The use of composite materials in several sectors, such as aeronautics and automotive, has been gaining distinction in recent years. However, due to their high costs, as well as unique characteristics, consequences of their heterogeneity, they present challenging gaps to be studied. As a result, the finite element method has been used as a way to analyze composite materials subjected to the most distinctive situations. Therefore, this work aims to approach the modeling of composite materials, focusing on material properties, failure criteria, types of elements and main application sectors. From the modeling point of view, different levels of modeling—micro, meso and macro, are presented. Regarding properties, different mechanical characteristics, theories and constitutive relationships involved to model these materials are presented. The text also discusses the types of elements most commonly used to simulate composites, which are solids, peel, plate and cohesive, as well as the various failure criteria developed and used for the simulation of these materials. In addition, the present article lists the main industrial sectors in which composite material simulation is used, and their gains from it, including aeronautics, aerospace, automotive, naval, energy, civil, sports, manufacturing and even electronics.

Metalworking is an essential process for the manufacture of machinery and equipment components. The design of the die geometry is an essential aspect of metalworking, and directly affects the resultant product’s quality and cost. As a matter of fact, a comprehensive understanding of the die bearing geometry plays a vital role in the die design process. For the specific case of wire drawing, however, few efforts have been dedicated to the study of the geometry of the bearing zone. In this regard, the present paper involves an attempt to investigate the effects of different geometries of the die bearing. For different forms of reduction as well as bearing zones, measurements are carried out for the wire-drawing process. Subsequently, by extracting the friction coefficients from the electrolytic tough pitch copper wire in cold-drawn essays, the numerical simulations are also implemented. We present the results on both the superficial and center radial tensions obtained by finite element methods. It is observed that the reduction of the friction coefficient leads to an increase in radial stress, while for a given friction coefficient, the substitution of the C-type die by the R-type one results in a decrease in the superficial radial stress of up to 93.27%, but an increase at the center of the material. Moreover, the die angle is found to play a less significant role in the resultant center radial stress, but it significantly affects the superficial radial stress. Lastly, R-type dies result in smaller superficial radial stress, with a change of up to 34.48%, but a slightly larger center radial stress up to 6.55% for different die angles. The implications of the present findings are discussed.

Controlling oil well pressure during drilling is one of the most complex and hazardous processes in the exploration stage. The drilling system undergoes constant variations, influenced by factors such as drilling depth, which in turn affects other process parameters. Consequently, applying a time-invariant control strategy becomes impractical. This study aimed to identify the PID parameters necessary to regulate bottom-hole pressure during drilling across different operating depths, with the goal of maintaining system stability and robustness. To achieve this, the parameters were tested using a Gain Scheduling (GS) controller, which adjusted the control gains according to various operating points. In the first section, the development of a mathematical model of the process, based on fluid mechanics, is presented. Linearizing this model introduced an integrating element, which complicated the process dynamics. In the second section, we present the design of the controller using the Internal Model Control (IMC) tuning methodology to address the integration challenges. Finally, PID parameters for different drilling depths were obtained and integrated into the GS controller via Matlab Simulink. The controller’s performance was then evaluated through simulations of typical drilling issues, such as simulated disturbances, confirming its viability. The GS-controlled system was compared to a system using an adaptive controller, demonstrating superior performance in the former.

This study presents an experimental and numerical investigation into the stress field in cylinders manufactured from photosensitive resin using the Masked Stereolithography (MSLA) technique. For material characterization, tensile and bending test data from resin specimens were utilized. The stress field in resin disks was experimentally analyzed using photoelasticity and Digital Image Correlation (DIC) methods, subjected to compressive loads, according to the cylinder–plane contact model. Images were captured during the experiments using polarizing film and a low-cost CPL lens, coupled to a smartphone. The experimental results were compared with numerical and analytical simulations, where the formation of fringes and regions indicating the direction and magnitude of normal and shear stresses were observed, with variations ranging from 0.6% to 8.2%. The convergence of the results demonstrates the feasibility of using parts produced with commercially available photosensitive resin on non-professional printers for studying contact theory and stress fields. In the future, this methodology is intended to be applied to studies on stress in gears.

The future of the automotive industry appears to hinge on the integration of dissimilar materials, such as aluminum alloys and carbon steel. However, this combination can lead to galvanic corrosion, compromising the structural integrity. In this study, laser-welded joints of 6013-T4 aluminum alloy and DP980 steel were evaluated for their morphology, microhardness, and corrosion resistance. Corrosion resistance was assessed using the electrochemical noise technique over time in 0.1 M Na₂SO₄ and 3.5% NaCl solutions. The wavelet function was applied to remove the DC trend, and energy diagrams were generated to identify the type of corrosive process occurring on the electrodes. Corrosion on the electrodes was also monitored using photomicrographic images. Analysis revealed an aluminum–steel mixture in the melting zone, along with the presence of AlFe, AlFe₃, and AlI₃Fe₄ intermetallic compounds. The highest Vickers microhardness was observed in the heat-affected zone, adjacent to the melt zone, where a martensitic microstructure was identified. The 6013-T4 aluminum alloy demonstrated the highest corrosion resistance in both media. Conversely, the electrochemical noise resistance was similar for the DP980 steel and the weld bead, indicating that the laser welding process does not significantly impact this property. The energy diagrams showed that localized pitting corrosion was the predominant form of corrosion. However, generalized and mixed corrosion were also observed, which corroborated the macroscopic analysis of the electrodes.

The stress concentration appears in components that have abrupt changes in its geometry or discontinuities such as holes, etc. Because of the presence of these discontinuities occurs a increasing of the stress value. There are several studies to estimate the increase of stress in metallic materials, however, a specific literature for calculating the stress concentration in composite materials is still low, even with the increase of its use in replacement of components made of metallic materials in recent years, particularly in the aerospace and automotive industries.This study was elaborates a computer simulation program of a component with a cylindrical holy and used the finite element method for calculating the stress concentrations using the commercial software ANSYS 10.0. This simulation has the objective to analyze the structural behavior of the component. The material used in the simulation and the test is a laminated composite consisting of a polymeric matrix of PPS (Poly phenylene sulphide) reinforced with carbon fibers, which has the general characteristic of combining the high strength fibers with a low density of the polymeric matrix. The simulation program was validated by tests. In tests and simulation were used material with and without the hole and the results stress obtained will be used for the application of generalized failure criterion of Tsai-Wu.The generalized failure criterion more popular is the criterion of Tsai-Wu. This theory considers that the criterion of von Mises, proposed for the initial yield of isotropic metals, could be modified to include effects of anisotropy in orthotropic materials ideally plastic.