts are compared: (i) odd–even receiving, (ii) 8-transmit/8-receive, and (iii) 16-transmit/8-receive, arranged as two axially separated groups. The spacing between the groups is chosen to suppress parasitic modes such as L(0,1) and to strengthen L(0,2). Results show that the two-group configuration sharpens the defect echo and reduces modal interference; increasing the number of transmitters further raises the defect-wave amplitude and improves the separation from end-reflection echoes. Among the schemes, 8×8 performs well for small-defect identification, while 16×8 yields the clearest boundaries and fastest defect indication. These findings clarify how sensor number and placement govern modal purity and sensitivity, and they offer practical guidance for designing guided-wave arrays that improve the reliability of long-range pipeline inspection. - Ultrasonic guided waves Pipeline non-destructive testing L(0,2) mode; Sensor array layout; Finite element simulation; Guided wave signal processing.
Liao, Wei, Li, Tengfei, Zhang, Wenhui, Lin, Qingming, Guo, Yanbing
Seismic Performance and Reinforcement Strategies for ±600 kV Suspended Converter Valves — Part1: Seismic Vulnerabilities2026-99-01457/31/2026
The suspended converter valve constitutes the fundamental equipment essential for the functioning of direct current power transmission infrastructure. The electrical equipment has been severely damaged in historical seismic events, underscoring the earthquake resistance of thyristor valve is critical for maintaining secure and consistent performance of energy delivery systems. Current seismic research focuses on ±800 kV converter valves, while studies on ±600 kV converter valves are lacking. Due to significant differences in the length of suspended insulators between ±600 kV and ±800 kV converter valves, their seismic responses differ considerably. A three-dimensional finite element model encompassing both the ±600 kV suspended converter valve and its supporting valve hall structure was developed to accurately capture their dynamic interactions under seismic excitation. The modal analysis is conducted, and the natural frequencies and mode shapes of converter valve and valve hall system are obtained. The seismic analysis results indicate that under 1 g seismic excitation, the calculated maximum seismic displacement of the suspended valve tower is 421 mm, exceeding the engineering design limit of 400 mm. The calculated minimum stress safety factor for the converter valve suspended insulators is 1.46, failing to meet the specified requirement of no less than 2. Both the swing amplitude of the converter valve and the stress on the suspended insulators exceed design limits. It not only poses a mechanical safety risk to the converter valve, but the excessive seismic displacement can also lead to seismic coupling effects between the converter valve and critical equipment. Therefore, further research on damping measures is required for the seismic vulnerabilities of ±600 kV suspended converter valves.
Lin, Sen, Zhu, Zhubing, Lu, Zhicheng, Sun, Yuhan
Finite Element-Based Structural Optimization for UAV Storage-Launch Container2026-99-01647/31/2026
To fulfill the multi-tube launch requirements for a specific folding-wing UAV, this study improves the structure of the existing storage-launch container. Based on the finite element method, a parametric model of the container is established, and a multi-condition mechanical analysis is carried out for various storage, transportation, and launch conditions. The difference between the first six natural frequencies of the free mode and the prestressed mode is compared and analyzed. The modal analysis model considering prestress is used to identify the optimization area of the container. The variable density method (SIMP) is used to optimize the topology of the container, with the volume of the container as the constraint condition and the minimum strain energy as the optimization goal. The optimization results show that the first-order modal natural frequency of the container is increased by 108%, and the first six natural frequencies are increased to a safe range, which effectively avoids the resonance risk. At the same time, the quality is reduced by 29%, and good optimization results are achieved.
Yuan, Weiyang, Ji, Yuguo, Liu, Zhipeng, Yu, Wenxin
Micro-Groove Fabrication and Simulation Analysis on PEEK Surface under UV Nanosecond Laser Irradiation2026-99-02257/31/2026
This study investigates the interaction mechanism between ultraviolet nanosecond pulsed lasers and polyetheretherketone (PEEK). By integrating finite element simulations with experimental validation, the work explores the laser microtexturing characteristics of PEEK surfaces and evaluates the influence of microtextures on the material’s surface biocompatibility. First, the interaction between the laser and the PEEK polymer was analyzed, and a laser ablation model was established using the COMSOL Multiphysics simulation platform. Using finite element simulation, the effects of spot overlap ratio were investigated by adjusting the average laser power, while the influence of single-pulse energy on the ablation characteristics of the PEEK surface was examined by varying the scanning speed. Subsequently, ultraviolet nanosecond laser processing experiments were conducted on planar PEEK microtextures based on the simulation results. Taking surface microgrooves on PEEK as representative structures, the variations in groove depth and width under different combinations of laser parameters were analyzed. The parameters, including average laser power, scanning speed, and repetition frequency, were optimized to identify processing conditions that yield stable depth and width, along with good surface flatness. Finally, experiments have initially verified that the microtextured PEEK surface may improve biocompatibility and regulate surface wettability to a certain extent.
Wu, Yifan, Wang, Xiaohui, Han, Yujie, Jin, Shuo
Method for Quantitatively Determining Stress Intensity Factors for Complex Metal Structures by Analogy2026-99-02077/31/2026
For the strength verification of metal structures, in addition to fundamental static strength analysis, fatigue analysis is also indispensable for structures subjected to cycle fatigue loads. Notably, accurate calculation of the stress intensity factor (SIF) is a prerequisite for the quantitative evaluation of crack propagation life. For real structures such as civil aircraft or steel bridge, the complexity of geometry, component connections, and mutual constraints makes the determination of SIFs along the crack propagation path both complex and time-consuming. If the cracked structure is simplified into a two-dimensional model for analysis, the beneficial effects of structural constraints on crack opening are often neglected, leading to overly conservative life predictions, which has been confirmed in the full-scale fatigue tests. Alternatively, while finite element analysis (FEA) can be used to estimate SIFs, inaccuracies or non-convergence may arise due to improper meshing around the crack tip, particularly when singular elements are not properly incorporated. To solve these problems, an analogy method for efficient and accurate evaluation of SIFs in complex metallic structures (particularly those used in civil aircraft) is proposed in this study. The method estimates the SIF in a real structure by comparing the crack opening displacement (COD) at the crack tip with that of a reference model (an infinite plate containing a central crack) using the same local mesh refinement. Extensive validation has demonstrated that the SIFs obtained using the proposed analogy method exhibit sufficient accuracy for engineering applications, offering a practical alternative to traditional analytical or finite element-based techniques in crack propagation analysis.
Luo, Yifan, Zhu, Wuxue, Xu, Haisheng, Huang, Fu, Bao, Haisheng, Lan, Xinlei
Mechanical Response and Crashworthiness of Twisted Primitive Triply Periodic Minimal Surface (TPMS) Lattices2026-01-50487/31/2026
In recent years, triply periodic minimal surface (TPMS) structures have attracted considerable attention due to their excellent mechanical properties, lightweight characteristics, and remarkable potential for energy absorption in various engineering applications, particularly in automotive safety. To address the demand for enhanced energy absorption, a TPMS design strategy incorporating controllable twisting along the build direction is proposed in this study, enabling the regulation of local deformation paths and global absorption responses. Standard Primitive unit cells were constructed using an implicit function formulation, and twisted Primitive (TPS) structures with various twist angles were subsequently generated. TPS specimens were fabricated from 316 L stainless steel via selective laser melting (SLM) to evaluate the influence of twisting features on their mechanical behavior. To systematically elucidate the role of twisting in energy absorption, quasi-static compression tests were conducted and complemented by finite element simulations to analyze deformation modes and absorption characteristics under different twist angles. The results indicate that the twisting strategy significantly enhances the energy absorption capability of the Primitive structure. Compared with the standard Primitive configuration, TPS structures exhibit a higher specific energy absorption and a more stable progressive collapse mode under compression. In particular, increasing twist angles lead to notable improvements in both absorption efficiency and deformation controllability. Overall, the proposed controllable twisting design provides an effective approach for improving the energy absorption performance of TPMS lattices, offering theoretical guidance and technical support for their application in automotive passive safety and other energy-management systems.
Liu, Zhe, Lian, Yuehui, Li, Youguang, Guo, Pengbo, Zhong, Gaoshuo
Collapse Strength and Crush Space Analysis in Lateral Side Pole Impact of an Electric Vehicle2026-01-50527/31/2026
High-Voltage Battery (HVB) protection in lateral pole impact is very important due to severe nature of the impact. Unlike frontal impacts, vehicles have limited range of space and capacity to absorb kinetic energy in lateral side impacts. Nowadays, computer-aided engineering (CAE) using finite element analysis (FEA) is utilized routinely to simulate high-speed crash events of varied type, including side pole impact. These CAE applications focus on the analysis and design of HVB when the vehicle structure is well-developed. CAE methods are time-consuming and are not suited during the pre-program stage when the structure is only in a concept stage and not even a reasonable CAD is available/developed in any sense to use these methods. There is no analytical tool available to understand how to define the characteristics of the structure that surrounds and protects the HVB. The primary motive of this publication is to help with this aspect of vehicle planning/development. Needless to state that this procedure can also be used in planning/developing of internal combustion engine (ICE) and hybrid vehicles, as well. The objective therefore is to develop a simple method/procedure that can give reasonably accurate estimation of the collapse/crush force required for a specified crush space and hence protect the critical components, such as HVB and fuel tank. This analytical method also gives some insight into the optimal use of the upper body (rocker and floor cross-members) and underbody (ladder frame) parts. It was found, for a problem under consideration, optimum kinetic energy to be absorbed by the upper body is 32.5% to avoid intrusion into HVB.
Alavandi, Bhimaraddi, Midoun, Djamal, Frank, Randy
Simulation of Compression and Bending Performance of GFRP Rod of Composite Hollow Post Insulator2026-99-01077/31/2026
Composite hollow core station post insulators utilize fiber-reinforced epoxy resin as the core rod material, offering advantages such as high specific strength, high specific stiffness, and excellent fatigue resistance. This enables them to effectively meet the flexible, variable, and complex operational demands of modern power systems. However, composite materials exhibit anisotropic characteristics, resulting in complex mechanical properties. Additionally, the core rod of hollow pillar composite insulators is typically fabricated through a spiral-plus-circumferential winding process, which significantly complicates structural design and computational analysis. This study establishes a finite element model of the hollow pillar composite insulator core rod in ABAQUS. It analyzes the influence of fiber content on composite material parameters and performs finite element numerical calculations to examine the stress state of core rods with different winding angles under compressive and bending loads. The research findings provide theoretical support for the optimized structural design of hollow pillar composite insulator core rods.
Liu, Jianbiao, Du, Yijun, Quan, Xiaoxi, Zhou, Songsong
Design and Optimization of an External Rotor Permanent Magnet Motor with a Three-Segment Non-Uniform Halbach Array2026-99-01537/31/2026
To further enhance the performance of the drive unit motor, a novel three-segment non-uniform Halbach array magnetic pole structure is proposed, which is applied to an external rotor permanent magnet motor with magnetic pole optimization. First, the overall motor design is carried out according to the requirements, determining the fundamental parameters of the motor. Then, four common magnetic pole structures—conventional arc-shaped, three-segment, Halbach array, and three-segment non-uniform Halbach array—are analyzed. A finite element analysis model of the motor is established for electromagnetic analysis, comparing the air-gap flux density, torque, and torque ripple of the four magnetic pole structures. Finally, optimized parameters for the stator and rotor tooth shapes are determined, and an optimization model is established. The NSGA-II algorithm is employed to optimize the stator and rotor tooth shapes. After optimization, the motor maintains its torque output while reducing torque ripple by 50%, effectively improving its performance.
Zhao, Changle, Yang, Liu
Adaptability Analysis of The Depth and Curvature Radius of Automatic Fiber Placement2026-99-01127/31/2026
This study explored the relationship between the placement roller and the radius of curvature of the mold. In the production process, it is better to judge the feasibility of placement based on the actual placement profile. It is calculated that when the prepreg with a tow width of 6.35 mm is used for automatic fiber placement and forming, the 4-tow, 8-tow, and 16-tow laying rollers can be laid at a maximum depth of 2 mm. The formulas for the length of the automatic fiber placement roller and the axial radius of curvature of the die are obtained. At the same time, through geometric analysis, a formula for calculating the minimum radius of curvature of the pressure roller is obtained. The finite element software Abaqus was used to simulate the contact of the 4-tow, 8-tow, and 16-tow laying rollers with the minimum axial critical radius of curvature at a 2 mm depth, and output the force curve of the node where the mold surface contacts the pressure roller. It is found that the simulation results are consistent with the calculation results.
Ma, Cheng, Xiu, Zhifeng, Xue, Hongming, Yang, Maowei, Zhang, Pin
Collaborative Optimization of Tooth Parameters in Cemented Carbide-Tipped Circular Saw Blades for Sand Willow Cutting Machines2026-99-01987/31/2026
To enhance the service life of cemented carbide brazed circular saw blades used in sand willow stump cutting machines and to mitigate the problem of uneven stress distribution on saw teeth during cutting, this study investigates the circular saw blade as the research object. Sand willow, widely distributed in arid and desertification-prone regions of northern China, plays a vital role in ecological restoration and biomass utilization. However, due to the high density and toughness of its stems, conventional saw blades often experience severe tooth wear and premature failure, limiting the efficiency and stability of stump cutting operations. In this work, the dynamic simulation module of ABAQUS was employed to establish a finite element model of the cutting process. A Box–Behnken Design (BBD) combined with response surface methodology was then applied to systematically evaluate the influence of key tooth parameters on stress distribution. Using the maximum equivalent stress at critical nodes as the optimization criterion, a cooperative optimization strategy was developed to balance tooth strength and cutting efficiency. The optimized design markedly improved the mechanical performance of the saw teeth. Compared with conventional blades, the maximum stress value was reduced by 51%, resulting in enhanced reliability and prolonged service life. These findings demonstrate the feasibility of integrating finite element simulation with statistical optimization for tool design in forestry machinery, and provide both theoretical insights and practical support for advancing specialized sand willow cutting equipment, thereby contributing to ecological restoration and sustainable biomass utilization in desertification-affected regions.
Li, Zhong, Zhang, Binbin, Han, Yiliang, He, Jinjun, Ren, Yuyan, Yang, Jianjun, Wang, Haichao, Pei, Zhiyong
Multi-Objective Topology Optimization of Wing Rib Structures for Additive Manufacturing2026-99-02287/31/2026
With the advance of high-end manufacturing and the rise of green design, lightweight structures have become a central concern in aerospace. Topology optimization offers a principled route to shed mass while preserving performance, yet most additive manufacturing (AM) studies still emphasize process tuning and new materials rather than structural layouts constrained by AM realities. This work targets a representative wing rib from a specific unmanned aerial vehicle (UAV) and formulates a multi-objective topology optimization that explicitly embeds AM constraints. Using the Solid Isotropic Material with Penalization (SIMP) variable-density framework, we couple static stiffness and strength measures with modal objectives so that the optimized rib not only resists deformation and limits stress but also improves the first three natural frequencies, thereby mitigating adverse vibration interactions at the wing level. A compromise-programming strategy balances these competing objectives under volume and manufacturability requirements, including AM-driven minimum feature scales and related geometric restrictions. Finite-element analyses are used throughout the loop to evaluate displacement, von Mises stress, and eigenfrequencies, ensuring that the emerging material distribution is both efficient and physically meaningful. The resulting topology exhibits clearer load paths and smoother stress flow, reduces peak displacements, and delivers a marked rise in the first three natural frequencies. Overall mass is lowered by approximately 55% while meeting all imposed constraints, achieving the dual aims of structural optimization and lightweighting. The study demonstrates that integrating AM constraints directly into the optimization stage yields designs that are performance-robust and fabrication-ready, and it provides a reusable workflow for thin-walled aerospace components such as wing ribs where stiffness, strength, and vibration behavior must be jointly considered.
Zhao, Fei, Zhang, Heran, Li, Xiaoting, Shi, Bowen, Kong, Xiangwei
Resilience Evaluation of HVAC Outdoor Units Against Typhoons Using Finite Element Method2026-99-01067/31/2026
In view of the practical problem that the air-conditioner outdoor units in the spacecraft test workshops of coastal launch sites are severely damaged under the influence of super typhoon, this paper employs the finite-element simulation method to establish a finite-element model of the outdoor units. The implicit Euler solution method is used to calculate the stress conditions of each component of the unit under the influence of typhoons with wind speeds of 50.9 m/s and 61.2 m/s respectively. By combining with the material yield strength, the weak links in the design are identified, and targeted improvement measures are proposed. The simulation results demonstrate good agreement with the actual impact of the typhoon, which can effectively guide the typhoon-resistance optimization design of subsequent air-conditioning units.
Gu, Yufei, Chen, Shaojiang, Shi, YunShan, Fu, Yuanming, Chen, Xi, Yang, Degang
Analysis and Verification of the Stiffness of Flexible Mechanisms2026-99-01037/31/2026
Recent advances in precision motion technology have heightened the requirement for precise stiffness analysis in flexible mechanisms. This paper begins with a theoretical analysis, constructing a mathematical expression for the stiffness of flexible mechanisms, providing a systematic framework for analysis. Subsequently, the study employed finite element analysis on both single and double parallelogram flexible mechanisms to validate the proposed theoretical stiffness formulas. This process not only confirmed the effectiveness of the proposed expressions but also highlighted the influence of different structures on stiffness characteristics. The finite element analysis results validate the proposed theoretical model as an effective and reliable tool for predicting the stiffness of flexible mechanisms. By establishing a reliable predictive model, this research paves the way for the informed design and systematic optimization of next-generation flexible mechanisms in precision motion engineering.
Cai, Dongchen
Optimization Design of the Lifting Platform Mechanism for a Sand 3D Printing Equipment2026-99-01407/31/2026
This paper addresses the stiffness issue of a lifting platform mechanism in a sand mold 3D printing device through finite element analysis (FEA) and proposes a multi-faceted optimization design approach. A finite element model of the lifting platform was established to analyze its stress and deformation distribution under extreme working conditions, revealing that the maximum deformation occurred at the platform edges. Based on the analysis results, structural design optimization, topology optimization of the top plate, and multi-objective parameter optimization of the bracket were implemented, significantly improving the platform's stiffness. After optimization, the maximum deformation of the lifting platform was reduced by 51.6%, demonstrating the effectiveness of the proposed methods. The results indicate that this approach has strong practical engineering value and can serve as a reference for optimizing similar structures.
Hong, Haichun, Yang, Wenliang, Xu, Jifu, Wang, Haitao, Jing, Wenxia, Niu, Longlong, Wang, Zhibing
Stress Analysis of Key Equipment in Carbon-Based Catalytic Multi-Pollutant Control Technology2026-99-02407/31/2026
The desulfurization and denitrification tower is the core equipment of the carbon-based catalytic multi-pollutant synergistic control technology. Its design strength ensures the system’s pollutant removal efficiency and stable operation. This study utilized ANSYS finite element analysis software to establish a three-dimensional model of the tower and divide high-precision grids. Combined with the load analysis, calculation and work condition analysis under actual conditions, the deformation and stress distribution of the tower body, as well as the film stress and bending stress of each component, were calculated, and strength verification and stress assessment were conducted. When ignoring the calculation error, the overall design strength of the tower body meets the requirements, but the local reinforced beam stress exceeds the limit, so it is recommended to replace the steel with a material with a higher allowable stress value.
Gu, Jiangong, Wu, Linlin, Shi, Lina, Hu, Yifan, Cheng, Wenyu, Liu, Yining, Sun, Lei, Wu, Jiayu, Luo, Zheng, Jiao, Lingyu
Design and Control of a Target Plate Fastener Assembly and Disassembly Actuator for Divertor Maintenance in Fusion Reactors2026-99-01827/31/2026
With the development of controlled nuclear fusion technology, the tokamak device, as the most promising magnetic confinement fusion reactor for advanced engineering applications, requires remote maintenance of its internal components, which has become a key factor affecting both operational efficiency and safety. As a critical component directly exposed to high-temperature plasma, the divertor target plate needs to be periodically replaced and carefully maintained to ensure stable and reliable reactor operation. However, this region is subject to extreme conditions, including high temperature, high vacuum, and intense radiation, making conventional manual maintenance infeasible. This necessitates the development of intelligent and automated teleoperation systems. To address the automated assembly and disassembly requirements of divertor target plates, this study designs an integrated target plate actuator comprising key functional units: a positioning module, a screwing module, a quick-change module, and a passive compliance structure. The actuator achieves rapid and precise alignment with target plate holes, accommodates bolts of different specifications, and exhibits excellent impact resistance. Furthermore, stiffness and mechanical analyses, supported by finite element simulations, verify the actuator’s safety and reliability under high loads and impact forces. To further enhance operational performance, a segmented disassembly and assembly control strategy based on reinforcement learning is proposed, enabling the actuator to adaptively handle torque variations and ensure precise and stable bolt operations. The results demonstrate that the proposed actuator and control strategy significantly improve the accuracy, stability, and efficiency of target plate operations under complex working conditions, providing a reliable solution for automated divertor maintenance in tokamak devices.
Zang, Xizhe, Yu, Xingzu, Cao, Zhangbin
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