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“V-bending” is the most commonly used bending process in which the sheet metal is pressed into a “V-shaped” die using a “V-shaped” punch to form a required angular bend. When the punch is removed after the operation, because of elastic recovery, the bent angle varies. This shape discrepancy is known as spring back which causes problems in the assembly of the component in the modern aerospace industry. Regarding the optimization of spring-back accuracy, this research will illustrate the laws of the transition area (TA) of the nondeformation area (NDA) during the 90° “V-shape” bending process.

According to the traditional “V-bending” process to optimize the spring-back accuracy, the bent sheets are divided into deformation area (DA) and NDA. For this reason, the traditional “V-bending” process may prolong error to optimize the spring-back accuracy because NDA has a certain amount of deformation, which the researcher always avoids. Firstly, bent sheets are divided into three parts in this research: DA, TA and NDA to avoid the distortion error in TA that are not considered in the NDA in traditional theory. Then, the stress and strain in the DA and TA were discussed during theoretical derivation and some hypotheses were proposed. In this research, the interval, position and distortion degree of the TA of the bending sheet are used by finite element analysis. Finally, V-shape bending tests for aluminum alloy at room temperature are used and labeled all the work pieces' TAs to realize the deformation amount in the TA.

The bending radius does not affect the range of the TA, it only changes the position of TA in the bending sheet. It is evident that the laws of TA were explored in the width direction and gradually changed from the inner layer to the outer layer based on the ratio of width and thickness of the bending plate/sheet.

In the modern aerospace industry, aircraft manufacturing technology must maintain high accuracy. This research has practical value in the 90° “V-shape” bending of metal sheets and the development of its spring-back accuracy.

This paper gives a review of the finite element techniques (FE) applied in the area of material processing. The latest trends in metal forming, non‐metal forming and powder metallurgy are briefly discussed. The range of applications of finite elements on the subjects is extremely wide and cannot be presented in a single paper; therefore the aim of the paper is to give FE users only an encyclopaedic view of the different possibilities that exist today in the various fields mentioned above. An appendix included at the end of the paper presents a bibliography on finite element applications in material processing for the last five years, and more than 1100 references are listed.

Engineered stone is a material which can be described as an artificial stone. The exemplary application area is sink production. There are very few research projects about this type of material. In fact, most of them are research conducted by the manufacturing company, which are limited to the basic properties of the material. However, knowledge about fracture mechanic of this material may be crucial in terms of usage. The paper aims to discuss this issue.

Analysis of the inside structure was made using an optical microscope as well as SEM. In the paper, methods which can be used to obtain data about fracture behaviour of material are presented. Using eXtended Finite Element Method and experimental data from three-point bending of notched specimens stress intensity factors (SIFs) for I and II load modes were obtained. Finally, a comparison between the fracture initiation angle in the function of the ration of SIFs for I/II load modes and maximum tangential stress hypothesis prediction was presented.

Analysis of the inside structure proves that this type of material has an uneven distribution of particle size. This can follow to void and micronotches formation and, later, to the failure of the material. A method of obtaining stress intensity factors for the discussed type of material and specimens can be successfully applied to other similar material, as proposed in this work. Standard crack angle propagation criteria are not sufficient for this type of material.

There are very few research papers about this type of material. The subject of fracture mechanic is not properly discovered, despite the fact that IT is important in terms of the application area of these materials.

Impingement and forced convection are preferable methods for cooling gas turbine components. However, influences of various design parameters like crossflow and surface enlargements (like ribs) are not well understood. Thus there is a request for reliable and cost‐effective computational prediction methods, due to the experimental difficulties. Such methods could be based on the numerical solution of the Reynolds‐averaged Navier‐Stokes equations, the energy equation and models for the turbulence field. This paper describes some recent advances and efforts to develop and validate computational methods for simulation of impingement and forced convection cooling in generic geometries of relevance in gas turbine cooling. Single unconfined round air jets, confined jets with crossflow, and three‐dimensional ribbed ducts are considered. The numerical approach is based on the finite volume method and uses a co‐located computational grid. The considered turbulence models are all the so‐called low Reynolds number models. Our recent investigations show that linear and non‐linear two‐equation turbulence models can be used for impinging jet heat transfer predictions with reasonable success. However, the computational results also suggest that an application of a realizability constraint is necessary to avoid over‐prediction of the stagnation point heat transfer coefficients. For situations with combined forced convection and impingement cooling it was revealed that as the crossflow is squeezed under the jet, the heat transfer coefficient is reduced. In addition, inline V‐shaped 45° ribs pointing upstream performed superior compared to those pointing downstream and transverse ribs.

This paper aims to examine the static compression characteristics of cell topologies in body-centered cubic with vertical struts (BCCZ) and face-centered cubic with vertical struts (FCCZ) along with novel BCCZZ and FCCZZ lattice structures.

The newly developed structures were obtained by adding extra interior vertical struts into the BCCZ and FCCZ configurations. The samples, composed of the AlSi10Mg alloy, were fabricated using the selective laser melting (SLM) additive manufacturing technique. The specific compressive strength and failure behavior of the manufactured lattice structures were investigated, and comparative analysis among them was done.

The results revealed that the specific strength of BCCZZ and FCCZZ samples with 0.5 mm strut diameter exhibited approximately a 23% and 18% increase, respectively, compared with the BCCZ and FCCZ samples with identical strut diameters. Moreover, finite element analysis was carried out to simulate the compressive response of the lattice structures, which could be used to predict their strength and collapse mode. The findings showed that while the local buckling of lattice cells is the major failure mode, the samples subsequently collapsed along a diagonal shear band.

An original and systematic investigation was conducted to explore the compression properties of newly fabricated lattice structures using SLM. The results revealed that the novel FCCZZ and BCCZZ structures were found to possess significant potential for load-bearing applications.

The purpose of this paper is to perform two-dimensional numerical simulation involving fluid-structure interaction of flexible filament. The filament is tethered to the bottom of a rectangular channel with oscillating fluid flow inlet conditions at low Reynolds number. The simulations are performed using a temporal second-order finite volume-based immersed boundary method (IBM). Further, to understand the relation between different aspect ratios i.e. ratio of filament length to channel height (Len/H) and fixed channel geometry ratio, i.e. ratio of channel height to channel length (H/Lc) on mixing and pumping capabilities.

The discretization of governing continuity and Navier–Stokes equation is done by finite-volume method on a staggered Cartesian grid. SIMPLE algorithm is used to solve fluid velocity and pressure terms. Two cases of oscillatory flow conditions are used with the flexible filament tethered at the center of bottom channel wall. The first case is sinusoidal oscillatory flow with phase shift (SOFPS) and second case is sinusoidal oscillatory flow without phase shift (SOF). The simulation results are validated with filament dynamics studies of previous researchers. Further, parametric analysis is carried to study the effect of filament length (aspect ratio), filament bending rigidity and Reynolds number on the complex deformation and behavior of flexible filament interacting with nearby oscillating fluid motion.

It is found that selection of right filament length and bending rigidity is crucial for fluid mixing scenarios. The phase shift in fluid motion is also found to critically effect filament displacement dynamics, especially for rigid filaments. Aspect ratio, suitable for mixing applications is dependent on channel geometry ratio. Symmetric deformation is observed for filaments subjected to SOFPS condition irrespective of bending rigidity, whereas medium and low rigidity filaments placed in SOF condition show severe asymmetric behavior. Two key findings of this study are: symmetric filament conformity without appreciable bending produces sweeping motion in fluid flow, which is highly suited for mixing application; and asymmetric behavior shown by the filament depicts antiplectic metachronism commonly found in beating cilia. As a result, it is possible to pin point the type of fluid motion governing fluid mixing and fluid pumping. The developed computational model can, thus, successfully demonstrate filament-fluid interaction for a wide variety of similar problems.

The present study uses a temporal second-order finite volume-based IBM to examine flexible filament dynamics for various applications such as fluid mixing. Also, it highlights the relationship between channel geometry ratio and filament aspect ratio and its effect on filament sweep patterns. The study further reports the effect of filament displacement dynamics with or without phase shift for inlet oscillating fluid flow condition.

This paper aims to present the simulation, fabrication and testing of a novel ultra-wide band (UWB) band-pass filters (BPFs) with better transmission and rejection characteristics on a low-loss Taconic substrate and analyze using the coupled theory of resonators for UWB range covering L, S, C and X bands for radars, global positioning system (GPS) and satellite communication applications.

The filter is designed with a bent coupled transmission line on the top copper layer. Defected ground structures (DGSs) like complementary split ring resonators (CSRRs), V-shaped resonators, rectangular slots and quad circle slots (positioned inwards and outwards) are etched in the ground layer of the filter. The circular orientation of V-shaped resonators adds compactness when linearly placed. By arranging the quad circle slots outwards and inwards at the corner and core of the ground plane, respectively, two filters (Filters I and II) are designed, fabricated and measured. These two filters feature a quasi-elliptic response with transmission zeros (TZs) on either side of the bandpass response, making it highly selective and reflection poles (RPs), resulting in a low-loss filter response. The transmission line model and coupled line theory are implemented to analyze the proposed filters.

Two filters by placing the quad circle slots outwards (Filter I) and inwards (Filter II) were designed, fabricated and tested. The fabricated model (Filter I) provides transmission with a maximum insertion loss of 2.65 dB from 1.5 GHz to 9.2 GHz. Four TZs and five RPs are observed in the frequency response. The lower and upper stopband band width (BW) of the measured Filter I are 1.2 GHz and 5.5 GHz of upper stopband BW with rejection level greater than 10 dB, respectively. Filter II (inward quad circle slots) operates from 1.4 GHz to 9.05 GHz with 1.65 dB maximum insertion loss inside the passband with four TZs and four RPs, which, in turn, enhances the filter characteristics in terms of selectivity, flatness and stopband. Moreover, 1 GHz BW of lower and upper stopbands are observed. Thus, the fabricated filters (Filters I and II) are therefore evaluated, and the outcomes show good agreement with the electromagnetic simulation response.

The limitation of this work is the back radiation caused by DGS, which can be eradicated by placing the filter in the cavity and retaining its performance.

The proposed UWB BPFs with novel resonators find their role in the UWB range covering L, S, C and X bands for radars, GPS and satellite communication applications.

To the best of the authors’ knowledge, for the first time, the authors develop a compact UWB BPFs (Filters I and II) with BW greater than 7.5 GHz by combining reformed coupled lines and DGS resonators (CSRRs, V-shaped resonators [modified hairpin resonators], rectangular slots and quad circle slots [inwards and outwards]) for radars, GPS and satellite communication applications.

The purpose of this paper is to describe design and development of a pole climbing robot (PCR) for inspection of industrial size pipelines. Nowadays, non‐destructive testing (NDT) methods are performed by dextrous technicians across high‐level pipes, frequently carrying dangerous chemicals. This paper reports development of a PCR that can perform in situ manipulation for NDT tests.

Introduces a PCR including a novel four‐degrees of freedom climbing serial mechanism with the nearly optimal workspace and weight, unique V‐shaped grippers and a fast rotational mechanism around the pole axis. Simplicity, safety, minimum weight, and manipulability were concerned in the design process.

The developed prototype proved possibility of application of PCRs for NDT inspection on elevated structures. Design and development of PCRs which are able to pass bends and T‐junctions faces much more difficulties than those which should climb from a straight pole.

The robot is successfully tested on an industrial size structure (exterior diameter of 219 mm) with bends and T‐junctions.

Design and development of a novel pole climbing and manipulating robot for inspection of industrial size pipelines. The robot is able to pass bends and T‐junctions. The V‐shaped grippers offer many advantages including safety and tolerance to power failure. After grasping the structure, in case of power failure in any of the grippers' motors, the robot does not slip on the structure. The Z‐axis rotational mechanism provides fast navigation around the pole which is not possible with the traditional serial articulated arms.

An automated sheet‐metal manufacturing systems for low‐volume production utilises an industrial robot to move blanks from a store to a press brake.

The purpose of this study is to address the issue that the traditional V-shaped ball valve profile shape is limiting the flow control characteristics in a series structure and to optimize the design profile by proposing an open-hole profile.

This paper proposes a Gaussian process regression surrogate model based on the genetic algorithm optimization of swarm intelligence, combined with the Expected Improvement point addition criterion, to optimize and correct the design profile. The flow regulation performance of the optimized V-shaped regulating ball valve is verified through a combination of numerical simulation and experiment.

The results demonstrate that the optimized V-shaped regulating ball valve has higher flow regulation accuracy and a more stable flow regulation process. After optimization, the flow characteristic curve of the spool is closer to the ideal equal percentage characteristic. The simulation results of the flow field are consistent with the experimental results.

The proposed method significantly reduces the optimization time, has higher efficiency and solves the problem that traditional optimization methods struggle with, which is ensuring optimal flow regulation performance. Compared to the traditional trial-and-error optimization method, the proposed method is more effective. The feasibility of the method is supported by experimental results.