Finite Element Analysis Approach Research Articles

Performance improvement of set of worm gears used in soot blower through profile modification

The present design of a set of worm gears used in a soot blower produced by a certain manufacturer has an efficiency of 68.8%. A soot blower is one of the most critical components in industrial applications for removing the large amounts of soot generated by boilers and is required to be operational 24×7. The energy consumption of the soot blower depends on its working efficiency and ultimately the design of its set of worm gears. This paper focuses mainly on the design and analysis of available industrial worm-gear sets used in soot blowers. The theoretical, experimental, and finite-element analysis approaches are validated for the stability of the worm gear set under typical input conditions. This paper also describes an analytical design of experiments (DOE) approach to identify the most significant factor for performance (efficiency) improvement and suggests some design improvements for the worm gear set using the profile modification approach. These ensure the efficiency improvement of the current industrial design of the set of worm gears used in a soot blower. The analytical DOE approach helped identify that the number of worm wheel teeth (Z2) and gear module (m) are the two most significant factors affecting performance. Accordingly, based on the improved design, the final efficiency increased from 68.8% to 74.6% (∼8.5% increment), resulting in lower power consumption during industrial application.

Prediction of allowable compression load for notched composite laminates combining FEA simulation and machine learning

Determining the allowable compression load (ACL) of notched composite laminates (NCL) requires consideration of buckling, intra- and inter-laminar damage, which is a costly and repetitive task due to the high dimensional and nonlinear relation of ACL to the numerous design variables. In this work, a high-throughput finite element analysis (FEA) and machine learning (ML) combined approach is proposed to predict ACL of laminates. First, the high-throughput FEA model of NCL covering all of the design variables is generated, and the corresponding critical compression loads in terms of buckling, intra- and inter-laminar damage are obtained. Then, ML models are trained, with inputs being the design variables of NCL and outputs being the critical compression loads. ACL and initial failure mode are determined by the minimum compression load of the three failure modes. Moreover, transfer learning is introduced to laminates with new design variables of new ply number, notch shape and laminate type. By fine-tuning the pre-trained ML model using scarce new data, the fine-tuned models are suitable for new laminates. Consequently, ACL and initial failure mode of notched laminates with various design variables are predicted.

Research on the Influence of Cone Angle on the Sealing Performance of Pipeline Joint

In order to evaluate the sealing performance of the pipe connectors, we developed a simplified 3D model by adjusting the cone angle of the nozzle and analyzing the contact pressure of the sealing structure, the width of the contact surface, and the equivalent stress as the response quantities. Based on a finite element analysis approach, we found that increasing the cone angle of the nozzle improves the sealing performance, but may negatively affect structural reliability and maintenance. As such, the optimal range for the nozzle cone angle is relatively reasonable between 55° and 60°. Furthermore, we use a sealed interface leakage model to calculate the joint leakage rate under theoretical conditions.

Real-time Finite Element Analysis based on surrogate model

In the field of engineering, Finite Element Analysis (FEA) serves as a pivotal numerical simulation tool. Nevertheless, its inherent offline nature and dependency on real-time data pose limitations on its versatility. To confront this challenge, a real-time FEA approach centered on surrogate modeling has been developed. This method enables the instantaneous prediction of critical performance parameters, thereby providing crucial support for real-time decision-making and process monitoring. In the context of this study, the focus is on the glass compression molding process, a process that is not easily observable. The research commences with preliminary thermal conduction simulations conducted using ABAQUS software. Subsequently, a surrogate model is constructed to facilitate real-time FEA for the temperature field of the glass preform. Finally, Unity 3D software is harnessed for visualization, offering an effective tool for the real-time monitoring and control of the glass-forming process.

Thermal analysis of 4-phase 8/6 SRM for EV application

This article provides a comprehensive analysis of the thermal characteristics of a 4-phase 8/6 switching reluctance motor (SRM) designed for use in an e-rickshaw (3-wheeler) application. The determination of core and copper losses is achieved through electromagnetic analysis using Finite Element Analysis (FEA). The analysis is conducted via MOTORCAD, a multiphysics design software. This work includes the examination of both static and transient temperature conditions. Static analysis entails the estimation of losses by taking into account the motor's maximum current and operating the motor under steady-state conditions. Transient analysis involves the examination of two separate scenarios. One possesses a simple transient characteristic, while the other possesses a distinct duty cycle. The losses obtained from the electromagnetic analysis are used as the input for the simple transient thermal analysis. During transient analysis involving the duty cycle, losses are assigned to certain operating conditions, such as changes in the operating speed of the motor. This study employs the Lumped Parameter Thermal Network (LPTN), as well as 3D and 2D FEA techniques to conduct thermal analysis. The findings were compared and subsequently given in the article. The findings produced from the LPTN and 3D FEA approaches demonstrate a strong correlation. The motor's maximum temperature is limited to 180 °C. The findings indicate that the highest temperature, both under static and transient conditions, is below the maximum attainable value.

A micromechanical study on shear performance of unidirectional composites with randomly distributed fibers in the transverse cross‐section

AbstractThe properties of unidirectional (UD) composites has been investigated by analyzing their elastic and strength characteristics under shear loading. The UD fiber‐reinforced polymer (FRP) composites usually consist of fibers randomly dispersed throughout the cross‐section in the transverse direction which is generally not accounted for. A micromechanical model based on finite element analysis (FEA) approach is utilized here to examine these properties. The study begins by identifying micro scale unit cells or repetitive unit cells (RUCs) at the micro scale, as well as representative volume elements (RVEs). The distribution of fiber volume fraction (Vf) varies among various micro scale unit cells positioned in the transverse cross‐section. The elastic properties and strength are estimated by considering the properties of the matrix and fibers, and the configuration of micro scale unit cells, which feature a fiber arrangement which is categorized as hexagonal and varying Vf at different locations (from 0.35 to 0.75). However, the overall Vf for the UD composite remains constant at 0.65. Studies are also carried out with the random distribution of fibers at micro scale unit cells. The findings reveal that the random distribution of fibers significantly impacts the shear behavior of the composite. This investigation provides valuable insights into how the mechanical properties of the UD composite are subjective by the distribution of fiber, thereby contributing to the design and development of this light weight high‐performance material.Highlights Elastic and strength analysis of UD composites is presented. Emphasis is on fiber dispersion in transverse plane. Microscale unit cells, RUCs and RVE are identified. Studies are carried out based on micromechanical model. Influence of fiber distribution on shear behavior is investigated.

Mitigating Frame Cracks in Off-Highway Vehicle: A Combined Approach of Finite Element Analysis and IoT-based Chassis Health Monitoring System

A Heavy-duty cargo truck manufactured by the Chinese company SHACMAN X3000 is designed and analyzed in this paper. Here, this paper developed a Chassis Health Monitoring System (CHMS). The objective of the system is improving the safety measures by combining computational techniques using FEA on static structural and Modal analysis followed by experimental work by implementation of IoT for monitoring and validation purposes. In this paper, for analysis purpose, we selected four critical points based on the survey and underwent the analysis by computational tool. The CHMS consists of a Force sensor, a Flux sensor, and RGB with Arduino, which is to collect and analyze to monitor the frame. The analyzed results give the optimal value in the frame near the critical areas, which results the crack. The CHMS, it a pre-alert system and safe guard the chassis.

The Tensile Behavior of Hybrid Bonded Bolted Composite Joints: 3D-Digital Image Correlation versus Finite Element Analysis.

This study examines the behavior of hybrid bolted/bonded (HBB) joints loaded in tensile shear comprising plain weave carbon/epoxy laminates in quasi-isotropic (QI) and cross-ply (CP) layups. It proposes a combined approach of 3D digital image correlation and finite element analysis (FEA) to assess their behavior. To apply the FEA simulation accurately, a single layer of plain fabric was replaced with [0/90]s lamination. Experimental standard open-hole tension test results, as well as only bolted (OB) and HBB, along with FEA predictions, confirmed the accuracy of the substitution method. The FEA, calibrated by experimental results, provides insight into the distinctive characteristics of HBB joints in comparison with bonded and bolted joints. Critical considerations include material properties, damage modeling, adhesive characteristics, and mass scaling. The FEA results underscored the pivotal role of adhesives in HBB joints, rendering them akin solely to bonded configurations. HBB joints retain their geometry better than OB joints with considerably less out-of-plane displacement, following a sinusoidal trend. Moreover, the overall behavior of the two layups demonstrates that CP benefits from having higher strength than QI, especially at the critical hole located closer to the grip side.

Dynamic behaviors of concrete gravity dam against combined blast wave and bubble pulsation of underwater explosion

Underwater explosion process mainly includes the preceding blast wave and the succeeding bubble pulsation, while the effect of bubble pulsation on hydraulic structures is always neglected. This paper aims to numerically study the dynamic behaviors of prototype concrete gravity dam against underwater explosion, considering the combined effects of blast wave and bubble pulsation. Firstly, a finite element analysis (FEA) approach for predicting the underwater explosion loadings, as well as the damage evolution and dynamic responses of dam against underwater explosions was proposed, in which the hydrostatic pressure of reservoir and the dead load of dam were considered. Based on Cole's formula and the existing underwater explosion tests, the reliability of FEA approach, including the mesh sizes, material models and the corresponding parameters, as well as the mapping, Fluid-Structure Interaction and contact algorithms, was comprehensively validated. Secondly, to realize the simulation of the prototype gravity dam impeded by the validated small Lagrange mesh size, a mesh transition strategy was proposed based on the equivalence of dam damage modes and total eroded element mass. Finally, the dynamic behaviors of a typical 120 m-height concrete gravity dam against underwater explosion, i.e., 1 t of TNT equivalence detonated at a depth of 35 m and standoff distances of 4–16 m, were examined. The dimensionless distance λR, i.e., the ratio of the standoff distance to the maximum bubble radius, was introduced to quantitatively evaluate the underwater explosion loadings and dynamic behaviors of the dam. It indicates that, the blast wave firstly leads to the local compressive damage on the upstream surface, as well as the tensile damage on the downstream folded slope and dam heel. The succeeding free vibration and bubble pulsation will further aggravate the damage degree, resulting in the cracking of dam neck and heel. Especially for the scenarios when λR ≤ 1.22, the overall sliding of dam is highly prone to occur.

Development of High-Temperature Permanent Magnet Synchronous Motor for Autonomous Robotic Navigation: A Design and Finite Element Analysis Approach

The traditional industrial robots come with the prime mover, i.e. Electric Motors (EM) which ranges from a few hundred too few kilo watts of power ratings. However, for autonomous robotic navigation systems, we require motors which are light weighted with the aspect of high torque and power density. This aspect is very critical, when the EMs in robotic navigations are subjected to harsh high temperature survival conditions, where the sustainability of the performance metrics of the electromagnetic system of the EMs degrade with the prevailing high temperature conditions. Hence, this research work address and formulate the design methodology to develop a 630 W High Temperature PMSM (HTPMSM) in the aspect of high torque and power density, which can be used for the autonomous robotic navigation systems under high temperature survival conditions of 200°C. Two types of rotor configurations i.e. the Surface Permanent Magnet type (SPM) and the Interior Permanent Magnet type (IPM) of HTPMSM are examined for its optimal electromagnetic metrics under the temperature conditions of 200°C. The 630 W HTPMSM is designed to deliver the rated torque of 2 Nm within the volumetric & diametric constraints of D x L which comes at 80 x 70 mm at the rated speed of 3000 rpm with the survival temperature of 200°C with the target efficiency of greater than 90%. The FEM based results are validated through the hardware prototypes for both SPM and IPM types, and the results confirm the effectiveness of the proposed design methodology of HTPMSM for sustainable autonomous robotic navigation applications.

The Stability of Corroded Circular Steel Tubes Under Axial Compression Investigated Through Testing, Finite Element Analysis and Theoretical Approaches

Circular steel-tube members are extensively used in various large-scale steel structures. The detrimental effects of corrosion on the ultimate bearing capacities of these structures require urgent attention. This study designed six circular steel tube specimens to explore the degradation pattern of the ultimate bearing capacity of corroded circular steel tubes under axial compression; three were subjected to accelerated corrosion by electrification, and the other three were used as the control group. Following the accelerated corrosion test, both groups of specimens were subjected to material-property and axial-compression tests. These tests provided data on the bearing capacity and midspan displacement of the corroded circular steel tubes, allowing for the construction of load–displacement relationship curves. The test results demonstrate that corrosion significantly affects the bearing capacity of circular steel tubes. As the severity of the corrosion increased, the bearing capacity and stiffness of the corroded circular steel tubes progressively weakened. To simulate the behavior of circular steel tubes, a numerical model was established that provided the ultimate bearing capacity under axial compression and generated load–displacement curves. The simulation results closely aligned with the test results. This study introduced a novel approach for accurately computing the stability-bearing capacity of circular steel tubes subjected to corrosion and axial compression. Comparative analyzes with test results validated the superior performance of the proposed method in accurately predicting the ultimate bearing capacity.

Wire plus arc additive manufacturing of stainless steel wall for predicting parametric influences on strength: Experimentation and finite-element analysis approach

The purpose of this study is to provide functional insight into the tensile behavior of wire plus arc additively manufactured (WAAM) stainless steel 304 plate simulated using finite-element analysis (FEA) and the Johnson-cook (J-C) model of ductile damage. The plate is manufactured using WAAM and ideal process parameters chosen after multiple attempts. The strength of additively produced specimen (543.6 ± 3 MPa) is significantly higher than that of wrought alloys sample (518.2 ± 6 MPa). The tensile test was successfully simulated using FEA, and the results were anticipated with an error percentage of less than one. The considerable increase in strength is attributed to microstructure variations such as dendritic development and phase changes (presence of residual δ-ferrite) driven by complicated heat cycle. The presence of residual δ-ferrite is also clear through the evaluation of ferrite number as it varied from bottom to top in the range of 5.0–4.8. Hence, this study provides knowledge to the engineering society such that it finds potential application in various sectors.

Facile green synthesis of novel tantalum doped tungsten trioxide for photocatalytic degradation: Correlation with COMSOL simulation

The facilegreen synthesis techniqueis becoming more and more important, and it has been proposed as a potential substitute for chemical techniques. The current study describes a low-cost, environmentally friendly method for producing tungsten trioxide (WO3) and tantalum (Ta) doped WO3nanoparticles that uses 15 % (w/v) Azadirachta indica (Neem) leaf extract and different concentrations of Ta dopant (1 to 5 %) due to its well-matched ionic radius with WO3. Various techniques FESEM, TEM, EDX, BET, UV–Vis and PL, XRD, and FTIR were used to illustrate the morphological, elemental, optical, structural, and vibrational analysis of the synthesized nanoparticles respectively. Interestingly, the band gap was significantly reduced to 1.88 eV by the addition of a dopant element. For 3 % Ta/WO3, the average particle size was also reduced to 31.6 nm. The synthesized WO3nanoparticles employed in the current study have been used for photocatalytic activitypurposes. Methylene blue (MB), one of the principal water pollutants, was degraded more quickly by the synthesized Ta/WO3nanoparticles when exposed to UV radiation. Among them, 3 % Ta/WO3 gives significantly higher photodegradation 89 % attributed to the Burstein-Moss effect. The significant output of optimized nano-photocatalyst has been observed from the trapping experiment and reusability test. Furthermore, Zeta potential and TOC analysis have been taken to check the stability and mineralization performance. Additionally, the results of the simulation that was carried out using the finite element analysis approach in the RF module of COMSOL Multiphysics 5.3a are quite similar to the experimental findings. This simulation method made it easier for readers to understand the numerous aspects of the photocatalytic process that has been discussed here.

Finite Element Analysis Approach for Optimal Design and Mechanical Performance Prediction of Additive Manufactured Sandwich Lattice Structures

Finite Element Analysis Approach for Optimal Design and Mechanical Performance Prediction of Additive Manufactured Sandwich Lattice Structures

A sensing platform for highly sensitive immunoassay based on metal-enhanced fluorescence of CdSe@ZnS

Insufficient sensitivity caused by low radiative intensity of employed fluorescent material is the main obstacle toward early accurate diagnosis of fatal diseases when applying fluorescence analysis. Herein, we have developed a dual amplification procedure to overcome this issue. We first synthesize high-quality CdSe@ZnS@SiO2 core/shell quantum dots (QDs) with type-I band alignment to confine the carrier wave functions, thus ensuring high quantum yield (∼ 80%). The fluorescence intensity of those QDs is further amplified by localized surface plasmon resonance effect enabled by gold nanoparticles. We finally construct CdSe@ZnS@SiO2 and Au@SiO2 immune sandwich biosensor platform, and take C-reaction protein (CRP) as a test case. It is shown that this biosensor platform exhibits a wide detecting range between 0.5 and 100 ng/mL, and detecting limit of 0.076 ng/mL. We further apply this detecting scheme in serum and actual clinical, competing performance compared with the prevailing standard measurements in hospital has been obtained. Both experiment and the finite element analysis (FEA) approach calculation results indicate that a highly enhanced electric field between Au@SiO2 and CdSe@ZnS@SiO2 enhances the radiative recombination rates of the QDs@SiO2 and decreases the fluorescence lifetime of that. The fluorescence intensity amplification scheme proposed herein is of great significance for the real-time and high-sensitivity early detection of biomarkers in the biomedicine.

Impact behavior of spark plasma sintered Ti–Al–Mo/TiN composites: a finite element analysis approach using Abaqus CAE

BackgroundThe utilization of Finite Element Analysis (FEA) has emerged as a crucial methodology in the field of structural and elasticity analysis, facilitating researchers in their understanding of material responses to diverse thermal or structural loads. This study investigates the utilization of FEA to simulate the Impact characteristics of titanium composites, with specific emphasis on the Charpy impact test. The research utilizes the Abaqus Explicit software, which is widely recognized for its explicit dynamic analysis functionalities, to simulate high-speed and short-duration events such as impacts. The primary objective of this study is to examine the impact behavior of Ti–7Al–1mo/TiN composites fabricated through the spark plasma sintering technique. The impact behavior is simulated using FEA, wherein the shear failure model is utilized to replicate fracture phenomena. This paper examines the methodology employed in the FEA approach, with a particular focus on various factors including boundary conditions, explicit dynamic analysis settings, and material properties.ResultsThe outcomes and analyses involve the examination of the von Mises stress distribution, displacement magnitude, and energy behavior of the models that were tested. Reinforcement of Ti–Al–Mo ternary alloy with TiN led to a progressive increase in maximum von Mises stress, reaching a peak at 3 wt% TiN. Conversely, displacement magnitude decreased with increasing TiN content, with CP-Ti and the unreinforced alloy exhibiting the highest values. Absorbed energy also declined with higher TiN levels. While models containing 5 and 7 wt% TiN displayed limited plastic deformation before fracture, composites with ≤ 3 wt% TiN maintained acceptable ductility despite enhanced strength and stiffness.ConclusionThe FEA methodology effectively simulates the Charpy impact characteristics of Ti–7Al–1Mo/TiN composites, thereby offering significant contributions to understanding their mechanical behaviors. These findings suggest that TiN reinforcement up to 3 wt% presents a promising strategy for improving the mechanical performance of Ti–Al–Mo alloys while minimizing the trade-off in toughness. This research emphasizes the inherent trade-off between toughness and strength/stiffness, suggesting the possibility of optimizing the composition of materials to suit particular applications. This study makes a valuable contribution to the expanding field of impact behavior research, demonstrating the potential of FEA, specifically utilizing Abaqus Explicit software, for enhancing material design and evaluation.

Biomechanical Evaluation of Plantar Pressure Distribution towards a Customized 3D Orthotic Device: A Methodological Case Study through a Finite Element Analysis Approach

Plantar pressure distribution is a thoroughly recognized parameter for evaluating foot structure and biomechanical behavior, as it is utilized to determine musculoskeletal conditions and diagnose foot abnormalities. Experimental testing is currently being utilized to investigate static foot conditions using invasive and noninvasive techniques. These methods are usually expensive and laborious, and they lack valuable data since they only evaluate compressive forces, missing the complex stress combinations the foot undergoes while standing. The present investigation applied medical and engineering methods to predict pressure points in a healthy foot soft tissue during normal standing conditions. Thus, a well-defined three-dimensional foot biomodel was constructed to be numerically analyzed through medical imaging. Two study cases were developed through a structural finite element analysis. The first study was developed to evaluate barefoot behavior deformation and stresses occurring in the plantar region. The results from this analysis were validated through baropodometric testing. Subsequently, a customized 3D model total-contact foot orthosis was designed to redistribute peak pressures appropriately, relieving the plantar region from excessive stress. The results in the first study case successfully demonstrated the prediction of the foot sole regions more prone to suffer a pressure concentration since the values are in good agreement with experimental testing. Employing a customized insole proved to be highly advantageous in fulfilling its primary function, reducing peak pressure points substantially. The main aim of this paper was to provide more precise insights into the biomechanical behavior of foot pressure points through engineering methods oriented towards innovative assessment for absolute customization for orthotic devices.

Static, Dynamic, and High Cycle Fatigue Analysis of Crossed Spherical Gearing for Robotic Arm Ball Joint: A Finite Element Analysis Approach

Crossed spherical gearing is used in the joints of robotic arm prostheses and allows mobility in 3 degrees of freedom. This paper aims to evaluate the design of a cross-spherical gear with three different materials, PEEK, AISI 304L, and Ti-6Al-4V, for a robotic arm prosthesis by finite element analysis. ANSYS mechanical software (version 2021 R1) was used to perform the static analysis and evaluate the deformations and stresses, modal analysis of natural frequencies and vibration modes, and high cycle fatigue analysis to determine fatigue resistance. The results obtained in the static analysis show that the maximum stresses are in the same zones for the three materials and have similar values. However, the Ti-6Al-4V and ASI 304L materials have a higher safety factor than PEEK, with a value of 5.17. In conclusion, the crossed spherical gearing is numerically validated using the finite element analysis so that the prototype can be later manufactured at an experimental level, and the values obtained for the crossed spherical gearing of the robotic arm prosthesis can be verified.

Scope of magnesium ceria nanocomposites for mandibular reconstruction: Degradation and biomechanical evaluation using a 3-dimensional finite element analysis approach

Magnesium/Ceria nanocomposites (Mg/xCeO2 NCs (x = 0.5 %, 1 % and 1.5 %)) prepared by using powder metallurgy and microwave sintering method are assessed for their corrosion rate for a period of 28 days. As per the immersion tests results, the addition of ceria nanoparticles to pure Mg, brought about a noteworthy improvement to corrosion resistance. A corrosion rate of approximately 0.84 mm/year for Mg/0.5CeO2 and 0.99 mm/year for Mg/1.0CeO2 nanocomposites were observed. Another aspect of the study involves employing the simulation method i.e. finite element analysis (FEA) to compare the stress distribution in magnesium-ceria nanocomposite based screws and circular bars especially for Mg/0.5CeO2 and Mg/1.0CeO2. Further, the simulation also gives a perception of the impact of masticatory forces, the biting force and shear stress exerted on the Mg/0.5CeO2 and Mg/1.0CeO2 based screws. The simulations results show that the screws showed an acceptable level of stresses for a biting force up to 300 N. The circular bar as well kept its stresses at acceptable levels for the same load of 300N. The shear stress results indicated that a biting force up to 602 N can be safely absorbed by Mg/0.5CeO2 screw. The comprehensive approach allows for a better understanding of the corrosion behavior, stress distribution, and mechanical properties of the Mg/CeO2 nanocomposites, enabling the development of effective temporary implants for craniofacial trauma fixation that can withstand normal physiological forces during mastication. The study reported in this paper aims to target Mg/xCeO2 NCs for temporary implants for craniofacial trauma fixation.

Modal and dynamic analysis of damaged steel column-beam frame structure subjected to seismic vibrations using experimental and finite element analysis approach

Modal and dynamic analysis of damaged steel column-beam frame structure subjected to seismic vibrations using experimental and finite element analysis approach