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An Experimental–Numerical Framework for Springback Prediction and Angle Compensation in Air Bending with Additively Manufactured Polymer Tools
Vesna Mandic
,Marko Delić
,Dragan Adamovic
,Dušan Arsić
,Nada Ratković
,Djordje Ivković
,Andjelka Ilic
Additive manufacturing of polymer tools represents a promising alternative to conventional steel tooling for low-force and low-volume sheet metal air bending. However, accurate prediction of sheet springback and the resulting deviation of the bending angle after elastic unloading remains a major challenge. This study presents an integrated experimental–numerical framework for the analysis of air bending with additively manufactured polymer tools, with emphasis on material characterization, springback prediction, and tool angle compensation. The methodology combines uniaxial tensile testing, controlled air-bending experiments, finite element modelling with rigid and deformable tools, and optical 3D scanning for angle measurement. Low-carbon steel DC04 sheets were modeled using an elastoplastic constitutive law, while FDM-printed ABS tools were described by experimentally calibrated material models. Numerical simulations were performed over a range of forming forces to evaluate springback behavior and elastic tool deformation. The results show very good agreement between experiments and simulations. Deviations in bending angle were below 1.5% for metallic tools and below 0.5% for springback compensation, with the smallest discrepancy obtained using a two-dimensional model with deformable tools. Experimental validation with ABS tools confirmed bending accuracy within ±1°. The proposed framework provides a reliable basis for springback prediction and rational design of additively manufactured polymer tools for air-bending applications.
Additive manufacturing of polymer tools represents a promising alternative to conventional steel tooling for low-force and low-volume sheet metal air bending. However, accurate prediction of sheet springback and the resulting deviation of the bending angle after elastic unloading remains a major challenge. This study presents an integrated experimental–numerical framework for the analysis of air bending with additively manufactured polymer tools, with emphasis on material characterization, springback prediction, and tool angle compensation. The methodology combines uniaxial tensile testing, controlled air-bending experiments, finite element modelling with rigid and deformable tools, and optical 3D scanning for angle measurement. Low-carbon steel DC04 sheets were modeled using an elastoplastic constitutive law, while FDM-printed ABS tools were described by experimentally calibrated material models. Numerical simulations were performed over a range of forming forces to evaluate springback behavior and elastic tool deformation. The results show very good agreement between experiments and simulations. Deviations in bending angle were below 1.5% for metallic tools and below 0.5% for springback compensation, with the smallest discrepancy obtained using a two-dimensional model with deformable tools. Experimental validation with ABS tools confirmed bending accuracy within ±1°. The proposed framework provides a reliable basis for springback prediction and rational design of additively manufactured polymer tools for air-bending applications.
Posted: 23 December 2025
Input Variable Effects on TBM Penetration Rate: Parametric and Machine Learning Models
Halil Karahan
,Devrim Alkaya
In this study, both linear and nonlinear parametric models (M1–M6) and machine learning (ML)–based approaches were evaluated for the reliable and interpretable prediction of tunnel boring machine (TBM) penetration rate (ROP). The analyses incorporated rock hardness index (BI), uniaxial compressive strength (UCS), joint angle (α), excavation depth (DPW), and BTS as input variables. Parametric model coefficients were optimized using the Differential Evolution (DE) algorithm, and variable effects were examined via Jacobian-based elasticity analysis under both original and standardized data scenarios. Parametric results indicate that the proposed M6 model outperforms existing literature correlations in terms of prediction accuracy and represents variable contributions in a more balanced and physically meaningful manner. While the dominant influence of BI and UCS on ROP is preserved across all models, interaction terms allow the indirect contributions of variables such as DPW and BTS to be captured more clearly. Model performance systematically improves when moving from linear to nonlinear and interaction-inclusive structures, with R² increasing from 0.62 for M1 to 0.69 for M6. Machine learning–based variable importance analyses largely corroborate the parametric findings, highlighting BI and α in tree-based methods, and UCS and α in SVM and GAM models. Notably, the GAM model exhibited the highest predictive performance under both data scenarios. Overall, the combined use of parametric and ML approaches provides a robust hybrid framework for accurate and interpretable prediction of TBM penetration rates.
In this study, both linear and nonlinear parametric models (M1–M6) and machine learning (ML)–based approaches were evaluated for the reliable and interpretable prediction of tunnel boring machine (TBM) penetration rate (ROP). The analyses incorporated rock hardness index (BI), uniaxial compressive strength (UCS), joint angle (α), excavation depth (DPW), and BTS as input variables. Parametric model coefficients were optimized using the Differential Evolution (DE) algorithm, and variable effects were examined via Jacobian-based elasticity analysis under both original and standardized data scenarios. Parametric results indicate that the proposed M6 model outperforms existing literature correlations in terms of prediction accuracy and represents variable contributions in a more balanced and physically meaningful manner. While the dominant influence of BI and UCS on ROP is preserved across all models, interaction terms allow the indirect contributions of variables such as DPW and BTS to be captured more clearly. Model performance systematically improves when moving from linear to nonlinear and interaction-inclusive structures, with R² increasing from 0.62 for M1 to 0.69 for M6. Machine learning–based variable importance analyses largely corroborate the parametric findings, highlighting BI and α in tree-based methods, and UCS and α in SVM and GAM models. Notably, the GAM model exhibited the highest predictive performance under both data scenarios. Overall, the combined use of parametric and ML approaches provides a robust hybrid framework for accurate and interpretable prediction of TBM penetration rates.
Posted: 23 December 2025
An Analysis of Notch Toughness of Electron Beam Powder Bed Fused (EB-PBF) Ti-6Al-4V in Relation to Build Orientation and Mechanical Properties
Mohammad Sayem Bin Abdullah
,Vidit Tambi
,Aditya Koneru
,Dwayne Arola
,Ramulu Mamidala
Posted: 23 December 2025
A False Sense of Privacy: Evaluating the Limitsof Textual Data Sanitization for Privacy Protection
Apeksha Bhuekar
Posted: 23 December 2025
Technological and Urban Innovation in the Context of the New European Bauhaus: The Case of Sunglider
Ewelina Gawell
,Dieter Otten
,Karolina Tulkowska-Słyk
Posted: 23 December 2025
Strategy Development for Solar Power Integration in Power Grids to Enhance Energy Security and Resilience
Nicolae Daniel Fita
,Mila Ilieva-Obretenova
,Mihai Popescu-Stela
,Florin Muresan-Grecu
,Adrian Mihai Schiopu
,Constantin Razvan Olteanu
,Aurelian Nicola
,Marius Gheorghe Manafu
Posted: 23 December 2025
Data-Driven Dielectric Elastomers Soft Human Lenses Imitation Interactive Control System
Hui Zhang
,Zhijie Xia
,Zhisheng Zhang
,Jianxiong Zhu
Posted: 23 December 2025
Collaborative Optimisation of Electronic Product Production Decisions Using Dynamic Programming and Bayesian Networks
Siyuan Songa
,Lizhu Su
,Jiarun Cui
,Wenzhuang Liu
,Jiazhe Ji
,Xinyu Wang
,Rui Yan
Posted: 23 December 2025
Simulation and Experimental Study of Vessel-Borne Active Motion Compensated Gangway for Offshore Wind Operation and Maintenance
Hongyan Mu
,Ting Zhou
,Binbin Li
,Kun Liu
Posted: 23 December 2025
VMPlaceS Enables Scalable Evaluation of Virtual Machine Placement Strategies Using a High-Fidelity Simulation Framework
Apeksha Bhuekar
Posted: 23 December 2025
Chronic In Vivo Biostability and Biocompatibility Evaluation of Polyether Urethane–Based Balloon Implants for Cardiac Application in a Porcine Model
Min-Gi Kim
,Jae-Young Seo
,June-hong Kim
,Jin-Chang Kim
,Jun-Young Park
,Hyun-A Song
,Kyeong-Deok Song
,Min-Ku Chon
Polyurethane-based implantable devices(PUIDs) delivered via catheter are increasingly used in structural heart interventions; however, limited in vivo data exist regarding their long-term biostability and biological safety. This study evaluated a balloon-shaped implant made of Pellethane®, a polyether-based polyurethane, designed as a three-dimensional intracardiac spacer and deployed via percutaneous femoral vein access. The device was chronically positioned adjacent to the tricuspid valve annulus in seven pigs for 24 weeks. Explanted devices and surrounding tissues were evaluated through material characterization (SEM, GPC, FT-IR, and 1H-NMR) and histological analysis. SEM and FT-IR confirmed preserved surface morphology and chemical bonds, GPC showed stable molecular weight, and ¹H-NMR revealed intact urethane and ether linkages. Materials characterization revealed no evidence of hydrolytic or oxidative degradation, indicating structural stability of the devices. Histological analysis showed stable device positioning with minimal thrombosis or inflammatory response. Biocompatibility was confirmed via ISO 10993-1:2018 Standard, and extractable substances were evaluated under aggressive extraction conditions specified by ISO 10993-18:2020, with no toxicologically significant findings. These findings support the long-term biostability and biological safety of the PUIDs in dynamic cardiac environments, informing future design criteria for catheter-delivered cardiovascular devices.
Polyurethane-based implantable devices(PUIDs) delivered via catheter are increasingly used in structural heart interventions; however, limited in vivo data exist regarding their long-term biostability and biological safety. This study evaluated a balloon-shaped implant made of Pellethane®, a polyether-based polyurethane, designed as a three-dimensional intracardiac spacer and deployed via percutaneous femoral vein access. The device was chronically positioned adjacent to the tricuspid valve annulus in seven pigs for 24 weeks. Explanted devices and surrounding tissues were evaluated through material characterization (SEM, GPC, FT-IR, and 1H-NMR) and histological analysis. SEM and FT-IR confirmed preserved surface morphology and chemical bonds, GPC showed stable molecular weight, and ¹H-NMR revealed intact urethane and ether linkages. Materials characterization revealed no evidence of hydrolytic or oxidative degradation, indicating structural stability of the devices. Histological analysis showed stable device positioning with minimal thrombosis or inflammatory response. Biocompatibility was confirmed via ISO 10993-1:2018 Standard, and extractable substances were evaluated under aggressive extraction conditions specified by ISO 10993-18:2020, with no toxicologically significant findings. These findings support the long-term biostability and biological safety of the PUIDs in dynamic cardiac environments, informing future design criteria for catheter-delivered cardiovascular devices.
Posted: 23 December 2025
A Simplified DEM Approach to Predict the Grinding Process in a Stirred Mill
Tinashe Manzini
,Murray M Bwalya
,Ngonidzashe Chimwani
Posted: 23 December 2025
Performance-Based Seismic Resistance Assessment of Reinforced Slopes Using the Force-Equilibrium Finite Displacement Method
Ching-Chuan Huang
Posted: 23 December 2025
Comparative Study of Pulsed Alkaline Electrolysis in Two Electrode Materials
Emanuel Mango
,Rui Filipe Marmont Lobo
Posted: 23 December 2025
Federated Continual Learning Framework for Robust mmWave Human Activity Recognition Under LOS–NLOS Domain Shifts
Yisi Ai
,Boon-Chong Seet
Posted: 23 December 2025
Key Management Indicators to Increase Productivity in an Ice Plant
Carmen Becerra
,Josías Huerta
,Juan Flores
Posted: 23 December 2025
Rain Erosion Atlas of Wind Turbine Blades for Japan Based on Long-Term Meteorological and Climate Dataset CRIEPI-RCM-Era2
Eiji Sakai
,Atsushi Hashimoto
,Kazuki Nanko
,Toshihiko Takahashi
,Hiroyuki Nishida
,Hidetoshi Tamura
,Yasuo Hattori
,Yoshikazu Kitano
Posted: 23 December 2025
Parallel Message Passing Decoders for Uncoded Transmitted Data: Towards the Unit Code Rate
Anoush Mirbadin
Posted: 23 December 2025
Experimental Evaluation of the Impacts of Suspended Particle Device Smart Windows with Glare Control on Occupant Thermal and Visual Comfort Levels in Winter
Sue-Young Choi
,Soo-Jin Lee
,Seung-Yeong Song
Posted: 23 December 2025
The Potential of Hydrogen Fuel Cell Buses for Sustainable Urban Transportation: A Life Cycle Perspective
Camila Padovan
,Ana Carolina Angelo
,Marcio D'Agosto
,Pedro Carneiro¹
Posted: 22 December 2025
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