Commercial Finite Element Analysis Research Articles

Design and Testing of Vehicle-Mounted Crop Growth Monitoring System

The aim of this study was to overcome the impact of vibration generated by agricultural machinery on the monitoring accuracy and performance of vehicle-mounted crop growth monitoring systems during field operation. This paper developed a vehicle-mounted crop growth monitoring system with vibration damping capability to achieve this goal. The system consists of a multispectral crop growth sensor, signal conditioning module, and truss-type sensor bracket with self-vibration damping capability. The commercial finite element analysis software ABAQUS 6.10 was used to conduct modal and dynamic simulation analyses of the sensor bracket, which indicate that the truss-type sensor bracket can damp vibrations effectively. The p-values (least significant differences) of crop canopy DNRE (red edge normalized difference vegetation index) under different operating speeds (1.5, 3, and 4.5 km/h) are 0.454, 0.703, 0.81, and 0.838, respectively, for four different crop growth stages. In a comparative experiment between the proposed monitoring system and two similar vehicle-mounted sensors (CropSpec and GreenSeeker RT 200) for measuring agronomic parameters at different stages of crop growth, the proposed monitoring system yielded R2 values of 0.8757, 0.7194, and 0.795, respectively, and RMSE values of 0.7157, 2.2341, and 2.0952, respectively, in the tillering stage, jointing stage, and tillering and jointing stage, outperforming the other two sensors.

Evaluation of borehole interface shear test simulations for cohesive soils under monotonic loading: A comparison of Mohr–Coulomb and hypoplasticity constitutive models

The Cyclic Interface Shear Test (CIST) device was recently developed to evaluate the response of soil–structure interfaces subjected to monotonic or cyclic loading. Numerical models of the CIST have not been documented. Such simulations may be beneficial to help guide the design of experiments, interpret results, and inform the development of further experimental device modifications. In the present paper, a series of interface shear tests utilizing the CIST system on a cohesive soil under monotonic loadings were simulated using a proposed three-dimensional model in the commercial finite element analysis software ABAQUS/Standard. Comparisons of simulations with experimental results are presented for the Mohr–Coulomb and hypoplasticity models for cohesive soils. It is found that (i) the clay-based hypoplasticity model outperformed the simpler Mohr–Coulomb model in terms of predicting the interface shear stress evolution and the soil volume change and (ii) the clay-based hypoplasticity model allows for identification of trends in shear response as a function of normal confining pressures at the soil–structure interface (e.g. soil–structure interface shear zone thickness). Neither of these capabilities have previously been documented or experimentally validated for cohesive soil–structure interface simulations using clay-based hypoplasticity models.

Carbonized hemp hurd powder for eco-friendly polybenzoxazine composite brake material: Excellent friction property and high mechanical performance

Non-asbestos and non-copper polybenzoxazine friction composites were developed with varying mass ratios of synthetic graphite (SG)/carbonized hemp hurd (CHH). Mechanical, thermal, and tribological properties of the polybenzoxazine friction composites were studied. The wear simulation of the polybenzoxazine friction composites has been performed with commercial ANSYS finite element analysis software. The strength and modulus under flexure mode, glass transition temperature of the polybenzoxazine friction composite samples were observed to be improved with increasing CHH content. It appears that the incorporation of the CHH into the polybenzoxazine friction composites not only enhanced the coefficient of friction (COF) but also improved the overall wear resistance of the units. The wear resistance and wear pattern obtained by the wear simulation also showed a good correlation with the experimental results. Based on the findings in this study, it is evident that the carbonized hemp hurd possesses a great potential to be used in green brake pad application.

A Study on the Residual Stress of Seam Pipe Cutting and Girth Welding

Seam pipes are easier to manufacture and cheaper than seamless pipes, and are widely used in the manufacture of pipe spools for marine plant facilities. The manufacturing and assembly of seam pipes involve welding and cutting. The localized heating and cooling that occur during these processes may change the existing residual stress and cause deformation. Uncontrolled deformation can accumulate as assembly errors at the next step, potentially delaying the entire process and causing economic losses. Therefore, characteristics of residual stress redistribution caused by cutting and girth welding of seam pipes need to be studied further. In this study, we performed thermo-mechanical analysis of the manufacturing, cutting, and girth welding processes of seam pipes using the commercial finite element analysis (FEA) software MSC Marc and analyzed the characteristics of residual stress. Furthermore, we measured the residual stress in each process using the hole drilling method, analyzed the characteristics of redistributed residual stress, and ensured reliability. Based on the results of FEA and measured residual stress redistribution, we can provide a basis for reasonable mitigation when performing structural integrity evaluation if there is a defect in the weld of the pipe.

User subroutines platform development for rubber hyperelastic constitutive models and its application in finite element analysis

Aiming at the problem that not enough hyperelastic constitutive models (HCMs) built-in commercial finite element analysis (FEA) software could be utilized, and it is difficult to achieve a high-precision description of the mechanical response behavior of various complex rubber and its composite materials, we developed a UHYPER and UMAT subroutine integration platform based on the user-defined material subroutine function in Abaqus/Standard. The integration platform including 70 HCMs can effectively improve the selection comprehensiveness of HCMs in the material property module of FEA software and the accuracy of simulation results. On the premise that the material parameters are consistent, it is found that the calculation results of the UHYPER subroutine in our integration platform are completely consistent with the calculation results of the built-in HCMs in Abaqus, and the error between the UMAT subroutine result and the built-in model result is within 5.0%. This study indicates the effectiveness and reliability of the user-defined material subroutine integration platform.

Strategies for Reducing Booming Noise Generated by the Tailgate of an Electric Sport Utility Vehicle

This article investigates the source of booming noise emanating from the tailgate of an electric sport utility vehicle (SUV), along with proposed strategies to mitigate it. This annoying low-frequency booming noise, which significantly impacts interior sound quality, is less perceptible in conventional internal combustion engine vehicles. However, this noise is more readily detected in electric SUVs, highlighting the necessity for focused measures to reduce it. This study involved the measurement of booming noises during on-road vehicle tests to pinpoint their origins. Additionally, ODSs were extracted from the tailgate vibration signals to gain insight into its dynamic behavior. Modal tests were conducted on the tailgate to determine its dynamic characteristics and compared with driving test results to reveal the mechanism responsible for tailgate-induced booming noise. It was established that such noise is primarily due to the tailgate modes, resulting from a combination of rigid body motion in the fore-aft direction and deformation in the central section of the panel. An analytical model of the tailgate was developed using commercial finite-element analysis software to propose measures for reducing booming noise. Experimental findings validated this model’s accuracy. Structural enhancements were implemented to enhance the panel stiffness and improve the connection between the vehicle and tailgate via bushings to reduce the booming noise resulting from tailgate motion. Under random force inputs, the analytical results demonstrated a 13.8% reduction in maximum deformation in the tailgate model in the improved structural configuration with increased panel stiffness. This study identifies the mechanism generating booming noise, establishes a practical and simple dynamic model, and proposes improvement measures aimed at reducing the booming noise.

Finite Element Method in L-PBF of Ti-6Al-4V: Influence of Laser Power and Scan Speed on Residual Stress and Part Distortion

Laser powder bed fusion (L-PBF) is widely used in automotive, aerospace, and biomedical applications thanks to its ability to produce complex geometries. In spite of its advantages, parts produced with this technology can show distortion due to the residual stresses developed during the printing process. For this reason, numerical simulations can be used to predict thermal gradients and residual stresses that can result in part distortion. Thus, instead of performing experimental tests and using a trial and error approach, it is possible to use numerical simulation to save time and material. In this work, the effect of laser power and scan speed on residual stress and part distortion was analysed using a commercial finite element analysis (FEA) software DEFORM-3D™ with a layer-by-layer approach. Moreover, the accuracy of the numerical model with respect to process parameters and the utilised mesh was also studied. The results obtained from the numerical simulation were compared to the actual distortions to evaluate the accuracy of the FEM model. The predicted distortions using FEM analysis well fit the trend of the measured ones. The accuracy of the numerical model increases by considering a finer mesh.

Hermeticity of SiC/SiC composite and monolithic SiC tubes irradiated under radial high-heat flux

Demonstration of hermetic SiC fiber–reinforced SiC matrix composite cladding under normal operating environments has been identified as one of the most critical feasibility issues for accident-tolerant fuel cladding in light-water reactors. This study provides critical experimental data needed for understanding the effects of irradiation on hermeticity. SiC composite and monolithic tubes were neutron-irradiated to 2 displacements per atom with and without a nominal radial heat flux of 0.6 MW/m2 to produce a simulated in-pile stress state for the normal operation of a light-water reactor. The through-thickness temperature gradient under irradiation results in a gradient in swelling, which causes a significant stress buildup. Such irradiation-induced stress was modeled using a commercial finite element analysis code. The radial heat flux–irradiation synergism was experimentally investigated by constructing a special irradiation capsule and evaluating the helium hermeticity of the specimens. The simulated stress state exhibited a near equi-biaxial tensile axial and hoop stress of ∼150 MPa at the inner surface of the SiC composite tube. This stress level is potentially beyond the matrix cracking stress. Degradation of hermeticity of the SiC composite tubes was observed after irradiation, indicating irradiation-induced cracking, whereas the irradiated monolithic SiC tubes remained hermetic. The results indicate that loss of hermeticity caused by radiation-induced microcracking is a potential issue for SiC composite cladding, depending on the magnitude of the temperature gradients. Coating the outer surface of the cladding was identified as a mitigation strategy that might overcome the cracking issue.

Prediction and Deformation Mechanism Analysis of High Porosity in U–10Mo Monolithic Fuels at High Burnup

High porosity phenomena of U-10Mo fuel foil appear in the U–Mo/Al monolithic fuel plate under deep burnup. In this study, the fuel skeleton creep-based bubble growth model is further improved with the intrusion effect of solid fission products, multiplying the reduction factor in the bubble volume to obtain the bubble pressure. With the locally enhanced irradiation creep of the Mo-depleted region considered, a simulation of the thermo-mechanical coupling behaviors of the monolithic fuel plate L1P7A0 is carried out, based on the commercial finite element (FE) analysis code ABAQUS. A fission-induced creep rate coefficient of 250 × 10−22 mm3/(fission·MPa) is identified for the Mo-depleted region, with the predictions of porosity and the thickness deformation of U–Mo fuel foil agreeing well with the experimental data. The research results indicate that: (1) the locally enhanced fuel skeleton creep ability is responsible for the higher porosities near the U–Mo/Zr interface; (2) the entrance of solid fission products into the fission bubbles at high burnup is the dominant factor in inducing high porosity in the regions of the most heavily irradiated fuel foil, especially near the fuel foil edge bearing the elevated external hydrostatic pressures; (3) with the intrusion effect of solid fission products considered, the prediction of the porosity increases from ~15% to ~35% near the fuel foil edge; (4) the intrusion of solid fission products leads to extra differences between the bubble pressure and the external pressure, and simultaneously results in the strengthened fuel skeleton creep deformation contributions to the bubble growth.

Investigation of the influence of sinusoidal internal waves on a SPAR buoy structure

Offshore wind has a great potential as a competitive source of renewable energy, especially in deep waters where wind speeds are more consistent and fewer restrictions apply for running large wind turbines. Previous analyses of Floating Offshore Wind Turbines (FOWTs) mostly considered obvious sources of loading: surface waves, currents, wind and mooring. However, in some deep-water locations, internal waves can occur and these have been shown to significantly affect floating structures. Since the hydrodynamic response of an FOWT governs the structure’s general stability, the aim of this research is to investigate the impact of sinusoidal internal waves on the platform motion of a free-floating SPAR-type cylinder. A potential flow model and Morison’s equation are applied numerically to calculate the forces acting on a free-floating cylinder in an oscillating flow. The commercial Finite Element Analysis software OrcaFlex is verified by the potential flow model of the oscillating flow and is then used to mimic sinusoidal internal waves acting on a free-floating cylinder in a stratified flow. Three different internal wave amplitudes and peak velocities are analysed, and the nine resulting cases are investigated for the oscillating and stratified flow each. It has been found that the pitch rotations of the SPAR cylinder were small (< 0.1°) in all cases and can likely be disregarded. The surge displacements of the free-floating cylinder were substantial in both oscillating and stratified flows, with maximum surge magnitudes of 423m and 120m, respectively. Therefore, significant additional mooring loads due to internal waves could be sustained by SPAR-type FOWTs.

Development of a Treatment Planning Framework for Laser Interstitial Thermal Therapy (LITT).

Develop a treatment planning framework for neurosurgeons treating high-grade gliomas with LITT to minimize the learning curve and improve tumor thermal dose coverage. Deidentified patient images were segmented using the image segmentation software Materialize MIMICS©. Segmented images were imported into the commercial finite element analysis (FEA) software COMSOL Multiphysics© to perform bioheat transfer simulations. The laser probe was modeled as a cylindrical object with radius 0.7 mm and length 100 mm, with a constant beam diameter. A modeled laser probe was placed in the tumor in accordance with patient specific patient magnetic resonance temperature imaging (MRTi) data. The laser energy was modeled as a deposited beam heat source in the FEA software. Penne's bioheat equation was used to model heat transfer in brain tissue. The cerebrospinal fluid (CSF) was modeled as a solid with convectively enhanced conductivity to capture heat sink effects. In this study, thermal damage-dependent blood perfusion was assessed. Pulsed laser heating was modeled based on patient treatment logs. The stationary heat source and pullback heat source techniques were modeled to compare the calculated tissue damage. The developed bioheat transfer model was compared to MRTi data obtained from a laser log during LITT procedures. The application builder module in COMSOL Multiphysics© was utilized to create a Graphical User Interface (GUI) for the treatment planning framework. Simulations predicted increased thermal damage (10-15%) in the tumor for the pullback heat source approach compared with the stationary heat source. The model-predicted temperature profiles followed trends similar to those of the MRTi data. Simulations predicted partial tissue ablation in tumors proximal to the CSF ventricle. A mobile platform-based GUI for bioheat transfer simulation was developed to aid neurosurgeons in conveniently varying the simulation parameters according to a patient-specific treatment plan. The convective effects of the CSF should be modeled with heat sink effects for accurate LITT treatment planning.

An experimentally validated anisotropic visco-hyperelastic constitutive model for knitted fabric-reinforced elastomer composites

A new anisotropic visco-hyperelastic constitutive model has been developed to predict the time-dependent deformation response of flexible, knitted fabric-reinforced elastomer composites. These composites exhibit a time-dependent response due to the viscoelastic behavior of the elastomer, while the anisotropic reinforcement effect is attributed to the knitted fabrics. The proposed modeling approach features an invariant-based strain energy density function that incorporates the architecture of knitted fabrics and the hyper-viscoelastic behavior of elastomers. In this study, the elastomer is considered as a viscous neo-Hookean material, and the knitted fabrics are modeled as cords with negligible stiffness in bending. The proposed material model is implemented in commercial Finite Element Analysis (FEA) software, Abaqus (version 2017), through a user-defined material subroutine, UMAT. This approach enables the determination of the constitutive behavior of the composite based on the constituent elastomer, fiber properties, and fabric architectures. The proposed model is verified through a discrete 3D FEA model, in which the elastomer and fabric reinforcement are modeled explicitly. The approach is further validated through physical testing including uniaxial tension, torsion, and three-point bending. Since the proposed strain energy-based constitutive model can predict the deformation response of knitted fabric-reinforced elastomer composites based on the fabric architecture, it can be employed as an efficient modeling tool to aid the design of knitting pattern for target mechanical properties.

Structural Reliability Analysis of Large Planar Steam Solid Oxide Electrolysis Cells

Solid oxide electrolysis cells (SOEC) have been receiving significant attention recently because of their high energy efficiency and fast hydrogen production. In our previous study, a multi-physics modeling framework to simulate the SOEC performance and structural reliability of planar SOEC design was developed and demonstrated. The electrochemical reactions, fluid dynamics, species transport, electron transfer, and heat transfer were modeled in the commercial computational fluid dynamics (CFD) software STAR-CCM+. The thermomechanical analysis and the associated structural reliability evaluations were conducted using the commercial finite element analysis software ANSYS. The electrochemistry model was validated by using the experimentally obtained current-voltage (I-V) characteristics of the electrode-supported SOECs. In this study, this framework was applied on a large 300 cm2 steam planar SOEC design, and systematically studied the structural reliability under combinations of cell operating conditions, with cell voltage 1-1.5 V, steam fraction in fuel inlet 0.7-0.9, air inlet flow rate 0-10 L/min, fuel inlet flow rate 2.5-12.5 L/min, and inlet temperature 600-900 C. In the modeling framework, all the cells were investigated under the adiabatic thermal conditions, which is equivalent to packing the cell in an insulated container. This induced the relatively larger temperature variation than in the smaller cell designs. This cell internal temperature non-uniformity may further enhance the spatial variations of open circuit voltage, activation loss, and ionic conductivity in the cell, which all influence the overall cell performance. This situation is more obvious when the cell voltage is higher than 1.35V, under which the cell is significantly heated along the steam flow direction. Traditionally, it is assumed that the cell internal temperature spatial variation plays an important role on cell structural reliability. However, because it was assumed that all the components in cell are stress free at 850 , the cell temperature deviation from 850 is more critical to the stress distribution and structural reliability in the cell. For the investigated cells in the practical conditions, like 750 C inlet temperature and varying voltage from 1.05 to 1.5 V, the highest first principal stress is always in the air side electrode, which is around 45 MPa. This is explained by the higher coefficient of thermal expansion of LSCF-GDC with respect to the other layers. This may indicate that the failure would possibly occur in the air side electrode, but at low risk due to the relatively higher Weibull characteristic strength.

Progressive Failure Analysis of Composite Overwrapped Pressure Vessel

Stress and progressive failure analysis (First Ply Failure to Last Ply Failure) of a composite overwrapped pressure vessel (COPV) with an aluminum liner using the finite element method (FEM) in general and commercial finite element analysis (FEA) software ANSYS in particular is presented in this paper. Ply failure prediction is based on failure criteria implemented in ANSYS software. The first-ply failure (FPF) does not necessarily imply the total failure of a laminate. After FPF, the laminate stiffness is reduced consistent with identified ply failure mode. The strength of the composite laminate is evaluated again to see if it could carry additional load. This ply-by-ply analysis progresses, until the ultimate strength is reached. In the present study the methodology is validated using benchmarks and applied to a filament wound fibre reinforced plastic composite pressure vessel with an aluminum liner. Significant results are presented and critically assessed. Directions for further work in this field are identified.

The transformation matrix in the 7DOFs beam formulation

A non-negligible percentage of steel products for civil and industrial constructions is realised with members characterised by a mono-symmetric cross-section. The non-coincidence between the centroid and the shear centre reflects in a quite complex behaviour that is remarkably influenced by the warping effects. Usually, frame design is based on the output data of commercial Finite Element Analysis Packages (FEAPs) but only few of them offer a refined beam element formulation able to reproduce the response of non-bisymmetric cross-section members (like the 7 degrees of freedom, DOFs, beam element). As a consequence, warping effects are usually neglected in routine design, leading in several cases to assess non-correct internal stresses, global displacements and critical buckling multipliers.This paper is focussed on mono-symmetric cross-section members and deals with the influence of the interaction between axial force, bending moments and bimoment in linear elastic range. In particular, the two strategies that FE developers usually adopt, in the 7 DOFs beam formulation, to pass from the local to the global reference system are herein shortly introduced and discussed. The effects of the associated transformation matrices have been investigated in few examples, also reproduced via closed expressions derived from the mixed torsion theory and FE shell models. Paper outcomes show that the results in terms of generalised displacements, internal forces and, consequently, stress distribution along the member cross-section are significantly different, strictly depending on the adopted transformation matrix. The importance of a correct evaluation of the bimoment distribution is stressed also by the fact that the new edition of the EN1993-1-1, expected in the next months, includes also the bimoment contribution for member checks.

Collision Simulation of a Floating Offshore Wind Turbine Considering Ductile Fracture and Hydrodynamics Using Hydrodynamic Plug-in HydroQus

This paper intends to introduce the applicability of HydroQus to a problem of a tanker collision against a semi-submersible type floating offshore wind turbine (FOWT). HydroQus is a plug-in based on potential flow theory that generates interactive hydroforces in a commercial Finite element analysis (FEA) code Abaqus/Explicit. Frequency response analyses were conducted for a 10MW capacity FOWT to obtain hydrostatic and hydrodynamic constants. The tanker was modeled with rigid elements, while elastic-plastic elements were used for the FOWT. Mooring chains were modeled to implement station keeping ability of the FOWT. Two types of fracture models were considered: constant failure strain model and combined failure strain model HC-LN model composed of Hosford-Coulomb (HC) model &amp; localized necking (LN) model. The damage extents were evaluated by hydroforces and failure strain models. The largest equivalent plastic strain observed in the cases where both restoring force and radiation force were considered. Stress triaxiality and damage indicator analysis showed that the application of HC-LN model was suitable. It could be stated that applications of suitable failure strain model and hydrodynamics into the collision simulations were of importance.

Uplift resistance of caisson foundation in NGI-ADP soil using FEA and ANN

The paper presents a novel solution for evaluating the uplift resistance of caisson foundations in anisotropic clay using displacement finite element analysis (FEA) and artificial neural network (ANN). The commercial FEA PLAXIS code is used to examine the uplift resistance of caisson foundations with a built-in anisotropic soil model developed by Norwegian Geotechnical Institute (NGI) based on the Active-Direct Shear-Passive concept (NGI-ADP model). The uplift resistance is expressed by a dimensionless stability factor that is a function of four dimensionless design parameters, i.e., the ratio of depth to diameter, the adhesion factor at the interface between caisson and clay, the shear strength gradient ratio, and the anisotropic strength ratio. Using the produced numerical results, ANN is adopted as the data driven technique to propose an empirical equation to estimate the uplift resistance factor. Furthermore, a sensitivity study is implemented to evaluate the relative importance of the four considered parameters on the uplift resistance of the caisson. Design charts, tables and empirical equations are developed and can be used to assist in practical designs.

A simplified finite element method for failure analysis in adhesive-bonded nozzle diffuser of solid rocket motors

The adhesive bond between the nozzle diffuser shell and the insulation layer of solid rocket motors (SRM) is widely used due to its lightweight, simple design, and easy operation. The mechanism of adhesive-bonded failure between them is a concern for designers. In this paper, a simplified finite element method for failure analysis in the adhesive-bonded nozzle diffuser of SRM is proposed. In the method, the diffuser shell, insulation layer, and adhesive between them are considered elastic. The maximum Von Mises stress failure criterion is assumed to be suitable for the adhesive. The adhesive-bonded failure is simulated by using the user subroutine VUSDFLD in the commercial Finite Element Analysis software ABAQUS. The method is verified to be simple but effective based on the comparison with experimental results. The adhesive-bonded failure process under external load can be well simulated, and the critical external load of adhesive-bonded failure can be accurately predicted. In addition, the method is utilized to study the failure of the nozzle diffuser with several kinds of original debonding. It is suggested that the original axial debonding ratio should be less than 60%, and the circumferential debonding angle should be smaller than 30° in the conical section of the nozzle diffuser.

An Analytical Study for Safety Evaluation of Demolition-Assembled Permeable Steel Open-Type Erosion Control Dam

Recently, localized torrential rains are occurring worldwide due to global warming and abnormal temperatures, and in Korea, where most of the land is composed of mountainous areas, flood damage such as landslides is continuously increasing. Accordingly, the importance of erosion control dams, one of the structures for preventing flood damage in mountainous terrain, is mentioned, but mostly dams need alternatives due to material limitations composed of concrete. In this study, an improved open-type erosion control dam was studied to reduce the cost of rapid recovery and maintenance based on the problems of the existing erosion control dam consist of concrete. For this purpose, an analytical study using a commercial finite element analysis program was conducted to implement the dam shape and drift prevention structure, and to calculate the external load under extreme environmental conditions to comprehensively confirm the safety of the target structure.

A study of a slim compact piezo inertia actuator

Most previously reported inertia actuators suffer from the problems of low speed and large size. To overcome these shortcomings, this study proposes a slim compact piezo inertia actuator based on the principle of stick–slip drive. Actuated by the transverse motion of a cantilever beam forming part of a monolithic elastomer, this actuator achieves a high velocity. The construction and basic operating principle of the actuator are discussed in detail. Commercial finite element analysis software is employed to determine the appropriate geometry for the monolithic elastomer. To study the actuator’s mechanical characteristics, a prototype is fabricated and a series of experimental tests are performed. According to the results of these tests, the maximum velocity and maximum load force are about 24.03 mm/s and 1.96 N, respectively, and the minimum step size is about 0.47 μm. It is shown that the inertia actuator based on a monolithic elastomer with a cantilever beam not only has a slim compact structure, but also exhibits good output characteristics.