Mechanical Stress Distribution Research Articles

Analysis of mechanical properties and stress distribution in self-healing microcapsules using micro-compressive test, nanoindentation test, and finite element analysis

Abstract This study analyzed self-healing microcapsules composed of melamine, urea, and formaldehyde (MUF). The thin shell’s mechanical properties were predicted using various techniques to gain a comprehensive understanding of their behavior. The compressive behavior of the microcapsules was assessed through micro-compression testing. The elastic modulus of the thin shell was precisely determined using nanoindentation, a method known for its accuracy in measuring material properties. Finite element analysis (FEA) was then applied, modeling the microcapsule between two plates and treating the core, which contains the healing agent, as an incompressible liquid. The mechanical properties of the thin shell, based on the elastic modulus derived from the nanoindentation test, were incorporated into the FEA, and the results were compared with those from the micro-compression test. Additionally, we analyzed the von Mises stress distribution to evaluate stress concentration within the spherical core–shell structure, ensuring the reliability of our conclusions. The test methods and analysis techniques presented in this study provide guidelines for improving the stiffness of MUF microcapsules. They can be further applied to predict the properties of materials with a spherical core–shell structure.

Finite element analysis of the Fibula's contribution to lower extremity torsional stiffness

AimsThe purpose of this article is to investigate the effects of the fibula on the torsional stiffness of the lower limb. A comprehensive model of the lower limb was constructed, including the resected femur, patella, tibia, fibula, and foot, with tendons and ligaments. Two configurations were developed, with and without the presence of the fibula, to evaluate the resulting stress state and consequently determine the contribution of the fibula to the torsional stiffness of the lower limb. MethodsThe finite element method was used to analyse how the fibula affects the stress distribution in the lower extremity under body weight loading and torsional forces. A detailed three-dimensional solid model of the lower extremity with and without the fibula was constructed. Loading conditions were imposed simulating an axial compressive load of 700 N applied to the upper extremity of the resected femur and a torsional load of 6000 Nmm applied to the proximal femur, and a fixed constraint was imposed on the foot. ResultsRemoving the fibula results in an increase in stress on all the tendons and ligaments tested. The increases ranged from 4 % (patellar tendon) to 21 % (lateral retinaculum). This suggests that the fibula plays a significant role in the distribution of mechanical stress in the lower extremity. The most affected structures are the lateral retinaculum and the posterior cruciate ligament, both with a 21 % increase in stress, suggesting that these structures may compensate more for the absence of the fibula. ConclusionThe fibula plays a critical role in maintaining the structural integrity and biomechanical function of the lower extremity. It acts as a lateral strut, contributing to the stability of the ankle and knee by providing an attachment point for several muscles and ligaments that are essential for coordinating complex movements and providing stability during dynamic activities.

Разработка прогностической математической модели травматических повреждений печени

Intra-abdominal bleeding is a leading cause of adverse outcomes in liver trauma, underscoring the critical importance of timely surgical intervention and optimal hemostasis strategies. This study investigates the impact of liver model segmentation on the distribution of mechanical stresses during impact simulation using the finite element method. By discretizing a computer-aided design (CAD) model into finite elements of two types – 4-node linear isoparametric elements for the parenchyma and 3-node Kirchhoff plate elements for intersegmental partitions – we developed a computational liver model adequately captures the organ's anatomy. Our results show that incorporating segmentation significantly affects the simulation outcomes, enabling a more realistic assessment of tissue damage patterns upon impact. This approach facilitates the simulation of a wide range of real-world traumatic effects, allowing for arbitrary specification of impact direction, speed, and affected area. By accounting for liver segmentation, our study provides a more accurate and comprehensive understanding of traumatic liver injuries, ultimately informing clinical decision-making and improving patient outcomes.

Mechanical stress distribution over the palate by different pacifiers assessed by finite element analysis and clinical data.

The mechanical behavior of each type of pacifier on rigid structures and their various impacts on orofacial growth have yet to be discovered. The study aimed to evaluate the stress distribution over a child's palate by three types of pacifiers using finite element analysis and clinical and laboratory data. Modulus of elasticity was obtained from 30 specimens comprising 10 of each conventional (A), orthodontic (B), and breast-shaped (C) pacifiers. Tongue strength was assessed in eight 3-year-old children (kPa). A hemi-maxilla model was obtained from 2- to 3-year-old skull tomography, and the images of pacifiers A, B, and C were captured using 3D scanning. The Hypermesh® program generated a mesh of 6-node tetrahedral elements for applying forces in the X, Y, and Z directions to enable a nonlinear analysis. Pacifier B exhibited the highest values for distributed stress on the palate, followed by pacifier A. Pacifier B stimulated the maxilla forward and sideways. In contrast, pacifier A promoted a forward and upward load, favoring a more atresic palate. Pacifiers A and B tended to rotate in the sagittal plane, generating tensions in the anterior incisors and favoring the open bite. Pacifier C exhibited lateral expansion by stress induction over the mid-palatal suture with less influence on incisor inclination. Pacifiers showed different detrimental stress distributions on the palate. This information can be helpful for improving recommendations given to parents.

Influence of the biomechanical evaluation of rupture using two shapes of same intramedullary implant after proximal interphalangeal joint arthrodesis to correct the claw/hammer pathology: A finite element study.

We used finite element analysis to study the mechanical stress distribution of a new intramedullary implant used for proximal interphalangeal joint (PIPJ) arthrodesis (PIPJA) to surgically correct the claw-hammer toe deformity that affects 20% of the population. After geometric reconstruction of the foot skeleton from claw toe images of a 36-year-old male patient, two implants were positioned, in the virtual model, one neutral implant (NI) and another one 10° angled (10°AI) within the PIPJ of the second through fourth HT during the toe-off phase of gait and results were compared to those derived for the non-surgical foot (NSF). A PIPJA was performed on the second toe using a NI reduced tensile stress at the proximal phalanx (PP) (45.83 MPa) compared to the NSF (59.44 MPa; p < 0.001). When using the 10°AI, the tensile stress was much higher at PP and middle phalanges (MP) of the same toe, measuring 147.58 and 160.58 MPa, respectively, versus 59.44 and 74.95 MPa at corresponding joints in the NSF (all p < 0.001). Similar results were found for compressive stresses. The NI reduced compressive stress at the second PP (-65.12 MPa) compared to the NSF (-113.23 MPa) and the 10°AI (-142 MPa) (all p < 0.001). The von Mises stresses within the implant were also significantly lower when using NI versus 10°AI (p < 0.001). Therefore, we do not recommend performing a PIPJA using the 10°AI due to the increase in stress concentration primarily at the second PP and MP, which could promote implant breakage.

Numerical simulation and mathematical modeling of biomechanical stress distribution in poroelastic tumor tissue via magnetic field and bio-ferro-fluid

Based on scientific evidence, it seems that bio-magnetic systems can change the process of cancer cell death by affecting the distribution of pressure and mechanical stress in the tumor tissue. Already most of the research has been done experimentally and few mathematical modeling and numerical simulations have been done to investigate the relationship between the magnetic parameters and the mechanical stress of the tumor tissue. This is despite the fact that in order to be able to make new equipment with the help of medical engineering methods, it is definitely necessary that the mathematics governing the problem and changes in the effective magnetic parameters (such as the shape of the magnetic source, magnetic flux density, magnetic source distance and ferro-fluid volume fraction) should be studied as much as possible. In this research, using numerical simulation and mathematical modeling, four common geometrical shapes (rectangular and circular) of the static magnetic field source were used to investigate the relationship between the change of the effective magnetic parameters and the mechanical stress created in the tumor tissue. The results of this research showed that when the magnetic flux density and ferro-fluid volume fraction and also the distance between the magnet and the tissue are kept constant, as well as without spending any extra energy, for a rectangular magnet, just by changing the way the source is placed on the tissue, the average biomechanical stress inside the tumor tissue causes a 25 % change. Also, for a circular magnet, just by doubling the radius of the magnet, the average biomechanical stress inside the tumor tissue causes a 73 % change.

On a Method for Calculating Bending and Shear Vibrations of a Porous Piezoelement in the Low-Frequency Region

Introduction. Devices for collecting and storing energy from the external environment are low-power sources of electric energy that are actively used. The autonomous devices for monitoring the damaged condition of various structures include them as well. The working element of these devices is a piezoelectric generator (PEG) — a converter of mechanical energy into electrical energy. The design of PEG is associated with the preliminary construction of their mathematical and computer models, with the help of which the calculation and optimization of structures is carried out. One of the ways to model and calculate PEG is to develop approximate calculation methods based on applied theories. The applied theories for calculating bending vibrations of multilayer piezoactive plates are known and previously developed in the literature. However, in the scientific literature there is not enough information about bending and shear vibrations as a tool for improving the efficiency of engineering calculations of the described structures. The objective of this work was to develop an applied method for calculating bending and shear vibrations of piezoceramic plates, including porous ones.Materials and Methods. Piezoceramics PZT-4, including porous ones, were used as the piezoactive material of the plate. When using porous ceramics, the rigidity of the structure decreased to a greater extent than the piezoelectric modules, which made it possible to obtain a more effective PEG under mechanical action. The mathematical formulation was carried out within the framework of the linear theory of electroelasticity with plate polarization in thickness. The sides of the plate were electrodated, the right side was fixed, and a smooth contact in the vertical wall was set on the left side. Steady-state vibrations of the plate were caused by pressure on the front surfaces of the plate or the difference in electrical potentials at the electrodes. To calculate the characteristics of PEG, the authors proposed an applied theory based on hypotheses about the distribution of characteristics of the stress-strain state and the electric field.Results. Transverse vibrations of a piezoceramic plate in the low-frequency region (below the first bending-shear resonance) were studied. Due to the fact that the mathematical formulation was considered within the framework of the linear theory of elasticity, the problem was divided into the sum of two. The first one took into account the mechanical effect: a distributed load and a transverse force at the left end acted on the front surfaces of the plate, and the potentials at the electrodes were zero. In the second task, there were no mechanical loads, but the potential difference was set at the electrodes. Based on hypotheses about the distribution of deformations, mechanical stresses and electric potential, both problems were reduced to a system of ordinary differential equations and boundary conditions. Comparison with the results of calculations by the finite element method in the ACELAN package showed the adequacy of the proposed applied theory in the low-frequency region.Discussion and Conclusion. Since the formulation of the problem was considered in the linear theory of electroelasticity, and the low-frequency region was studied, the work succeeded in dividing the problem of bending-shear vibrations of a porous piezoceramic plate into two: bending — with mechanical action at zero potentials, and shear — when setting the potential difference and zero mechanical action. The corresponding hypotheses about bending and shear were used. Two systems of ordinary differential equations and boundary conditions, which were solved analytically without the use of “heavy” finite element packages, were constructed. To compare the results and confirm the adequacy of the proposed method, the finite element modeling of such tasks was carried out in a specialized ACELAN package. The comparison showed that the error in determining displacements and electric potential when using this approach, in the case of setting mechanical loads and potential differences, did not exceed 6%. The method developed in the paper can be applied in the design of piezoelectric generators for energy storage in the low-frequency region.

Three-dimensional finite element analysis of cement-cup junction in total hip prosthesis: Mechanical stress distribution, crack initiation, and rupture dynamics

Three-dimensional finite element analysis of cement-cup junction in total hip prosthesis: Mechanical stress distribution, crack initiation, and rupture dynamics

A peridynamic differential operator modeling approach for ceramic matrix composites microstructure with uniform or non-uniform discretization

Based on the theory of peridynamic differential operator (PDDO), a novel three-dimensional (3D) peridynamic (PD) model for isotropic and orthotropic material is proposed to investigate the elastic mechanical behaviors and stress distribution of Ceramic Matrix Composites (CMC) microstructure. The non-local expressions of strain and stress tensors are derived by employing PDDO and the classical constitutive equations. The bond forces in interface region crossing two different constituent materials are obtained by converting the partial differential terms into the non-local forms. The weak form of PD equations of motion is derived by using the principle of virtual work and PDDO. The validity of this approach is verified by predicting the elastic response and stress distributions of isotropic and orthotropic materials under uniaxial tension and pure shear deformation. Finally, simulations are conducted on a CMC microstructure with fiber and matrix under periodic boundary conditions. It is demonstrated that the current approach can effectively build 3D CMC microstructure with uniform or non-uniform discretization, and accurately predict the stress fields and effective elastic properties.

Microstructure and mechanical behavior of rhombic dodecahedron-structured porous β-Ti composites fabricated via laser powder bed fusion

Porous β-Ti composites hold large promise for lightweight components due to their exceptional strength-ductility synergy. However, their microstructural behavior under both impact and compressive conditions have received limited attention. This study investigates the compressive and impact behavior of porous β-type Ti–25Nb (at.%) composites fabricated using laser powder bed fusion (LPBF). The composites feature a rhombic dodecahedron (RD) lattice structure and incorporate a central solid cylinder with varying diameters. Microstructural characterizations and finite element simulations were employed to analyze mechanical properties and stress distribution. Incorporation of 3 mm radius cylinders (TIII ∼45% porosity) significantly enhances compressive yield stress (88 ± 10 MPa), impact yield stress (153 ± 10 MPa), and impact energy absorption (41.2 J/cm³) while maintaining material plasticity. Compressive and impact loading initiate a martensitic transformation from β to α″ phase, strengthening the alloy through refined α″ formation with a finer grain size than β phase. Notably, a β→ α″ transformation and grain refinement occur in the node region that connects the solid cylinder and lattices, which undergoes significant deformation during impact. This observation suggests the impact resistance of porous β-Ti composites can be enhanced through tailored microstructures and strategic structural design.

Features of Mechanical Properties and Residual Stress Distribution in Butt Joint of HSB690-SM355 Dissimilar Steel

Features of Mechanical Properties and Residual Stress Distribution in Butt Joint of HSB690-SM355 Dissimilar Steel

FEM Analysis And Design Optimization Of The Piston

The workings of an engine rely on the piston rod and/or connecting rod to transmit the force of the expanding gas in the cylinder to the crankshaft. Because of its critical role in engines, the piston is subject to inertial stresses and cyclic gas pressure, which may lead to fatigue damage in the form of side wear, fractures in the piston head or crown, and other issues. According to the research, the top of the piston experiences the highest level of stress, which is a major contributor to fatigue failure. This study uses finite element analysis to illustrate the stress distribution on an internal combustion engine's piston. It is the CAD and CAE programs that carry out the FEA. Examining and analyzing the distribution of thermal and mechanical stresses on the piston under real-world engine conditions during combustion is the primary focus. Predicting the component's critical area and greater stress using finite element analysis is also detailed in the paper. Created a structural model of a piston using CATIA software. We ran simulations and stress analyses with the help of ANSYS V14.5.

DESIGN AND ANALYSIS OF THE PISTON USING COMPOSITE MATERIALS LIKE AA7275 STRUCTURAL AND THERMAL ANALYSIS DONE IN ANSYS SOFTWARE

This project focuses on the design and analysis of a piston utilizing composite materials, particularly AA7275, to enhance structural integrity and thermal efficiency. The study employs ANSYS software to conduct comprehensive structural and thermal analyses. The structural analysis evaluates the mechanical behavior, stress distribution, and deformation characteristics of the piston under varying operating conditions. Meanwhile, the thermal analysis investigates the heat transfer mechanisms, temperature distribution, and thermal stress accumulation within the piston. By integrating composite materials and utilizing advanced simulation techniques, this project aims to optimize the performance and reliability of the piston, contributing to advancements in engine technology. ANSYS software facilitates Multiphysics simulations, allowing engineers to study the interactions between different physical phenomena such as structural mechanics, fluid dynamics, electromagnetics, and thermal effects. Its robust solvers and algorithms enable accurate prediction of system behavior under various operating conditions, helping engineers optimize performance, reliability, and efficiency. Moreover, ANSYS provides a range of specialized modules tailored to specific industries and applications, including automotive, aerospace, electronics, healthcare, and renewable energy. These modules incorporate domain-specific features and workflows, empowering engineers to address industry-specific challenges and design requirements effectively. Recent advancements in ANSYS software include enhanced computational capabilities, improved user interfaces, and integration with emerging technologies such as artificial intelligence and additive manufacturing. These developments enable engineers to accelerate the design iteration process, reduce time-to-market, and achieve superior product performance. Furthermore, ANSYS supports collaborative engineering workflows through its integration with product lifecycle management (PLM) and computer-aided design (CAD) software. This integration facilitates seamless data exchange between design, simulation, and manufacturing teams, ensuring consistency and accuracy throughout the product development lifecycle. KEY WORDS : AA7275; Piston; Structural integrity and Thermal Efficiency; Structural analysis; ANSYS; CAD.

Biomechanical evaluation of a modified intramedullary nail for the treatment of unstable femoral trochanteric fractures

BackgroundThe Proximal Femoral Nail Antirotation (PFNA) device is the most commonly used implant to fix unstable femoral trochanteric fractures (UFTFs), but it has a relatively high incidence of complications. Due to this factor, the modified intramedullary nail (MIN) was created to treat patients with UFTFs. The aim was to exhibit the MIN and make a comparison with PFNA and InterTAN using biomechanical methods. MethodsAn adult UFTF model was developed using Mimics software. The PFNA, InterTAN nail, and MIN models were drawn referring to the corresponding parameters and installed in the fracture models. Vertical, anteroposterior (AP) bending, and torsion loads of the femoral head were set in advance and loaded onto the fracture models. The value of maximal displacement and von Mises stress was evaluated via finite element analysis (FEA). ResultsThe MIN model had smaller values for maximal displacement than that of the PFNA model, and the increase in displacement was less pronounced for the MIN compared to PFNA under increasing vertical loads. For the indicator of von Mises stress, the MIN model showed lower stress compared with the PFNA model in vertical loads ranging from 300 N to 2100 N. Except for the maximal stress at implants under AP bending loads, the MIN demonstrated the most superior biomechanical properties under AP bending and torsional loads. ConclusionThe MIN offered obvious advantages in terms of mechanical stability and stress distribution among the three studied implants, providing a promising implant option for patients with UFTFs.

Analysis of Mechanical Stress on Fowler-Nordheim Tunneling for Program Operation in 3D NAND Flash Memory

This study investigated the relationship between mechanical stress and program efficiency in three-dimensional (3D) NAND flash memory devices. A stacked memory array transistor (SMArT) 3D NAND flash structure was modeled using a technology computer-aided design (TCAD) simulation. The mechanical stress distribution in the device depended on the deposition temperature (TD) of the constituent material. In particular, the TD of tungsten (TD,W) dominated the mechanical stress. The tensile stress on the polycrystalline silicon (poly-Si) channel increased as the TD,W decreased, and the compressive stress on the tunneling oxide (Tox) decreased. Consequently, the barrier height between Tox and poly-Si, and the effective electron mass decreased as the electric field in the Tox increased. These changes significantly increased the Fowler-Nordheim (FN) tunneling process and program efficiency, indicating the crucial performance of 3D NAND flash. Moreover, the mechanical stress caused by the differences in TD,W improved the program efficiency at a lower program voltage (VPGM). Therefore, a change in the mechanical stress based on decreasing TD,W improved the program efficiency through a higher FN tunneling process.

Finite Element Analysis for Degenerative Cervical Myelopathy: Scoping Review of the Current Findings and Design Approaches, Including Recommendations on the Choice of Material Properties.

Degenerative cervical myelopathy (DCM) is a slow-motion spinal cord injury caused via chronic mechanical loading by spinal degenerative changes. A range of different degenerative changes can occur. Finite element analysis (FEA) can predict the distribution of mechanical stress and strain on the spinal cord to help understand the implications of any mechanical loading. One of the critical assumptions for FEA is the behavior of each anatomical element under loading (ie, its material properties). This scoping review aims to undertake a structured process to select the most appropriate material properties for use in DCM FEA. In doing so, it also provides an overview of existing modeling approaches in spinal cord disease and clinical insights into DCM. We conducted a scoping review using qualitative synthesis. Observational studies that discussed the use of FEA models involving the spinal cord in either health or disease (including DCM) were eligible for inclusion in the review. We followed the PRISMA-ScR (Preferred Reporting Items for Systematic Reviews and Meta-Analyses extension for Scoping Reviews) guidelines. The MEDLINE and Embase databases were searched to September 1, 2021. This was supplemented with citation searching to retrieve the literature used to define material properties. Duplicate title and abstract screening and data extraction were performed. The quality of evidence was appraised using the quality assessment tool we developed, adapted from the Newcastle-Ottawa Scale, and shortlisted with respect to DCM material properties, with a final recommendation provided. A qualitative synthesis of the literature is presented according to the Synthesis Without Meta-Analysis reporting guidelines. A total of 60 papers were included: 41 (68%) "FEA articles" and 19 (32%) "source articles." Most FEA articles (33/41, 80%) modeled the gray matter and white matter separately, with models typically based on tabulated data or, less frequently, a hyperelastic Ogden variant or linear elastic function. Of the 19 source articles, 14 (74%) were identified as describing the material properties of the spinal cord, of which 3 (21%) were considered most relevant to DCM. Of the 41 FEA articles, 15 (37%) focused on DCM, of which 9 (60%) focused on ossification of the posterior longitudinal ligament. Our aggregated results of DCM FEA indicate that spinal cord loading is influenced by the pattern of degenerative changes, with decompression alone (eg, laminectomy) sufficient to address this as opposed to decompression combined with other procedures (eg, laminectomy and fusion). FEA is a promising technique for exploring the pathobiology of DCM and informing clinical care. This review describes a structured approach to help future investigators deploy FEA for DCM. However, there are limitations to these recommendations and wider uncertainties. It is likely that these will need to be overcome to support the clinical translation of FEA to DCM.

Flower-like carbon spheres formed by self-assembly of nitrogen-doped porous nanoribbons to boost SnS2 nanosheets for advanced lithium storage

SnS2 is a two-dimensional layered material with high theoretical capacity, but its further application in lithium-ion batteries is limited by problems such as low intrinsic conductivity and dramatic volume expansion during lithiation process. Therefore, SnS2 nanosheets were designed to anchor in the interlayer nanospaces of flower-like carbon spheres self-assembled from nitrogen-doped porous carbon nanoribbons (SnS2/N-FC). Nitrogen-doped porous nanoribbons facilitated the uniform distribution of SnS2 nanosheets in the interlayer nanospaces of the flower-like carbon spheres, establishing a face-to-face interaction with the nanoribbons and the SnS2 nanosheets. This composite structure enhances the transfer of electrons between the components. In addition, the integration of spherical flower-like electrodes with the reserved interlayer nanospaces provided a buffering space for volume expansion which ensured an even distribution of mechanical stress. As a result, SnS2/N-FC exhibited a high reversible specific capacity of 1322.3 mAh g−1 after 200 cycles at 0.1 A g−1, with the capacity kept growing to 1329.4 mAh g−1 after 1000 cycles at 1 A g−1. This study introduces a novel approach for the design of anode materials which demonstrate excellent lithium storage.

Mathematical modelling of thermal stresses of induction surface hardening in axi-symmetric formulation

The paper presents the original general model of induction surface hardening based upon analysis of coupled electromagnetic, thermal, mechanical and metallurgical phenomena. The distribution of mechanical strains and stresses in surface layers of steel materials subjected to induction hardening is determined. This distribution is not caused only by the thermoelastic processes, but often, it is also influenced by plastic deformations of the exposed layers and transformation of particular levels of steel. An illustrative example shows the methodology of solution for an axi-symmetric configuration.

Mechanical responses and stress distribution of rock-like specimen containing a spherical defect under uniaxial compression

Spherical defect is often seen in rock material, and the size and position of the defect seriously affect the stability of rock mass. In this study, a locating device for preparing spherical defects was designed. A series of uniaxial compression tests and simulations were conducted to study the influence of the defect size and location on the mechanical, micro-cracking, failure characteristics, and stress distribution of the sample containing a spherical defect. The results indicate that the uniaxial compressive strength (UCS) and Young’s modulus both decrease with increasing defect size. The location variation of the same-sized spherical defect has a significant influence on the UCS but hardly influences Young’s modulus. The closer the defect is to the boundary, the lower the UCS is. The acoustic emission (AE) monitoring results indicate that the damage point aggregates and expands around the defect, forming a failure surface in the later stage of specimen loading. The failure modes of the specimen are divided into tensile failure, shear failure, and tensile-shear failure. Laboratory test results match well with the numerical simulation results obtained through the PFC3D program. The numerical stress monitoring results indicate that there is significant stress concentration near the defect. And the concentrated stress at the defect boundary drops before the the model reaches its peak stress, which can be used to predict the failure of the defected rock mass. The research findings could supply a certain reference for stability analysis and control of rock material containing similar types of defects.

FEM Analysis on Thermo-mechanical behavior and experimental validation of Al20Cr20Fe25Ni25Mn10 High Entropy Alloy during Spark Plasma Sintering

High entropy alloy developed with spark plasma sintering was modelled with COMSOL Multiphysics. This focus at examining the effect of spark plasma sintering fabrication parameters on thermal and mechanical stress distribution in the sintered Al20Cr20Fe25Ni25Mn10 high entropy alloy (HEA). And to achieve this, a fully thermal-electrical-mechanical integrated and dynamic finite element model (FEM) was adopted. The simulation utilised the optimal parameters employed in the laboratory to produce the samples. The geometry for the modelling was 2D axisymmetric as the parameters were based on temperature-dependent characteristics noting that only the sintered sample was modelled and simulated in order not to simplify the modelling. The FEM maintained constant sintering temperature, pressure, and heating rate but concentrated on the impact of residence durations. To verify the simulation results, morphological alterations and densification validation tests were conducted. The microstructural characterization of the sintered sample demonstrated the relationship between the stress distribution and computational temperature found in the current FEM. Noting good particle-to-particle necking. From the model, results showed that the sintered sample at different points depicted a yield stress far greater than the von Mises stress with least thermal stress at 30 MPa. This validate that the developed sample is mechanically stable based on the factor of safety failure criterion and design. However, the study recommend that further work should be conducted considering different sintering pressure of variation 10 to 30 MPa.