Laser Powder Bed Fusion (L-PBF) of nickel superalloy Inconel 625 (IN625) is widely adopted for fatigue-critical aerospace and energy applications. The accuracy of finite element method (FEM) fatigue predictions depends critically on the Basquin fatigue constants used, yet most FEM studies apply generic material library values without calibration to the actual process-specific material state. This study presents a systematic FEM-based fatigue assessment of L-PBF IN625 specimens (ASTM E466) under constant amplitude axial loading (20–60 kN, R = 0.1) and quantifies the effect of Basquin constant calibration on fatigue life, damage, and safe load predictions. Stress-life (S-N) analysis was performed in ANSYS Workbench 2021 R2 using SOLID187 tetrahedral elements (148,563 nodes; 35,532 elements). The Basquin fatigue strength coefficient was calibrated from published fatigue failure data for L-PBF IN625 (Poulin et al., ≤0.1% porosity, R = 0.1), yielding σ'f = 2050 MPa with b = −0.134 fixed at the literature consensus value. Compared to the ANSYS library constants (σ'f = 2282 MPa, b = −0.134), the calibrated constants reduce predicted fatigue life by 55% across all load levels. The critical safe load threshold (safety factor SF = 1.0) shifts from 23.6 kN (library) to 21.2 kN (calibrated), a 10.2% reduction with direct design implications. The calibrated model is validated against three independent published experimental datasets for L-PBF IN625, showing improved agreement in the finite-life regime. These results establish that uncalibrated material library constants systematically overestimate L-PBF IN625 fatigue performance and provide quantitative guidance for safe load determination in fatigue-critical AM components.

This study presents a finite element modeling framework for predicting dry sliding wear in WC–Co by integrating Archard’s wear law with the UMESHMOTION subroutine in Abaqus. Pin-on-disk experiments were conducted to obtain the steady-state friction coefficient, wear coefficient, and surface profile, which were used to calibrate the numerical model. A short sliding distance of 1 mm was simulated and subsequently scaled to represent a 1000 m sliding test, enabling substantial reduction in computational cost. The model accurately reproduced the experimental wear behavior, predicting a maximum wear depth within 8% relative error (0.23 μm simulated vs. 0.25 μm measured), and captured the overall geometry of the wear track. Sensitivity analysis confirmed the linear dependence of wear depth on the wear coefficient and sliding distance, supporting the validity of the scaling strategy. The results demonstrate that combining FEM, UMESHMOTION, and a sliding-distance scaling approach provides an efficient and reliable method for long-distance wear prediction in hard materials. This framework is applicable to tribological component design and can be extended to more complex multi-physics wear mechanisms in future studies.

Bast fibers are promising natural materials known for their biodegradability, affordability, and eco-friendliness, making them an alternative to synthetic options. Extensive research has been conducted to examine the effects of integrating various bast fiber reinforcements into epoxy and polystyrene matrices to boost the properties of the composite materials. However, there is limited research on ensete fiber and its utilization as a reinforcement that needs more in-depth research to be used as an alternative bast fiber. This paper aimed to predict and compare the performance of ensete fiber composites with six other bast fiber-reinforced polystyrene and epoxy composites. In this study, flax, hemp, jute, ramie, banana and kenaf were selected bast fibers for comparison purposes. This article employed various micromechanics models and finite element method (FEM), varying the fiber volume fraction. Our findings revealed that hemp fiber-reinforced composites exhibited the best predicted elastic properties, while banana fiber-reinforced composites showed the weakest performance. Notably, composites made with ensete fibers outperformed those made with jute and banana fibers in both epoxy and polystyrene matrices. Comparisons were made between results from the micromechanics models and FEM for all bast fiber-reinforced epoxy and polystyrene composites and there was an agreement between the effective elastic properties and fiber volume fraction (FVF). Further, bast-fiber reinforced epoxy composites showed higher values than polystyrene for strain analysis while for stress analysis, polystyrene composites showed higher stress loads than epoxy composites.

Fatigue crack growth studies require models that accurately predict component life with low uncertainty. Despite the large number of proposed models, there is no clarity on their applicability, which justifies a comparative analysis between some of them. The dual boundary element method (DBEM) was applied for cracked bodies, whereby the stress intensity factors (SIF), the growth rate, and the number of cycles were computed. Three crack increment models were studied under constant amplitude fatigue loads: the Paris, the Klesnil-Lucas, and the Forman models. Results were validated with experimental literature and through the finite element method, indicating that each model represents a specific zone of the crack growth curve. Klesnil-Lucas model reproduces the region near the fracture threshold, Paris fits the controlled crack growth zone, whereas Forman’s model recreates the unstable fracture zone, i.e., when the stress intensity factor approaches the material’s fracture toughness. The J-integral with stress field decomposition gave errors below 0.8% for mode I. Results were similar for the propagation path and the number of cycles to those obtained with the finite element method, with errors of about 3% considering different K-effective approaches. Klesnil-Lucas accurately predicts the number of cycles with an error margin below 3%, considering the curved region in the growth rate at the propagation onset, while the Paris model becomes very conservative, predicting values up to 50% lower than experimental data. The Klesnil-Lukas model is advised for simulating the entire crack propagation.

The article presents an analysis of the stress state of workpieces during upsetting of workpieces with an additional shear. For the analysis, the slip line method and the finite element method were used. A schematic diagram of upsetting in dies with “floating” elements, contributing to the implementation of additional shear, reduction of barreling, inhomogenous deformation and contour tensile stresses, is presented. The analysis of the research results showed that during upsetting of workpieces with additional shift forces, tensile stresses on the side surface of the workpieces decrease, which excludes the appearance of cracks on the side surface of the samples, especially when processing low-plastic alloy steels and alloys, and also reduces the barreling of the side surface.

Reinforced concrete wall critical zones are the responsive areas of dissipated earthquake loads. They are formed in the connection of the wall panels and the fixed restraints. The longitudinal and transversal steel reinforcements with certain spacing are designed according to the required nominal strength at the connections. Under certain conditions, the reinforcement distance becomes very tight, making working on castings using normal concrete difficult. This condition also occurs in boundary elements consisting of longitudinal and transversal reinforcements in tight spaces. A concrete material that flows easily and solidifies itself is required to avoid segregation. One type of this material is Self-Compacting Concrete (SCC). The SCC performance as a wall panel material that withstands gravity and cyclic lateral loads still require further research. This study aimed to analyze the hysteretic performance of reinforced SCC wall panels with variations of shear reinforcement in resisting cyclic lateral loads. The analysis used software based on numerical analysis. The drift ratios, hysteretic curves, stress patterns, ductility, and stiffness of the wall panels were analyzed. The SCC wall panel with ordinary shear reinforcement resisted lateral positive and negative loads of 152.32 kN and 143.09 kN, respectively. In comparison, the wall panel with boundary elements and tighter shear reinforcements could withstand the positive and negative lateral loads of 187.62 kN and 145.98 kN, respectively. The SCC wall panel reached the best ductility of 21.38 with ordinary shear reinforcement because the yield occurred faster than in other wall panels. The results showed that the boundary elements and shear reinforcements of reinforced SCC wall panels affected the performance in resisting cyclic lateral loads.

Strain-softening material models have conventionally had a pathological mesh sensitivity in finite element simulations and composite materials are indifferent to this problem. Spurious localization is inherent to the structural problem in strain-driven softening. This limitation is caused as the partial differential equations (that govern the structural problem) become ill-posed as the tangent modulus becomes negative, for which uniqueness of the solution with respect to the spatial discretization is lost. This causes the numerical results to unrealistically concentrate in a single layer of elements. A basic theory of overcoming mesh sensitivity is the non-local continuum theory. In this work, three different non-local models with isotropic weight function have been proposed and implemented to work in conjunction with a composite micro-mechanical material model. The effect of a weighing function in each of these formulations has been studied in detail. All three non-local formulations have been observed to produce a nice smeared effect of damage unlike the local damage models.

The current study measures the mechanical behavior of both natural and the monobloc elastomeric disc prosthesis (CadiscTM-L) by employing a finite element method (FEM) to study the fiber-reinforced constitutive formulation provided in the literature. The three-dimensional geometry was created by computed tomography (CT) scan imaging technique. Frontal pure rotational, sagittal, and axial momentum of 7.5 N·m were applied on the top of L3 while the lower half of the L5 was fixed in all directions. This investigation was performed considering two stages: (1) intact L3–L5 lumbar spine (INT model), and (2) Cadisc implemented between L4 and L5 (IMP model). The numerical results for the INT model were validated by experimental data from the literature. Several parameters including the inter-segmental rotation, range of motion in flexion-extension, axial rotation and lateral bending were analyzed. Our numerical results show that the IMP model has a 50% reduction in the ‘range of motion’ and a 33% reduction in flexion in lateral bending compared to the INT model. These outcomes of this paper reveal the feasibility of applying a fibre-reinforced constitutive formulation to generate an accurate three-dimensional FEM model.

An in-house finite element code was utilized to evaluate mode I/II stress intensity factor (SIF) of an edge cracked semi-circular disc subjected to three-point bending. The specimen was considered as an isotropic and homogeneous material. Relative span length ratios of 0.3 to 0.8 in steps of 0.1 were invoked. Relative crack length ratios of 0.1, 0.2, 0.3, 0.4, 0.5 and 0.6 were analyzed with crack angles up to 60° in steps of 5°. At the same crack length, mode I SIF decreases with increasing crack angle or decreasing the span length. The range of pure mode II decreases with increasing the span length. For the same crack length, the crack angle corresponding to the transition from a mixed mode I/II to a pure mode II increases with increasing the relative span length ratio. On the contrary, that angle decreases with increasing the crack length for the same span length. Good agreement has been generally obtained with relevant results found in the literature.

The identification of optimal tire design parameters for satisfying different requirements, i.e. tire performance characteristics, plays an essential role in tire design. In order to improve tire performance characteristics, formulation and solving of multi-objective optimization problem must be performed. This paper presents a multi-objective optimization procedure for determination of optimal tire design parameters for simultaneous minimization of strain energy density at two distinctive zones inside the tire. It consists of four main stages: pre-analysis, design of experiment, mathematical modeling and multi-objective optimization. Advantage of the proposed procedure is reflected in the fact that multi-objective optimization is based on the Pareto concept, which enables design engineers to obtain a complete set of optimization solutions and choose a suitable tire design. Furthermore, modeling of the relationships between tire design parameters and objective functions based on multiple regression analysis minimizes computational and modeling effort. The adequacy of the proposed tire design multi-objective optimization procedure has been validated by performing experimental trials based on finite element method.