Coupling Finite Element Model Research Articles

Abnormal temperature rise and discharge characteristics of decay-like composite insulators

Abstract In recent years, there have been multiple incidents of fracture faults caused by the deterioration of composite insulators in China, seriously threatening the safe operation of the power system. This article takes a 500 kV decay-like composite insulator collected from the operation site as the research object, conducts visual inspection and analysis of its shed and core rod degradation status, and tests its infrared temperature rise and ultraviolet discharge distribution under power frequency operating voltage and related electrical parameters. Finally, an electric thermal coupling finite element model is established to analyze its discharge and tem-perature rise mechanism. The research results found that the infrared temperature rise characteristics and ultraviolet discharge characteristics of decay-like composite insulators can reflect their degradation status. As the testing distance increases, the measured infrared temperature rise gradually decreases. The distortion of dielectric parameters and the decrease in insulation resistance have caused partial discharge and abnormal temperature rise of decay-like insulators. In addition, compared to ultraviolet imaging detection, infrared temperature measurement can better reflect the internal defects of decay-like composite insulators and is less susceptible to interference from unrelated discharges around them.

Finite element modeling of a piezoelectric actuator coupled to the cochlear round window

Abstract Round window (RW) stimulation is an application of active middle ear implants. However, its clinical outcomes show a substantial degree of variability due to the mismatch of the diameter of the actuator and the RW membrane, and the surgically challenging for placing the actuator. To address this problem, we developed a new piezoelectric actuator for RW stimulation. Firstly, we specifically designed the actuator’s mechanical structure for the RW stimulation. Then, we constructed a finite element (FE) model of the piezoelectric actuator coupled with the human ear’s RW membrane. Using this coupled FE model, we studied the influence of the actuator’s supporting stiffness and the number of piezoelectric stack layers on the stimulated stapes velocity. Finally, we fabricated the piezoelectric actuator and tested its output on human cadaver temporal bones. The results show that the developed piezoelectric actuator has the advantages of a wide operating frequency range and controlled preload on the RW membrane.

Effect of considering thermoplasticity of gun steel on thermomechanical coupling response of barrel

Abstract To explore the effect of considering thermoplasticity of gun steel on the thermomechanical coupling of the barrel during artillery firing, the thermoplastic coupling behavior of the barrel under transient thermal and mechanical loads is investigated. A thermomechanical coupling finite element model of the barrel was established. The transient temperature field and stress field of the barrel during the gun firing process were analyzed. By comparing the results of the thermoelastic model with that of thermoplasticity model, the effect of considering thermoplastic of gun steel on thermomechanical coupling response of barrel was investigated. The results show that the peak of Mises stress evolution considering thermoplasticity of material in the bore of the barrel is significantly reduced during the gun firing process, and the hoop stress evolution appears double-peak phenomenon. In addition, at the peak moment of bore pressure, the peak values that the hoop and Mises stress distributions along the radial direction at the midpoint of the land are reduced by 14.5 % and 20.9 %, respectively. This paper can provide a reference for the design of a large-caliber barrel.

Mechanism of initiation and propagation of surface cracks in gun bore under thermomechanical coupling impact

Surface cracks in gun bore may exacerbate rifling ablation and wear and in turn shorten barrel life. Thermomechanical coupling finite element (FE) models of bore are established and the dynamic responses of the bore under high-temperature and high-pressure are numerically simulated. The stress distribution characteristics on the inner surface are analyzed and the effects of autofrettage, number of firings and harden layer on the stress distribution are discussed. Based on the stress distribution characteristics, FE models with two initial cracks on the ledge of land surface are set up and the propagation, interaction and intersection of the cracks are numerically simulated, considering the effect of the distance between the two cracks. Based on simulation results, the initiation and propagation pattern and mechanism of the cracks on the inner surface are analyzed. An ablation test system was designed and produced, and used to experimentally verify the initiation and propagation mechanism of the cracks. The observed crack patterns on the inner surface of a real gun bore are also used to illustrate the mechanism obtained in this work. Understanding of the initiation and propagation mechanism of cracks in gun bore can be applied to improve and optimize the design of barrels.

Flow corrosion simulation study of local defects in CO2 saturated solution

The inner walls of oil and gas transportation pipelines are prone to the formation of localized pitting defects due to the presence of solid particles in multiphase flow. The continuous flow poses a risk of perforation leakage in the pipe wall. To investigate the development of defects under flow corrosion and assess the impact of flow, a multi-field coupling finite element model incorporating fluid dynamics, reactions, and mass transfer was developed. The flow corrosion of local defects with various depths in a CO2-saturated solution was simulated. The calculation of mass transfer in corrosion is coupled with the precise flow field solved by large eddy simulation (LES) method. It has been observed that the distribution of corrosive substances is significantly affected by the flow due to local defects. Within these defects, the maximum concentration of corrosion product Fe2+ is observed on the upstream surface of defects. While the H+ accumulates at the downstream wall, which affects the corrosion rate. The local turbulent state is influenced by the depth of defects, and the interplay of the turbulence intensity with reflux velocity determines the mass transfer.

The thermal responses of composite box girder bridges with corrugated steel webs under solar radiation

Owing to the direct exposure to complex atmospheric environments, the temperature field of composite box girder bridge with corrugated steel webs (CBGB-CSW) is likely non-uniformly distributed. Whereas, the current researches regarding the thermal responses of CBGB-CSW are insufficient, and the thermal responses of CBGB-CSW under solar radiation are still unknown. Therefore, this paper conducted a long-term temperature experiment on a scaled model to explore the temperature distribution characteristics in CBGB-CSW. Meanwhile, a three-dimensional thermal–mechanical coupling Finite Element (FE) model is established to simulate the temperature field in the experiment girder. The accuracy and effectiveness of the developed FE model has been verified by the measured temperature data. Therewith, the thermal responses (i.e., stress and displacement) of a full-scale continuous CBGB-CSW with a span of 150 m are numerically investigated. The results indicate that the maximum stresses always occur at the midspan section (with a depth of 5 m) of the continuous CBGB-CSW, and considerable concentrations of stress are observed in the steel-concrete junction. The maximum longitudinal tensile and compressive normal stresses within 0.4 m of the upper junction can reach 5.55 MPa and −8.46 MPa respectively, and those of the lower junction can reach 6.96 MPa and −7.05 MPa respectively. Besides, owing to the impacts of vertical and horizontal temperature gradients, significant displacements of the whole bridge can also be observed. The maximum vertical displacement (5.33 mm) of the CBGB-CSW is estimated at the top plate in the midspan, while the maximum horizontal displacement (0.74 mm) is estimated at the trough of the southern corrugated steel web in the midspan. Notably, the outcomes of this paper can provide some useful references for engineers and scholars to understand the thermal responses of the CBGB-CSW.

Research on the castor oil pressing extraction mechanism based on multi-physics coupling simulation.

Castor oil has been widely used in various fields due to its properties, leading to large attention for its extraction mechanism. To research the castor oil extraction mechanism during pressing, a self-developed uniaxial compression device combined with an in situ observation is established. The effects of pressure, loading speed, and creep time are investigated, and a finite element model coupling with multi-physics is established for castor oil pressing extraction, verified by the seed cake experimental compression strain matching with numerical simulation under the same condition. Simulation results indicated that the pressing oil extraction process can be divided into two stages, Darcy's speed shows the first sharp decreasing stage and the second gradual increasing stage during porosity and pressure interaction. In the first stage, porosity is dominant on Darcy's speed. With porosity decreasing, the pressure effect on Darcy's speed exceeds porosity in the second stage. With seed thickness increasing, Darcy's speed first increases and then decreases. With loading speed increasing, Darcy's speed increases. Darcy's speed decreases constantly with creep time increasing. This study can provide basic theoretical and practical guidance for oil extraction.

Equal heat flux loading optimization approach for uniform wear of the wet brake

Due to their exceptional ability to endure heavy loads, cam-lobe radial-piston hydraulic motors are extensively utilized in heavy machinery. The wet brake is a key part capable of providing highly braking torque, which has numerous friction pairs and a compact structure. However, there exists a challenge in solving the issue of irrational pressure distribution which leads to non-uniform heat flux distribution and severe wear failure of the brake discs. For this, an innovative method to optimize the wet brake's loading structure has been developed to address the issue of non-uniform heat flux distribution. A thermomechanical coupling finite element (FE) model was established to establish a clear correlation between loading structure parameters and contact pressure distribution on the brake disc. An innovative equal heat flux criterion was introduced to guide the optimization process. Simulation results confirmed that the optimized loading structure achieved a brake disc contact pressure distribution aligned with the ideal heat flux density criteria. Experimental validation further demonstrated a notable reduction of up to 44.39 % in maximum wear depth (hmax) across different radii of the brake disc compared to the unoptimized structure. These findings underscore the efficacy of our approach in reducing wear rates and enhancing durability of the wet brakes.

Thermal–Electrical–Mechanical Coupled Finite Element Models for Battery Electric Vehicle

The safety of lithium-ion batteries is critical to the safety of battery electric vehicles (BEVs). The purpose of this work is to develop a method to predict battery thermal runaway in full electric vehicle crash simulation. The thermal–electrical–mechanical-coupled finite element analysis is used to model an individual lithium-ion battery cell, a battery module, a battery pack, and a battery electric vehicle with 24 battery modules in a live circuit connection. The lithium-ion battery is modeled using a representative approach, with each internal battery component individually modeled to represent its geometric shape and realistic thermal, mechanical, and electrical properties. A resistance heating solver and Randles circuit model built with a generalized voltage source are used to simulate the electrical behavior of the battery. The thermal simulation of the battery considers the heat capacity and thermal conductivity of different cell components, as well as heat conduction, radiation, and convection at their interfaces. The mechanical property of battery cell and battery module models is validated using spherical punch tests. The electrical property of the battery cell and battery module models is verified against CircuitLab simulation in an external short-circuit test. The simulation results for the battery module’s internal resistance are consistent with both experimental data and literature values. The multi-physics coupling phenomenon is demonstrated with a cylindrical compression simulation on the battery module. The multi-physics BEV model with 24 live battery modules is used to simulate the external short-circuit test and the side pole impact test. The simulation run time is less than 24 h. The results demonstrated the feasibility of using a representative battery model and multi-physics analysis to predict battery thermal runaway in full electric vehicle crash analysis.

Sealing Performance Evaluation and Structural Optimization for Reducing Leakage Failures of Lip Seal Considering High-Speed Rotation Frictional Heat

This article proposes a high-speed rotating thermo-solid coupling finite element model for a lip seal that simulates the lip temperature changes during rotation by cyclically applying thermal loads to achieve lip temperature distribution characteristics. Considering the influence of working condition parameters and structural parameters, the lip temperature and sealing interface contact pressure distribution are obtained, and the lip seal structure is optimized. The results show that ignoring the uneven distribution of lip friction heat will lead to a 25.6% error in the radial force. The optimized lip seal yields an impressive 14.3% reduction in leakage rate compared to the original configuration, showcasing a significant performance enhancement in lip seal.

Experimental and numerical investigations of post-fire behaviour of circular steel tube confined steel-reinforced concrete columns under eccentric loading

Experimental and numerical analysis were conducted to investigate the post-fire behaviour of circular steel tube confined steel reinforced concrete (STCSRC) columns. A total of fifteen circular STCSRC columns, including five stub specimens and ten slender specimens, were tested under eccentric loading after heating following the ISO-834 standard fire curve. The test findings, such as cross-sectional temperature, failure modes, column deformation, residual load-bearing capacity, strains of steel tubes, etc., were all discussed in detail. A sequential thermal-stress coupling finite element (FE) model, including a heat transfer FE model and a mechanical FE model, was then developed using ABAQUS software and verified using the test results. To obtain further numerical data over a wide range of parameters, a parametric analysis was carried out using the established FE models. A simplified calculation method was presented to estimate the residual load-bearing capability of circular STCSRC columns subjected to eccentrical compression after ISO-834 fire exposure.

Simulation of Frost-Heave Failure of Air-Entrained Concrete Based on Thermal-Hydraulic-Mechanical Coupling Model.

The internal pore structural characteristics and microbubble distribution features of concrete have a significant impact on its frost resistance, but their size is relatively small compared to aggregates, making them difficult to visually represent in the mesoscopic numerical model of concrete. Therefore, based on the ice-crystal phase transition mechanism of pore water and the theory of fine-scale inclusions, this paper establishes an estimation model for effective thermal conductivity and permeability coefficients that can reflect the distribution characteristics of the internal pore size and the content of microbubbles in porous media and explores the evolution mechanism of effective thermal conductivity and permeability coefficients during the freezing process. The segmented Gaussian integration method is adopted for the calculation of integrals involving pore size distribution curves. In addition, based on the concept that the fracture phase represents continuous damage, a switching model for the permeability coefficient is proposed to address the fundamental impact of frost cracking on permeability. Finally, the proposed estimation models for thermal conductivity and permeability are applied to the cement mortar and the interface transition zone (ITZ), and a thermal-hydraulic-mechanical coupling finite element model of concrete specimens at the mesoscale based on the fracture phase-field method is established. After that, the frost-cracking mechanism in ordinary concrete samples during the freezing process is explored, as well as the mechanism of microbubbles in relieving pore pressure and the adverse effect of accelerated cooling on frost cracking. The results show that the cracks first occurred near the aggregate on the concrete sample surface and then extended inward along the interface transition zone, which is consistent with the frost-cracking scenario of concrete structures in cold regions.

Research on the identification method based on energy distribution of adaptive WPD for railway tunnel lining void

ABSTRACT As the main disease of railway tunnels, void disease affects the safe operation of railways. The traditional detection technology recognition void relies on the intuitive characteristics of the signal, there are still problems such as poor void edge recognition capability and low intelligence level. To solve this problem, this study used Comsol software to establish a sound-solid coupling finite element model of the tunnel, extracted the acoustic signals of voids under various conditions, analysed the acoustic signal characteristics under different conditions and proposed the acoustic sensitive frequency band of tunnel lining void. The test model of Partial tunnel lining is established by the method of layering pouring. The wavelet packet algorithm is improved by the maximum cross correlation coefficient, the optimal wavelet basis decomposition algorithm is proposed. The layer number of the wavelet packet decomposition (WPD) algorithm was calculated based on the sensitive frequency band and the energy distribution of the sub-signal is obtained. Then, the energy distribution of the sensitive frequency band is used to estimate the void boundary. The experimental results show that the acoustic frequency band of the tunnel void mainly distributes in the range of 0–10,000 Hz and the sensitive frequency band of the void concentrated around 0–3000 Hz. According to the sampling frequency and the sensitive frequency band of the void, the sub-signal energy distribution of each layer is obtained. The energy distribution of sub-signal 1 has strong void boundary recognition ability. The research results will be beneficial to the damage detection and state assessment of tunnel lining.

Influence of soil and pile properties on the critical length of laterally loaded piles

Piles could undergo various deformation and failure modes which were depended on their classification. Previous research primarily utilized the equation proposed by Poulos and Hull to classify the pile. While the Poulos and Hull method offers advantages in terms of its simplicity, it is not entirely suitable for contemporary applications involving large-diameter piles and complex soil profiles. In this study, a three-dimensional pile-soil coupling finite element model is proposed using the hypoplastic constitutive model. The main goal of this paper was to present extensive three-dimensional finite element analyses to examine the lateral response of a monopile embedded in sand. This research reevaluates five existing methods for determining the critical length of laterally loaded piles. The evaluation considers both directly assigned and indirectly calculated methods for determining the soil's elastic modulus. The findings reveal that Dobry's equation offers superior prediction for the critical length across various soil conditions. However, for low relative density soils, the Poulos and Hull method demonstrates better suitability. The numerical results presented in this study are expected to provide design references for further practical applications of the monopiles.

Study on the generation mechanism of curve squeal and its relationship with wheel/rail wear

This paper aims to create a friction coupling finite element model of the wheelset–track system, taking into account various curve radii and corresponding wheel/rail contact states. This model will serve as a tool to analyze the underlying causes of curve squeal phenomena. Furthermore, we conducted an investigation into the impact of rail and wheel wear on system stability. This paper utilized a complex eigenvalue analysis (CEA) method to accurately calculate and predict vibration instabilities in the system. The results show that the smaller the radius of the curve, the more prone to it is lateral creep between the rail and the leading wheelset, so that the system is more prone to self-excited frictional vibrations, ultimately resulting in the generation of curve squeal. In addition, the wear of the wheel tread/rail head increases the instability of the system. When the train passes through a section with rail corrugation, rail corrugation suppresses the occurrence of curve squeal.

Building responses to soil removal, dewatering, and artificial recharge during deep excavation in water-rich sandy strata

In water-rich sandy strata, deep excavations necessitate dewatering within the excavation site, leading to significant groundwater drawdowns and surface subsidence behind walls, which can result in severe damage to adjacent buildings. Nonetheless, the individual impacts of soil removal and dewatering in such permeable sandy formations on building responses remain ambiguous,with scant reported protective experience in literature. This study introduces a validated three-dimensional fluid-solid coupling finite-element model to simulate the construction of an 18-19.8 m deep subway station in Nantong, China. Artificial recharge was applied to mitigate adverse effects on nearby buildings caused by drainage. The investigation explores the separate effects of soil removal, dewatering, and water recharging on the settlements of buildings with three different foundations (natural, raft, and piled footings). Additionally, the influence of post-recharging groundwater levels on building responses was scrutinized. The present findings indicate that discharging confined aquifers significantly contributes to building settlements, while artificial recharge can substantially reverse the deformations in buildings, especially those with natural and raft foundations. As excavation depth and the bearing capacity of the building foundation increase, the relative impact of soil removal on building settlements grows, whereas the influence of dewatering diminishes. Compared to enhancing foundation-bearing capacity, artificial recharge emerges as a more cost-effective strategy to safeguard pre-existing buildings near deep excavations in water-rich sandy strata, provided the post-recharging groundwater levels achieve a certain threshold.

Study on Dynamic Damage of Crash Barrier under Impact Load of High-Speed Train

The derailment of a high-speed train in a tunnel will cause a very serious accident, but there are few research articles on anti-collision facilities in tunnels. In order to promote the sustainable development of high-speed trains and reduce the severity of accidents caused by derailment in tunnels of high-speed trains, this paper puts forward a crash barrier scheme in tunnels through the method of numerical simulation; the coupling finite element model of train–crash barrier–tunnel is established by using ABAQUS. The changes in lateral velocity and lateral displacement after the train hits the crash barrier without embedding steel bars are explored. We also explore the influence of different reinforcement amounts on the changes in the lateral speed and lateral displacement of trains under the condition of embedding steel bars. The results show that with the increase in stirrups and vertical reinforcement, the anti-impact and sustainable operation capability of the crash barrier are greater. It can also be seen from the lateral displacement of the train that the train shows the reverse movement trend, and the crash barrier plays a good role in intercepting the train. These research results can provide a reference for the sustainable development of transportation infrastructure construction.

Interface debonding defect detection for CFST columns based on EMI measurements: Experiment, numerical simulation and blind inspection in practice

Concrete-filled steel tube (CFST) members have been widely used in skyscrapers and long-span bridges. Non-uniformly distributed hydration heat during curing, inadequate compaction during construction and unavoidable shrinkage and creep of mass concrete in service most likely lead to interface debonding defects between concrete core and steel tube, which has been a common concern. The development of effective non-destructive inspection methods for interface bonding condition of existing CFST members is critical. In this study, an interface debonding defect detection method based on electromechanical impedance (EMI) measurement using surface-mounted piezoelectric-lead-zirconate-titanate (PZT) sensors is proposed at first. Then, experimental study on the feasibility of the proposed approach is carried out with scaled CFST specimens with artificially mimicked interface debonding defects. EMI of surface-mounted PZT sensors at different frequency bands are measured and compared to verify the detectability of the proposed approach for the mimicked interface debonding defects. Thirdly, a multi-physics CFST-PZT coupling finite element model (FEM) with interface debonding defects is established, and EMI of surface-mounted PZT sensors at different locations is simulated. The influence of interface debonding defects on EMI measurements is illustrated. Finally, a blind inspection on the interface bonding condition of selected CFST columns in an existing skyscraper in service using the proposed approach is carried out. Both bonding and debonding defect in the tested CFST columns are detected correctly and validated with drilling hole observation. Experimental, numerical and engineering application results show the proposed approach is effective for interface debonding detection of CFST members and sensitive to minor debonding defect of 0.3 mm in CFST members.

Thermo-metallo-mechanical based phase transformation modeling for high-speed milling of Ti–6Al–4V through stress-strain and temperature effects

The optimization of machining parameters, tool longevity, and surface quality in High-Speed Milling (HSM) of Ti–6Al–4V relies immensely on understanding the local phase transformation. This study endeavors to build a Finite Element (FE) model capable of forecasting phase alterations during the rapid thermal fluctuations intrinsic to Ti–6Al–4V machining. Dynamic phase transformation models were initially introduced to capture rapid heating and cooling phenomena. Using a user-defined subroutine, the phase transitions predictive models were integrated into the HSM simulation within Abaqus/Explicit. Simulation outcomes unveiled phase transitions primarily occurring within the serrated chip and at the tool-workpiece interface. Notably, during rapid heating, when the cutting speed increased to 350 m/min, the β-phase volume fraction surged from 7.5 to 96.38%. A similar trend was observed with feed rate adjustments (i.e., 0.15–0.25 mm/tooth), where β-phase increased from 7.5 to 67.84%. Rapid cooling facilitated the reversion of the transformed β-phase back into the α'-phase. Finally, some advanced characterization techniques were employed to validate the developed thermo-metallo-mechanical coupled FE model for phase transformation. The simulation results verified by the experimental data promotes a better understanding of phase alteration mechanisms and microstructural evolution in HSM of Ti–6Al–4V. The current research is also beneficial for crucial insights into optimizing the machining conditions and their impact on tool-material interactions and surface integrity.

Influence of different tectonic settings on fracture formation and fluid flow around upper-crustal magmatic intrusion: insights from numerical modelling

Large porphyry Cu and epithermal Au deposits tend to form in distinct tectonic, porphyry and high-sulfidation epithermal deposits in compressional settings, and low-sulfidation epithermal deposits in extensional settings. Given that the analysis of the shallow metallogenic dynamic processes at the upper-crust scale is insufficient, especially the ore-bearing fracture formation and fluid-focusing mechanism around the mineralizing magmatic intrusion under different tectonic backgrounds, we aimed to study how tectonic settings influence fracture formation and fluid hydrodynamics in and around a hot intrusion. We developed a finite element model coupling thermal-hydrological-mechanical processes to simulate the fracture formation, evolution of fluid velocities, and accumulation of water-rock interactions. The model results show that tectonic compression increases the degree of fracturing, hydrothermal fluid velocities, and water-rock interaction within and laterally around the intrusion; tectonic extension enhances fracturing, hydrothermal fluid velocities, and water-rock interaction at shallow depth. These results confirm that tectonic compression may promote the formation of porphyry Cu deposits, while tectonic extension may promote the formation of shallow hydrothermal deposits. Our model explains the effects of tectonic activity on fracture formation and fluid flow around hot magmatic intrusions in upper crust and deepens our understanding of the relationship between tectonic activity and deposit formation there.