This paper presents a comprehensive analysis of the nonlinear dynamic response of stepped rectangular plates made of functionally graded porous material (FGPM), supported by the Kerr foundation, in a thermal environment. A novel analytical framework is developed to explore geometric and material variations. The study investigates structural variations in plate thickness with abrupt changes in uni- or bi-directional orientations, examining both single and double stepped thickness profiles. Material properties vary with thickness, featuring distinct horizontal discontinuities across plate segments. Porosity distributions, both even and uneven, are addressed using modified mixture rules. Nonlinear kinematic relationships are established using Reddy’s third-order shear deformation plate theory and von Kármán’s nonlinear geometric assumptions, with equations of motion solved via Galerkin’s technique. This improved model effectively addresses non-continuous thickness variation through integral calculus, enhancing computational efficiency. Validation is achieved by comparing outcomes with published literature and Finite Element Analysis (FEA). The study investigates the influence of material properties, elastic foundation, boundary conditions, and geometric parameters on the free vibration and nonlinear behaviors of the plates. Some of the key findings include: increasing the thickness of the stepped segment significantly heightens the fundamental frequency while reducing vibrational amplitudes; optimizing the location of the stepped segment directly impacts the plate’s fundamental frequency and vibrational amplitudes; and as the load factor increases, the difference between linear and nonlinear deflection becomes evident. Therefore, accurate FGPM stepped plate design requires incorporating nonlinear terms in the strain–displacement relationships. Suggestions for future model modifications are also discussed, contributing to advancements in structural design and analysis.
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