Abstract Metaheuristic algorithms are optimization techniques inspired by natural processes, widely used to solve complex real-world problems. Traditional methods like swarm-based established optimizers often face challenges like premature convergence and high computational costs. The aim of this research is to develop a new optimization method for optimizing electric vehicle components and real-world problems. This research introduces a new chaotic fishing cat optimization algorithm (CFCO), a new optimization algorithm based on recent fishing cat optimization algorithm and chaotic maps. The chaotic maps are integrated into FCO to improve the balance between exploration and exploitation. This research is the first application of the CFCO to the optimum design of electric vehicle components in the literature. The algorithm is applied to various industrial design optimization problems, including structural optimization of cantilever beams, weight optimization of a coupling with a bolted rim, optimization of side profile of an electric vehicle battery enclosure, and heat exchanger economic optimization. The results demonstrate that the developed CFCO outperforms existing recent metaheuristic techniques, achieving superior efficiency and accuracy in industrial applications.

Abstract In engineering and other fields, metaheuristic algorithms are increasingly used to solve challenging optimization problems. High-dimensional and multimodal issues are complex for traditional optimization techniques, which has led to the development of hybrid metaheuristics that are improved by artificial neural networks (ANNs). To improve search efficiency and solution accuracy, this work presents an ANN-assisted Catch Fish Optimization Algorithm (MCFOA), which draws inspiration from conventional fishing methods. Numerous engineering applications, such as the optimal design of the side profile of an electric vehicle battery box, shell and tube heat exchanger, industrial gear optimization, and welded beam cost minimization, show off the efficacy of MCFOA. For the novel battery case problems, the modified optimizer realized a 20 % improvement in the design compared to the initial design, as well as a 4.5 % improvement compared to the Starfish optimizer. Moreover, for the engineering design problems, the modified optimizer realized 4–10 % better results in terms of the best values of the fitness function. This shows the applicability and implementation of the proposed optimizer for the optimization of real-world engineering problems.

Abstract In this study, it was tried to determine whether it is possible to produce the slide parts of light firearm from polyamide or glass fiber reinforced polyamide composite material by examining the stresses formed in the body after firing with the finite element method. The slide part of the 25 ACP model pistol with a caliber of 6.35 mm was used for solid modeling, and then the stress and deformation conditions were examined with finite element analysis. In the analysis to be made for the experiments, the firing was carried out using a pistol bullet with a diameter of 6.35 mm. The 6.35 mm caliber is particularly appealing for daily carry or easy storage due to its compact and lightweight design. As a result of the analysis, it was determined that the slide section modeled with both materials experienced plastic deformation. In terms of stress values, it was observed that the stress value of PA66 GF30 during firing was significantly higher compared to PA66. On the other hand, it was determined that the stress in the slide section of the PA66 GF30 composite material during firing was close to the stress of PA66.

Abstract Optimizing real-world engineering design challenges is inherently complex and difficult, especially when optimal solutions are expected. To this end, the creation of new and efficient optimization algorithms is not an option but a necessity. This paper presents an improved version of the recently developed Polar fox optimization technique. The addition of dynamic adversarial learning improves the dynamic adversarial learning Polar fox optimization algorithm by improving the performance of the algorithm to optimize real-world optimization problems not only very quickly but also accurately. Using test problems from the field of engineering disciplines, such as car crash test, welded beam structure, three-bar truss, and cantilever beam problem, the new optimizer known as the modified Polar fox optimization algorithm (MPROA) was validated before being used to optimize an automobile suspension arm. MPROA achieved superior results in achieving the goal quickly and accurately and proved its potential to solve complex engineering problems. Moreover, the comparison will also reveal the power of the MPROA developed in this work to tackle multiple issues that constrained the reach of a globally optimal solution.

Abstract Rod ends used in automotive industry are the utmost important elements that play a critical role in suspension system and steering devices. They are exposed to high sudden forces in both axial and radial directions and so the life performance is one of the big challenge for the manufacturers. In this study, the effect of design parameters on increasing the fatigue life of rod ends was investigated. Existing rod ends were subjected to fatigue tests under ±40 kN, ±50 kN and ±70 kN loading. The analysis and test results showed that the fatigue life of the existing design was low and the damage generally started in areas with sharp corners or low radii. Thus, a new road end design was proposed and thanks to the optimized new design, the fatigue life of rod ends was increased from 135,310 cycles to 884,043 cycles on average under ±50 kN load. The obtained results show that the improvement of the sharp corners and radius of the road end enhance the fatigue performance significantly, which is very important for the manufacturers and designers in the automotive steering mechanisms.

Abstract The purpose of this research is to examine the absorbed energy, resistance to impact load of sandwich composite, and power exercised by impactor, experimentally. Therefore, low velocity impact tests were performed at three different energy levels for two distinct noses on sandwich composite with a PVC core and varying amounts of S2-glass layers. The vacuum-assisted resin infusion method (VARIM) was used to manufacture sandwich composites. S2-glass fabric with an areal density of 190 gm−2 and polyvinyl chloride (PVC) core material with a thickness of 10 mm were utilized. For every face sheet material, three distinct layer numbers of S2-glass fabrics were used. It is seen that composites exposed to flat impactors absorb considerably more energy than hemispherical ones.

Abstract Cast iron components made of gray iron that come into contact with liquids under oscillating pressure may suffer damage caused by cavitation erosion. Understanding the mechanisms of initiation and development of their degradation in operating environments is essential for improving the lifespan and durability of the materials used in these engineering components. This study illustrates the cavitation erosion behavior of gray cast iron with lamellar graphite and a pearlitic metallic matrix, providing a detailed analysis of microstructural images of the damaged surface areas. The tests were conducted using an ultrasonic vibratory apparatus, with potable water from the public supply network as the test liquid. Based on cavitation curves, which were compared to those of unalloyed C45 steel that underwent annealing for softening to achieve a hardness similar to that of cast iron, as well as microscopic observations of the cavitated surfaces, a sequence of deterioration models is proposed to explain the cavitation erosion behavior of this material. The implosion of collapsed bubbles on the surface leads to chipping at the centers of graphite clusters, accompanied by their removal and pitting phenomena along the graphite filaments as well as direct pitting of the metallic matrix. As the number of bubble collapses increases, the number of pits also rises, leading to their coalescence and the formation of fatigue microcracks, which expand and cause ductile removal of the metallic matrix material.

Abstract Dissimilar welding between copper and aluminum presents a challenge because Cu–Al intermetallic compounds (IMCs) are easily generated in the weld seams. Due to the low welding heat input, friction stir welding minimizes contact between the two dissimilar metals and enhances joint performance. In the present study, friction stir lap welding between 6,061 alloy and T2 copper was achieved using two distinct sets of welding parameters. The hardness, shear strength, and microstructure of the two welded joints were comparatively investigated and analyzed. It was found that the hardness of the stir zone in Sample 1, characterized with a low heat input parameter, remained below 100 HV, exhibiting minimal variation. In contrast, regions with significantly higher hardness, reaching a maximum value of ∼370 HV, were observed in the stir zone of Sample 2, characterized by high heat input parameters. Moreover, the shear strength of Sample 1 was 25 % higher than that of Sample 2. Both welded samples fractured at the hook-shaped structures of the copper/aluminum interface. Serrated fracture lines were particularly evident in Sample 1, with a lower hardness value in the fracture region compared to Sample 2.

Abstract Applying a coating to substrates is widespread across various industrial domains, aimed at tailoring base material properties for specific applications. The three-point bending test has emerged as a critical tool for evaluating the mechanical characteristics of coating/substrate systems, ensuring integrity and safe operation under high contact loads and harsh environments. This paper reviews the literature pertaining to the assessment of coated specimens by the three-point bending test. Interesting insights are reported on describing test process, coating/substrate configurations, and important techniques used in combination for an easier and clearer understanding of the obtained results. Specifically, this paper comprehensively discusses and reviews the various outstanding goals that could be achieved by subjecting the coated specimen to the three-point bending test. The mechanical properties that could be acquired from this test are exhaustively enumerated, along with an explanation of the methodology. Finally, the different methods to assess the coating/substrate integrity are summarized. These insights aim to provide guidelines for gaining benefits and using them effectively for studying other coating/substrate assemblies.

Abstract Hole-drilling method is a standardized technique for obtaining residual stresses in isotropic structures. Previous studies provide a foundation that enables the use of this method to investigate orthotropic structures, such as fiber-reinforced composites. In this study, the incremental hole-drilling method was applied to investigate residual stresses in filament wound type 4 composite pressure vessels. The investigated composite cylinders were manufactured with different internal pressure functions during the winding process, to achieve distinct residual stress states. Additionally, the influence of the initial loading under sustained internal pressure and increased temperature on the stress distribution was investigated. It was shown that the residual stress state can be influenced by varying the internal pressure in the winding process. After testing at sustained load and increased temperature, a stress redistribution was observed, which took place due to creep phenomena. Finally, a discussion of the challenges for the application of the hole-drilling method to composite pressure vessels is provided.