ANSYS APDL Research Articles

Numerical modeling of induction heating systems with load of azimuthal periodicity

The paper presents developed numerical modelling methodology of induction heating problems of disks with a simple and complex profile in 3D for calculating the coupled electromagnetic and thermal tasks in the parametric design language (ANSYS APDL). We demonstrate that the developed tools can be used for products of various sizes, as well as for other metal engineering components using the example of local electromagnetic processing of a metal disk and a diaphragm spring. The authors used development for parametric research and design of induction heaters. The described methodology has particular specificity, due to which it is possible to expand the scope for a number of engineering units with azimuthal periodicity property.

Numerical Simulation on The Onion Dryer Frame Capacity of 5 kg/hour

<h1>Typical technology for processing red onion affects the quality of red onion produced. The process of drying red onion is one of the important factors in producing the best quality of red onion. Environmentally friendly and easy operation and maintenance technology is the desired technology. In the process of engine design, the strength of the material and structure are the main factors of the building of the machine. Calculation with finite element method (FEM) is the best choice to obtain information on stress distribution on a machine structure. In this study, the calculation of the FEM method was assisted by Ansys APDL 15.0 software. The objectives of this study were: (1) calculation of the load on the tray structure, (2) the distribution of stress on the tray structure, seat, and frame for red onion dryers, and (3) analyzing the strength of the material using the Tresca and Energy Distortion methods. The input load comes from the weight of the tray and red onion. The analytical method used is the finite element method with the type of structural analysis and Beam 3Node 189 element type. Based on the FEM simulation results, the maximum stress that occurs in the tray is 1.22 MPa and the maximum deflection is 0.0055 mm. The maximum stress in the tray support structure is 33.25 MPa and the maximum deflection is 0.014 mm. The maximum stress on the frame structure of the onion drying machine is 0.89 MPa and the maximum deflection is 0.000235 mm which occurs in the middle of the machine structure. Using the Tresca and Distortion Energy theories, it is found that the stresses that occur are still far from the failure criteria for all structures. Likewise, the deflection that occurs is very small so that the construction of the onion drying machine is safe to use.</h1>

The “Projection-by-Projection” (PbP) criterion for multiaxial random fatigue loadings

This work is motivated by the increasing interest towards the application of the “Projection-by-Projection” (PbP) spectral method in finite element (FE) analysis of components under multiaxial random loadings. To help users and engineers in developing their software routines, this paper presents a set of numerical case studies to be used as a guideline to implement the PbP method. The sequence of analysis steps in the method are first summarized and explained. A first numerical example is then illustrated, in which various types of biaxial random stress are applied to three materials with different tension/torsion fatigue properties. Results of each analysis step are displayed explicitly to allow a plain understanding of how the PbP method works. The examples are chosen with the purpose to show the capability of the method to take into account the effect of correlation degree among stress components, and the relationship between material and multiaxial stress in relation to the tension/torsion fatigue properties. A case study is finally discussed, in which the method is applied to a FE structural durability analysis of a simple structure subjected to random excitations. The example describes the flowchart and the program by which to implement the method through Ansys APDL software. This final example illustrates how the PbP method is an efficient tool to analyze multiaxial random stresses in complex structures.

Реализация топологической оптимизации методом BESO в среде ANSYS APDL и ее применение для оптимизации формы шатуна тепловозного дизеля

Реализация топологической оптимизации методом BESO в среде ANSYS APDL и ее применение для оптимизации формы шатуна тепловозного дизеля

Parametric design and optimization of engine disc

With the development of science and technology, traditional design methods can no longer meet the needs of modern design and production development. Parametric and optimal design has become one of the most popular application technologies in CAD. Parametric and optimal design was studied based on VB.net language for secondary development of AutoCAD and MATLAB language for secondary development of ANSYS Apdl for disc of aero-engine. The structural parameterization technology was used to realize the rapid forming, and genetic algorithm retains elite was used to optimal design. The optimal design was carried out by using the developed software in this paper, and the optimal results shown that the disc weight was reduced by 34.48 %, the reduction effect of weight was obvious.

A Multi-Scale Modeling Approach for Simulating Crack Sensing in Polymer Fibrous Composites Using Electrically Conductive Carbon Nanotube Networks. Part II: Meso- and Macro-Scale Analyses

This is the second of a two-paper series describing a multi-scale modeling approach developed to simulate crack sensing in polymer fibrous composites by exploiting interruption of electrically conductive carbon nanotube (CNT) networks. The approach is based on the finite element (FE) method. Numerical models at three different scales, namely the micro-scale, the meso-scale and the macro-scale, have been developed using the ANSYS APDL environment. In the present paper, the meso- and macro-scale analyses are described. In the meso-scale, a two-dimensional model of the CNT/polymer matrix reinforced by carbon fibers is used to develop a crack sensing methodology from a parametric study which relates the crack position and length with the reduction of current flow. In the meso-model, the effective electrical conductivity of the CNT/polymer computed from the micro-scale is used as input. In the macro-scale, the final implementation of the crack sensing methodology is performed on a CNT/polymer/carbon fiber composite volume using as input the electrical response of the cracked CNT/polymer derived at the micro-scale and the crack sensing methodology. Analyses have been performed for cracks of two different lengths. In both cases, the numerical model predicts with good accuracy both the length and position of the crack. These results highlight the prospect of conductive CNT networks to be used as a localized structural health monitoring technique.

Modelling of non-conventional instrument transformers (NCIT) by Finite Element Method FEM

In this paper, we have shown that the proposed non-conventional instrument transformer using magnetic shape memory (MSM) alloys can be used for current measurement in high voltage overhead transmission lines. By modelling one of the most used conductors at high voltage overhead transmission lines (400kV, 300–600A, AC) and our sensor consisting of a magnetic circuit and an MSM element, NCIT’s design was optimised for these lines and it was shown that the typical values of electrical current expected in a normal working regime would trigger the MSM element. Different designs of magnetic circuits were modelled in ANSYS APDL and discussed, comparing the obtained results for several different materials for magnetic circuit.

Simulation of the behavior of aluminum alloys welded in Friction Stir Welding FSW

The friction stir welding FSW is a topical technique to date, either for experimental or numerical research topics. Based on the fact that the majority of the heat generated, comes from the contact between the workpiece and the shoulder, and from the work of friction done by the pin. Thus, it is crucial to approach the reality, by simulating the most of the conditions, related to the FSW process. The development of a numerical model allows us, not only to simulate the FSW welding process, but also to conduct a parametric study and vary the welding conditions as desired. Therefore, a numerical study is conducted on the friction stir welding of AA 5083H111 work piece, in order to perceive the optimal settings. A three dimensional model designed by ANSYS APDL was used. Before proceeding with this, a preliminary experimental study was carried out on FSW welded AA 6082 –T6 specimens and base material, using tensile and fatigue tests. The numerical results obtained, essentially longitudinal residual stresses, are compared to other studies, experimental and numerical.

Modeling and Calibration of Electrical Capacitance Tomography Sensor for Medical Imaging

Electrical Capacitance Tomography (ECT) is an imaging technique which generates a cross-sectional image representing the internal permittivity distribution based on external capacitance measurements. It possesses the advantages of being non-radioactive, non-intrusive, non-invasive, high imaging speed and low cost over the conventional imaging techniques. Inter-electrode capacitance measurements are done by exciting electrodes placed around the non-conductive dielectric medium cylinder inside which, the material to be imaged is placed. This paper emphasizes on modelling and calibrating an electrical capacitance tomography sensor using ANSYS APDL with medium as air, water and extending the procedure for normal bone and cracked bone. ECT sensor is modelled by mounting 12 electrodes symmetrically outside the cylinder. The cylinder is made up of Polyvinyl Chloride (PVC) which is non-conductive dielectric medium while the electrodes are made up of Copper (Cu) which is conductive. The electrodes are excited in pairs and the potential distribution which is based on permittivity of the medium is analysed using ANSYS and the capacitance between the electrodes were calculated. The entire electrode modelling, calibration and capacitance measurement for the simulated bone model with and without crack is presented in this paper.

Combined modelling methodology for optimisation of box design based on hybrid genetic algorithm

The hybrid genetic algorithm (HGA) was used to optimise box design to maximise cooling performance, mechanical performance, pallet footprint, and container packing efficiency and to minimise cardboard usage. These factors are normally investigated independently, but the industry requires combined functionality. Here, we present a case study, for optimisation of regular slotted carton boxes filled with wrapped beef mince. After packing, individual boxes are chilled to a desired storage temperature and then palletised for shipping. Four models were developed to predict design performance, including cooling rate, mechanical performance, cardboard usage, and box stacking on pallets. The combination of the model results was used to score the average performance of box designs. The models were solved by Comsol Multiphysics, Ansys APDL, and Cape Pack. The overall design generation and optimisation were developed with Matlab that controls all these software packages, evaluates the interactions between results, and runs the HGA for box optimisation. The HGA was conducted for 10 generations each with a population of 100 individuals. The optimisation routine successfully found optimum dimensions for the box for the defined conditions with relative short simulation times (about 3 hours per generation). This paper demonstrates how overall optimisation of packaging can be achieved through combining the strengths of multiple simulation software packages.

Studies of temperature distribution for laser welding of dissimilar thin sheets through finite element method

A three-dimensional numerical model has been prepared for the simulation of temperature profile and temperature gradient in similar and dissimilar laser welding. A three-dimensional Gaussian heat distribution equation for moving heat source with conical shape has been incorporated in the present study. A finite element code using software ANSYS APDL has been developed which takes into account the thermal and mechanical aspect of the materials. Properties of the materials AISI 304 austenitic stainless steel and St37 low carbon steel are taken as temperature dependent in the present simulation, which has great influence on the temperature profile. The laser welding temperature distribution was measured using K-type thermocouples with the help of data logger. A good agreement was found between the numerical and experimental results.

A robust design of an innovative shaped rebar system using a novel uncertainty model

The current paper has investigated a newly developed re-bar system by implementing uncertainty models to optimise its geometry. The study of the design parameters of this re-bar system has been carried out utilising a novel uncertainty model that has been developed at Swansea University. The importance of this invention comes from the fact that the whole process of optimisation has been automated by linking ANSYS Workbench to MATLAB via the in-house written code, Despite the fact that in the past, ANSYS APDL was linked to MATLAB, however, the APDL was very limited to only simple geometries and boundary conditions unlike the Workbench which can simulate complex features. These shortfalls have been overcome by automating the process of optimisation, identifying the key influential parameters and the possibility to carry out a huge number of trials. Moreover, the tools that have been developed can pave the way for robust optimisation of this proposed structure. The uncertainty in the design parameters of this re-bar system is of a paramount importance in order to optimise the bond strength between the newly developed rebar and the concrete matrix as well as to fully understand the behaviour of the proposed system under pull-out conditions. The interface between the rebar and the concrete matrix was considered as a ‘cohesive zone’ whereby the interfacial area is studied as a function of the bonding strength.

Crack Growth Direction in Mixed Mode Loading: A Strain Energy Density Approach

The crack growth in metallic materials using fast and reliable simulations of 2-D and linear elastic finite element models is investigated. The effect of the stress intensity factor in mode I and II (KI, KII) on the fracture behavior of stainless steel and the associated strain energy density factor in mixed mode crack propagation were studied numerically to determine crack propagation angle θ in linear elastic fracture investigation. In order to implement the determination of the crack propagation direction using the strain energy density criterion S, the numerical finite element program ANSYS was used. ANSYS APDL macros were developed to generate the geometry, material properties, boundary conditions and mesh size of the model for the conducted analyses. To demonstrate the capability of crack propagation trajectories using the proposed method under mixed mode situation, an edge crack specimen was considered with initial crack having the same length but at different inclination angles under a uniaxial tension load. Results obtained from the developed models had a good agreement (average deviation of 4.63%) with the results available in the literatures.

Free Vibration Behavior of Carbon Nanotube Reinforced Composite Conical Shell Panel Under Thermal Environment

The free vibration of carbon nanotube reinforced composite conical shell panel is examined under temperature field. In this analysis, single-walled carbon nanotube and poly(m-phenylenevinylene-co-2,5-dioctoxy-pphenylenevinylene) are used as fibre and matrix materials, respectively. The material properties are considered as temperature-dependent. The effective material properties of carbon nanotube reinforced composite panel are evaluated through the extended rule-of-mixture. The finite element model is prepared using commercially available finite element tool ANSYS APDL. An eight node Serendipity shell element (SHELL281) is used to discretize the present conical model. The displacement field is framed in the first-order shear deformation theory with six degrees of freedom. The Block Lanczos eigenvalue extraction method is used to obtain the frequency responses. In order to obtain the appropriate mesh density for the said model, the convergence study is executed for various mesh sizes. The present results are compared and validated with the previously reported results. Finally, the influences of different parameters such as length-to-thickness ratio, volume fraction and temperature on the frequency responses of the carbon nanotube reinforced composite conical shell panel are demonstrated through numerical illustrations. The results reveal that the frequency parameters of conical shell panel enhance with the volume fraction and the length-to-thickness ratio, whereas reduce with the temperature value.

Effect of Perforation on the Bending Behavior of Temperature-Dependent Carbon Nanotube Reinforced Composite Plate

In the present article, the bending behaviour of carbon nanotube reinforced composite plate subjected to thermomechanical loading is examined with and without perforations. For the computational purpose, fully clamped support condition is considered. The carbon nanotube reinforced composite plate is comprised of single-walled carbon nanotube reinforced composite as fibre and PmPV as matrix material. The extended rule-of-mixture is employed to evaluate the temperature-dependent material properties of carbon nanotube reinforced composite panel. The bending responses are obtained through finite element tool ANSYS APDL via eight-nodded shell element (SHELL281) with forty eight degrees-of-freedom per element. The kinematic model of the present carbon nanotube reinforced composite plate is based on the first-order shear deformation theory. To exhibit the efficacy of the present model, the present responses are compared with those of the previously published literature. The effect of different parameters such as temperature, thickness ratio, volume fraction and perforation on the bending behaviour of carbon nanotube reinforced composite plate is illustrated through numerous numerical examples.

Numerical Study of Dual Web Steel Plate Girders Under Buckling, Monotonic Load Response And Hysteresis Behaviour

Steel Plate Girders are generally I shaped steel beams made of two or more individual steel plates which are bolted, welded or riveted to form the girder’s flanges and web. Plate girders are usually used in railway bridges. Predominantly, these girders contain only a single central web plate. In this paper, we propose and study the behavior of dual parallel web girders under buckling, monotonic loading, and hysteresis response. The control beam is first modeled and validated based on experimental results and a comprehensive numerical investigation has been discussed in this paper. From the analysis results, model with 20 mm web spacing shows better performance The finite element code of ANSYS APDL 16.2 is used for modeling the test cases.

Parametric Study of EWECS (Engineering Wood Encased Concrete-Steel) Columns Using 3D FE Modelling

This paper presents an analytical study on the behavior of composite column that consist of an exterior wood panel with concrete encased steel (CES) core, hereafter referred to as Engineering Wood Encased Concrete-Steel (EWECS) columns. A detailed three-dimensional (3D) nonlinear finite element model is developed to study the response and predict the seismic performance of EWECS columns subjected to both axial and cyclic loads by using finite element program, ANSYS APDL v.14. A reference model is validated with previous test results and is used as a reference for the parametric study. The parameters considered in the parametric study are the thickness of the wood panel and the compressive strength of concrete. The analytical results obtained from the finite element analysis can accurately simulate the behavior of the EWECS column on the experimental study. The results show that the EWECS column has excellent seismic performance. Moreover, the results of the parametric study show that the thickness of wood panel has the greatest influence on the seismic behavior of the EWECS columns, with the increment of flexural capacity of 15% by addition of 10 mm thickness of the wood panel. Meanwhile, the increase of concrete strength has not much influence on the flexural capacity of the EWECS columns, in which the flexural capacity of the EWECS column only increases around 3% with the increase of concrete strength from 35 to 60 MPa.

Dynamic Analysis of Fuel Assembly for Accident Condition Based on ANSYS

The process of fuel assembly dynamic analysis for accident condition was studied. Method of axial and lateral dynamic modeling was developed. The axial and lateral dynamic response calculation method was established, and then the grid impact force and guide thimble stress calculation were carried out. Based on ANSYS APDL and UIDL language, introducing the idea of parameterization and modularization, the fuel assembly dynamic analysis program (program-developed) for accident condition was developed. Compared validation was carried out using program-developed and software-specific respectively for a certain type of fuel assembly. Comparison results show that the difference was small, and in the range of engineering permissible error. The program developed can be used to analyze the fuel assembly accident instead of software-specific. Analysis ability of the program developed was stronger and calculation efficiency was higher than that of the specific software. Selecting a nuclear power plant as the analysis object, the program developed is used to do the dynamic calculation of fuel assembly for accident condition, and the analysis results meet the requirements of the code.

Analysis of Harmonic Vibration Characteristics for a Composite Honeycomb Panel of the Spacecraft Scanner

The coordinate and frequency distributions of the values of displacement and acceleration amplitudes, the vibration acceleration amplification factors, and the equivalent von Mises stresses are obtained from the data on the simulation modeling of harmonic vibration of the composite honeycomb panel for spacecraft scanner and its related operational equipment (a scanner, magnetometer, optical devices, etc.) mounted on it. A dynamic simulation model of the composite honeycomb panel was developed using modern finite element analysis tools, such as ANSYS APDL. Carbon fiber reinforced plastic plates with an aluminum foil honeycomb core in the form of regularly shaped hexagonal cells that make up the honeycomb panel are approximated by multilayer plate finite elements. The related operational equipment, such as optical devices, a scanner and magnetometer, are represented in the model by lumped masses rigidly attached to the panel. The spectrum of natural frequencies and vibration modes of the spacecraft scanner honeycomb panel is determined using the developed simulation model. The resonant displacement and acceleration amplitudes, the vibration acceleration amplification factors as well as the distributions of the amplitudes of the equivalent von Mises stresses are obtained in the operating frequency range of the investigated harmonic vibration mode of the spacecraft scanner honeycomb panel.

Electromagnetically assisted sheet metal stamping with non-disposable foil coils

Coil in electromagnetic forming (EMF) process commonly requires high strength and long longevity to be robust enough to accommodate great input energy that makes the coil difficult and costly to be manufactured. However, foil coils, in most cases, utilized for part calibration, vaporized for shearing, welding and embossing are less consuming in both time and outlay, easier to be fabricated and replaced, but are mostly disposable. Therefore, the purpose of this paper is to study feasibility of utilizing non-disposable foil coils in EMF process via forming the part (150mm×150mm) with hyperbolic curve like cross-section feature with 1mm thickness AA 2524-T3 aluminum alloy sheet. Copper foil of 0.5mm, 1mm thickness, wrapped in polyimide insulation foil are used as coils in two steps of a quasi-static two-mould-closing pre-forming and EMF process. Besides, practical orthogonal tests are deployed to explore these coils’ forming performance and find the factors’ influential sequence to obtain appropriate process parameters. Results of loose coupling simulation with selected parameters, using ANSYS APDL macro and ABAQUS keywords will be presented and compared with formed components corresponding to simulation load steps. Eventually, formability of sheet component under conditions of diverse charging voltage, foil thickness, foil layers and number of loading repetition and longevity of these coils were experimentally investigated. And the study demonstrates that this technique can be used to improve sheet metal stamping process.