Browse Topic: Simulation and modeling

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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
Reliability Calculation and Analysis of Influencing Factors for Girth Welds in High-Grade Steel Pipelines Based on HMC-SS2026-99-03428/14/2026
Fracture failure of girth welds in high-grade steel pipelines poses a critical threat to pipeline integrity. Leveraging enhanced digitalization in pipeline engineering, a statistical database has been developed to support reliability analysis based on actual operational data. This study utilizes real project data to analyze the failure probability and key influencing factors of girth welds containing crack defects, thereby providing theoretical support for safety design and risk management. To overcome the conservatism of traditional deterministic methods, a probabilistic reliability model was established, incorporating a modified PRCI-CRES ultimate tensile strain criterion. Addressing the inefficiency of standard Monte Carlo (MC) simulation in high-dimensional low-probability contexts, an efficient Hamiltonian Monte Carlo-Subset Simulation (HMC-SS) strategy was introduced. Results show that HMC-SS improves computational efficiency by 99.95% over MC, with only 0.90% relative error. Key findings include: crack depth has the strongest influence – variation from 0.92 mm to 3.68 mm, which increases failure probability by 103 times; the strength matching coefficient is dominant, and higher values reduce failure risk; strain demand exhibits a positive correlation with failure probability and couples with material properties. It is concluded that high- or equal-strength material matching should be emphasized in welding, and reliability-informed design should account for multi-parameter interactions to ensure global safety.
Yang, Kai, Wang, Kaihong, Wang, Bin, Shao, Jia, Yu, Weichao, Zhang, Dong
Anti-splash System of Sprinkler Based on Millimeter Wave Radar and Machine Vision Fusion2026-99-03238/14/2026
In view of the problems that it is difficult to accurately control the spraying area of the mining sprinkler, and the resource waste caused by the mis-spraying material stacking area, as well as the failure of traditional radar monitoring in the complex electromagnetic environment, this paper proposes an anti-splashing system for the mining sprinkler. By combining millimeter wave radar and visual recognition fusion technology, the overall scheme of the anti-splash system is proposed. Then the control simulation of the whole system is carried out. The results show that the problem of poor control in traditional sprinkler operation can be effectively solved, and the sprinkler area can be adjusted intelligently. Finally, in order to verify the accuracy of the algorithm used in this paper, different algorithms are used for comparative experimental verification. The results show that the Modified YOLOv4 algorithm has a high accuracy of 98.75 %, which has good applicability and provides a theoretical basis for subsequent research.
Hou, Lin
Comparative Study on the Strength Calculation Method for Pumped-Storage Power Plant Head-Cover-to-Stay-Ring Bolts and on Relevant Preload and Strength Standards2026-99-03248/14/2026
Head-cover-to-stay-ring bolts in pumped-storage plants face fatigue fracture risks due to axial alternating loads, with catastrophic failure cases reported globally. In China, the absence of a unified design code in early projects produced widely divergent bolt designs. This study proposes a hybrid “field measurement and Computational Fluid Dynamics (CFD) correction” method to analyze bolt forces under turbine load-rejection transients (max. stress: 780 MPa, error <3.1%), benchmarks three Chinese standards (GB/T 22581-2024, NB/T 10135-2019, GB/T 15468-2020) for preload design, and refines their technical clauses to provide actionable guidance for future tender specifications and long-term bolt maintenance.
Long, Zhe, Guo, Meichao, Kang, Caini, Li, Chengjun
Comparative Analysis of CDTire Model and FTire Model in Vehicle Comfort and Durability Simulation2026-99-03018/14/2026
Applicability of the CDTire tire model in vehicle handling and stability simulations is studied in this paper by comparison with the PAC2002 tire model. Based on the physical tire 245/50 R20, corresponding CDTire and PAC2002 models are established and assembled on the multibody dynamics model of an SUV. After simulating 5 handling and stability conditions, it is found that the CDTire calculation is more time-consuming compared with PAC2002, but the increased time cost does not exceed 10%. In addition, the relative errors of the 17 evaluation indices obtained based on CDTire compared to PAC2002 do not exceed 5%. Therefore, in terms of both computational accuracy and efficiency, CDTire is suitable for application in vehicle handling and stability simulation.
Gao, Fengling, Wu, Wenwen, Fei, Yuanjun
Numerical Simulation Study on Fire Prevention in Aero-Engine Fuel Tube2026-99-03038/14/2026
Transient gas-liquid two-phase flow in aero-engine fuel pipelines was examined using numerical simulations, focusing on the influence of flow rate on phase change behavior. Under low-flow conditions, phase change occurred repeatedly near the pipe wall, where vapor layers formed and collapsed in an intermittent manner. These processes introduced noticeable unsteadiness in the local mass flow and pressure fields. When the flow rate was increased, vapor generation was largely confined to a narrow region adjacent to the wall, and the overall flow exhibited a more stable character. The results suggest that flow-rate-dependent phase change plays an important role in determining the stability of fuel transport and should be considered in the fire safety assessment of aircraft fuel systems.
Wu, Bin, Xin, Bo, Zeng, Tai, Su, Zhengliang
Dynamics of Quayside Container Cranes with Anti-Wind Devices under Strong Winds2026-99-03198/14/2026
Quayside container cranes (QCCs), essential for cargo handling in seaport operations, are particularly vulnerable to damage under strong wind conditions. This study investigates the wind-induced dynamic behavior of QCCs equipped with active anti-wind systems, focusing on the mechanisms that govern cable stress and sliding instability. A five-degree-of-freedom mathematical model is established, incorporating nonlinear cable stiffness, restricted sliding through a Kelvin-Voigt collision model, and a combined Stribeck-Coulomb friction model for the wheel-rail interface. Parametric studies are conducted to evaluate the influence of three key factors, the anti-wind cable diameter, the sliding displacement of the QCC wheel, and the wheel-rail friction coefficient, on cable stress responses. The results show that increasing the cable diameter and friction coefficient significantly reduces peak cable stress, whereas greater sliding displacement increases stress accumulation and structural vulnerability. Sensitivity analysis reveals that cable diameter has the most dominant effect on cable stress, followed by sliding displacement and friction coefficient. This work might provide theoretical foundations for the design and optimisation of wind-resistant QCC structures, as well as for the development of more reliable anti-wind protection systems in extreme conditions.
Xiang, Lei, Ji, Huanyu, Liu, Zhiwei, Wang, Ziyou, Xu, Xinyue
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
Influence of Roundness and Geometric Errors on Lubrication Performance of Engine Journal Bearings2026-99-03218/14/2026
This paper focuses on the critical issue of lubrication performance in journal bearing manufacturing, employing numerical simulation techniques to investigate how manufacturing errors from processing accuracy impact lubrication behaviors. As core components in mechanical systems—especially diesel engine crankshaft bearings operating under complex conditions—journal bearings’ lubrication performance directly determines equipment stability, energy efficiency, and service life. Manufacturing deviations-induced poor lubrication can cause increased friction, severe wear, or even failures, underscoring the research’s practical value. The study constructs a refined numerical model based on the Navier-Stokes equations within the Computational Fluid Dynamics (CFD) framework, ensuring it reliably depicts fluid flow in bearing clearances. It then systematically analyzes the lubrication responses of diesel engine crankshaft bearings under diverse operational scenarios, varying key manufacturing-related parameters: roundness degrees and clearance dimensions, which mimic real production discrepancies like tool wear or machining vibration. Additionally, the research explores shaft center trajectory variations under two extreme operating conditions, as shaft movement reflects the lubrication film’s loadbearing and stability capacities. Surface roundness and clearance are identified as pivotal to journal bearing performance: they significantly alter oil film thickness distribution—critical for avoiding metal contact—and determine the maximum fluid pressure within bearings, a key load-bearing indicator. Moreover, the amplitude and phase angle of roundness fluctuations (often overlooked) exert substantial impacts on lubrication stability and load-bearing properties, offering insights for optimizing manufacturing processes to mitigate such adverse effects: -Journal bearings. -hydrodynamic lubrication. -Form error.
Liu, Jun, Liu, Deliang
Modeling Method of Aircraft Hydraulic Pipeline Cleaning Test Equipment Based on MBSE2026-99-03318/14/2026
With the continuous improvement of performance requirements for aviation equipment, the importance and complexity of hydraulic systems as the core carrier of flight control are becoming increasingly prominent. The cleanliness of aircraft hydraulic pipelines directly affects the reliability and flight safety of hydraulic systems, and it is necessary to use specialized cleaning and testing equipment during design and manufacturing to achieve efficient cleaning. The design of traditional cleaning equipment relies on experience-driven development, with mechanical, hydraulic, and electrical systems developed independently. There are problems such as unclear requirement definitions, low efficiency of interdisciplinary collaboration, and lagging validation, making it difficult to achieve the goal of forward design. Therefore, this study introduces Model-based Systems Engineering (MBSE) method in the development process of pipeline cleaning test equipment, proposes a modeling process based on RFLP (Requirements-Function-Logical-Physical), and uses SysML system modeling language to construct a top down design model system for aircraft hydraulic pipeline cleaning equipment. Through requirement analysis modeling, functional behavior definition, and system architecture design, the significant advantages of MBSE method in the development of complex aviation test equipment have been verified, effectively improving the bold design capability and top down design efficiency. MBSE method can not only improve the design efficiency of equipment, but also promote the intelligent and efficient operation of equipment, which has important significance for the development of intelligent manufacturing and electromechanical integration technology.
Zhang, Yuxin, Ma, Zichen, Li, Qi, Song, Guoqiu, Li, Haiwei, Zhang, Jingjing
Research on Asymmetric Gear Stiffness2026-99-03328/14/2026
To meet the need for optimizing the dynamic performance of asymmetric gear transmissions operating under high-speed and heavy-load conditions, this study presents a refined stiffness modeling approach. A tooth-surface contact stiffness model is formulated based on Hertzian contact theory. By integrating the energy method, a coupled stiffness model is established that incorporates bending, shear, axial compression, and foundation stiffness components. Stable curves depicting the variation of mesh stiffness with the path of contact are subsequently derived by leveraging the principle of stiffness superposition. The findings demonstrate that the proposed mathematical model accurately represents the stiffness behavior of asymmetric gears as governed by the changing contact length, thereby providing a theoretical foundation for enhancing gear dynamics and extending the service life of transmission systems.
Zhao, Zeyi, Sun, Xiaoyan, Wu, Ziheng, Tang, Xin, Liu, Yanxia, Li, Fajia
Vibration Simulation of Guide Mechanism Based on Rigid-Flexible Coupling Dynamics2026-99-03108/14/2026
For vibration issues induced by coupling effects between flexible barrel guide mechanisms and moving bodies in high-speed dynamic systems, this study investigated their interaction mechanism using flexible multibody dynamics principles. A solid model was developed in 3D CAD software. The modal neutral file (MNF) of the guide mechanism was generated in ABAQUS, and its contact dynamics with the moving body were simulated in ADAMS via flexible contact theory and the modal superposition method. Comparative simulations revealed that incorporating structural flexibility yielded smoother fluctuations in the moving body’s axis inclination angle, providing more accurate system behaviour characterization. Exit velocity and spin rate errors remained below 5% against theoretical values, demonstrating model reliability.
Zhu, Qing, Cheng, Zixiang, Zhuo, Changfei
Dynamic Sliding-mode Control with Backstepping for Offshore Boarding Gangway2026-99-03398/14/2026
This paper focuses on the control challenge of the movable ladder section of an offshore boarding ladder. A dynamic sliding mode control (DSMC) method based on the backstepping approach is proposed. To address the disturbance mismatch problem in traditional control strategies, the backstepping approach is adopted for the hierarchical design of the control law, decomposing the complex nonlinear system into low-order subsystems for step-by-step processing. Meanwhile, by integrating the strong anti-disturbance advantage of DSMC, a composite control framework with disturbance compensation capability is constructed, which effectively suppresses the nonlinear disturbances caused by external disturbances and system parameter perturbations during the movement of the movable ladder section. The stability of the proposed control method is strictly proven using the Lyapunov function. Simulation results show that the speed response adjustment time of the movable ladder section is less than 10.3 ms, and the position tracking error is controlled within 1.03 mm. Compared with the traditional PID control, the rise time of DSMC is improved by 89.16%, and the tracking accuracy is improved by 90.98%. Facts fully prove that the effectiveness of the proposed method is solidly established.
Yang, Lixin, Guo, Lidong, Xu, Liang
SAE TOMORROW TODAY - How Aerospace Safety Standards Enable the Future of Flight135808/12/2026
Whether it's supersonic travel, commercial space, or AI-enabled aircraft, one message remains constant: safety standards are the common language that enable the future of flight. Listen in as we sit down with Craig McMillan, Model Based Systems Engineering (MBSE) Growth Leader at GE Aerospace, to discuss the intersection of AI, digital engineering, and the growing complexity of modern aircraft. The conversation examines why independent verification, rigorous systems engineering, and collaboration across the aerospace industry remain essential as aircraft become more software-driven and interconnected. We'd love to hear from you! Share your comments, questions and ideas for future topics and guests to podcast@sae.org. Don't forget to take a moment to follow SAE Tomorrow Today--a podcast where we discuss emerging technology and trends in mobility with the leaders, innovators and strategists making it all happen--and give us a review on your preferred podcasting platform. Follow SAE on LinkedIn, Instagram, Facebook, X, and YouTube. Follow host Grayson Brulte on LinkedIn, X, and Instagram.
Patterson, Lori
Molecular Dynamics Simulation of Temperature Effects on the Hot Deformation and Microstructural Evolution of Al-Mg-Si Aluminum Alloy2026-99-10108/7/2026
In this work, molecular dynamics simulations are applied to systematically examine the influence of varying temperatures (300 K, 500 K, and 700 K) on the Elevated-temperature compression behavior and micromechanical characteristics of polycrystalline Al-Mg-Si aluminum alloy. A nanopolycrystalline model was established to analyze the stress–strain response, dislocation evolution, and crystal structure changes occurring during the deformation process. The simulation results show that the yield strength and elastic modulus both decline as temperature increases, indicating a pronounced thermal softening effect. During the early stage of plastic deformation, dislocations mainly have their nucleation sites at grain boundaries and then propagate into the grain interiors, where they form interconnected networks along with stacking faults and twin structures. This work reveals the thermal deformation mechanisms of Al-Mg-Si aluminum alloy at the atomic scale and provides theoretical guidance for the optimization of its hot-working processes.
Sun, Ruifeng, Liu, Shoukui, Wang, Rui, Sun, Xuemei, Ding, Shuli, Ma, Xiaofei
Research on the Intelligent Design Method of Roof Frame Based on the Middle Layer and Component Technology2026-99-09078/7/2026
This study proposes an intelligent automotive roof frame design method based on the middle layer and component technology on CATIA. It aims to solve core roof modeling issues: determining geometric input quantity but uncertain attributes (tangent vectors, normal vectors, number of curve segments, number of surface patches, and boundaries), high manual interaction dependence, and poor knowledge reuse, to realize efficient design knowledge reuse. Methodologically, it builds a feature-driven parametric template, develops a knowledge rule-embedded componentized UDF library (reducing repeated modeling and geometric reconstruction needs), and integrates knowledge engineering for geometric input verification and operation direction control, eliminating curve/surface attribute uncertainty impacts. Verification shows the template stably generates roof crossbeams under simple/complex inputs, improving model robustness and reuse rate, reducing design workload, shortening verification cycles, and providing an extensible solution for white body design.
Jin, Chunning, Fu, Xinyu, Hou, Wenbin
Research on Ventilation Performance of Slotted Honeycomb Panels for Civil aircraft2026-99-09138/7/2026
Auxiliary fuel tank systems for civil aircraft are typically employed in extended-range aircraft. As a critical structure for fuel storage, the structural safety of auxiliary fuel tanks directly impacts aircraft safety. Such tanks are generally constructed from honeycomb sandwich composite panels. Owing to their outstanding advantages, including high specific strength, light weight, and corrosion resistance, honeycomb sandwich composite panels have become the material of choice for civil aircraft fuel tanks. However, to meet the safety requirements for ventilation and leakage drainage in the sandwich structure of fuel tanks, dedicated flow channels must be created by slotting inside the honeycomb composite panels to ensure timely discharge of fuel vapor and accumulated fluid from the tank sandwich. Conventional flow channels are symmetrically arranged on the end faces of the honeycomb core, making it difficult for ventilation airflow to penetrate the center of honeycomb cells. This results in ventilation and drainage blind spots within the cells, which tend to cause accumulation of fuel vapor and residual fluid over prolonged service. Consequently, the aging of the core layer is accelerated, compromising the structural integrity of the composite panel and the service life of the fuel tank. This paper proposes an asymmetric ventilation flow channel design. By optimizing the slotting position, size, and distribution pattern of the flow channels, the limitations of the traditional symmetric layout are overcome. To accurately investigate the effect of this design on the internal ventilation performance of honeycomb composite panels, a three-dimensional flow field model of the honeycomb sandwich composite panel is established using computational fluid dynamics (CFD). The ventilation airflow distribution, velocity, and flow rate characteristics under different flow channel designs are simulated and compared with those of the conventional symmetric flow channel design. The results demonstrate that the asymmetric ventilation flow channel design improves the ventilation uniformity inside the honeycomb cells and completely eliminates the ventilation and drainage blind spots at the cell center inherent in the traditional design. Meanwhile, the design significantly enhances the ventilation gas velocity and flow rate at the center of honeycomb cells, accelerating the discharge of fuel vapor and drainage of accumulated fluid. The overall ventilation efficiency is considerably higher than that of the traditional symmetric design. This study provides a theoretical basis and technical support for the safety design of honeycomb composite panels used in auxiliary fuel tanks of civil aircraft.
Yao, Lijun, Chen, Jun
Accelerometer Mass Compensation on Frequency Response Functions in Impact Testing Based on the Substructure Method2026-99-09118/7/2026
Impact testing utilizing instrumented hammers and accelerometers is a widely adopted technique in dynamic testing. The mass loading effect of the accelerometer alters the dynamic response of the test structure, leading to deviations between the measured frequency response functions (FRFs) and their true values. Furthermore, the effects on the FRFs are contingent upon the positioning of the accelerometer, thereby causing the measured FRFs between two points to fail to meet the principle of reciprocity. This paper investigates the compensation method for the mass of a single accelerometer in impact testing. Compensation formulas for both origin–FRF and cross–FRF are derived using the frequency domain substructure decoupling method. Numerical simulations on a cantilever beam and experimental tests with milling tools validate the proposed methodology. The compensation formulas for FRFs presented in this paper are expected to enhance the measurement accuracy of FRFs in modal testing of small structures, particularly relevant for lightweight components in aerospace, aircraft, and transportation systems, where precise dynamic characterization is critical.
Tang, Zhenrong, Yao, Zhenqiang
Mechanical Structure Design and Dynamics Simulation of an Exoskeleton Leg Rehabilitation Robot2026-99-09028/7/2026
In response to the challenges of training and rehabilitation for patients with leg dysfunction, this research focuses on two core requirements: “bionic adaptation” and “safety assistance”. It introduces a novel exoskeleton leg rehabilitation robot designed to support diverse rehabilitation exercises for individuals with leg disabilities during therapy. The robot system consists of a lumbar support structure, thigh mechanical components, calf mechanical components, leg fixation straps, and foot mechanical structures, and achieves multi degree of freedom motion simulation through three main joints: hip joint, knee joint, and ankle joint. Each mechanical leg has three independent degrees of freedom, which can effectively simulate the natural movements of the human lower limb, such as flexion, extension, abduction, etc., during the gait cycle, thus meeting the functional needs of patients for different movement modes during rehabilitation training. On the basis of structural design, this study further utilizes multi-body dynamics simulation software ADAMS to conduct kinematic and dynamic analysis of the exoskeleton robot. By simulating the joint torque of the exoskeleton legs under ideal working conditions, the rationality and smoothness of the mechanism design are verified. The simulation results not only reflect the performance of the robot in typical rehabilitation actions, but also provide a theoretical basis and data support for the selection and parameter matching of key execution components (such as servo motors, reducers, etc.), laying an important foundation for the physical development and control strategy optimization of the robot system.
Mu, Xiaoqi, Ma, Chao, Li, Weijie, Pu, Shuai, Liu, Jiaqi, Wang, Ruiyin, Zhang, Xiaodong
A Foundational CFD Validation for an Occupant-Centric HVAC Digital Twin: Paving the Way for Real-Time Control2026-99-10028/7/2026
The heating, ventilation, and air-conditioning (HVAC) systems are one of the main factors that contribute to the building’s energy usage. Achieving an effective balance between reducing energy use and maintaining acceptable thermal comfort is the key challenge in conventional HVAC systems. To overcome this challenge, integrating the occupant-centric controls coupled with digital twins into HVAC systems is another potential technique for this effective balance. For this purpose, computational fluid dynamics (CFD) offers the potential, in combination with other surrogate models for real- time applications to enhance the system's performance further. In general, the CFD is applied to investigate indoor airflow/temperature distributions. These are essential for occupant health, comfort, and energy optimisation for the HVAC design state. The objective of this study is to propose an initial step toward building an occupant-centric HVAC digital twin by validating a CFD model of an office against dense in-situ sensing data. The model has been used to resolve airflow and temperature stratification under conventional HVAC operations, using ANSYS Fluent. The boundary conditions have been derived from measured supply parameters, internal gains, and local weather conditions. The results from this study show that the air velocity and temperature at selected durations follow the same trend with low errors, compared to the sensing and measurement data. The model validation from this study establishes the basis for a weather- aware, occupant-feedback digital twin for larger floorplates and multi-zone systems. To achieve the target of the energy and comfort co-optimisation in Industry 4.0-ready buildings, the future work will focus on surrogate modelling to enable near-real-time inference for closed-loop occupant-centric controls, which will directly support dynamic set-point adjustments and multi-zone system ventilation.
Larpruenrudee, Puchanee, Hellany, Ali, Famakinwa, Tosin, Shrestha, Surendra, Attwater, Roger, Calheiros, Rodrigo Neves
Unlocking Simulation Study of Convection Heat Transfer Magnesium Strip Solid Spring Mechanism2026-99-10098/7/2026
This study investigates the convective heat transfer mechanism in the unlocking process of magnesium strip-based solid propellant mechanisms, supported by numerical simulations. Through developing a multiphysics coupled model for the unlocking mechanism, we analyze magnesium strip fracture and unlocking processes, revealing how convective heat transfer affects unlocking duration. The simulation results demonstrate excellent agreement with experimental data, providing theoretical guidance for engineering design of magnesium strip-based solid propellant systems.
Wang, Haoxu, Zhong, Jianlin
Simulation Study on the Equilibrium Strategy and Thermal Runaway Suppression of Lithium Iron Phosphate Module Based on SOC Inconsistency Regulation2026-99-10138/7/2026
With the rapid development of the new energy vehicle energy storage industry, lithium-ion battery technology is undergoing a phase of rapid technological advancement. Enhancing battery energy density and safety remains a core challenge in overcoming industrial bottlenecks. During long-term cycling operations, deviations in state of charge (SOC), voltage, and temperature of individual cells inevitably occur, leading to reduced energy utilization efficiency. These deviations may also induce local overcharging and internal short circuits in individual cells, ultimately triggering thermal runaway incidents. While existing battery balancing strategies primarily focus on uniformity regulation, they fail to adequately address the coupling mechanisms of heat generation, heat storage, and thermal runaway propagation during balancing processes. Furthermore, the poor coordination between these strategies and thermal management systems makes it difficult to meet the complex safety requirements of high-energy-density batteries. To enhance the safety and energy utilization efficiency of battery systems during operation, this study focuses on the synergistic optimization of balancing strategies and thermal runaway prevention control. By establishing computer models of individual cells and battery packs in CATIA software, the research analyzes the evolution mechanisms of thermal runaway triggered by system state inconsistencies, while exploring the regulatory patterns of balancing parameters on thermal safety. Utilizing the ANSYS simulation platform, the study systematically examines the impact of three critical parameters—ambient temperature, discharge rate, and coolant flow rate—on battery temperature rise, providing theoretical support and technical references for the design of high-reliability lithium-ion battery pack systems.
Yu, Zheng, Gong, Ji, Fan, Yi, Liang, Wei, Li, Yuewei, Liu, Fashen, Xie, Maojun, Cen, Zucai
Analysis of Annular Pressure Drop Resistance across Tubing Joints Based on CFD and Nonlinear Fitting2026-99-09098/7/2026
During well testing and killing operations, tubing couplings with a larger diameter than the tubing body significantly increase the flow friction in the casing-tubing annulus, alter the rheological behavior of the kill fluid, thereby affecting operational accuracy and even leading to operational failure in severe cases. Most existing relevant studies focus on the impact of changes in flow area on flow, but ignore the effect of the coupling’s own structural configuration. Moreover, the research conclusions lack verification by downhole measured data, and there is an urgent need to further improve the analysis accuracy. Taking an ultra-deep well in the Xinjiang Oilfield as the engineering background, this paper conducts targeted research: first, a physical model of the flow field in the casing-tubing annulus passing through the tubing coupling is established, and a method for judging and determining the rheological properties of the kill fluid based on the fitting of the physical model and key parameters is proposed; on this basis, a numerical model including the coupling’s structural configuration is established and solved, and the friction calculation equation for the casing-tubing annulus passing through the tubing coupling is obtained through nonlinear fitting; finally, the calculation results of this equation are compared and verified with the measured data and numerical simulation results. The research results show that: under six working conditions, the flow characteristics of the kill fluid all conform to the characteristics of Bingham fluid, which is also consistent with the general flow regime of kill fluid flow; comparing the numerical analysis results of the target well in the Xinjiang Oilfield with the calculation results of the fitting equation, the maximum error, minimum error, and average error of friction analysis under the six working conditions are 14.46%, 0.39%, and 6.15% respectively; the total friction of the casing-tubing annulus in the entire well section calculated based on the theoretical equation is 12.085 MPa, and the relative error compared with the field measured 13 MPa is 7.57%, which meets the engineering accuracy requirements. The equation proposed in this study provides a universal equation for predicting the pressure drop of non-uniform flow in the wellbore, and also has an important reference value for predicting the wellbore pressure in drilling and oil-gas production operations.
Song, Zhitong, Jiang, Wu, Mi, Hongxue, Cao, Yinping, Dou, Yihua
Experimental Study on the Combined Effects of Swirl and Inlet Offset on the Flow through an Automotive Catalyst Monolith Substrate03-19-04-00198/7/2026
Maldistributed flow within an automotive catalyst can cause reduced conversion efficiency, high pressure loss, and premature deactivation. However, packaging constraints often result in uneven flow distribution between the monolith channels, thus compromising design and, inevitably, performance of the device. Flow uniformity may be improved by the introduction of swirl upstream of the catalyst assembly, and in turbocharged applications the residual swirl from the turbine can serve that purpose. Indeed, low swirl has been shown to provide favorable flow uniformity in the monolith substrate in an axisymmetric flow setup. However, the automotive exhaust aftertreatment setups are seldom axisymmetric, and the combined effects of inlet swirl and offset on the flow profile through a monolith substrate are unknown. To address this gap, this study provides the first systematic experimental characterization of the coupled influence of inlet swirl and packaging-relevant inlet offset on flow development and uniformity in a sudden expansion catalyst assembly. Particle image velocimetry (PIV), wall pressure measurements, and hot-wire anemometry (HWA) are combined to link the upstream separation and recirculation structures to the velocity distribution downstream of the monolith. The results reveal a previously unreported swirl-dependent sensitivity to geometric asymmetry: under no-swirl and moderate-swirl conditions, flow uniformity is robust to inlet offset, varying by no more than 1.4%, whereas at low swirl the offset reduces uniformity by up to 8% at high mass flow rate. Increasing mass flow rate reduces uniformity by up to 15%, while swirl improves uniformity by up to 19% relative to axial flow. These findings demonstrate that improvements observed for swirl in axisymmetric assemblies cannot be assumed to transfer directly to offset geometries. Swirl intensity and inlet alignment must instead be considered as coupled design variables. The measurements also provide a benchmark dataset for validating computational fluid dynamics simulations before their application to production-type systems.
Rusli, Ijhar, Aleksandrova, Svetlana, Medina, Humberto, Benjamin, Stephen F.
Analysis of the Impact on Ride Comfort from Splitting the Unsprung Mass in Vehicle Modeling2026-01-50578/6/2026
The study was conducted to investigate the differences in ride comfort analysis between treating the unsprung mass as a whole and modeling it separately. A classical two-degrees-of-freedom single-wheel vehicle vibration model and a three-degrees-of-freedom single-wheel vehicle vibration model with split unsprung mass were established, with their state-space descriptions determined. The fundamental vibration response quantities of both models were identified, and time-domain simulations under random road excitation were performed using MATLAB/Simulink. The results indicate that the two modeling approaches exhibit minimal differences in ride comfort analysis for the sprung mass, but there are certain differences for the unsprung mass. Additionally, for the three-degrees-of-freedom single-wheel vehicle vibration model with split unsprung mass, the axle-to-wheel mass ratio was introduced to analyze the changes in the fundamental vibration response quantities when the unsprung mass increases by a fixed value and is distributed differently between the axle and the wheel. The results show that variations in the axle-to-wheel mass ratio have no significant impact on the vibration characteristics of the sprung mass. Reducing the mass ratio, i.e., transferring part of the unsprung mass to the wheel, can somewhat reduce the vertical acceleration of the unsprung mass, but it will slightly increase the relative dynamic load on the wheel. Finally, the other two models were simplified by combining the two masses connected by the bearings.
Jie, Li, Wei, Deng, Chengyu, Li
Numerical Study on Measurement Accuracy of Liquid Level/Capacity Measurement Device and System in a Shipboard Environment2026-99-01227/31/2026
In the marine environment, navigation safety and operational effectiveness depend heavily on the precision of liquid level/capacity measurement equipment and systems. In order to examine their measurement accuracy under complex operational situations, including ship navigation states and water tank sloshing, this study employed computational fluid dynamics (CFD) methodologies. The numerical technique performs a thorough examination of how various operating conditions impact measurement accuracy and integrates the volume of fluid (VOF) model and laminar flow model with appropriately defined boundary conditions and solver settings. The findings indicate that constant-speed navigation has minimal impact on accuracy, horizontal acceleration causes moderate deviations, and accelerated diving greatly reduces precision. The amplitude of water tank sloshing has a positive correlation with measurement error. When sloshing amplitudes are less than 1 m, the integration of the resulting acceleration efficiently lowers deviations while preserving excellent accuracy. In light of these results, we advise adding accelerometers to differential pressure transmitters to improve measurement precision. This investigation provides data-driven references and technical solutions for system design and operational standard formulation in marine measurement systems.
Shang, Jin, Qin, Ziming, Wang, Yingwei, Wu, Chao, Zhao, Fenggang, Chen, Liang, Xia, Wei, Yan, Jin, Chen, Min, Chen, Guoao
Application of the Coupled Volume of Fluid and Level Set (CVOFLS) Method for Moving Interface Tracking in the Zalesak Disk Problem2026-99-01387/31/2026
Addressing the inaccuracies in interface curvature computation using the Volume of Fluid (VOF) method and the lack of mass conservation in the Level Set (LS) method, a novel interface tracking method, the Coupled Volume of Fluid and LS (CVOFLS) method, is established. This approach synergistically integrates the strengths of both VOF and Level Set methodologies. It simultaneously solves for the VOF and LS functions based on fluid velocity, corrects fluid mass using the surface obtained by the VOF approach, and computes interface normals using the LS function, thereby eliminating the need for LS function reinitialization. This effectively overcomes the shortcomings of both methods. Numerical simulations of interface tracking demonstrate that the CVOFLS method ensures high tracking accuracy of free interfaces, good mass conservation, and improved computational efficiency.
Cui, Liying, Sun, Hui, Xu, Wei
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
Optimization of Pneumatic Conveying Elbows to Reduce Grain Particle Normal Contact Forces via CFD-DEM Coupling Method2026-99-01167/31/2026
This study presents a refined design for pneumatic conveying pipelines, featuring a grooved structure at the bend aimed at reducing particle breakage during transportation. Using soybean particles as a focus, the research employs a gas-solid two-phase flow approach to explore how different groove depths and widths influence the breakage rate. We used CFD-DEM simulation techniques, combining fluid mechanics with discrete element modeling to achieve a more accurate representation of particle motion and collision forces during expressing. Based on these simulations, we identified the most effective combination of groove width and spacing. Experimental results showed that a groove width of 4.5 mm coupled with a 40 mm spacing could decrease impact forces on particles by approximately 5% to 10% at expressing speeds of 15 m/s and 20 m/s. Throughout all measured time intervals, the impact forces remained stable, with turbulence exerting minimal influence on the particle forces.
Luo, Xinhao, Yang, Tiancheng, Huang, Bo, Mao, Genwu, Dong, Deliang, Shi, Heng, Li, Xiaoliang, He, Bo
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
Research on Fault-Tolerant Control Strategy for Drive System Failure of Corner Module-by-Wire Chassis Vehicles2026-01-50547/31/2026
As an emerging research focus, corner module-by-wire chassis vehicles overcome the limitations of traditional chassis in flexibility, cost, and development efficiency, serving as a key infrastructure in the autonomous driving era. However, their numerous actuators raise significant actuator failure risks. This paper analyzes the characteristics of such vehicles and studies fault-tolerant control for drive system failures. Firstly, a vehicle model for the corner module-by-wire chassis was established based on CarSim and Simulink. Then, a hierarchical lateral stability control strategy was designed for the non-faulty actuators: the decision control layer employed sliding mode control (SMC) and fuzzy PID control, selecting the optimal method to output additional yaw moments; the control allocation layer distributed the upper-level target yaw moments based on the vertical load of the tires, converting them into individual wheel torques to meet the constraints. For the drive system, potential fault scenarios were analyzed and their fault modes were classified. By using the non-faulty actuators for torque reconstruction, fault-tolerant strategies were designed for single-motor, diagonal dual-motor, and coaxial dual-motor faults. A co-simulation platform was built using MATLAB/Simulink and CarSim, testing the stability control strategies under three fault modes in constant-speed straight-line and double-lane change conditions. Simulation results show that the designed drive system fault-tolerant control strategy effectively maintains the vehicle’s expected dynamic performance and stability.
Zheng, Hongyu, Zhang, Tianhao, Zhang, Yuzhou
A Data-Driven Model for Predicting Casting Solidification Time and Mold Thermal Stress2026-01-50557/31/2026
This study proposes a data-driven surrogate modeling framework for predicting solidification time and mold thermal stress during low-pressure die casting (LPDC) of aluminum alloy wheels. The methodology employed an optimal Latin hypercube design (OLHD) to sample key parameters including cooling channel geometry and process conditions. A sequential simulation methodology combining ProCAST and Abaqus was implemented to generate a comprehensive dataset of solidification times and thermal stress distributions. Based on this dataset, surrogate models were developed using Support Vector Regression, Kriging, and Polynomial Response Surface Methodology, with their hyperparameters automatically tuned through Bayesian Optimization (BO). The optimized models were rigorously evaluated using four statistical metrics: Coefficient of Determination (R2), Mean Squared Error (MSE), Mean Absolute Error (MAE), and Root Mean Squared Error (RMSE). The evaluation results show that the BO–SVR model demonstrated superior prediction accuracy for both output responses and exhibited exceptional nonlinear fitting capability. This work establishes an effective modeling approach for simultaneous quality and efficiency optimization in wheel manufacturing.
Fuhao, Fan, Zhan, Yunlang, Zhan, Zhenfei, Yang, Yutong, Xiao, Yong, Huang, Shiyao
Weld Formation, Microstructure, and Mechanical Properties of High-Speed Friction Stir-Welded 6061-T6 Aluminum Alloys2026-99-01267/31/2026
In this paper, 6061-T6 aluminum alloys were subjected to high-speed friction stir welding. The associated weld formation, microstructure, and mechanical properties were systematically examined via combined experimental observation and numerical simulation approaches. At a welding speed of 3000 mm/min and a rotation rate of 3800 rpm, the defect-free weld was simply achieved due to the simultaneous intense thermal input and enhanced material flow. Microstructural analysis further demonstrated a fine equiaxed grain structure featuring a predominant simple shear texture with A/A components. The resultant joint exhibited an ultimate tensile strength equivalent to 80% of the base material, accompanied by excellent fracture elongation. This research provides experimental evidence for designing high-efficiency and high-quality bonding processes for aluminum alloys.
Guan, Yuankai, Wang, Ruiyang, Zhang, Kexin, Lin, Zhicheng, Deng, Jun, Liu, Zhe, Ganushchak, Oleg, Voitenko, Oleksandr, Zhao, Yunqiang, Gao, Shiyi
Research on Machining Deformation Simulation and Prediction of Low-Stiffness Structural Components under Cutting Force2026-99-02377/31/2026
During the cutting process of low-stiffness structural components, the coupling effect between dynamic deformation and cutting forces presents a significant challenge in accurately predicting machining-induced deformations, thereby complicating quality control in the manufacturing of such parts. To address this issue, a cutting force-structural coupling simulation method that combines experiment and finite element is proposed, which takes into account the low-stiffness characteristics of structural components. Focusing on thin-plate parts as the research object, an orthogonal experimental scheme is designed considering workpiece thickness that serves as an indicator of rigidity. A milling force prediction model correlated with workpiece thickness is established. Based on the predicted cutting forces, a multi-analysis-step simulation method is introduced to analyze the machining deformation of structural parts. Additionally, a theoretical analytical model for the machining deformation of thin-plate workpieces is developed. A comparison between the theoretical and simulation results shows a relative error of less than 1.03%, validating the accuracy of the proposed simulation method. Finally, the exponential regression model for the machining deformation is constructed using training data obtained from the simulations. The prediction error of the regression model is less than 15%. The findings of this study are also applicable to predicting machining deformations in other large and low-stiffness structural components.
Zhao, Yongsheng, Gao, Pengfei, Xu, Jingjing, Liu, Zhifeng
The Influence of Stator Vane Lean on the Rotor Blade Forced Response of an Axial Turbine2026-99-02107/31/2026
Forced response resulting from rotor-stator interaction is a primary cause of high-cycle fatigue (HCF) failure in axial turbine blades. To investigate the mitigating effect of stator vane lean on the forced response of a downstream rotor blade, this paper conducts a numerical analysis based on a fluid-structure interaction (FSI) method, comparing a baseline radial vane with a leaned vane configuration in a single-stage axial turbine. Unsteady computational fluid dynamics (CFD) was used to analyze the unsteady flow field and aerodynamic excitation, and the resulting harmonic pressures were applied to a finite element (FE) model for harmonic response analysis. The results show that, compared to the radial vane, the leaned vane design effectively weakens the potential field and wake interactions by introducing a spanwise phase difference, which significantly reduces the amplitude of the unsteady pressure fluctuations. The harmonic response analysis further validates the effectiveness of this approach, demonstrating that under the first harmonic excitation, the leaned vane configuration reduces the maximum dynamic stress on the rotor blades by 37.7%. This study confirms that stator vane lean is an effective aerodynamic detuning strategy that mitigates the excitation at its source, leading to a substantial reduction in the rotor’s dynamic stress and thus offering a valuable method for improving turbine blade reliability.
Huang, Zhi, Zhang, Ying, Xiong, Zhonggang
Design and Research of Robotic Arm for Belt Conveyor Roller Replacement2026-99-01877/31/2026
To address the high failure rate of rollers in coal mine belt conveyors, the inefficiency of manual replacement, and the operational disruptions caused by maintenance shutdowns, this study proposes a robotic arm system capable of replacing rollers without halting conveyor operations. The research focuses on the kinematic performance and path planning strategy of the robotic arm. A kinematic model is established using the Denavit–Hartenberg (DH) parameters, and the workspace distribution is analyzed via the Monte Carlo method. The results show that the horizontal reach exceeds 2020 mm and the vertical reach extends up to 2000 mm, which fully satisfies the spatial requirements for roller replacement across the entire conveyor system. In the path planning phase, an obstacle expansion model is constructed, and an improved Informed RRT* algorithm is implemented to generate collision-free trajectories, ensuring effective obstacle avoidance. To improve trajectory smoothness, path pruning and cubic B-spline interpolation are applied to refine the initial paths. For trajectory planning in joint space, quintic polynomial interpolation is employed, with boundary conditions set to ensure zero velocity and zero acceleration at both the start and end points, thereby guaranteeing smooth and stable motion of the robotic arm. Simulation results indicate that joint angles, angular velocities, and angular accelerations vary smoothly throughout the roller grasping process, without abrupt changes, and converge to zero at the beginning and end of the trajectory. End-effector trajectory tracking error analysis reveals positioning errors within 0.8 mm for side rollers and 3 mm for central rollers, well within acceptable engineering accuracy thresholds. This work provides a theoretical foundation and a practical implementation framework for advancing automation and intelligent operation in roller replacement tasks within coal mine belt conveyor systems.
Pu, Congyuan, Qian, Ke
Docking Methodology for Large-Sized Irregular Castings via Industrial Robot Manipulation2026-99-01707/31/2026
Large-sized irregular castings are critical components extensively employed in large-scale equipment manufacturing. Due to their substantial dimensions and complex geometries, the assembly and docking processes between different components present significant challenges. To address the docking problem between large-scale irregular castings, this study proposes a casting docking method based on relative pose, along with a modeling approach for irregular castings, and accomplishes the docking process through the control of an industrial robot. Firstly, the current poses of feature points on the docking surfaces are measured. Based on these measurements, the relative pose transformation relationship between the center point of the docking surface and the robot’s Tool Center Point (TCP) is established, thereby constructing the docking model. This model calculates the relative deviation between the current pose and the theoretical pose. Subsequently, the robot motion is controlled according to this deviation to achieve precise docking. Finally, a simulation environment was built using KUKA. Sim Pro with Office Lite to simulate the docking process of large-sized irregular castings. The results demonstrate that the relative pose-based docking method effectively accomplishes the docking task. This study provides an effective solution for the docking of large-sized irregular castings.
Liu, Haoran, Jia, Haili, Wang, Aimin, Xigang, Fan, Peidong, Su
Research on the Erosion and Wear Characteristics of Gathering and Transportation Pipelines by Cyclone Abrasive Process Parameters2026-99-01847/31/2026
Cyclone abrasive pigging technology, with advantages like environmental friendliness, easy construction, and low destructiveness, has broad application prospects. Studying how the process parameters affect the erosion-wear characteristics of gathering pipelines is crucial for improving pigging efficiency and effectiveness. This study adopted numerical simulations based on gas-solid two-phase flow erosion theory to explore such effects and verified the simulations via a self-designed experimental platform. Results showed that within the given parameter range, erosion rate rose significantly with velocity, especially at 20-30 m/s, peaking at 60 m/s; 0.6 mm abrasives and 0.25 kg/s mass flow rate led to higher erosion rates. Experimental data matched simulations with <10% error, confirming accuracy. Thus, cyclone abrasive process parameters significantly influence pigging performance, and the findings can guide practical operations within the studied range.
Wang, Haoran, Zhou, Xianjun, Li, Long, Song, Huifang, Zhang, Jin, Jv, Xiaolong
Design and Dynamic Analysis of Deployable Support Mechanism for Cylindrical Sunshield2026-99-02267/31/2026
With the deepening of space exploration, deep space exploration missions face formidable challenges. Among these, intense solar radiation and high-temperature environments pose severe threats to precision instruments and equipment in space. Stray light suppression and protection against external heat flow inputs have emerged as critical technical requirements in the design of modern spacecraft over recent years. To address the demand of space applications, this paper proposes a cylindrical deployable sunshield with axial deployment capability. First, drawing on the 6UU/3UPU/3UKU mechanism as a foundational reference, the basic module was defined through in-depth analysis of the multi-layer Kresling origami pattern. Guided by the modular composition principle, these basic modules were further assembled into an integrated deployable support mechanism. Secondly, the overall kinetic and potential energy of the full mechanism system were computed and incorporated into the second-type Lagrange equation. To verify both the correctness of the established dynamic model and the reliability of follow-up simulation studies, an integrated validation strategy was implemented: SolidWorks was used for three-dimensional modeling and kinematic simulation of the mechanism, while Matlab was employed for numerical solving and result analysis of the dynamic model, with consistent outcomes from both tools confirming the model’s correctness.
Liu, Yongyu, Chang, Boyan
Advancing Reliability Centered Maintenance: A Robust Statistical Approach for MTBF Estimation in Aero-Engine Fleets via Subgrouping Strategy and Dual Weibull Modeling2026-99-02137/31/2026
Fleet heterogeneity, from manufacturing variations and diverse operating conditions, complicates reliability analysis by obscuring true failure patterns in aero-engines. This is a critical challenge in an industry as inaccurate Mean Time Between Failures (MTBF) estimates threaten safety and inflate operational costs, by forcing a choice between inefficiently conservative maintenance or the risk of in-service failures. Conventional analysis often fails by pooling all fleet data. To address this, our paper presents an analytical framework that improves predictive accuracy by filtering, rather than aggregating statistical noise. The methodology uses a Randomized Block Design (RBD) and ANOVA hypothesis test to screen a diverse dataset and isolate statistically homogeneous subgroups. This filtration identifies a core fleet with a consistent failure signature, providing a purified dataset for modeling. This refined data is then modeled using both Weibull and the Exponentiated Inverse Weibull distributions to ensure the results are robust and not model-dependent. Applying this framework to a 25-engine dataset that experienced 66 failures, we isolated a stable failure pattern, yielding a primary MTBF of 171.16 hours and a cross-validated MTBF of 176.35 hours. The close 3% convergence between these models validates our approach. By providing a dependable MTBF, this work establishes a stronger foundation for data-driven Reliability Centered Maintenance (RCM). It empowers maintenance planners to move toward evidence-based intervals, safely extending engine time-on-wing, optimizing spare parts inventory, and significantly reducing direct operational costs for airlines.
Jubaid, Mayin Uddin, Bebe, Gibson, Bigyen, Musa Pethuel, Anik, S M Kullul Mehedee, Yasmin, Ashrafi, Sahran, Mohamed Sideek Mohamed
Test and Simulation Analysis of Edgewise Compressive Performance of Marine Composite Sandwich Structures with Delamination Defects2026-99-02007/31/2026
In this paper, PTFE membranes were used to preform delamination defects, and VARI technology was employed to prepare marine composite sandwich structures with such defects. The cohesive zone model was used to emulate the interfacial bonding characteristics, thereby establishing a simulation analysis model to assess the edgewise compressive behavior of marine composite sandwich structures with delamination discontinuities. By combining experimental data with simulation results, the edgewise compressive resistance of marine composite sandwich structures was evaluated. Additionally, various parameters including the size, depth, quantity, and geometry of the delamination defects were studied to investigate their effects on the edgewise compressive performance of the marine laminated structures. The research results indicate that as the number of delamination defects increases, the edgewise compressive strength of the sandwich structure gradually decreases. Particularly, when the diameter of the layering defect is less than 30 millimeters, the influence of the defect on the edgewise compressive strength of the sandwich structure can be negligible. Conversely, when the diameter of the defect exceeds 30 millimeters, the rate of decrease in edgewise compressive strength increases significantly with the increase in the diameter of the defect, thereby greatly exacerbating the adverse effects of the delamination defects and ultimately resulting in a 10.77% reduction in the edgewise compressive strength. Furthermore, it was observed that the delamination defects located at the interface between the two panels and the core material on both sides of the sandwich structure do not affect each other, and to a certain extent, improve the compressive stability of the specimen. The degree of edgewise compressive strength reduction caused by elliptical delamination defects with the same area and long axis length is less than that of corresponding circular delamination defects, indicating that using circular delamination defects in the analysis of composite material structures with delamination defects is safer.
Zhang, Yao, Xu, Mingcai, Bian, Tianya, Zhou, Songqiang, Ji, Bing, Cheng, Jiahuan, Zhuang, Ya, Li, Xiang
Research on Ultrasonic Measurement Technology for Submarine Pipeline Deformation2026-99-02237/31/2026
Aiming at the measurement of buckling deformation defects of submarine pipelines in turbid waters, a precise measurement method for submarine pipeline deformation was proposed based on ultrasonic ranging technology. A unified underwater coordinate system for submarine pipelines and measurement sensors is established, and a three-dimensional model of the pipeline outer surface is constructed on this basis to provide a basis for calculating pipeline deformation elements. On the basis of underwater ultrasonic velocity correction, measurement accuracy control measures were proposed. Two types of ultrasonic measurement transducers and measurement systems were designed, and engineering applications were carried out to measure the deformation of submarine pipelines in the project. The measurement results indicate that the ultrasonic measurement system operates well under harsh sea conditions such as high turbidity, low visibility, and high flow velocity in the construction sea area, with high measurement accuracy. The three-dimensional model of the deformed pipeline is constructed accurately, and the deformation characteristics of the pipeline can be accurately calculated, meeting the requirements of engineering applications and providing effective data support for submarine pipeline maintenance.
Wang, Kekuan, He, Yazhang, Wang, Hong, Zhang, Tao, Cheng, Peiliang, Sun, Xinyan, Bai, Qian
Fluid Force Optimization on Multi-Way Valve Blades via CFD Simulation and Surrogate Modeling2026-99-01867/31/2026
To optimize fluid forces on the multi-way valve blades within thermal management systems of new energy vehicles, this study employs a systematic design methodology integrating parametric modeling, surrogate modeling, and multi-objective optimization. Using the Tesla Model Y 8-way valve as a case study, a parametric model is established. A high-fidelity sample dataset is generated through computational fluid dynamics (CFD) simulations utilizing optimal Latin hypercube sampling (OLHS). A radial basis function-thin plate spline (RBF-TPS) surrogate model is subsequently developed to replace computationally expensive CFD analyses. Global sensitivity analysis is performed using an improved Sobol’s method. Structural optimization of the valve core blades is then conducted via the NSGA-II genetic algorithm. Results indicate that valve core structural parameters significantly influence the fluid force on individual blades, with inner diameter, outer diameter, and blade thickness exhibiting the greatest impact. Multi-objective optimization achieves a substantial reduction in the fluid force acting on each blade. Simulation verification confirms the optimization outcomes with minor discrepancies.
Liu, Jiaming, Sun, Xiaoxia, He, Xiwang, Du, Changqing, Song, Xueguan, Shen, Lili
Research on the Axial Assembly Stress and Fatigue Life of 60-Series Harmonic Reducers2026-99-01917/31/2026
This study presents a systematic investigation into the assembly stress and fatigue life of 60-series harmonic reducers. A sophisticated finite element simulation model is constructed to precisely simulate the real assembly process and calculate stress distribution in the flexspline under axial assembly errors. In addition, corresponding fatigue life tests are designed to explore the influence of different axial assembly errors on the number of rotation cycles and transmission efficiency of the harmonic reducer. By comparing the predictions of the fatigue life mathematical model with the test data, a reliable fatigue life prediction method is established, providing a solid theoretical basis for the whole-machine assembly process and reliability design of this series of harmonic reducers.
Du, Yuefei, Qiu, Haodong, Fan, Yong, Li, Ziyuan, Dong, Yi, Zhang, Chi, Li, Chenzheng, Li, Yuan
Discussion on Methods for Studying Material Fatigue Life: Taking Aluminum Alloy as An Example2026-99-01217/31/2026
Fatigue design is a key common quality technology for improving the quality control capability of China’s automotive products. The fatigue of materials is a multi-scale damage evolution process. Characterizing and processing the large number of three-dimensional defects inside the material, which have different shapes and distributions, and predicting the material’s lifespan based on the cross-scale damage evolution mechanism, is one of the key technologies for fatigue optimization design. This paper discusses the research methods for the fatigue life of aluminum alloy materials. Firstly, based on the staged fatigue damage experiments, the three-dimensional defect features are obtained through CT scanning and reconstruction, and a defect characterization and processing method based on k-d tree and multi-scale feature pyramid is established to accurately represent the topological and geometric relationships of non-uniformly distributed three-dimensional defects. Secondly, a mathematical model for the evolution of micro-damage and macro-cracks is constructed, and the cross-scale transformation of defects is achieved through hierarchical and recursive methods, revealing the cross-scale evolution mechanism of fatigue damage in aluminum alloy materials. Finally, a remaining life prediction model based on defect information and feature weights is established through the support vector regression algorithm (SVR). This research method can provide technical support for the fatigue life optimization design application of lightweight materials such as aluminum alloys.
Zhang, Liangxia, Niu, Zhijun, Cheng, Fangfang, Chen, Hao, Yang, Yali
Angular Vibration Model of Frictional plates in High Speed Open Wet clutch2026-99-02347/31/2026
High-speed wet clutches may experience dynamic instability between the friction plates, leading to rattling vibrations and a significant increase in drag torque. This study employs a homogeneous flow model to characterize the gas-liquid two-phase flow within a high-speed clutch. It establishes a dynamic model for the angular oscillation of friction plates. Finite-element numerical simulations and stability analyses were conducted. The results indicate that as the clutch speed difference increases, the density and viscosity of the two-phase flow decrease rapidly, leading to a sharp reduction in fluid stiffness and damping. Consequently, the friction plates become more susceptible to angular oscillation. The stability of angular oscillation is determined by two key parameters: dimensionless comprehensive stiffness and critical frequency ratio. Higher dimensionless comprehensive stiffness and a lower critical frequency ratio enhance oscillation stability. Numerical evaluations of various groove types reveal that as rotational speed and friction plate clearance increase, the fluid stiffness coefficient, damping coefficient, dimensionless comprehensive stiffness, and critical moment of inertia all decrease, thereby reducing angular oscillation stability. Among the tested groove geometries, enclosed grooves and spiral grooves exhibit superior stability due to their strong hydrodynamic effects, yielding the highest dimensionless comprehensive stiffness. The critical frequency ratio for the self-excited angular oscillation of friction plates is approximately 0.5, termed the half-frequency oscillation characteristic. Experimental data validate the proposed angular oscillation model and its frequency response, providing a theoretical foundation for performance prediction and stability optimization in high-speed clutch design.
Cheng, Xu, Peng, Zengxiong, Zhang, Jing, Jin, Jiayin
Enhanced Vibration Damping Properties of Novel Mn-Cu Alloy for Ship Structural Applications2026-99-02367/31/2026
Low-frequency vibrations in ships have detrimental effects on the lifespan of onboard equipment and the comfort of crew members, thereby highlighting the importance of developing efficient vibration-damping materials as a critical research area. This study investigates the application of Mn-Cu damping alloys for mitigating vibrations within the 0–1000 Hz frequency range, which is typical of ship environments. The vibration-damping characteristics of the material were examined through a combination of experimental and numerical simulations. A numerical simulation framework was developed to predict the vibration response of manganese-copper damping alloys, incorporating a frequency-dependent damping ratio model derived from experimental characterization. Comparative analyses validated the accuracy of vibration simulations that incorporate frequency-dependent damping ratios and demonstrated the superior vibration attenuation performance of the Mn-Cu damping alloy across the 0-1000 Hz frequency band. Deck application analysis revealed that manganese-copper damping devices reduced the root mean square (RMS) vibration acceleration of the ship deck by up to 17.5% in the 0-1000 Hz frequency range compared to aluminum alloy counterparts. The damping effect was particularly significant in the 400–1000 Hz range, where vibration energy dissipation was most effective due to the material's intrinsic damping mechanisms. Additional engineering evaluation confirmed that the Mn-Cu alloy components maintain structural integrity while providing enhanced damping performance under typical marine environmental conditions. This study establishes a theoretical foundation for the design of ship vibration-damping materials, expands the potential applications of damping alloys in marine engineering, and provides valuable reference data for material selection and vibration control design in shipbuilding and offshore engineering applications.
Yao, Sitong, Tian, Ali, Zhao, Xianghua
Finite Element Simulation of Hot-Rolled TC4 Bulb Flat Titanium Alloy2026-99-02397/31/2026
To facilitate the development and application of bulb-flat titanium alloys in aerospace and automotive industries, this study selects TC4 as the research material and employs finite element simulation software to simulate the hot rolling process of TC4 bulb flat titanium. The temperature field, strain field, and metal flow velocity in each rolling pass are analyzed, and rolling experiments are conducted after optimizing the roll pass system. The results indicate that during the rolling process of TC4 bulb flat titanium, the head undergoes relatively smaller deformation, resulting in a slower temperature decrease, whereas the waist experiences greater deformation and a faster temperature drop. A significant temperature difference exists between the core and surface, which can be mitigated by appropriately increasing the roll temperature to reduce heat transfer. Prior to the K4 pass, the billet temperature drops to a level that may affect rolling performance, necessitating furnace reheating. Strain increases progressively with each rolling pass, with higher values observed at the waist compared to the head. A gradual strain transition occurs at the interface between the head and waist. Furthermore, the irregular design of the roll pass leads to a considerable difference in metal flow velocity between the upper and lower surfaces. During the K1 pass rolling, this imbalance can cause the guide guard to be displaced upward and result in roll wrapping. Without altering the roll diameter, shifting the entire roll pass system toward the side with higher metal flow velocity effectively reduces the linear velocity and prevents these issues, ensuring stable billet rolling. Rolling experiments successfully produced the final TC4 bulb flat titanium, thereby validating the feasibility of the optimized roll pass system and the rationality of the selected rolling parameters. It provides the possibility for its development and application in fields such as aircraft and automobiles.
Wu, Xiaojuan, Liu, Dongming, Wen, Mingyue
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
Comparative Analysis of CDTire Model and FTire Model in Vehicle Comfort and Durability Simulation2026-99-01097/31/2026
This paper studies the applicability of the CDTire tire model in vehicle comfort and durability simulations by comparing it with the FTire tire model. Based on a physical 250/50 R19 tire, the corresponding CDTire and FTire models are developed and integrated into a multibody dynamics model of an SUV. After simulations of two handling comfort conditions and one durability condition using the CDTire and FTire models, it is found that, when FTire is used as the base case, CDTire produces a smaller relative error in vehicle comfort simulation, with a maximum of +5.6%. In the durability simulation, the relative error is larger, but the maximum value remains within ±10% at + 9.7%. Therefore, it can be concluded that CDTire is one tire model with acceptable simulation accuracy for vehicle comfort and durability.
Gao, Fengling, Wu, Wenwen, Geng, Hao
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