Designs

The Digital Twin is one of the major technology trends of the last decade. During the course of its rapid expansion into various fields of application, many definitions of the Digital Twin emerged, tailored to its respective applications. Taxonomies can cluster the diversity and define application-specific archetypes. This paper presents a systematic characterization of the Digital Twin in the context of structural mechanics and lightweight design. While the importance of a shared understanding and the development of holistic solutions for implementing Digital Twins in various application areas is widely recognized, a general framework for implementing Digital Twins in structural mechanics has not yet been established. In this paper, we systematically characterize Digital Twins and develop a framework for their application in structural mechanics, enabling the digital design and monitoring of structures for improved performance and maintenance strategies. The key contributions include collecting and clustering design and operational requirements and deriving two central archetypes: structure-designing and structure-monitoring Digital Twins. The primary goal is to reduce the complexity of conceptualizing Digital Twins of structures by providing a preliminary framework and reconsidering the Digital Twins of structures as a holistic system throughout the product life cycle. Overall, in this paper, we take a systematic approach to enhancing the conceptualization and implementation of Digital Twins in structural mechanics. Full article

To reduce the carbon footprint of manufacturing processes, it is necessary to reduce the number of stages in the development process. To this end, integrating additive manufacturing processes with three-dimensional (3D) printing makes it possible to eliminate the need to use tooling for component manufacturing. Furthermore, using 3D printing allows the generation of complex models to optimize different components, reducing the development time and realizing lightweight structures that can be applied in different industries, such as the mobility industry. Printing process parameters have been studied to improve the mechanical properties of printed items. In this regard, although the failure of most structural components occurs under dynamic load, the majority of the evaluations are quasistatic. This work highlights an improvement in fatigue strength under dynamic loads in 3D-printed components through heat treatment. The fatigue resistance was improved regarding the number of cycles and the dispersion of results. This allows 3D-printed polylactic acid components to be structurally used, and increasing their reliability allows their evolution from a prototype to a functional component. Full article

The prohibitive costs of small-scale solar photovoltaic (PV) racks decrease PV adoption velocity. To overcome these costs challenges, an open hardware design method is used to develop two novel variable tilt racking designs. These are the first stilt-mounted racking designs that allow for the manual change of the tilt angle from zero to 90 degrees by varying the length of cables. The racks are designed using the calculated dead, wind, and snow loads for Canada as a conservative design for most of the rest of the world. Structural capacities of the wooden members are then ascertained and the resisting bending moment, shear force, tensile force, and compressive force is calculated for them. A structural and truss analysis is performed to ensure that the racking design withstands the applicable forces. Moreover, the implications of changing the tilt angle on the wooden members/cables used to build the system are also determined. The systems offer significant economic savings ranging from one third to two thirds of the capital expenses of the commercially available alternatives. In addition, the racking designs are easy-to-build and require minimal manufacturing operations, which increases their accessibility. The stilt-mounted designs can be employed for agrivoltaic settings while allowing farm workers shaded, ergonomic access to perform planting, weeding, and harvesting. Full article

Constant pressure variable flow reciprocating axial pumps (CPAP) are used in various applications, where a constant output pressure is maintained when the flow rate changes. When the hydraulic system is at rated pressure or less, the swash plate has maximum tilt, and the pump delivers maximum flow. The swash plate comes into this position thanks to the action of a reactive piston in which there are two springs. However, when the pressure rises above the nominal pressure value, the piston of the hydraulic pressure transducer (HPT) distributes the fluid under pressure to the hydraulic cylinder (HC), which causes a decrease in the tilt angle of the swash plate and a decrease in flow. The CPAP was selected as a component of the hydraulic system of the aircraft for the experimental tests in this paper. The experimental tests covered the structural and working parameters of the pump and analyzed their performance, efficiency and reliability. Experimental tests of structural and operating parameters of the CPAP were carried out in the Laboratory for Hydraulics and Pneumatics “PPT-Namenska” Trstenik on the hydraulic system, which simulated the real conditions prevailing in the hydraulic system of the aircraft. A system was used for data acquisition and recording of pump characteristics, which were obtained during experimental testing. The results of the measurement and testing of the structural parameters of the CPAP are shown in tabular form, and the experimental tests of static characteristics and dynamic behavior are shown diagrammatically. Full article

This paper proposes a robust design-optimization approach for eBike drive units that incorporates the highly variable driver-dependent load collectives and system conditions into a fatigue calculation. In an initial step, the relevant influences and loads on the investigated system are examined and reviewed in relation to the current normative requirements. From a methodical viewpoint, this paper presents a surrogate-based simulation-based approach to assess reliability across the entire geometry according to a probabilistic fatigue calculation. The probabilistic evaluation considers the several measured load collectives of different drivers and driving scenarios to enable a robust and type-oriented bike design. In addition to methods of fatigue calculation, this approach also includes common methods of order reduction and reliability-based design optimization. To avoid additional uncertainties in the calculation, this approach considers a complex critical-plane-based multiaxial-fatigue calculation to correctly evaluate the multiaxial and non-proportional stress state across the whole geometry. A data-based surrogate model that supports the fatigue calculation by predicting the load across the given uncertainties is the key to the efficient assessment of the service life of the eBike. Lastly, the identified uncertainties in the design of eBike drive units are investigated and evaluated by this method. Full article

This study aims to assess the impact of the water ratio and nanoparticle concentration of neat diesel fuel on the performance characteristics of and exhaust gas emissions from diesel engines. The experimental tests were conducted in two stages. In the first stage, the effects of adding water to neat diesel fuel in ratios of 2.5% and 5% on engine performance and emissions characteristics were examined and compared to those of neat diesel at a constant engine speed of 3000 rpm under three different engine loads. A response surface methodology (RSM) based on a central composite design (CCD) was utilized to simulate the design of the experiment. According to the test results, adding water to neat diesel fuel increased the brake-specific fuel consumption and reduced the brake thermal efficiency compared to neat diesel fuel. In the examination of exhaust emissions, hydrocarbons (HC), carbon monoxide (CO), and nitrogen oxides (NOx) in the tested fuel containing 2.5% of water were decreased in comparison to pure diesel fuel by 16.62%, 21.56%, and 60.18%, respectively, on average, through engine loading. In the second stage, due to the trade-off between emissions and performance, the emulsion fuel containing 2.5% of water is chosen as the best emulsion from the previous stage and mixed with aluminum oxide nanoparticles at two dose levels (50 and 100 ppm). With the same engine conditions, the emulsion fuel mixed with 50 ppm of aluminum oxide nanoparticles exhibited the best performance and the lowest emissions compared to the other evaluated fuels. The outcomes of the investigations showed that a low concentration of 50 ppm with a small amount of 11 nm of aluminum oxide nanoparticles combined with a water diesel emulsion is a successful method for improving diesel engine performance while lowering emissions. Additionally, it was found that the mathematical model could accurately predict engine performance parameters and pollution characteristics. Full article

Understanding the phenomena that cause jet oscillations inside funnel-type thin-slab molds is essential for ensuring continuous liquid steel delivery, improving flow pattern control, and increasing plant productivity and the quality of the final product. This research aims to study the effect of the nozzle’s internal design on the fluid dynamics of the nozzle-mold system, focusing on suppressing vorticity generation below the nozzle’s tip. The optimized design of the nozzle forms the basis of the results obtained through numerical simulation. Mathematical modeling involves fundamental equations, the Reynolds Stress Model for turbulence, and the Multiphase Volume of Fluid model. The governing equations are discretized and solved using the implicit iterative-segregated method implemented in FLUENT^®. The main results demonstrate the possibility of controlling jet oscillations even at high casting speeds and deep dives. The proposed modification in the internal geometry of the nozzle is considered capable of modifying the flow pattern inside the mold. The geometric changes correspond with 106% more elongation than the original nozzle; the change is considered 17% of an inverted trapezoidal shape. Furthermore, there was a 2.5 mm increase in the lower part of both ports to compensate for the inverted trapezoidal shape. The newly designed SEN successfully eliminated the issue of jet oscillations inside the mold by effectively preventing the intertwining of the flow. This improvement is a significant upgrade over the original design. At the microscale, a delicate force balance occurs at the tip of the nozzle’s internal bifurcation, which is influenced by fluctuating speeds and ferrostatic pressure. Disrupting this force balance leads to increased oscillations, causing variations in the mass flow rate from one port to another. Consequently, the proposed nozzle optimization design effectively controls microscale fluctuations above this zone in conjunction with changes in flow speed, jet oscillation, and metal–slag interface instability. Full article

Eliminating microbes in low-moisture foods (LMFs) is challenging because this requires the preservation of their raw quality during pasteurization. Vacuum steam pasteurization (VSP) has been shown to be effective in reducing microbes while maintaining food quality. These studies were conducted at a laboratory scale where issues such as steam distribution, penetration, and condensation are not a concern, but in larger samples, these are of primary concern. Hence, this study repurposes a pilot-scale grain moisture conditioner (GMC) into a VSP system with the aim of replicating the lab-scale conditions in larger-scale applications. The modification entailed a series of design alterations, conducting a structural analysis of the conditioning chamber, creating a vacuum environment, ensuring uniform steam distribution, and designing and adding a preheater and a cooling system. Performance tests confirmed that the adapted system replicates the VSP’s lab-scale functionality. The results demonstrated that the VSP system can preheat to beyond 40 °C and achieve an absolute pressure of 11.7 kPa at 85 °C with a 344.7 Pa pressure increase per minute. Furthermore, steam distribution inside the chamber showed no significant variations, and rapid steam evacuation and chamber cooling could be performed simultaneously. The success of these modifications will be used in future experiments. Full article

Polymers have gained a foothold in the international market and are actively utilized at a large scale in various industries. They are used as sliding layers in various types of friction units. However, there is a lack of research on their deformation behavior under different design conditions. This work is focused on studying the influence of the geometrical design of lubrication recesses in a polymer sliding layer operating under conditions of frictional contact interaction. The article investigated an element of bridge-bearing steel plate with recesses for lubrication. Two geometrical configurations of recesses are studied: the annular groove and spherical well in the engineering software package ANSYS Mechanical APDL. Polytetrafluoroethylene (PTFE) is considered an elastic-plastic sliding layer. A comparative analysis of two models with different geometrical configurations of cutouts for lubrication, with/without taking into account its volume in the recess, has been conducted. The article establishes that in the absence of lubrication in the recesses, large deformations of the polymer sliding layer occur. This effect negatively affects the structure as a whole. Changing the geometry of the recess for lubrication has the greatest effect on the intensity of plastic deformations. Its maximum level is lowered by almost ~60% when spherical notches are used for lubrication instead of grooves. The friction coefficient of the polymer has a great influence on the contact tangential stress. At the experimental coefficient of friction, it is lowered on average by ~85%. The friction coefficient of the lubricant has almost no effect on the deformation of the cell (<1%). Full article

Modular precast construction is a methodological approach to reduce environmental impacts and increase productivity when building with concrete. Constructions are segmented into similar precast concrete elements, prefabricated with integrated quality control, and assembled just-in-sequence on site. Due to the automatised prefabrication, inaccuracies are minimised and the use of high-performance materials is enabled. As a result, the construction process is accelerated, and the modules can be designed to be lightweight and resource-efficient. This contribution presents the fundamentals of modular constructions made from precast concrete components. Then, to elaborate the requirements of a contemporary modular precast construction, the historic developments are described. Further, concepts and technical processes–comprehensible to non-expert readers–are introduced to formalise the discussion about the current state-of-the-art methods. Three case studies treating ongoing research are introduced and related to the conceptual fundamentals. The research is evaluated with regard to current barriers and future directions. In conclusion, modular precast construction is able to reduce emissions and increase productivity in the sector if researchers and firms coordinate the development of suitable technologies that bring value to critical stakeholders. Full article

Accurate pavement design and evaluation requires the execution of response analysis. Pavement materials’ behavior does not necessarily conform to the assumptions of the multi-linear elastic theory usually adopted during pavement analysis. In particular, the unbound granular materials located in the base and sub-base layers behave in a nonlinear elastic manner, which can be captured through advanced constitutive modeling of their resilient modulus. The finite element method enables us to code constitutive models and quantify potential variations in pavement responses because of different mechanistic assumptions. In this study, variations in response are investigated for a typical structure of a flexible pavement considering the nonlinear anisotropic behavior of the unbound materials together with their initial stress–strain state. To demonstrate the impact of their behavior on the outcome of pavement analysis, variable asphalt concrete layer thicknesses and moduli are assumed, such that they cover a large spectrum of roadways. It was found that pavement responses can be calculated up to 3.5 times higher than those retrieved from the conventional linear analysis. This comparison means that the alterative mechanistic modeling of the unbound granular materials can be proved to be more conservative (i.e., leading to higher strains) in terms of pavement design and analysis. From a practical perspective, this study alerts pavement scientists and engineers engaged in pavement design to a more reliable performance prediction, which is needed to bridge the gap between advanced modeling and routine analysis. Full article

The development of electronic systems and wireless communication has led to a proportional increase in data traffic over time. One potential solution for alleviating data congestion is to augment the bandwidth capacity. This study presents a novel asymmetric circular slotted semi-circle-shaped monopole antenna design using a defective ground structure. The extended ultrawide bandwidth is achieved by implementing a design where the semi-circle radiator is etched in a specific asymmetric circular slot. This involves etching a circle with a radius of 1.25 mm at the center of the radiator, as well as a succession of circles with a radius of 0.75 mm along the edges of the radiator. In addition, the ground plane is situated at a lower elevation and features a U-shaped truncation that has been etched onto its surface. The expansion of the impedance bandwidth can be accomplished by making adjustments to the radiator and ground plane. The UWB antenna under consideration possesses a geometric configuration of 21.6 × 20.8 × 1.6 mm³ and the antenna is fabricated using an FR-4 glass epoxy substrate. The UWB antenna operates throughout the frequency range of 2.2–16.5 GHz, exhibiting a gain of at least 3.45 dBi across the entire impedance bandwidth and the maximum peak gain of 9.57 dBi achieved at the mid-resonance frequency of 10.5 GHz. The investigation of the antenna’s physical properties is conducted utilizing characteristic mode analysis. The investigation also includes an analysis of the time-domain characteristics, revealing that the group delay was found to be less than 1 ns across the operational frequency range. The predicted and measured findings demonstrate consistency and confirm that the suggested antenna is suitable for electronic systems and wireless applications. Full article

This study addresses the pressing energy constraints in nations like Bangladesh by proposing the implementation of photovoltaic (PV) microgrids. Given concerns about environmental degradation, limited fossil fuel reserves, and volatile product costs, renewable energy sources are gaining momentum globally. Our research focuses on a grid-connected solar PV system model at Char Jazira, Lalpur, Natore, Rajshahi, Bangladesh. Through PVsyst 7.1 simulation software, we assess the performance ratio (PR) and system losses, revealing an annual solar energy potential of 3375 MWh at standard test condition (STC) efficiency. After considering losses, the system generates 2815.2 MWh annually, with 2774 MWh exported to the grid. We analyze an average PR of 78.63% and calculate a levelized cost of energy (LCOE) of 2.82 BDT/kWh [1 USD = 110 BDT]. The financial assessment indicates a cost-effective LCOE for the grid-connected PV system, with an annual gross income of 27,744 kBDT from selling energy to the grid and operating costs of 64,060.60 BDT/year. Remarkably, this initiative can prevent 37,647.82 tCO₂ emissions over the project’s 25-year lifespan. Full article

As a result of the Internet of Things (IoT), smart city infrastructure has been able to advance, enhancing efficiency and enabling remote management. Despite this, this interconnectivity poses significant security and privacy concerns, as cyberthreats are rapidly adapting to exploit IoT vulnerabilities. In order to safeguard privacy and ensure secure IoT operations, robust security strategies are necessary. To detect anomalies effectively, intrusion detection systems (IDSs) must employ sophisticated algorithms capable of handling complex and voluminous datasets. A novel approach to IoT security is presented in this paper, which focuses on safeguarding smart vertical networks (SVNs) integral to sector-specific IoT implementations. It is proposed that a deep learning-based method employing a stacking deep ensemble model be used, selected for its superior performance in managing large datasets and its ability to learn intricate patterns indicative of cyberattacks. Experimental results indicate that the model is exceptionally accurate in identifying cyberthreats, exceeding other models, with a 99.8% detection rate for the ToN-IoT dataset and 99.6% for the InSDN dataset. The paper aims not only to introduce a robust algorithm for IoT security, but also to demonstrate its efficacy through comprehensive testing. We selected a deep learning ensemble model due to its proven track record in similar applications and its ability to maintain the integrity of IoT systems in smart cities. Full article

The use of coat-hanger dies is prevalent in the plastic film and sheet extrusion industry. The product quality and the power of the extrusion machine depend on the uniformities of the fluid velocity at the exit and the pressure drop. Die manufacturers face the challenge of producing coat-hanger dies that can extrude materials uniformly and with a minimal pressure drop. Previous studies have analyzed the die outlet’s flow homogeneity and pressure drop using various numerical simulations. However, the combination of the scheme programming language together with the Adjoint Method of Optimization has yet to be attempted. The adjoint optimization method has been demonstrated to be beneficial in addressing issues related to shape optimization problems and it may also be beneficial in optimizing the design of dies used in polymer melt extrusion. In this study, the proposed innovations involve incorporating both the Scheme programming language and Adjoint solver to examine and optimize the coat hanger’s flow homogeneity and pressure drop. Before optimization, the outlet velocity was almost 10 times higher at the die center than at the edges but after optimization, it became more uniform. The proposed optimized coat-hanger die geometry results in more uniform melt flow as demonstrated by the velocity contour plot and the outlet velocity graph in the die slit area, reducing the deviation value from 0.097 to 0.015. Additionally, the mass flux variance across the die outlet decreased by 71.6% from 0.015069 kg m⁻² s⁻¹ to 0.004281 kg m⁻² s⁻¹. Therefore, using this method reduces the amount of time wasted on trial and error or other optimization techniques that may be limited by design constraints. Full article

Aerial additive manufacturing (AAM) represents a paradigm shift in using unmanned aerial vehicles (UAVs, often called ‘drones’) in the construction industry, using self-powered and untethered UAVs to extrude structural cementitious material. This requires miniaturisation of the deposition system. Rheological properties and known hydration times are important material parameters. Calcium aluminate cement (CAC) systems can be advantageous over purely ordinary Portland cement (OPC) binders as they promote hydration and increase early strength. A quaternary OPC/pulverised fuel ash (PFA)/CAC/calcium sulphate (CS) system was combined with polyvinyl alcohol (PVA) fibres and pseudoplastic hydrocolloids to develop a novel AAM material for miniaturised deposition. CAC hydration is affected by environmental temperature. Intending material to be extruded in situ, mixes were tested at multiple temperatures. OPC/PFA/CAC/CS mixes with PVA fibres were successfully extruded with densities of ≈1700 kg/m${}^3$, yield stresses of 1.1–1.3 kPa and a compressive strength of 25 MPa. Pseudoplastic OPC/PFA/CAC/CS quaternary cementitious systems are demonstrated to be viable for AAM, provided mixes are modified with retarders as temperature increases. This study can significantly impact industry by demonstrating structural material which can be extruded using UAVs in challenging or elevated in situ construction, reducing safety risks. Full article

The most modern technique utilized to create intricate manufactured parts for a variety of applications is called additive manufacturing (AM). Fused deposition modeling (FDM) has been acknowledged as the greatest consideration in the development and industrial sectors. The main objective of this study was to investigate how printing factors affected the mechanical characteristics of printed samples. Samples were produced via an FDM 3D printer in compliance with an ASTM D638 using a variety of input settings, including orientation, layer thickness, speed, and infill pattern. Tensile tests and morphological analysis using a scanning electron microscope (SEM) were done on the printed samples. The results of this study demonstrate that factors including layer thickness, printing speed, and orientation significantly affect the tensile strength of the ABS-printed samples. The 45° orientations, 0.3 mm thickness, and normal speed had a significant impact on the tensile strength of the ABS-printed samples. On the other hand, samples with a 90° orientation, 0.4 mm thickness, and fast speed show better elongation performance than other samples, according to Young’s modulus results. The SEM results for microscopic analysis show that samples S2 (loose infill, 45° orientation, 0.3 mm thickness, and normal speed), S5 (solid infill, 45° orientation, 0.3 mm thickness, and normal speed), and S8 (hollow infill, 45° orientation, 0.3 mm thickness, and normal speed) had a highly packed structure and robust. Discovering the parameter settings that could lead to greater mechanical and physical characteristics would undoubtedly assist designers and manufacturers worldwide as the FDM 3D printer becomes more and more crucial in manufacturing engineering parts. Full article

This study aims to evaluate the precision of nine distinct hyperelastic models using experimental data sourced from the existing literature. These models rely on parameters obtained through curve-fitting functions. The complexity in finite element models of elastomers arises due to their nonlinear, incompressible behaviour. To achieve accurate representations, it is imperative to employ sophisticated hyperelastic models and appropriate element types and formulations. Prior published work has primarily focused on the comparison between the fitting models and the experimental data. Instead, in this study, the results obtained from finite element analysis are compared against the original data to assess the impact of element formulation, strain range, and mesh type on the ability to accurately predict the response of elastomers over a wide range of strain values. This comparison confirms that the element formulation and strain range can significantly influence result accuracy, yielding different responses in various strain ranges also because of the limitation with the curve fitting tools. Full article

The purpose of this paper is to summarize and share the field experiment results of KEPCO’s project consortium to create a TSO-DSO-DERA interaction scheme. The field experiment was conducted based on the prequalification algorithm proposed in previous research from the same consortium, and was designed to verify the validity of the algorithm under realistic grid conditions. In addition, during the course of the field experiment, it was found that points that were missed or not given much importance in the existing prequalification algorithm could affect the completeness of the overall system, and then practical improvements were made to improve this. The demonstration results confirm that the proposed algorithm is effective in real-world grid environments and can help DSOs to ensure the reliability of the distribution system while supporting DERA’s participation in the wholesale market using the proposed prequalification scheme. Full article