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High pressure die casting is a widely used industrial process to manufacture complex-shaped products in light alloys. Virtual prototyping techniques, especially numeric-based simulations of the casting process, allow the die filling process to be evaluated and help faster optimization of the gating system, which is the most critical element of the mould. The purpose of this paper is to present a four step approach to design optimal moulds taking advantage of the simulation tools.

No formalized method to design an optimal gating system is available yet and the majority of the studies aim to optimize existing geometries or to choose from alternative solutions. Rather than optimizing the geometries of predefined designs by running attempt trials, the proposed approach defines a procedure to position cavities, gating systems and, finally, to determine the whole mould geometry.

The approach is demonstrated through three different industrial applications. The design of a six-cavity mould for gas cooking burners is reported at first. Then, two test cases, a cup and a radiator, are reported for showing different arrangements of the gating system. The reached quality of the mould design has been assessed using metallographic analyses of the casts.

The design of a mould is strictly correlated to its product and mainly based on a trial-and-error approach. Numerical simulations offer a powerful and not expensive way to study the effectiveness of different die designs and filling processes. The paper proposes a structured approach for the definition of the gating system. It ultimately leads to improvements in both product quality and process productivity, including more effective control of the die filling and die thermal performance.

The determination of feasible self-stress modes and grouping of elements for tensegrities with predefined geometry and multiple self-stress modes is very important, though difficult, in the design of these structures. The purpose of this paper is to present a novel approach to the automated element grouping and self-stress identification of tensegrities.

A set of feasible solutions conforming to the unilateral behaviour of elements is obtained through an optimisation process, which is solved using a genetic algorithm. Each chromosome in the population having a negative fitness is a distinctive feasible solution with its own grouping characteristic, which is automatically determined throughout the evolution process.

The self-stress identification is formulated through an unconstrained minimisation problem. The objective function of this minimisation problem is defined in such a way that takes into account both the feasibility of a solution and grouping of elements. The method generates a set of feasible self-stress modes rather than a single one and automatically and simultaneously suggests a grouping of elements for every feasible self-stress mode. A self-stress mode with a minimal/subminimal grouping of elements is also obtained.

The method can efficiently generate sets of feasible solutions rather than a single one. The authors also address one of the challenging issues related to this identification, i.e., automated grouping of elements. These features makes the method very efficient since most of the state-of-the-art methods address the self-stress identification of tensegrities based on predefined groupings of elements whilst providing only a single corresponding solution.

The purpose of this paper is to investigate, develop and validate a three‐dimensional modelling strategy for the efficient generation of conformal textile data suitable for additive manufacture.

A series of additive manufactured (AM) textiles samples were modelled using currently available computer‐aided design software to understand the limitations associated with the generation of conformal data. Results of the initial three‐dimensional modelling processes informed the exploration and development of a new dedicated efficient modelling strategy that was tested to understand its capabilities.

The research demonstrates the dramatically improved capabilities of the developed three‐dimensional modelling strategy, over existing approaches by accurately mapping complex geometries described as STL data to a mapping mesh without distortion and correctly matching the orientation and surface normal.

To date the generation of data for AM textiles has been seen as a manual and time‐consuming process. The research presents a new dedicated methodology for the efficient generation of complex and conformal AM textile data that will underpin further research in this area.

The aim of the paper is to provide an economically viable solution for the blade repair process. There is a continual increase in the repair market, which requires an increased level of specialised technology to reduce the repair cost and to increase productivity of the process.Design/methodology/approach – This paper introduces the aerospace component defects to be repaired. Current repair technologies including building‐up and machining technology are reviewed. Through the analysis of these available technologies, this paper proposes an integrated repair strategy through information integration and processes concentration.Findings – Provides detailed description and discussion for the repair system, including 3D digitising system, repair inspection, reverse engineering‐based polygonal modelling, and adaptive laser cladding and adaptive machining process.Originality/value – This paper describes a 3D non‐contact measurement‐based repair integration system, and provides a solution to create an individual blade‐oriented nominal model to achieve adaptive repair process (laser cladding/machining) and automated inspection.

This study aims to design the rotor geometry of switched reluctance motor (SRM) in a completely flexible way. In the proposed method, there is no default geometry for the rotor. The initial geometry of the rotor can start from a circle or any other shape and depending on the required performance takes the final shape during the optimal design. In this way, the best performance, possible with geometric design, can be achieved.

The rotor boundary of a 4/2 SRM is defined by a few B-splines. Some control points are located around the rotor and changing their locations causes customized changes in the rotor boundary. Locations of these points are defined as design variables. A 2-D finite element analysis using MATLAB/PDE is applied to the SRM model and sensitivity analysis is used to optimization design by means of minimizing of objective function.

The proposed method has many more capabilities for matching different objective functions. For the suggested objective function, while the conventional rotor torque profile difference with the desired torque profile reaches 40%, this difference for B-spline rotor is about 17%. Experimental results from a prototype motor have a close agreement with analysis results.

The B-splines have been used to design machines and electromagnetic devices. However, this method is used for the first time in design of the whole rotor of a SRM.

Shell structures are highly efficient and are an elegant way of covering large uninterrupted spaces, but their complex geometry is notoriously difficult to model and analyse. This paper aims to describe a novel free-form shell modelling technique based on structural harmonics.

The method builds on work using weighted eigenmodes for three-dimensional mesh modelling in a computer graphics setting and extends it by specifically adapting the technique to an architectural design context. This not only enables the sculpting of free-form architectural surfaces using only a few control parameters but also takes advantage of the synergies between eigenmodes and structural buckling modes, to provide an efficient means of stiffening a shell against failure by buckling.

The result is a flexible free-form modelling tool that not only enables the creation of arbitrary doubly curved surfaces but also allows simultan. The tool helps to assist in the design of shells at the conceptual stage and encourages an interaction between the architect and engineer. A number of initiatives, including a single degree of freedom design, boundary constraints, visualisation aids and guidelines towards specific spatial configurations have been introduced to satisfactorily adapt the method to an architectural context.

The tool helps to assist in the design of shells at the conceptual stage and encourages an interaction between the architect and engineer. A number of initiatives, including a single degree of freedom design, boundary constraints, visualisation aids and guidelines towards specific spatial configurations have been introduced to satisfactorily adapt the method to an architectural context. This paper includes a full case study of the iconic British Museum Great Court Roof to demonstrate the applicability of the developed framework to real-world problems and the software developed to implement the method is available as an open-source download.

This paper aims to propose a study on the static behavior of prismatic tensegrity structures and an innovative form for determining the effect of mechanical properties and geometric parameters on the minimal mass design of these structures.

The minimal mass design in this paper considers a stable class-two tensegrity tower built through stable models. Using the proposed structures, comprehensive parametric studies are performed to examine the mass (in which the masses of joints are ignored), the mass ratio between a class-two tensegrity tower and a single element, both having the same diameter and length and afterward determine a reliable mass saving structure under various circumstances.

The simulations show that the mass ratio versus the number of units is a nonlinear regressive curve and predicts that the proposed model outperforms the standard model when the variation parameter considered is a vertical force. The difference in mass between these structures is visible when the gap gradually decreases while the number of units increases. On the geometrical aspect, the gap between the masses is not significant.

This paper helps to understand the influences of geometric parameters and the mechanical properties on the design of cylinder tensegrity structures dealing with a compressive force.

The purpose of this study is to study the simultaneous effect of embedded reverting microchannels on the cooling performance and mechanical strength of the electronic pieces.

In this study, a new configuration of the microchannel heat sink was proposed based on the constructal theory to examine mechanical and thermal aspects. Initially, the thermal-mechanical behavior in the radial arrangement was analyzed, and then, by designing the first reverting channel, maximum temperature and maximum stress on the disk were decreased. After that, by creating second reverting channels, it has been shown that the piece is improved in terms of heat and mechanical strength.

Having placed the second reverting channel on the optimum location, the effect of creating the third reverting channel has been investigated. The study has shown that there is a close relationship between the maximum temperature and maximum stress in the disk as maximum temperature and maximum stress decrease in pieces with more uniform distribution channels.

The proposed structure has decreased the maximum temperature and maximum thermal stresses close to 35 and 50%, respectively, and also improved the mechanical strength, with and without thermal stresses, about 40 and 24%, respectively.

This activity dealt with the thermal analysis of the launch vehicle Vega C through a lumped parameter model. The Vega C is the upgrade of the actual launch vehicle Vega within the Vega Consolidation and Evolution Program, whose objective is to develop a consolidated – hence the C – version of the Vega by 2020. The main aim of the study was verifying the thickness of the external thermal protection of the launch vehicle, such that the structure and equipment temperatures were kept within their operating ranges.

The analysis has been performed by means of ESATAN–TMS during a time-frame that included the stand-by on ground phase and a flight phase up to the separation of the second stage from the third one. Two operating conditions have been considered, i.e. the worst hot and worst cold cases. The study has been divided as follows: geometry definition through spatial discretization; application of materials and optical properties; application of thermal loads; thermal analysis; and post-processing of the results in ThermNV.

It was concluded that the calculated temperatures were within the supposed project specifications, while their trends reflected the expected behavior.

During the flight phase, the mutual separation of the investigated stages has been explicitly modelled through a routine specifically developed for this purpose. Therefore, the submodels of each stage have been disabled at the correct instant according to the known time-sheet.

This study investigates the impact of the fire decay phase on structural damage using the sectional analysis method. The primary objective of this work is to forecast the non-dimensional capacity parameters for the axial and flexural load-carrying capacity of reinforced concrete (RC) sections for heating and the subsequent post-heating phase (decay phase) of the fire.

The sectional analysis method is used to determine the moment and axial capacities. The findings of sectional analysis and heat transfer for the heating stage are initially validated, and the analysis subsequently proceeds to determine the load capacity during the fire’s heating and decay phases by appropriately incorporating non-dimensional sectional and material parameters. The numerical analysis includes four fire curves with different cooling rates and steel percentages.

The study’s findings indicate that the rate at which the cooling process occurs after undergoing heating substantially impacts the axial and flexural capacity. The maximum degradation in axial and flexural capacity occurred in the range of 15–20% for cooling rates of 3 °C/min and 5 °C/min as compared to the capacity obtained at 120 min of heating for all steel percentages. As the fire cooling rate reduced to 1 °C/min, the highest deterioration in axial and flexural capacity reached 48–50% and 42–46%, respectively, in the post-heating stage.

The established non-dimensional parameters for axial and flexural capacity are limited to the analysed section in the study owing to the thermal profile, however, this can be modified depending on the section geometry and fire scenario.

The study primarily focusses on the degradation of axial and flexural capacity at various time intervals during the entire fire exposure, including heating and cooling. The findings obtained showed that following the completion of the fire’s heating phase, the structural capacity continued to decrease over the subsequent post-heating period. It is recommended that structural members' fire resistance designs encompass both the heating and cooling phases of a fire. Since the capacity degradation varies with fire duration, the conventional method is inadequate to design the load capacity for appropriate fire safety. Therefore, it is essential to adopt a performance-based approach while designing structural elements' capacity for the desired fire resistance rating. The proposed technique of using non-dimensional parameters will effectively support predicting the load capacity for required fire resistance.

The fire-resistant requirements for reinforced concrete structures are generally established based on standard fire exposure conditions, which account for the fire growth phase. However, it is important to note that concrete structures can experience internal damage over time during the decay phase of fires, which can be quantitatively determined using the proposed non-dimensional parameter approach.