Jul 2026· International Journal of Precision Engineering and Manufacturing· 0 citations· 22 references
Abstract
This study presents an experimentally supported nonlinear finite element and topology optimization framework for the lightweight design of an automotive steering knuckle manufactured from GH60 grey cast iron. The baseline component was produced via sand casting and evaluated under three critical loading scenarios: braking, vertical impact, and lateral rim impact through physical bench tests. Nonlinear finite element analyses were performed using Simcenter software to replicate the experimental conditions, incorporating elastic–plastic material behaviour. An experimental–numerical correlation was established based on the observed failure load under lateral rim impact, resulting in an approximate deviation of 5.8% between the predicted stress and the material strength limit. This correlation was used as an engineering-level calibration of the numerical model at the governing loading condition. Following this calibration, topology optimization was carried out in Siemens NX under identical loading and boundary conditions. Three optimized knuckle geometries with different mass reduction levels were reconstructed and subsequently evaluated using nonlinear finite element analyses under braking, vertical, and lateral loading conditions. Among the investigated alternatives, Model 2 achieved approximately 14% mass reduction relative to the baseline configuration while maintaining acceptable stress levels across the considered loading scenarios. The results indicate that integrating experimental observations with nonlinear numerical analysis can provide a consistent basis for strength-based lightweight design of safety-critical components. The additional analyses demonstrated that the experimentally derived calibration approach remained applicable to the investigated topology-optimized geometries, as the governing load case and critical stress concentration regions were preserved after optimization. Nevertheless, the experimental calibration was established using the baseline geometry, and further experimental validation of optimized configurations would be beneficial to assess the applicability of the proposed approach to a broader range of geometries and loading conditions.
This study focuses on the fuel tank of a specific excavator model, employing CATIA for modeling and ANSYS Workbench for finite element analysis. Static strength, modal, and random vibration simulations were performed to address stress concentration, excessive deformation, and resonance risks caused by oil sloshing. An optimized design was proposed and experimentally validated. The original fuel tank was first simplified and modeled using Q235 material. A mesh convergence study determined a 10 mm element size, balancing accuracy and computational efficiency. Static analysis confirmed that maximum stress and deformation met material allowables. Modal analysis revealed a first natural frequency of approximately 67.40 Hz, significantly above the frame's excitation frequency of around 10 Hz, effectively avoiding resonance. Random vibration analysis indicated prominent Y-direction deformation and X-direction stress. An optimization scheme was developed: symmetrically lengthening the transverse anti-slosh baffles and adding rounded stiffening ribs at the bottom. Post-optimization, deformations and stresses decreased markedly in all directions, with X-direction stress reduced by over 60%. Bench strain testing agreed with simulation results to within 91%, verifying the reliability and safety of the optimized structure. Results demonstrate that combining anti-slosh baffles with stiffening ribs significantly enhances vibration resistance, reduces fatigue failure risk, and maintains controllable manufacturing processes and costs. This provides a reusable simulation and optimization methodology for lightweight, durable fuel tank design in construction machinery.
Bowen Chen, Peigang Jiao, Guoqing Qi et al.· Sound & Vibration· 0 citations
The gearbox housing in automotive transmissions plays a critical role in maintaining shaft alignment and supporting bearings and gears under operational loads, yet conventional designs frequently incorporate excess material that increases mass without enhancing performance. This study integrates transmission load analysis, finite element modeling, and topology optimization to derive an efficient material layout for a gearbox housing under realistic loading conditions obtained from a spur-gear transmission system. Loads were determined from detailed calculations of gear forces, shaft reactions, and bearing supports using specified vehicle parameters (maximum engine torque of 152 Nm, gross vehicle weight of 1850 kg). A finite-element model of the AA380 aluminum alloy housing was constructed with fixed boundary conditions at the clutch interface and bearing forces applied at the mounting locations. Topology optimization was then performed to minimize mass while constraining maximum von Mises stress and deformation. The optimized design achieved a 65% mass reduction. Post-optimization analysis confirmed that the peak stress remained below the material yield strength and that structural stiffness satisfied transmission requirements. These results demonstrate that topology optimization, when driven by transmission-derived loads, enables substantial lightweighting of gearbox housings without compromising functional integrity. The methodology offers a practical route toward more efficient drivetrain components.
Vo Thanh Tien, Bui Ngoc Trieu, Nguyen Tuan Phuong et al.· 2026 11th International Conf...· 0 citations
Structural failures caused by fatigue represent one of the main challenges in heavy industrial equipment operating under severe loading conditions. This study evaluates the structural performance of a Vibrocat head carriage subjected to a critical load of 200 kN through Computer-Aided Design (CAD) and Finite Element Analysis (FEA). The original geometry was reconstructed and numerically analyzed using SolidWorks Simulation, considering ASTM A36 structural steel and linear elastic material behavior. The initial results revealed a maximum Von Mises stress of 617.86 MPa and a safety factor of 0.40, confirming the occurrence of localized yielding and explaining the recurrent fatigue failures observed during operation. Based on these findings, the head mounting plate was redesigned and validated under identical boundary conditions. The optimized configuration reduced the maximum stress to 126.63 MPa and increased the safety factor to 1.97, maintaining the component entirely within the elastic regime. The proposed reinforcement proved technically feasible, economically viable, and capable of significantly improving structural reliability and operational safety.
Denilson de Campos Branco da Silva, Edgard Gonçalves Cardoso, Leandro Cardoso Da Silva et al.· Revista edUCA - Revista Mult...· 0 citations
This study focuses on the capacity design of earthquake-resistant steel structures incorporating knee bracing systems, which serve as dissipative elements. It also presents the development and validation of a numerical model for simulating the behavior of these systems. The proposed model accurately captures the response of the fuse element by accounting for the interaction among axial force, shear, and bending moment, including second-order effects, while maintaining low computational demands. Model validation was performed through comparison with two independent experimental campaigns: (1) three-point bending tests on isolated fuses to characterize their local behavior, and (2) cyclic push-over tests on a full-scale, single-story frame to evaluate the global response of the system under lateral loading. Following the validation, an extensive parametric study was carried out via nonlinear static analyses on a multi-story, multi-bay steel frame with semi-rigid joints equipped with knee bracing systems. The investigation examined the influence of the axial forces in the fuses, the fuse cross-sectional typology, the joint rotational stiffness, and the lateral load distribution. The proposed model provides a practical and computationally efficient tool to support performance-based design and optimization of energy-dissipative devices in steel frame structures. The paper also provides a series of design recommendations for practitioners involved in designing earthquake-resistant structures with knee bracing systems.
R. Piazzon, F. Gusella, P. Zampieri· Bulletin of Earthquake Engin...· 0 citations
As a lightweight load‐bearing member for aerospace truss structures, thin‐walled metal tubes require improved buckling resistance without additional mass. To this end, this paper innovatively designs a thin‐walled metal inflatable tube structure. The axial compressive behavior of the proposed tube and the influence of internal pressure are preliminarily investigated through experiments and numerical simulations. Axial compression buckling tests were conducted on two sets of specimens under 0 and 2 bar to evaluate the pressure‐induced changes in axial stiffness, critical buckling load, and buckling mode. Concurrently, a finite element model was established using material parameters obtained from independent tensile tests. The model was validated against the experimental results at 0 and 2 bar and was subsequently employed to numerically investigate the axial compressive response over a wider pressure range. In addition, initial local dimple imperfections were introduced into the finite element model to examine the imperfection sensitivity of pressurized thin‐walled tubes. Combining experimental and numerical simulation results reveals that pressurization significantly increases the buckling critical load of thin‐walled tubes and improves buckling morphology, thereby suppressing the occurrence of abnormal deformation. The numerical results also indicate that internal pressure can reduce the sensitivity of thin‐walled tubes to local dimple imperfections.
Dahai Zhang, Jiarong Jiang, Pengfei Yan et al.· Advanced Engineering Materia...· 0 citations
Steel wire ropes (SWRs) are exceptional load-bearing elements. However, conventional designs often treat them as passive structures, lacking strategies to actively program their ultimate load-bearing capacity and failure behaviors. To address this gap, this study systematically investigates the tunable load capacity and fracture characteristics of SWRs by developing a simplified power-law hardening elastoplastic constitutive model and a finite element framework integrated with a ductile-damage criterion. Following material parameter calibration via single-wire tests and independent experimental validation of the baseline model using 1 × 7 strand tensile tests, comprehensive numerical parametric studies were conducted to evaluate the simulation-based influence of core diameter (dcore), overall rope diameter (D), layer count (F), and strand configuration (S) on mechanical responses. The numerical results reveal that these geometric parameters act as effective tuning knobs that govern internal stress transfer pathways and ultimate load-bearing capacity. Specifically, simulations predict that increasing the dcore to 1.00 mm elevates the peak tensile force by 9.6% while maintaining a 90.07% tensile force efficiency (TFE, defined as the ratio of mean to peak tensile force). Furthermore, implementing a hybrid multi-strand architecture (SWR-S3) achieves an optimized TFE of 99.76%. These structural modifications facilitate internal strain synchronization, which effectively buffers localized stress peaks and dictates the progressive fracture sequence. Ultimately, this study demonstrates the potential of complementing traditional material enhancement strategies with active geometric parametrization. Rather than offering immediate industrial design rules, it provides a conceptual theoretical framework for exploring custom-tailored tensile strength profiles and predictable failure behaviors. However, because these advanced structural configurations are evaluated using idealized quasi-static finite element models, further experimental validation addressing real-world manufacturing constraints, residual stresses, and dynamic loading is required before practical engineering deployment.
Jing Xiao, Qiqi Li, Lin Hu et al.· Materials· 0 citations
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