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        <title>Frontiers in Mechanical Engineering | Solid and Structural Mechanics section | New and Recent Articles</title>
        <link>https://www.frontiersin.org/journals/mechanical-engineering/sections/solid-and-structural-mechanics</link>
        <description>RSS Feed for Solid and Structural Mechanics section in the Frontiers in Mechanical Engineering journal | New and Recent Articles</description>
        <language>en-us</language>
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        <pubDate>2026-04-10T01:40:56.930+00:00</pubDate>
        <ttl>60</ttl>
        <item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1681872</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1681872</link>
        <title><![CDATA[Experimental study on the road performance of reduced density fly ash–clayey sand subgrade mixtures from the Yellow River floodplain]]></title>
        <pubdate>2026-04-02T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Xiuru Jia</author><author>Qiaoling Ji</author><author>Yu Cheng</author><author>Meixue Wang</author>
        <description><![CDATA[To address challenges in subgrade construction using Yellow River floodplain soils, this study developed a reduced density filler by mixing aged fly ash with locally sourced clayey sand. The research aimed to establish a robust framework for bridging the gap between pavement design specifications (resilient modulus, E0) and construction quality control (compaction degree, K), enabling performance-based quality assurance. Laboratory experiments evaluated compaction characteristics, California Bearing Ratio (CBR), and Laboratory Static Resilient Modulus (E0lab) of the mixtures. Results showed optimal performance at 30%–36% fly ash content, achieving maximum CBR of 23.6% and E0lab of 54.56 MPa. A novel global regression model was established, directly linking CBR to both K and fly ash content (FA%), offering a powerful tool for construction quality assurance. Furthermore, a practical pathway was developed to convert E0lab to field design E0 (via CBR and existing correlations), facilitating the translation of laboratory findings into engineering design. This research culminates in a unified framework for construction quality control, providing recommended K and FA% acceptance windows to guarantee target E0 and CBR values. The developed mixtures are highly suitable for Class II (lower layers) and Class III/IV (top layers) highway subgrades. This study offers robust technical support for sustainable fly ash utilization and performance-driven subgrade construction.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2026.1713674</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2026.1713674</link>
        <title><![CDATA[An enhanced subset simulation algorithm integrating importance sampling for structural reliability analysis]]></title>
        <pubdate>2026-04-02T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Chunlong Xu</author>
        <description><![CDATA[IntroductionConducting reliability analyses for engineering problems with small failure probabilities and expensive computational models is challenging. Subset simulation (SS) is an excellent method that has been applied in many fields. However, SS still has several limitations that need to be addressed, such as correlated samples, a large coefficient of variation (COV), the risk of deviating from dominant failure regions, and inaccuracies in problems with multiple failure regions.MethodsIn this paper, a subset simulation algorithm integrating importance sampling is developed to address the aforementioned limitations, focusing on complex reliability problems characterized by low-to-moderate dimensionality and small failure probabilities. First, a seed placement strategy on intermediate limit-state curves is developed to reduce the COV and generate independent samples within each subset. Second, interval estimation combined with clustering algorithms is applied to precisely identify seeds. This strategy is designed to handle problems featuring multiple failure regions while mitigating the risk of divergence from dominant failure regions.ResultsThe performance of the proposed algorithm is demonstrated through seven case studies from the literature, including problems with multiple failure regions, nonlinear problems, system reliability problems, SS counterexamples, and structural reliability problems.DiscussionThe results show that the proposed method provides more accurate and robust failure probability estimates than the other tested methods.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2026.1800659</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2026.1800659</link>
        <title><![CDATA[Finite-element guided drilled-hole placement and fillet geometry effects on the structural and dynamic performance of spur gears]]></title>
        <pubdate>2026-03-31T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Ali Malik Saadoon</author><author>Nassear R. Hmoad</author><author>Suhair G. Hussein</author><author>Mohammad Qasim Abdullah</author>
        <description><![CDATA[In this research, a detailed finite-element (FE) analysis of the combined influence of the drilled-hole position, the shape of the hole, and the fillet design on the structural and dynamic performance of spur gears is investigated. ANSYS R16.2 was used to create a three-dimensional numerical model that can be used to assess the bending stress distribution and vibration response under realistic loading conditions. A trochoidal fillet and four circular fillet radii (0.5, 1.0, 1.5 and 2.0 mm) were studied to determine their effect on the stress concentration behavior. FE-guided hole-suggestion process was introduced which is an automated process in which low-stress zones to be cut away are identified so as to allow systematic recommendation of optimal locations, orientations and size of holes without any empirical relation. It was found that root stress decreased dramatically as fillet radius was increased, and 2 mm fillet had the minimum bending stress of all circular arrangements. The baseline configuration (Rf = 0.5 mm, without holes) exhibited a maximum bending stress of 69.45 MPa, whereas increasing the fillet radius to 2.0 mm resulted in a stress reduction of approximately 35%. The trochoidal fillet provided less stress gradients and a larger zone of low stress surrounding the tooth root. The holes proposed by FE were further incorporated, which increased structural performance. Hole size out of the chosen geometric parameters was statistically most impactful on bending stress and dynamic response, which ANOVA proved to be accurate (p < 0.001). The holes in the top the most desirable performance were medium-size (≈2.0–2.4 mm) drilled horizontally, which minimized bending stress by about 46%–50% relative to the baseline gear and ensured very low peak dynamic displacement (∼3.4 × 10−5 m at approximately 73 Hz). Structural integrity is well enhanced by optimizing fillet radius and drilled holes sizes, directions, and locations regarding the strength and dynamic stability. The proposed methodology offers a reliable and scientifically grounded framework for gear modification with strong potential for integration into advanced gear design and light weighting applications.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2026.1775256</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2026.1775256</link>
        <title><![CDATA[Design and finite element analysis of new energy bus body frame]]></title>
        <pubdate>2026-03-23T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Yingshuai Liu</author><author>Xueming Gao</author><author>Wenzhe Li</author><author>Jianwei Tan</author>
        <description><![CDATA[As the core load-bearing component of battery-integrated low-floor buses, the body frame faces critical challenges in structural analysis due to the conflict between computational accuracy and efficiency during preliminary design iterations. Existing finite element approaches for bus frames typically employ full-scale models with 300,000+ nodes, resulting in prohibitive computational costs (25–30 min per solve) that hinder rapid design symmetry-based simplification. Furthermore, separate treatment of static strength verification and modal analysis lacks unified validation against experimental data, raising concerns about model reliability for dynamic performance prediction. This study establishes an integrated finite element analysis framework that couples four critical load cases (bending, cornering, emergency braking, and extreme torsion) with dynamic performance evaluation within a unified computational model. A key methodological innovation is the systematic exploitation of structural symmetry, which reduces the computational scale from 310,000 nodes to 75,000 nodes while maintaining accuracy within 0.5% for stress predictions and 0.3% for natural frequencies—achieving a 58% reduction in GPU solution time (from 28 to 11 min). Experimental validation via hammer impact testing confirms the numerical model’s reliability, demonstrating an average frequency error of 3.2% and Modal Assurance Criterion values exceeding 0.85. Results demonstrate that the Q345 steel frame exhibits maximum equivalent stress of 134.11 MPa (38.9% of yield strength) under extreme torsion, with deformation metrics (bending deflection ratio 1/2,720, torsional angle 0.60°) satisfying urban bus design targets. Modal analysis reveals first-order vertical bending at 5.952 Hz and first-order torsion at 7.216 Hz, providing 3.65 Hz separation from maximum road excitation (2.3 Hz at 60 km/h) and eliminating resonance risks across the operational frequency range of 5.952–18.964 Hz. This validated methodology provides a reproducible workflow for rapid body-in-white development, bridging the gap between computational efficiency and experimental fidelity in new energy bus structural design.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2026.1781189</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2026.1781189</link>
        <title><![CDATA[Multi-operating-condition adaptability enhancement: simulation and experimental study on the roof beam structure of hydraulic support]]></title>
        <pubdate>2026-03-13T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Yang Liu</author><author>Guozhu Liu</author><author>Jingxi Li</author>
        <description><![CDATA[IntroductionThe mechanical properties of the hydraulic support top beam are a critical determinant of mine support safety. The ZY14790/15/25D hydraulic support top beam, tailored for one-pass full-seam mining of medium-thick coal seams, is subjected to extreme deep coal mine working conditions including high ground stress, intense rock burst, and large roof deformation, posing severe challenges to its structural reliability.MethodsA finite element model of the ZY14790/15/25D top beam was established via ANSYS software to analyze the stress and deformation characteristics under three typical working conditions (symmetric bending, diagonal torsion, and bending-torsion combination), and the structural weak areas under different conditions were identified. Aiming at the defects of the original top beam design (uneven stress distribution, discontinuous force flow transmission, insufficient local stiffness), an optimization technology focusing on enhancing structural continuity, optimizing rib load-bearing efficiency and strengthening local load-resistant capacity was proposed, with four specific optimization schemes constructed. A new top beam model was then established based on the optimized schemes, and finite element simulation and comparative cyclic loading tests were conducted to verify the optimization effect.ResultsFinite element simulation results showed that the optimized top beam achieved significant improvements in mechanical performance under all three working conditions: the maximum stress was reduced by 31.44% (symmetric bending), 19.28% (diagonal torsion) and 27.20% (bending-torsion combination), respectively; the maximum deformation was reduced by 12.91%, 12.26% and 15.63%, respectively. Cyclic loading test results indicated that the original top beam suffered fracture at the joint of the top plate and internal stiffening plate after only 16,522 cycles. In contrast, the optimized top beam exhibited a markedly improved fatigue life: although weld cracks appeared and propagated to the base metal at 19,100 cycles, the top beam could stably bear the full yield load after standardized repair, meeting the engineering requirements of actual working conditions.DiscussionThis study addresses the structural defects of the hydraulic support top beam under complex multi-working conditions through targeted structural optimization, and the proposed optimization technology and schemes are verified to be effective via both numerical simulation and experimental tests. The optimization not only significantly reduces the stress and deformation of the top beam and improves its fatigue life and load-bearing capacity, but also provides a practical and feasible technical scheme for the structural optimization of hydraulic support top beams. Meanwhile, the research results offer important reference value for improving the structural reliability of coal mining equipment and ensuring the safety of deep coal mine production.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2026.1759085</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2026.1759085</link>
        <title><![CDATA[Data-driven wear prediction method for complex engineering structures]]></title>
        <pubdate>2026-03-05T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Haibo Zhang</author><author>Qingyuan Zhao</author><author>Yingxin Zhao</author><author>Baiyang Zhao</author><author>Meng Zhao</author><author>Chuang Liu</author>
        <description><![CDATA[Predicting the evolution of wear in metallic structural components is vital for accurately estimating the lifetime of engineering equipment. However, this remains a significant challenge due to the prohibitively large number of cycles required for traditional experiments or simulations. To address this, we established a data-driven approach to predict metal wear evolution during dynamic mechanical interactions. Our methodology involves two main steps: developing a high-fidelity finite element (FE) model to accurately simulate the wear, and then training a deep learning model that uses applied loads and historical wear data to predict future wear evolution. We selected contact wire clips in a high-speed railway system as a practical example, where the accuracy of our numerical model was successfully validated by experimental results in calculating wear distribution. The subsequent deep learning model demonstrated high accuracy (R2>0.95) in predicting future wear depth at distinct positions against ground truth data. This presented approach offers a wide range of applications for predicting the wear evolution of equipment in various engineering fields.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1719154</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1719154</link>
        <title><![CDATA[A comprehensive review on femtosecond laser polishing of silicon nitride: fundamentals, current progress, and industrial outlook]]></title>
        <pubdate>2026-02-18T00:00:00Z</pubdate>
        <category>Review</category>
        <author>Huang Jian</author><author>Monsak Pimsarn</author><author>Varesa Chuwattanakul</author><author>Smith Eiamsa-ard</author>
        <description><![CDATA[Silicon nitride (Si3N4) ceramics are indispensable in aerospace bearings and semiconductor substrates due to their exceptional mechanical and thermal properties. However, achieving damage-free, atomic-level surface finishes remains problematic. Traditional mechanical polishing induces subsurface microcracks, while chemical mechanical polishing (CMP) is plagued by low material removal rates and environmental toxicity. This review critically evaluates femtosecond laser polishing as a transformative, “green” non-contact alternative. We first elucidate the laser-matter interaction mechanisms specific to wide-bandgap Si3N4 (Eg≈5.3 eV), clarifying how multiphoton absorption enables “cold ablation” by suppressing the heat-affected zone (HAZ) via the two-temperature model (TTM) dynamics. A distinct material removal mechanism driven by rapid thermal decomposition (Si3N4→Si+N2) and phase explosion is highlighted. Synthesizing recent experimental data, we establish a quantitative process window. Operating slightly above the ablation threshold (F≈1.4 J/cm2) with high spot overlap (70%–90%) is critical to balance surface leveling against the incubation effect, which otherwise triggers porosity. Furthermore, we address the unique challenges of inducing periodic structures (LIPSS) on dielectric surfaces and propose a hybrid manufacturing strategy—integrating high-speed laser roughing with CMP finishing—to resolve efficiency constraints. Finally, an industrial roadmap involving high-throughput polygon scanners and AI-driven closed-loop control is outlined, providing a comprehensive reference for advancing femtosecond laser polishing toward scalable, high-precision manufacturing.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1739057</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1739057</link>
        <title><![CDATA[Structural design and vibration characteristics of a contra-rotating drilling tool based on planetary gear trains]]></title>
        <pubdate>2026-01-12T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Li Qian</author><author>Liu Xuyong</author><author>Liu Huaiwei</author><author>Zhu Zhigang</author><author>Deng Hehong</author><author>Li Guangjun</author><author>Zhou Haina</author><author>Feng Xuming</author><author>Zeng Yuefei</author>
        <description><![CDATA[IntroductionTo reduce severe drill string vibration and improve drilling efficiency in deep drilling, which are often accompanied by significant energy loss.MethodThe contra- rotation of the inner and outer drill bits was facilitated by planetary gear transmission, and the anti-torque fluctuation was reduced by the torque balance principle, thereby suppressing vibration. In this paper, the design of the gear, bearing, and seal structure of the contra-rotating drilling tool was completed; single rotation and contra-rotating drilling tools were prepared alongside artificial rock samples; a drilling test rig was constructed; and vibration signals of the drilling tools were collected at different rotation speeds.ResultTime-domain and frequency-domain analyses revealed that the vibration acceleration amplitude of the contra-rotating drilling tool in the X, Y, and Z directions is significantly lower than that of the single rotation drilling tool. Furthermore, with increasing rotation speed, the vibration amplitude of the contra-rotating drilling tool remains stable or even decreases, whereas the vibration of the single rotation drilling tool increases significantly.DiscussionA mechanistic analysis revealed that the contra-rotating drill bit requires less driving force to break rock, produces more shear failure zones, breaks rock more easily, and generates less vibration. This study provides an effective active control method for reducing drilling vibration and has good prospects for application in the field of engineering.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1609543</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1609543</link>
        <title><![CDATA[Design and development of a flexural spindle mechanism enabled in micro drilling machine tool within a PLM environment]]></title>
        <pubdate>2026-01-12T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Sachin Manohar Shinde</author><author>Sachin Solanke</author><author>Mohit Diwan</author><author>Kiran S. Bhole</author><author>Sachin Salunkhe</author><author>Robert Cep</author><author>Emad Abouel Nasr</author>
        <description><![CDATA[The advent of designing flexural systems was to provide accurate micro and nano displacement between the assembly members of the mechanism. Applications that used these mechanisms included linear compressors, optomechanical devices, Stirling engines, cryocoolers, microcheck valves, Flexure-based Electromagnetic Linear actuators, and so on. This paper focuses on the machine-tool fabrication of a novel flexural mechanism encased within the spindle head of the microdrilling head. The mechanism cushioned the micro drill and protected it from permanent damage when encountering undeclared resistance in the material matrix. Furthermore, this paper focuses solely on building a 3-axis drilling machine tool in a Product Lifecycle Management environment. The study follows a systematized approach for validating the machine tool design, starting with the hierarchical assembly of components using various kinematic chains. The next phase involves assigning the necessary motions to these components. The final stage utilizes a virtual controller and post-processor to simulate and control machine tool movements. Validation is then performed on the simulated workpiece to ensure design accuracy and functionality. The key findings of the studies indicate that the designed mechanism can move in and out and can also puncture micro-holes in metal. This is the mechanism’s capability, which is the novelty.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1712960</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1712960</link>
        <title><![CDATA[Spatial dependency enhanced dam safety evaluation: a digital-twin based monitoring platform integrating multi-sensor correlation analytics]]></title>
        <pubdate>2026-01-09T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Yanpian Mao</author><author>Lei Hu</author><author>Zhiyong Qi</author><author>Zhengyang Tang</author><author>Jin Yuan</author><author>Xuhuang Du</author><author>Zhongming Dong</author><author>Haowen Fang</author>
        <description><![CDATA[The analysis of monitoring data plays a critical role in dam safety assessment. The data analysis process typically involves three stages: monitoring point information inspection, single-point analysis and early warning, and multi-point data fusion and evaluation. A key challenge in the multi-point evaluation stage is establishing an objective and reproducible standard that effectively links multi-point information with the dam’s structural behavior. For arch dams, the load-transfer system consists of horizontal arches and vertical girders. This study proposes an assessment system that utilizes three evaluation parameters: the alert level of individual monitoring points, the spatial correlation of alerted points, and the anomaly rate across all points. A deterministic correspondence is established between these parameters and the final score, thereby eliminating subjective judgment. The reliability of the evaluation results was verified using measured data and a typical case study. Furthermore, a digital twin (DT) platform was developed for managing, analyzing, and evaluating monitoring information. The proposed model was integrated into this platform. Both the monitoring data and the inferred dam behavior are visualized. This DT platform has been employed by a real arch dam in China. Operational results demonstrate its capability for integrated real-time analysis and presentation, significantly enhancing the intuitiveness of dam safety monitoring and the efficiency of decision-making.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1729043</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1729043</link>
        <title><![CDATA[Effect of different wing geometries on their vibration characteristics]]></title>
        <pubdate>2026-01-06T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Nassear R. Hmoad</author><author>Anmar H. Ali</author><author>Ali Malik Saadoon</author><author>Aveen A. Abdulkareem</author><author>Amjed H. Albayati</author>
        <description><![CDATA[Understanding how wing geometry and internal structural configuration influence vibration behavior is essential for ensuring the aeroelastic stability and structural integrity of modern aircraft. This study presents a comprehensive numerical investigation of the modal and deflection characteristics of aircraft wings with different geometries (symmetric tapered planform and swept-back) and spar configurations (box and I-section) using the finite element method (FEM) in ANSYS Mechanical APDL R.15. Six NACA airfoil profiles (0024, 2411, 2416, 2424, 4412, and 4421) with angle of attack 9° under 50 m/s speed and 1,100 kg pay load were analyzed under identical aerodynamic and material conditions using linear elastic and small-deformation theory. Aerodynamic coefficients were determined using thin airfoil and Prandtl’s lifting-line theories, while modal parameters were extracted through high-order 20-node solid brick elements and verified through mesh convergence analysis. Based on the results obtained, the tapered wings show a natural frequency nearly 22% higher than swept-back wings. The matter that confirms the dominant influence on geometric stiffness. On the other hand box spar wings reveal 9.5%–22% higher frequencies but showed 20%–30% higher deflection than I-section spars, demonstrating their superior torsional compliance and enhanced energy absorption under the dynamic effect. On the contrary, I-section spar resulted in higher bending stiffness and lower deformation, especially in higher-order modes. Based on airfoil series, the more the thick NACA 0024 as well as 2424 profiles revealed the highest levels of stiffness, based on 6th mode frequency that exceeded 250 Hz, but the thinner cambered sections like NACA 4412 and 4421 exhibited compliance and limited rigidity against torsion. Based on the findings, the obtained increase in the natural frequency and the reduced deflection with stiffer geometries reflect improved resistance to aeroelastic instability like flutter onset. A statistical analysis using ANOVA verified that the geometry of the wing has a statistically more significant effect on modal response than the spar type although both have a significant influence on vibration behavior. Furthermore, the result of analysis concludes that the taper wings reinforced with spars type I-section give the most balanced combination of weight efficiency, stiffness and stability against vibration for the aircraft type medium payload.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1735111</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1735111</link>
        <title><![CDATA[Microstructure of horizontally continuously cast Stellite rods]]></title>
        <pubdate>2026-01-02T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Anže Bajželj</author><author>Jaka Burja</author>
        <description><![CDATA[This study investigates the microstructural and phase characteristics of Stellite 6, Stellite 12, and Stellite 21 alloys produced by horizontal continuous casting. The alloys were synthesized from pure metallic elements and ferroalloy (FeW) under an argon atmosphere and solidified in a water-cooled copper mould (Ø3.3 mm–Stellite 6 and Stellite 21, and Ø6.1 mm–Stellite 12), resulting in extremely high cooling rates and fine-grained microstructures. Thermodynamic calculations were performed to predict equilibrium solidification, which was compared with experimental microstructural observations. Optical and scanning electron microscopy (SEM-EDS) analyses revealed Co-rich dendritic grains surrounded by eutectic regions containing carbides of the M7C3, M23C6, and M6C types. X-ray diffraction (XRD) confirmed the presence of an FCC Co matrix without HCP phase formation, attributed to rapid solidification. The volume fraction of carbides increased with carbon content, influencing hardness. Vickers hardness measurements showed that Stellite 6 exhibited the highest hardness (508 HV10), followed by Stellite 12 (470 HV10) and Stellite 21 (345 HV10). The finer grain size and higher carbide fraction in alloys with greater carbon content contributed to enhanced hardness and structural uniformity. These findings demonstrate that horizontal continuous casting enables the production of fine-grained Stellite rods with a homogeneous composition. The cast rods show excellent structural integrity and are well-suited for subsequent hard-facing applications in wear-resistant environments.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1697890</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1697890</link>
        <title><![CDATA[Investigating the impact of imperfections around a wellbore on liner deformation during hydraulic fracturing]]></title>
        <pubdate>2025-12-10T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Yanhui Han</author><author>Dung Phan</author><author>Younane Abousleiman</author><author>Khalid Ruwaili</author>
        <description><![CDATA[It is essential to maintain the integrity of liner–cement–formation in the well completion and production stages. However, large liner deformations have been extensively experienced during hydraulic fracturing operations in carbonate formations. This work reveals that local collapse and burst may cause the liner to deform during hydraulic fracturing operations. The stressing and deformation of liners are investigated using numerical simulation at two levels. First, a stand-alone liner is compressed from the outside or expanded from the inside to calibrate the plastic parameters by matching the collapse and burst pressures in the liner’s technical specifications. The influence of the non-uniformity of loads and confinement on the liner’s bearing capacity is then investigated. Second, the influence of imperfections in the cement or cavities in the formation on liner deformation in a liner–cement–formation system is explored. Simulation results indicate that the hydraulic communication between the cavities, vugs, or other imperfections in formation or cementing around a liner and hydraulic fractures can introduce an uneven load on the liner, subsequently threatening the integrity of the liner–cement–formation system and causing a large deformation in the liner. This mechanism has not received much attention in the practical hydraulic fracturing operation design.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1718011</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1718011</link>
        <title><![CDATA[Mechanical and material heterogeneity, strain localization and deformation rate effects in crushable expanded polystyrene foams]]></title>
        <pubdate>2025-12-09T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Francis Yao</author><author>Meet Joshi</author><author>Megan Bland-Rothgeb</author><author>Peter Cripton</author><author>Duane Cronin</author><author>John Magliaro</author>
        <description><![CDATA[Low-density expanded polystyrene (EPS) foams are widely used in lightweight energy absorption systems such as helmets due to their ability to readily mold into complex geometries. However, varying material flow and cooling rates during manufacturing produce exterior skin layers with substantially higher density and aspect ratio from the core, and the resultant mechanical properties have not been quantified. Previous studies assumed EPS foams were homogeneous, overlooking or intentionally removing the skin from test specimens and constrain their scopes to out-of-plane compression. In this study, closed-cell EPS foam pucks of 30, 50, 80, and 100 g/L were tested under in-and out-of-plane compression at loading rates spanning 0.001–10/s. Specimens were prepared with as molded and core (skin removed) configurations to quantify anisotropy from heterogeneity. Measurements revealed a 98% ± 8% higher density in the skin layers relative to nominal material density and cells skewed 41% ± 6% in the in-plane direction. As-molded specimens exhibited a 38% ± 4% higher plateau stress for in-plane loading compared to out-of-plane, highlighting foam cell elongation as a key strengthening mechanism. Quasi-orthotropic behavior was observed for the core foam material, which possessed more evenly sized cells. Digital image correlation quantified rate-dependent strain localization, providing novel evidence of internal pressure redistribution from viscous gas dynamics within the EPS beads, with 39% lower peak true strains, on average, measured at 10/s compared to 0.001/s. Unloading data also revealed progressive increases in post-crushing strain recovery, increasing an order of magnitude from 0.04 mm/mm to 0.42 mm/mm between 0.001-10/s for the 30 g/L group, confirming more even load distribution and cell fracture mitigation at elevated rates.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1708043</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1708043</link>
        <title><![CDATA[Strength analysis and structural optimization of UAV airframe]]></title>
        <pubdate>2025-12-01T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Longhai Ye</author><author>Yanpeng Zhao</author><author>Haifeng Zhang</author><author>Yao Zhang</author><author>Jiming Lv</author><author>Zonghan Yang</author>
        <description><![CDATA[IntroductionWith the booming low-altitude economy, UAVs drive transformative changes across sectors, but their design must balance lightweight demands and structural integrity. This study conducts static analysis of a quadrotor under hovering, using two optimization methods to enhance performance.MethodsTwo strategies were adopted: mass-constrained structural optimization (maintaining original mass) and unconstrained stiffener optimization (maximizing stiffness/strength without mass limits).ResultsMass-constrained optimization reduced max von Mises stress by 38.8% and displacement from 6.49 mm to 5.91 mm. Unconstrained stiffener optimization achieved 5.2% mass reduction, 60.9% stress reduction, and displacement down to 1.63 mm.DiscussionBoth methods maintain structural strength and boost payload capacity. The stiffener optimization (reinforced rib design) provides a practical solution for heavy-load quadrotor engineering.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1710902</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1710902</link>
        <title><![CDATA[Post-treatment to enhance the mechanical performance of printed Onyx]]></title>
        <pubdate>2025-11-10T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Moises Jimenez-Martinez</author><author>Julio Varela-Soriano</author><author>Rafael Carrera-Espinoza</author><author>Manuel Coca-Gonzalez</author>
        <description><![CDATA[Additive manufacturing has high potential to achieve a low carbon footprint because it offers the possibility of fabricating components without using manufacturing tooling. However, the mechanical properties of printed components need improvement. The flexibility of the designs generated by controlling the input of the material during filament extrusion in additive manufacturing allows the fabrication of components without tools; however, crystallization occurs because of the temperature gradient in the printed layers and the layers added during printing. Temperature governs polymer crystallization kinetics. Because the material extrusion process is non-isothermal at the welding interface, polymer crystallization kinetics and degree of crystallization are determined by the thermal history developed during manufacturing. Crystallization worsens the mechanical properties because internal forces are concentrated due to the residual stresses present during cooling. There is a wide range of literature and research on the effect of post-heat treatment on improving mechanical properties in metals. To the best of our knowledge, studies on the post-processing of 3D-printed polymers are limited. This research proposes post-processing to homogenize the structure of the printed component through thermal treatment to improve the ultimate tensile strength of Onyx. Annealing and normalizing treatments almost doubled the mechanical strength of raw printed Onyx.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1701456</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1701456</link>
        <title><![CDATA[Optimizing sandwich foam floats for amphibious aircraft: enhancing performance under water impact]]></title>
        <pubdate>2025-10-30T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Fauzan Djamaluddin</author><author>Zaini Ahmad</author>
        <description><![CDATA[Improving amphibian aircraft landing performance is the primary goal of this paper, which aims to optimize the design of sandwich aluminum foam (SAF) energy absorbers. To determine how various configurations of the sandwich structure’s layers affected landing performance, extensive transient dynamic simulations were used. Using simulation methodologies, the impact performance of the SAF’s design parameters was rigorously investigated. The first step of the study was to characterize the SAF as a material for use in impact applications. The three SAF samples were subjected to testing in a water impact environment with a 3.5-ton airplane weight and a landing speed of 76 knots. The core thicknesses of the samples were 3 mm, 5 mm, and 7 mm, respectively. The numerical simulation findings showed that crash behavior indicators like peak crushing force (PCF) and total energy absorption (TEA) are greatly affected by core thickness and material density. Finite element model compares with experiment test, it is found that the differences less than 5%. These meshes are simulated to obtain convergent points of the simulated model mesh size with the error value is 3.08%. Surrogate models based on the Radial Basis Function (RBF) and the Non-dominated Sorting Genetic Algorithm II (NSGA-II) were used in a multi-objective optimization strategy to improve the float’s crashworthiness. According to the optimization findings, the SAF float was far more crashproof than the previous float design. These optimal results differ from those derived solely from crushing analyses in prior studies, providing a more robust reference for practical engineering applications.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1647580</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1647580</link>
        <title><![CDATA[Redesigned crinkle washer for piezoelectric energy generation]]></title>
        <pubdate>2025-10-29T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Fergus Crawley</author><author>Khalifa Ibrahim</author><author>Qing Qin</author><author>Zhenhua Luo</author>
        <description><![CDATA[Structures are used for piezoelectric energy harvesters as a way of redirecting the path of an inputted force so that the piezoelectric element can better convert the mechanical energy to electrical energy. A popular structure used for energy harvesting in compressive force scenarios are the cymbal structure or disc spring due to larger spring rates and the ability to turn compression into radial expansion and thus create surface radial tensile stress on the face plane of a piezoelectric element which has been identified as a beneficial characteristic. The drawbacks of the cymbal washer are found when multiplying the washer in a stack configuration, as the shape of the cymbal is only able to activate a single face and the shape creates increased open space which affects power density of an energy harvesting system. This research is further investigating the wave (crinkle) washer and understanding the benefits of a washer that has a rotational symmetry which a single washer can be used to radially stress two piezoelectric elements simultaneously during compressive loading. Simulations show the iterations of the currently available crinkle washer, adjusting design parameters such as curvatures and waves to create an optimised structure resembling a hyperbolic paraboloid washer. The double piezo compression set up was then simulated to receive an area force of 1000 N/m2 vertically onto the top steel backing plate with a diameter of 22 mm and an area of 380 mm2 to demonstrate a total compressive load of 0.38 N, and resulted significant performance improvements. The final optimised circular disc washer charged two 10 nF capacitors to 1.13 mV and 0.89 mV, compared to just 0.01 mV and 0.009 mV achieved with the standard crinkle washer, the performance boost was achieved by removing internal stresses found to be localised to the internal diameter wave radii. The optimised novel crinkle hyperbolic paraboloid configuration was further optimised with slits to eliminate inner stress regions between wave peaks, vastly improving both power density and overall energy harvesting performance with final capacitor voltages of 16.03 mV and 19.77 mV.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1656081</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1656081</link>
        <title><![CDATA[Enhanced mechanical properties of AA7075 alloy through friction stir processing: a review]]></title>
        <pubdate>2025-10-15T00:00:00Z</pubdate>
        <category>Review</category>
        <author>Tukaram Patil</author><author>Dinesh Washimkar</author><author>Ashish Pawar</author><author>Mithul Naidu</author><author>Sachin Shinde</author><author>Sachin Salunkhe</author>
        <description><![CDATA[A friction stir-based material processing technique for improving the surface and microstructural characteristics of materials is called friction stir processing (FSP). Because FSP involves severe deformation caused by plasticity, material flow, heat transport, and microstructure evolution, it is a multi-physics problem that can be difficult to describe. The performance of the friction stir process is influenced by several factors, including plastic deformation, material flow, temperature, and residual stresses. Enhancing the process requires developing a numerical model that considers these influencing parameters for a specific workpiece material.Lightweight materials such as aluminum alloys offer high specific strength and ductility, making them ideal for applications in the automotive and aerospace industries. Today’s industries are primarily interested in metallic alloys that are lightweight and strong. Because of their low weight, aluminum alloys hold a special place in the industry. Much effort is being made to improve the mechanical qualities of aluminum through a surface modification technique called FSP. This study reviews the literature on the FSP of the AA7075 alloy, focusing on the influence of key parameters such as rotational speed, traverse speed, and machining conditions. Modeling and simulations of FSP for material change have not been extensively studied. This study uses ABAQUS/Explicit to create a computationally efficient process model based on the coupled Eulerian–Lagrangian (CEL) formulation to simulate the FSP of aluminum alloy. Tool plunging, dwelling, and stirring phases are all included in the simulation of the full FSP process using the three-dimensional (3D) finite-element model. The impact of tool rotational speed and tool pin profile during the FSP process is assessed using simulations. Comparing the proposed model’s computational efficiency to that of other models currently in use for friction stir welding procedures is another way to assess its effectiveness. To validate the model, the FSP experiment is conducted using temperature and process force measurements. This work shows that the CEL model can be a useful numerical tool for simulating complex process mechanics and optimizing FSP process parameters for industrial applications.]]></description>
      </item><item>
        <guid isPermaLink="true">https://www.frontiersin.org/articles/10.3389/fmech.2025.1680007</guid>
        <link>https://www.frontiersin.org/articles/10.3389/fmech.2025.1680007</link>
        <title><![CDATA[Research and modelling of the high-speed milling process of heat-resistant high-alloy steel]]></title>
        <pubdate>2025-09-15T00:00:00Z</pubdate>
        <category>Original Research</category>
        <author>Bakhytzhan Donenbayev</author><author>Karibek Sherov</author><author>Bakhtiyor Mardonov</author><author>Lutfiddin Makhmudov</author><author>Sabit Magavin</author><author>Asset Rakishev</author><author>Aibek Sherov</author>
        <description><![CDATA[This study investigates the high‐speed milling behaviour of heat‐resistant martensitic–ferritic steel 15Kh12VMF, widely used in energy and power engineering components but difficult to machine due to its high hardness, strength and low thermal conductivity. An integrated approach combining experimental trials and finite element modelling was applied to assess the influence of cutting parameters on surface quality, tool wear and thermo-mechanical responses. Experiments were conducted on a vertical machining centre under dry cutting conditions using TiAlSiN‐coated carbide tools. Milling parameters were varied within spindle speeds of 2000–12,000 revolutions per minute, feed rates of 500–4500 mm/min and cutting depths of 1–5 mm. Surface roughness was measured according to ISO 4287 standards. Finite element simulations were performed in ANSYS Workbench using the Johnson–Cook constitutive and damage models to reproduce chip formation, temperature distribution and cutting forces. Results indicated that increasing spindle speed from 3000 to 6000 revolutions per minute reduced surface roughness by up to 18%, whereas higher feed rates and depths of cut increased it by 25% and 32%, respectively. Optimal parameters were identified as 6000 revolutions per minute, 1500 mm/min and 2 mm. Tool wear accelerated beyond 6000–7000 revolutions per minute due to elevated cutting temperatures. Simulations predicted a peak temperature of 291.47 °C and cutting forces between –2500 N and +7500 N, consistent with experiments. This study provides validated reference data and modelling insights to support parameter optimisation and improve high-speed milling performance of martensitic–ferritic steels.]]></description>
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