Coupled Simulation Method Research Articles

A magneto-elastica reinforced elastomer makes soft robotic grippers

Soft robotics represents a burgeoning and interdisciplinary domain characterized by diverse research avenues encompassing actuation strategies, materials science, fabrication techniques, morphing mechanisms, and control methods. This work introduces a novel approach to soft actuators and robotic grippers by intricately exploring the magneto-elastica of spherical magnet chains. First, a kind of magneto-elastica reinforced elastomer is achieved by embedding millimetre-sized spherical neodymium-iron-boron (NdFeB) magnets into the polymer elastomer. By modulating the coupling effect of the magnetic and elastic contributions, the bending deformation of the magneto-elastica reinforced elastomer can be initialized. Subsequently, we analytically derive the coupled stiffness formula to integrate the discrete-scale magneto-elastica with the continuum elasticity using the transformed section method. For comparison, we further employ the multi-physics coupling simulation method to reveal the complex magnetics-mechanics interactions within the composite beam. As a proof of concept, we demonstrate two distinct configurations of rope-motor-driven robotic grippers respectively: three-finger soft robotic gripper and five-finger soft anthropomorphic hand. Pick-and-place experiments indicate that they have the good applicability to grasp objects with various sizes, surfaces and forms, including delicate, deformable, and irregularly shaped objects. In conclusion, the proposed method offers compelling advantages, including structural simplicity and modularity, facile manufacturability utilizing commonplace materials and 3D printing, in-situ active magneto-elastica-driven resilience and selectable actuation modalities via either magnetic or mechanical stimuli. We anticipate that the exploratory research can potentially manifest further contributions to soft actuators and soft robots.

Simulation analysis and optimization of pilot type electro-hydraulic proportional directional valve based on multi field coupling

The pilot-operated electro-hydraulic proportional directional valve is widely used in complex and precision engineering fields. Its operational stability and reliability determine the overall performance of the hydraulic system. During the working process of the pilot-operated electro-hydraulic proportional directional valve, the spool is deformed due to the influence of pressure and temperature, resulting in problems such as clamping or stagnation. In order to solve this problem, this study uses the fluid-solid-thermal coupling simulation method to analyze the flow field characteristics and thermal deformation of the spool with different structural throttling grooves, and optimizes the U-shaped throttling groove structure. The results indicate that as the valve opening increases, the front section of the throttling groove becomes the primary region where the maximum radial deformation of the spool occurs. In this paper, the steady-state flow force of the valve core is taken as the measurement standard, the constraint range of the structural parameters is determined, and the radial thermal deformation is included in the optimization analysis of the structural size. It’s verified that the optimized flow characteristics are improved by about 32 % compared with that before optimization, and the maximum steady-state flow force after considering thermal deformation is reduced by about 4N compared with that before optimization. This provides an important design basis and reference for the structural design and optimization of the pilot electro-hydraulic proportional directional valve.

Numerical and experimental study of the cavitation performance of a composite propeller

Cavitation, which is harmful and unavoidable, has troubled people for a long time and it is urgent to be solved. A composite propeller has the potential ability to improve the cavitation performance because of its distinctive hydro-elastic characteristic, but the related research is limited. In this paper, the cavitation performance of a composite propeller under uniform and non-uniform wake flow is investigated numerically and experimentally. A cavitation coupling simulation method is presented for predicting the cavitation performance of a composite propeller. Cavitation tests are conducted at a cavitation tunnel. The calculated and tested results of cavitation hydrodynamic performance and cavitation patterns are discussed and analyzed. The results show that they are quite consistent, more importantly, cavitation has a significant impact on the hydro-elastic response of a composite propeller.

Direct tensile failures of concrete with various moisture contents and sizes at low temperatures via mesoscale simulations with ice explicit modelling

The enhancement of mechanical properties of concrete meso-components and the interaction caused by non-uniform deformation as well as phase change can cause significant changes in the macro-mechanical performances of concrete at low temperatures. Based on the action mechanism of the above low-temperature effect, this paper established a thermal-mechanical sequential coupled simulation method with explicit modelling of pore ice at the mesoscale level to quantitatively investigate the direct tensile failures and the corresponding size effect of concrete with four structural sizes (D75, D150, D225 and D300) and three moisture contents (2.0 %, 4.0 % and 6.0 %) at different temperatures (20, −30, −60 and −90°C), in term of failure mode, deformation curve, peak strength and residual strength. The numerical results show that the direct tensile peak strength performs an obvious low-temperature enhancement effect due to the more damaged aggregates and more areas being in a state of multi-axial stress caused by low-temperature non-uniform stress field. However, with the decreasing temperature, the residual strength shows a decrease trend and the trend slows down with the increasing moisture content. Besides, as the temperature drops from 20°C to −90°C, both the size effects on direct tensile peak strength and residual strength are strengthened (with the increase approaches nearly 200 % for peak strength while 33 % for residual strength). Finally, a modified size effect theoretical model was developed considering the quantitative coupling effects of low temperature and moisture content. The present research results can provide a reference for the performance evaluation and safe design of large-sized concrete exposed to low-temperature environments.

Effect of friction block thickness on the high-temperature tribological behavior of the braking interface of high-speed train

Tests on a high-speed train braking platform with friction blocks of different thicknesses revealed data on friction heat, wear, and friction-induced vibration and noise (FIVN). A finite element model (FEM) was developed using a finite element software, and then a thermal-mechanical-wear coupling simulation method was proposed to simulate the high-temperature wear of friction blocks. The results show that thicker friction blocks led to higher temperatures, eccentric wear, and increased wear debris, forming a stiff third body layer causing high-intensity FIVN. Thinner blocks showed better tribological properties and reduced FIVN. Although block thickness affects FIVN, the main frequency differences are minor. Therefore, friction block thickness should be considered as an important factor in brake pad design to manage high-temperature tribological behavior.

Optimal design of multiple tuned liquid dampers with paddles for wind-induced vibration control of high-rise buildings

The optimal design of multiple tuned liquid dampers (MTLDs) is important for improving structural vibration control. However, current MTLD optimization studies typically take the response of the original structural frequency as the optimization objective, without considering the effect of the structural frequency shift under strong wind loads. Therefore, this paper proposes an MTLD frequency optimization method based on the weighted average of structural acceleration magnification factors. This method can target multiple responses in the structural frequency shift region, thereby overcoming the limitation that the optimal parameters can only be solved for a single structural frequency. It is also worth noting that this method can be applied to the frequency optimization of MTLDs with internal obstructions. A detailed procedure for determining the optimal frequency distribution of the MTLD based on a particle swarm algorithm is presented, and a coupled simulation method for the vibration response of the structure-MTLD system is developed to demonstrate the validity of the optimization results. The proposed optimization method is then further applied to the design of the MTLD with paddles for wind-induced vibration control in a 206 m super high-rise building. The results demonstrate that the modified MTLD optimization, which considers multiple structural frequencies, exhibits superior robustness compared to the traditional MTLD optimization, which considers only one original structural frequency. This implies that the modified MTLD can effectively mitigate the detuning effect caused by the structural frequency shift, which is beneficial for the practical design and application of the MTLD.

Mechanic-electric-thermal coupling simulation method of Lamb wave under variable temperature

The propagation mechanism of Lamb waves exhibits more intricate in the variable operational environment of high-speed trains. Simulation methods are widely used to study Lamb wave propagation characteristics due to economic and time constraints. A mechanic-electric-thermal coupling simulation method to study the propagation mechanism of Lamb waves under variable temperatures is proposed in this paper. To accurately simulate the dynamic behavior of Piezoelectric Transducer (PZT) under variable temperature, a nonlinear numerical model of the dynamic parameters (piezoelectric coefficient, dielectric constant) of PZTs has been developed based on the experiment of the temperature influence on Lamb wave. The model emphasizes the nonlinear pattern of change in the key dynamic parameters of the PZT with temperature fluctuations. In addition, a thermal expansion stress model of the PZT-bonding layers-structure is established to reveal the mechanical-thermal coupling mechanism. Based on the COMSOL, a mechanical-electrical-thermal direct coupling simulation model of PZT-bonding layers- structure under variable temperature is established. The simulation results at −40 °C to 80 °C are obtained and compared to the experiment. The results show that the simulation signal is highly consistent with the experimental measurement signal, and the simulation method proposed in this paper has high accuracy.

Thermal-fluid-structure coupling simulation of piston in large marine diesel engine

Abstract Traditionally, most simulation approaches for pistons are conducted based on thermal-structure coupling, where the cooling boundary conditions are determined by empirical formulas. However, these approaches often suffer some decreases in the accuracy of the simulation results. Aiming at the problem, this paper conducts a thermal-fluid-structure coupling simulation method for the piston of a large marine diesel engine, which employs computational fluid dynamics to identify the cooling boundary conditions. Firstly, the solid and fluid models are established. Then, the cooling process of the piston chamber is simulated, with the temperature and heat transfer coefficients being mapped onto the solid component. Finally, loads and constraints are imposed on the solid component to accomplish the simulation. Under the presumed simulation conditions, the obtained coupling stresses are within the permissible range, with a maximum value of 419.68 MPa, and the dangerous region occurs at the junction of the piston head and the cooling chamber.

Development and Evaluation of a Universal Seed Discharger for Precision Planting in Corn-Soybean Cropping System

Aiming at solving the problem of a wide variety of crop planting and addressing the concept of precision agriculture, a pneumatic universal seed-metering device suitable for corn and soybean was designed. According to the physical size of the above two crops crop planting, a seeding plate, a hole, and a guide tube were designed. The pressure distribution inside the seeding plate was studied, when the pressure, the diameter of the hole, and the rotation speed of the metering plate changed. Through the coupling simulation method of DEM and CFD, the effects of the air suction hole diameter, the air pressure intensity, and the seeding plate speed on the seeding performance were explored. The results showed that when the air suction hole diameter was 5.9 mm, the air pressure intensity was 3.5 kPa, and the seeding plate speed was 23.8 r/min, and the performance of corn seeding was the best, among which the seeding qualification index was 95.35%, the replay index was 1.45%, and the missed seeding index was 3.23%. When the air suction hole diameter was 6.1 mm, the air pressure intensity was 3.5 kPa, and the rotation speed of the seed plate was 24 r/min, the performance of soybean sowing was the best, in which the sowing qualification index was 95.76%, the reseeding index was 3.47%, and the missed sowing index was 0.77%. The bench verification test and the comparative test were carried out. The results showed that the seed-metering device had good seeding performance and could be applied to the general seeding operation of corn and soybean.

Structure optimization design approach of friction pairs for low-temperature rise wet brake in hydraulic motor

Cam-lobe radial-piston hydraulic motors are widely used in large heavy-duty machinery as direct-drive components of hydraulic systems. Due to their extremely high output torque and power density, the wet brake equipped with the hydraulic motors are necessary to achieve ultra-high braking torque in a compact space. However, due to a large number of internal friction pairs and small fit clearance between multiple friction pairs in wet brake, the rotation of the friction pairs in non-braking state will cause large friction torque loss and obvious temperature rise, thereby leading to the thermal failure of wet brake. How to optimize the structure of friction pairs to reduce the temperature rise of wet brake in non-braking state is a persistent challenge. Existing structure optimization design approaches of friction pairs in brakes mainly focus on the structure of each friction pair, which ignore the effect of fit clearance between the friction pairs on the temperature rise of brakes. Nevertheless, the fit clearance between friction pairs is an important factor that affect the temperature rise. For that, this study proposes a two-step structure optimization design approach of friction pairs for low-temperature rise wet brake in hydraculic motor, which simultaneously considers the fit clearance between the friction pairs and the structure of each friction pair. In this approach, the design process could be divided into two steps: firstly, the influence of fit clearance between multiple friction pairs on the temperature rise of wet brake in non-braking state is analyzed and optimized by the temperature rise theoretical model; secondly, in order to further reduce the temperature rise of wet brake, the oil groove structure of each friction plate are introduced and optimized by fluid-solid-thermal coupling simulation method. By this approach, the low-temperature rise structure of friction pairs with the optimized fit clearance between multiple friction pairs and oil grooves of each friction plate. Finally, a series of experiments are conducted to verify the effectiveness of the design approach. The result show that the temperature rise of wet brake could be effectively reduced 12 % by optimizing the structure of wet brake, demonstrating that the structure optimization design approach could provide a theoretical guidance to design low-temperature rise wet brake for large torque hydraulic motors.

Simulation and analysis of movement trajectories of fresh tea leaf particles based on CFD‐EDEM coupling

AbstractTo study the air‐suction separation mechanism of fresh tea leaves, this article adopts the coupling simulation method of discrete elements and computational fluid dynamics to conduct numerical simulation and experimental research on the movement of fresh tea leaves adsorbed by negative pressure air flow. In the gas–solid coupling model, three‐dimensional scanning technology is applied to establish a three‐dimensional model of fresh tea leaves with one bud and two leaves. Through the Fluent module in CFD, the negative pressure adsorption gas phase of the simulation process was established, bench tests were established, and parameters of the coupling model were optimized. Finally, the minimum error between the simulated value and the test value was 2.85% and the maximum error was 7.43%, indicating that the coupling model established had certain accuracy and could be theoretically analyzed according to the coupling model established. It is found that when the static pressure values of the adsorption surface are −120 Pa, −340 Pa, and −500 Pa respectively, the initial distance from the adsorption surface is 250–550 mm. It is found that fresh tea leaves with one bud and two leaves all fall to the pipe before adsorption, and then move to the adsorption surface. Under the same static pressure value of the adsorption surface, the initial falling distance of tea particles from the adsorption surface (250–550 mm) has a linear function relationship with the distance between the turning point and the adsorption surface. When the initial distance between falling tea particles and the adsorption surface is the same, the distance between the turning point and the adsorption surface is an exponential function when the initial position is 250–350 mm from the adsorption surface, and the distance between the turning point and the adsorption surface is a linear function when the initial position is 400–550 mm from the adsorption surface.

Enhancing Sustainable Afforestation through Innovative Earth Auger Design: A Simulation Study in Hilly Regions

The objective of this study was to advance sustainable forestry development through the creation of mechanical equipment, taking into account forestry operational methods. A suspended automatic feeding and retracting excavation device for tree pits was engineered, and its interaction with soil was investigated by integrating the Discrete Element Method (DEM) with Multi-Flexible Body Dynamics (MFBD). Based on simulation results, the research explored the impact mechanisms of the machine on soil transportation, working load, and fatigue lifespan of the spiral blades for different terrains and operating conditions. The coupling simulation method demonstrated the potential for designing and testing forestry equipment in specific operating environments, reducing time and resource consumption for field testing. Terrain significantly influenced soil disturbance variability, while the effect of operating direction was minor. Operational parameters should consider soil and water conservation, favoring the formation of fish-scale pits. Field tests in forested areas validate the practicality of the apparatus, providing valuable insights for the operation and equipment design of earth augers in hilly regions.

Analysis of Breaking and Separating Characteristics of Potato–Soil Aggregates Based on the New Type of Swing Separation Sieve

In response to the significant challenge posed by the trade-off between the efficiency of separating potato soil and minimizing potato peel damage in the 4SW-170 potato excavator, this study focused on enhancing the design of the swing separation sieve. The objective was to develop a novel separation sieve comprising three distinct orders of sieve surfaces. Building upon this foundation, the EDEM-Adams coupled simulation method was employed to explore the fragmentation and separation attributes of potato–soil aggregates. This investigation aimed to elucidate the behavior of potato–soil aggregates within the operational scope of the novel swing separation sieve. Subsequently, the optimized parameters were validated through field tests. The findings indicate a direct correlation between the fracture ratio of the cohesive bond and the crank speed, illustrating an increase in the former with higher crank speeds. Conversely, an inverse relationship exists between the fracture ratio and the sieve inclination angle, demonstrating a decrease in the ratio as the sieve inclination increases. At a machine speed of 1.9 km/h, the fracture ratio of the cohesive bond attains its peak value. The force exerted on potatoes at their maximum point escalates with rising crank speed but diminishes with increasing machine speed. Conversely, the effect of sieve inclination on the peak force applied to the potatoes is deemed inconsequential. The most effective parameter configuration for the separation sieve comprises a crank speed of 180 revolutions per minute (r/min), a machine speed of 1.9 km per hour (km/h), and a sieve inclination of 14.4°. Field trials have confirmed that the parameter combination yielded a potato detection rate of 98.01% and a mere 0.68% rate of potato skin breakage, meeting the stipulated technical specifications of the potato harvester.

Vibration of Variable Speed Pump-Turbine in Turbine Operating Range: Simulation by CFD+FEM

Abstract Variable speed pumped-storage unit can operate efficiently and stably in wide range of power and head through the coordinated control of the rotational speed and guide vanes. The regulation in rotational speed brings about frequency and amplitude changes of pressure pulsations, which further influence the avoidance margin of vibration and the dynamic response of the runner. The vibration characteristics of the variable-speed pump-turbine need to be studied when it runs in the wider operating region. Selecting an actual pumped-storage unit as the subject and using the CFD+FEM coupled simulation method as a tool, we conducted three-dimensional pump-turbine vibration simulations and analyse the flow patterns, pressure pulsations, and runner vibration characteristics of several typical operating points in turbine mode. The study focused on the variation laws of pressure pulsations and dynamic stresses when rotational speed is regulated. Comparison with the results for the constant speed unit under the corresponding working conditions was conducted. It is shown that the variable speed operation can effectively avoid the severe vibration conditions that the constant speed unit encounters; the amplitudes of pressure pulsations and dynamic stresses of the runner are small at low rotational speed; in the condition of high speed, low head, and small load, the vibration is the most obvious. This study can provide a reference for the design and operation of variable speed pump-turbine.

Experimental and numerical analysis of heat transfer mechanisms for two-phase oil-refrigerant flow process in the cylinder of rotary compressor

Investigating the heat transfer mechanisms in rolling piston type rotary compressors is crucial for improving their operational efficiency. A thermal test platform was established and steady-state temperature fields of key components were measured under various conditions, revealing a correlation between these temperatures and crank angles, except near the angle of 54° for the cylinder head-up. It provided important boundary conditions for simulation research. A novel three-dimensional fluid–solid-heat coupled simulation method was proposed, calculating heat transfer coefficients at fluid–solid interfaces. The two-phase heat transfer characteristics post oil–gas miscibility was studied, arising from the injection of lubricating oil into the working chamber. Two-phase oil-refrigerant mixtures, compared to single-phase refrigerant, increased heat transfer coefficients by 2.35 % in the suction channel and 2.99 % in the cylinder head-up, but decreased by 5.85 % in the cylinder head-down, 17.42 % in the piston, and 5.63 % in the cylinder. Oil injection was found to significantly enhance convective heat transfer in the suction chamber, increasing suction superheat in the cylinder by up to 29 K and reducing temperature of the compression chamber by up to 17 K. These results provide novel insights into the complex heat transfer in rotary compressors.

Structural Design of Pressurized Tube Based on the Discrete Element Method–Computational Fluid Dynamics Coupled Simulation

In order to elucidate the impact of pressurized tubes’ structures on the sowing performance of pneumatic seed delivery systems, the EDEM–CFD coupled simulation method was employed to analyze the influence of pressurized tube parameters, including length (L), corrugation depth (S), corrugation width (K), and the number of corrugations, on seed movement characteristics, distribution uniformity, and airflow patterns. Simulation-validated experiments were conducted to study the impact of the optimal pressurized tube structure on seeding performance. The results indicate that pressurized tubes significantly enhance the uniformity coefficient of seed distribution, reduce seed velocity, and decrease the coefficient of variation in distribution uniformity. When pressurized tube parameters, specifically length (L), corrugation depth (S), corrugation width (K), and the number of corrugations, are set at 800 mm, 8 mm, 50 mm, and 6, respectively, the uniformity coefficient of seed distribution exceeds 95%, and the coefficient of variation in seed discharge consistency for each row is less than 3.2%. Moreover, the seed velocity at the outlet of the pressurized tube, the relative velocity of two-phase flow, and pressure loss are all minimal, indicating superior seeding performance. This research provides valuable insights into the analysis of seed movement characteristics within pressurized tubes and the optimization of their structural parameters.

RecurDyn-EDEM 耦合仿真优化：三段式薯土低损分离装置优化试验

Aiming at the potato soil separation device of potato harvester, which generally has the problem of potato high damage in potato-soil separation, a three-stage potato soil low-loss separation device was developed, and orthogonal experiments were designed with the help of RecurDyn-EDEM coupled simulation method. A field bench was built for verification tests. The test proved that: when the lift transport chain speed was 1.40 m/s, travel speed was 0.60 m/s, amplitude was 32.0 mm, the impurity rate was 1.49% and the average force on potato was 1.801 N. The potato damage rate was 2.7%, indicating that the design of the three-stage potato soil low-loss separator device worked well.

Design and Parametric Optimization Study of an Eccentric Parallelogram-Type Uprighting Device for Ratoon Rice Stubbles

To address the issue of reduced yield in the second season caused by damaged stubbles resulting from being compressed during the harvesting process of the first season’s ratoon rice, a device for rectifying the compressed stubbles was designed. Utilizing the DEM-MBD coupling simulation method, a simulation analysis was conducted to determine the range of key parameters and verify the feasibility of the solution. Using rotational speed, forward speed, and stubble entry angle as experimental factors and stubble rectification rate and second-season yield as evaluation metrics, a three-factor, three-level Box–Behnken response surface field trial was conducted. The theoretically optimal working parameter combination was found to be a forward speed of 1.4 m/s, device rotational speed of 75 rpm, and stubble entry angle of 39°. Under these conditions, three parallel experiments were performed, resulting in a rectification rate of 90.35% in the mechanically harvested and compressed area and a second-season yield of 2202.64 ± 35 kg/hm². The deviation from the numerical simulation results of parameter optimization was less than 5%. These findings suggest that the designed stubble rectification device for ratoon rice can meet the requirements of stubble rectification during the first-season harvest of ratoon rice. Furthermore, it provides valuable insights for reducing harvest losses in the first season and further improving the level of mechanized harvesting for ratoon rice.

Study on stress distribution law of surrounding rock of roadway under the goaf and mechanism of pressure relief and impact reduction

To safely extract residual coal from a mine affected by rock bursts, the concept of “roadways under goafs” has been proposed as an effective layout. The pressure relief and shock reduction mechanism of roadways under goafs is elucidated through theoretical analysis, numerical simulation, and engineering verification. The stress model for goafs is established based on elastoplastic mechanics, followed by the construction of a force model for coal beneath the goafs. The stress composition of roof, floor and two sides of roadway under a goaf are analyzed. Using the FLAC-PFC coupling simulation method, the excavation process from top coal mining to bottom coal mining roadways of a No. 17 coal mine in Heilongjiang Province was simulated. The simulation results validate the spatiotemporal evolution of the stress and displacement in the surrounding rock mass of the roadway situated beneath goafs and determine the precise location of the roadway and length of its bottom coal face. A large diameter borehole of the roadway and presplitting blasting of the coal face roof are used to solve the local high stress danger area. Moreover, the roadway support mode of the “steel shed + spray arch support + monomer + π steel beam” is proposed. Finally, through the data of the field micro-seismic and stress monitoring system, the effectiveness of the pressure relief and shock reduction of roadways under goafs, the high efficiency of local danger relief of the roadways and working faces, and the practicability of the “steel shed + spray arch support + monomer + π steel beam” support of the roadways broken by surrounding rock are verified. A good basis for choosing a reasonable location for roadways and surrounding rock control methods for residual bottom coal mining and rock burst mining can be found in the research results.

Motion Error Mechanism Analysis and Simulation Verification of Ocean Electric Field Sensor

The electric field measurement based on Unmanned Underwater Vehicle (UUV) can monitor and evaluate real-time electric field of underwater targets in motion, which has the ability to adapt to harsh marine environments. However, electric field sensors generate new errors during underwater motion, and there is still absence of studies on the error theory and simulation. To address this, the error generation mechanism of Ag/AgCl electrodes induced by the flow field was analyzed in this paper. A coupled mathematical model of flow-chemical-electric multi-physical field was established for the first time, and finite element simulation analysis was carried out. The results show that the change value of electrode surface potential under the influence of flow rate is basically in agreement with the empirical formulae. R-squared value of the two fits reaches up to 0.968, and RMSE value is less than 0.003, confirming the robustness of the model and simulations. The multi-physical field coupling model and simulation method proposed in this paper can provide theoretical and methodological support for the design of electric field sensors and motion error correction.