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The purpose of this study is to offer a better and more effective hexacopter design for a 3 kg payload using finite element analysis (FEA), facilitating the use of different materials for different components that too without compromising strength.

A 3D computer-aided design (CAD) model of a hexacopter with a regular hexagonal frame is presented. Furthermore, a finite element model is developed to perform a structural analysis and determine Von Mises stress and strain values along with deformations of different components of the proposed hexacopter design.

The results establish that carbon fibre outperforms acrylonitrile butadiene (ABS) with respect to deformations. Within the permissible limits of the stress and strain values, both carbon fiber and ABS are suggested for different components. Thus, a proposed hexacopter offers lighter weight, high strength and low cost.

The use of different materials for different components is suggested by making use of static structural analysis. This encourages new research work and helps in developing new applications of hexacopter, and it has never been reported in literature. The suggested materials for the components of the hexacopter will prove to be suitable considering weight, strength and cost.

The purpose of this study, most recent advancements in threedimensional (3D) printing have focused on the fabrication of components. It is typical to use different print settings, such as raster angle, infill and orientation to improve the 3D component qualities while fabricating the sample using a 3D printer. However, the influence of these factors on the characteristics of the 3D parts has not been well explored. Owing to the effect of the different print parameters in fused deposition modeling (FDM) technology, it is necessary to evaluate the strength of the parts manufactured using 3D printing technology.

In this study, the effect of three print parameters − raster angle, build orientation and infill − on the tensile characteristics of 3D-printed components made of three distinct materials − acrylonitrile styrene acrylate (ASA), polycarbonate ABS (PC-ABS) and ULTEM-9085 − was investigated. A variety of test items were created using a commercially accessible 3D printer in various configurations, including raster angle (0°, 45°), (0°, 90°), (45°, −45°), (45°, 90°), infill density (solid, sparse, sparse double dense) and orientation (flat, on-edge).

The outcome shows that variations in tensile strength and force are brought on by the effects of various printing conditions. In all possible combinations of the print settings, ULTEM 9085 material has a higher tensile strength than ASA and PC-ABS materials. ULTEM 9085 material’s on-edge orientation, sparse infill, and raster angle of (0°, −45°) resulted in the greatest overall tensile strength of 73.72 MPa. The highest load-bearing strength of ULTEM material was attained with the same procedure, measuring at 2,932 N. The tensile strength of the materials is higher in the on-edge orientation than in the flat orientation. The tensile strength of all three materials is highest for solid infill with a flat orientation and a raster angle of (45°, −45°). All three materials show higher tensile strength with a raster angle of (45°, −45°) compared to other angles. The sparse double-dense material promotes stronger tensile properties than sparse infill. Thus, the strength of additive components is influenced by the combination of selected print parameters. As a result, these factors interact with one another to produce a high-quality product.

The outcomes of this study can serve as a reference point for researchers, manufacturers and users of 3D-printed polymer material (PC-ABS, ASA, ULTEM 9085) components seeking to optimize FDM printing parameters for tensile strength and/or identify materials suitable for intended tensile characteristics.

This paper presents an experimental investigation in establishing the relationship between FDM process parameters and tensile strength of polycarbonate (PC) samples using the I-Optimal design.

I-optimal design methodology is used to plan the experiments by means of Minitab-17.1 software. Samples are manufactured using Stratsys FDM 400mc and tested as per ISO standards. Additionally, an artificial neural network model was developed and compared to the regression model in order to select an appropriate model for optimisation. Finally, the genetic algorithm (GA) solver is executed for improvement of tensile strength of FDM built PC components.

This study demonstrates that the selected process parameters (raster angle, raster to raster air gap, build orientation about Y axis and the number of contours) had significant effect on tensile strength with raster angle being the most influential factor. Increasing the build orientation about Y axis produced specimens with compact structures that resulted in improved fracture resistance.

The fitted regression model has a p-value less than 0.05 which suggests that the model terms significantly represent the tensile strength of PC samples. Further, from the normal probability plot it was found that the residuals follow a straight line, thus the developed model provides adequate predictions. Furthermore, from the validation runs, a close agreement between the predicted and actual values was seen along the reference line which further supports satisfactory model predictions.

This study successfully investigated the effects of the selected process parameters - raster angle, raster to raster air gap, build orientation about Y axis and the number of contours - on tensile strength of PC samples utilising the I-optimal design and ANOVA. In addition, for prediction of the part strength, regression and ANN models were developed. The selected ANN model was optimised using the GA-solver for determination of optimal parameter settings.

The proposed ANN-GA approach is more appropriate to establish the non-linear relationship between the selected process parameters and tensile strength. Further, the proposed ANN-GA methodology can assist in manufacture of various industrial products with Nylon, polyethylene terephthalate glycol (PETG) and PET as new 3DP materials.

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

This review aims to give a critical view of the wheel/rail high frequency vibration-induced vibration fatigue in railway bogie.

Vibration fatigue of railway bogie arising from the wheel/rail high frequency vibration has become the main concern of railway operators. Previous reviews usually focused on the formation mechanism of wheel/rail high frequency vibration. This paper thus gives a critical review of the vibration fatigue of railway bogie owing to the short-pitch irregularities-induced high frequency vibration, including a brief introduction of short-pitch irregularities, associated high frequency vibration in railway bogie, typical vibration fatigue failure cases of railway bogie and methodologies used for the assessment of vibration fatigue and research gaps.

The results showed that the resulting excitation frequencies of short-pitch irregularity vary substantially due to different track types and formation mechanisms. The axle box-mounted components are much more vulnerable to vibration fatigue compared with other components. The wheel polygonal wear and rail corrugation-induced high frequency vibration is the main driving force of fatigue failure, and the fatigue crack usually initiates from the defect of the weld seam. Vibration spectrum for attachments of railway bogie defined in the standard underestimates the vibration level arising from the short-pitch irregularities. The current investigations on vibration fatigue mainly focus on the methods to improve the accuracy of fatigue damage assessment, and a systematical design method for vibration fatigue remains a huge gap to improve the survival probability when the rail vehicle is subjected to vibration fatigue.

The research can facilitate the development of a new methodology to improve the fatigue life of railway vehicles when subjected to wheel/rail high frequency vibration.

The purpose is to explore the free vibration behaviour of elastic foundation-supported porous functionally graded nanoplates using the Rayleigh-Ritz approach. The goal of this study is to gain a better knowledge of the dynamic response of nanoscale structures made of functionally graded materials and porous features. The Rayleigh-Ritz approach is used in this study to generate realistic mathematical models that take elastic foundation support into account. This research can contribute to the design and optimization of advanced nanomaterials with potential applications in engineering and technology by providing insights into the influence of material composition, porosity and foundation support on the vibrational properties of nanoplates.

A systematic methodology is proposed to evaluate the free vibration characteristics of elastic foundation-supported porous functionally graded nanoplates using the Rayleigh-Ritz approach. The study began by developing the mathematical model, adding material properties and establishing governing equations using the Rayleigh-Ritz approach. Numerical approaches to solve the problem are used, using finite element methods. The results are compared to current solutions or experimental data to validate the process. The results are also analysed, keeping the influence of factors on vibration characteristics in mind. The findings are summarized and avenues for future research are suggested, ensuring a robust investigation within the constraints.

The Rayleigh-Ritz technique is used to investigate the free vibration properties of elastic foundation-supported porous functionally graded nanoplates. The findings show that differences in material composition, porosity and foundation support have a significant impact on the vibrational behaviour of nanoplates. The Rayleigh-Ritz approach is good at modelling and predicting these properties. Furthermore, the study emphasizes the possibility of customizing nanoplate qualities to optimize certain vibrational responses, providing useful insights for engineering applications. These findings expand understanding of dynamic behaviours in nanoscale structures, making it easier to build innovative materials with specific features for a wide range of industrial applications.

The novel aspect of this research is the incorporation of elastic foundation support, porous structures and functionally graded materials into the setting of nanoplate free vibrations, utilizing the Rayleigh-Ritz technique. Few research have looked into this complex combo. By tackling complicated interactions, the research pushes boundaries, providing a unique insight into the dynamic behaviour of nanoscale objects. This novel approach allows for a better understanding of the interconnected effects of material composition, porosity and foundation support on free vibrations, paving the way for the development of tailored nanomaterials with specific vibrational properties for advanced engineering and technology applications.

This paper aims to investigate the thermal performance of equivalent square and circular thermal systems and compare the heat transport and irreversibility of magnetohydrodynamic (MHD) nanofluid flow within these systems.

The research uses a constraint-based approach to analyze the impact of geometric shapes on heat transfer and irreversibility. Two equivalent systems, a square cavity and a circular cavity, are examined, considering identical heating/cooling lengths and fluid flow volume. The analysis includes parameters such as magnetic field strength, nanoparticle concentration and accompanying irreversibility.

This study reveals that circular geometry outperforms square geometry in terms of heat flow, fluid flow and heat transfer. The equivalent circular thermal system is more efficient, with heat transfer enhancements of approximately 17.7%. The corresponding irreversibility production rate is also higher, which is up to 17.6%. The total irreversibility production increases with Ra and decreases with a rise in Ha. However, the effect of magnetic field orientation (γ) on total EG is minor.

Further research can explore additional geometric shapes, orientations and boundary conditions to expand the understanding of thermal performance in different configurations. Experimental validation can also complement the numerical analysis presented in this study.

This research introduces a constraint-based approach for evaluating heat transport and irreversibility in MHD nanofluid flow within square and circular thermal systems. The comparison of equivalent geometries and the consideration of constraint-based analysis contribute to the originality and value of this work. The findings provide insights for designing optimal thermal systems and advancing MHD nanofluid flow control mechanisms, offering potential for improved efficiency in various applications.

This paper aims to study the synergistic lubrication effects of Sn–Ag–Cu and MXene–Ti₃C₂ to improve the tribological properties of M50 bearing steel with microporous channels.

M50 matrix self-lubricating composites (MMSC) were designed and prepared by filling Sn–Ag–Cu and MXene–Ti₃C₂ in the microporous channels of M50 bearing steel. The tribology performance testing of as-prepared samples was executed with a multifunction tribometer. The optimum hole size and lubricant content, as well as self-lubricating mechanism of MMSC, were studied.

The tribological properties of MMSC are strongly dependent on the synergistic lubrication effect of MXene–Ti₃C₂ and Sn–Ag–Cu. When the hole size of microchannel is 1 mm and the content of MXene–Ti₃C₂ in mixed lubricant is 4 wt.%, MMSC shows the lowest friction coefficient and wear rate. The Sn–Ag–Cu and MXene–Ti₃C₂ are extruded from the microporous channels and spread to the friction interface, and a relatively complete lubricating film is formed at the friction interface. Meanwhile, the synergistic lubrication of Sn–Ag–Cu and MXene–Ti₃C₂ can improve the stability of the lubricating film, thus the excellent tribological property of MMSC is obtained.

The results help in deep understanding of the synergistic lubrication effects of Sn–Ag–Cu and MXene–Ti₃C₂ on the tribological properties of M50 bearing steel. This work also provides a useful reference for the tribological design of mechanical components by combining surface texture with solid lubrication.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2023-0381/

The purpose of this study is to investigate the application of non-destructive testing methods in measuring bearing oil film thickness to ensure that bearings are in a normal lubrication state. The oil film thickness is a crucial parameter reflecting the lubrication status of bearings, directly influencing the operational state of bearing transmission systems. However, it is challenging to accurately measure the oil film thickness under traditional disassembly conditions due to factors such as bearing structure and working conditions. Therefore, there is an urgent need for a nondestructive testing method to measure the oil film thickness and its status.

This paper introduces methods for optically, electrically and acoustically measuring the oil film thickness and status of bearings. It discusses the adaptability and measurement accuracy of different bearing oil film measurement methods and the impact of varying measurement conditions on accuracy. In addition, it compares the application scenarios of other techniques and the influence of the environment on detection results.

Ultrasonic measurement stands out due to its widespread adaptability, making it suitable for oil film thickness detection in various states and monitoring continuous changes in oil film thickness. Different methods can be selected depending on the measurement environment to compensate for measurement accuracy and enhance detection effectiveness.

This paper reviews the basic principles and latest applications of optical, electrical and acoustic measurement of oil film thickness and status. It analyzes applicable measurement methods for oil film under different conditions. It discusses the future trends of detection methods, providing possible solutions for bearing oil film thickness detection in complex engineering environments.

Polymethyl methacrylate (PMMA) is a remarkable biocompatible material for bone cement and regeneration. It is also considered 3D printable but requires in-depth process–structure–properties studies. This study aims to elucidate the mechanistic effects of processing parameters and sterilization on PMMA-based implants.

The approach comprised manufacturing samples with different raster angle orientations to capitalize on the influence of the filament alignment with the loading direction. One sample set was sterilized using an autoclave, while another was kept as a reference. The samples underwent a comprehensive characterization regimen of mechanical tension, compression and flexural testing. Thermal and microscale mechanical properties were also analyzed to explore the extent of the appreciated modifications as a function of processing conditions.

Thermal and microscale mechanical properties remained almost unaltered, whereas the mesoscale mechanical behavior varied from the as-printed to the after-autoclaving specimens. Although the mechanical behavior reported a pronounced dependence on the printing orientation, sterilization had minimal effects on the properties of 3D printed PMMA structures. Nonetheless, notable changes in appearance were attributed, and heat reversed as a response to thermally driven conformational rearrangements of the molecules.

This research further deepens the viability of 3D printed PMMA for biomedical applications, contributing to the overall comprehension of the polymer and the thermal processes associated with its implementation in biomedical applications, including personalized implants.