Critical Load Research Articles

Dynamic error prediction and link strain feedback control for a novel heavy load multi-DOF envelope forming machine

Thin walled and high rib components (TWHRC) are widely used for rocket cabins, aircraft wings, panels and frames in aerospace equipment as critical load bearing structures. This paper is aimed to develop a novel multi-DOF envelope forming machine (MEFM) with parallel kinematic mechanism (PKM) to realize efficient manufacturing of TWHRC with high performance. Since the heavy load MEFM with PKM has many total differences with the light load PKM, such as dynamic error and precision control, this paper conducts research on dynamic error prediction modelling and precision control method for this novel heavy load MEFM.Firstly, the configuration of MEFM is developed and the kinematic model of MEFM is established. Then, a RFC (rigid-flexible coupling) and RFE (rigid finite element) coupling dynamic model of MEFM is established considering time-variation of kinematic configuration caused by large deformation of all the kinematic elements. Based on the dynamic model, the dynamic deformation and error of MEFM are predicted and their generation mechanisms are revealed. It is found that the linear compression deformation of two-force links is the largest among all the kinematic elements, and it is the most sensitive to the heavy forming load and the most insensitive to the installation error of strain gauges, thus suiting for the feedback of large deformation of MEFM. Based on the above findings, a novel link strain feedback and dynamic error compensation control method is proposed. Finally, experiments under different control methods are conducted, showing that the motion precision of envelope tool and forming precision of formed components under the proposed control method are remarkably improved compared with that under the traditional control method (The geometric deviation of formed components under the proposed control method is remarkably reduced to −18 ∼ 32um from −64 ∼ 54um under the traditional control method). The experimental results verify that the proposed dynamic error prediction model and link strain feedback control method for heavy load MEFM are reasonable.

The experimental and numerical investigation of fracture behaviour in PMMA notched specimens under biaxial loading conditions – Tension with torsion

This paper presents the results of experimental fracture test of flat PMMA specimens under biaxial loading condition tension with torsion (proportional). The specimens were made in two thicknesses: 5 and 15 mm and were weakened with V-type edge notches with different root radii: 0.5; 2 and 10 mm. Thanks to the ARAMIS 3D 4 M non-contact vision system, measurement of the elongation and twist angle were recorded. During experimental part all of the deformation processes were observed using PHANTOM cameras. Obtained records made it possible to precisely indicate the moment of crack initiation (tensile force and torsional moment values). Using the microscopic observations the location of crack initiations were determined. Results obtained for biaxial loading were compared with those obtained for uniaxial tension and torsion. Based on experimental data the numerical calculation with FEM were carried out. The principal stress and plastic strain distribution under critical load, were obtained. The points of occurrence of stress maxima and plastic strain were indicated, which were taken as potential crack initiation sites. On the basis of the stress and plastic strain values measured at the critical points, a stress–strain fracture criterion was formulated, which was then positively verified. Additionally, new form of stress–strain fracture criterion was proposed. The bilinear form of the fracture criterion can be successfully used to predict fracture in PMMA flat specimens, regardless of the notch root radius, type of load or element thickness.

The role of hydrogen embrittlement in the near-neutral pH corrosion fatigue of pipeline steels

This study confirms that "Near-neutral pH Stress Corrosion Cracking" in steel pipelines propagates by hydrogen-enhanced corrosion fatigue. A critical cyclic loading frequency where maximum growth rate per cycle exists. The critical frequency at different temperatures is verified to correspond to hydrogen diffusion predictions. Growth is limited by crack-tip blunting below this frequency and hydrogen diffusion above this frequency. The critical frequency occurs when crack-tip deformation mechanisms that blunt the crack during the stress cycle overwhelm additional enhancement from diffusion. Growth occurs along cleavage planes and ductile slip planes, indicating hydrogen embrittlement, hydrogen-induced plasticity, and fatigue contribute to crack growth.

Numerical and Analytical Study of the Cyclic Behavior of ADAS Damper and the Effect of Axial Force on its Behavior

ABSTRACT The objective of this research was to study ADAS dampers and develop equations to calculate their seismic parameters. A model was used to analyze the dampers with various variables. The study proposed equations for stiffness, energy dissipation, and strength of the dampers. It also identified the variables with the most and least impact on the results. The effect of axial force on damper performance was investigated, including the calculation of critical load and examining its influence on stiffness, strength, and ductility. Reducing the opening area and height and increasing the width of the damper increased energy dissipation and effective stiffness.

Experimental research on the fracture of Laminated bamboo lumber using compact tension specimens based on the net section method and digital image correlation technique

This investigation evaluates the significance of thickness (B) and initial crack length-to-width ratio (α) on the fracture toughness of Laminated bamboo lumber (LBL) compact tension (CT) specimens under mode Ⅰ fracture conditions. The digital image correlation (DIC) technique is employed to analyse the result, while the net section method is utilised to determine the critical strain energy release rate (GIc). The fracture mode observed in LBL is characterised as brittle fracture, and the critical stress intensity factor (KIc) of CT specimens achieved a maximum value of 25.58 MPa·mm1/2. The fracture energy, calculated by the net section method, was determined by analysing the crack extension length (ae) of the CT specimen obtained by the DIC technique. This study aims to establish the mathematical connection between GIc, ae, and critical load (PQ) in terms of the strain energy release rate context, which offers an innovative approach to analysing GIc data of CT specimens subjected to mode I fracture. The calculated value for GIc was determined to be 12.18 J/mm2.

Nonlinear torsional stability and buckling of spiral stiffened sigmoid FG thin circular cylindrical shells

This research employs an analytical approach to explore nonlinear torsional buckling behaviors of spiral-stiffened sigmoid FG (SSSFG) thin circular cylindrical shells. The research encompasses two variations of SSSFG cylindrical shells: those with internal and external spiral stiffeners. Furthermore, this study explores effects of two distinct material distributions for SSSFG cylindrical shells, specifically metal-ceramic-metal and ceramic-metal-ceramic layers, both following a sigmoid-law distribution. Theoretical formulations are obtained using the smeared stiffeners technique and classical shell theory, incorporating geometrical nonlinearity in the von-Kármán sense. The discretized nonlinear governing equations are obtained through Galerkin's method, and the approximate three-term solution for deflection is developed. Hence, explicit formulations are presented to ascertain the critical torsional load and depict the post-buckling torsional load–deflection curves. The outcomes of this study are validated by comparing them with the related research results existing in the literature. Significantly, the research highlights the influence of diverse parameters and the efficacy of stiffeners in enhancing the stability of SSSFG cylindrical shells. Researchers and engineers in this field may utilize the findings of this research as reference points for their design and research involving SSSFG cylindrical shells.

Bolted connections in prefabricated cantilevered cap beam-column structures: A comprehensive experimental and numerical study

Prefabricated cantilevered beam-column structures have gained popularity in mountainous road construction. However, a notable research gap exists regarding the beam-column connections. To fill this gap, a new bolted connection method was introduced for the cantilevered beam-column structure. The mechanical performance of this novel structure was systematically investigated through reduced-scale experiments and finite element analysis. The structure's response under three critical loading conditions was experimentally examined, revealing the efficacy of bolted connections in preserving structural integrity and highlighting pronounced strain concentration at the connection region of the cap beam. Furthermore, to enhance structural design, a finite element model of this beam-column structure was established to simulate the influence of various materials and structural parameters on structural response and damage. Simulation results indicated that the anchor rod angle and the number of bolts had a minor impact on load-bearing capacity and damage modes. In contrast, the choice of concrete material and steel reinforcement ratio significantly influenced load-bearing capacity. The insights derived from this study offer valuable guidance for optimizing and extending the application of this structural design.

Study on the interference mechanism and fracture behavior of penetrating parallel double cracks

The existence of crack groups in structures is objective and inevitable during the process of manufacture and service. In this paper, the interactions between penetrating parallel double cracks are systematically investigated through finite element methods, experimental studies and theoretical analyses, where both the brittle dominant and ductile materials are taken as the research objects. The interactions between cracks are discussed through the interference factors C based on stress intensity factor K, which is related with the relative distance between crack tips. It is found that the fracture behaviors of multiple cracks are associated with all the interference factors at four crack tips. For the alignment double crack, shielding effects at all the crack tips cause the mutually exclusive crack propagations, and then strengthen the critical load of the specimen. For offset double cracks, the inner crack extension directions are attracted to each other, the outer crack extension directions are repelling each other, the critical loads depend on the degree of the attraction or the repelling effect. There exists a relationship between the comprehensive interference factor with all the crack tips included and the loading capacity. For the specimen with multiple surface cracks, the interference effects are also related with the relative distance between crack tips, through which it can be preliminary obtained that the regulations and the effect to the fracture behaviors are similar to those of penetrating cracked specimen, which will be discussed in detail in our next findings. The interference behaviors and critical loads of multiple cracks discussed above also provide an important basis on the coalescence and evaluation of multiple cracks.

Damage Development in a Cellular Axisymmetric Tank Additive-Manufactured from Plastic Filament. Part 1. Damage Development in Cellular Axisymmetric Multilayer Shells Under Critical Mechanical Loads and Quivalent Properties of Model Layers for Stress-Strain State Estimation

Damage Development in a Cellular Axisymmetric Tank Additive-Manufactured from Plastic Filament. Part 1. Damage Development in Cellular Axisymmetric Multilayer Shells Under Critical Mechanical Loads and Quivalent Properties of Model Layers for Stress-Strain State Estimation

Fracture toughness and slow crack growth behaviour of metal-proton conducting ceramic composites

The fracture toughness and slow crack growth behaviour of two load-bearing metal ceramic components adopted in negatrode-supported electrochemical devices, namely Ni-BCZY27 and Ni-BCZY442, are investigated via double torsion technique.The investigation showed that the two metal-ceramic composites are considerably less sensitive to slow crack growth when compared to oxide ceramics such as stabilized zirconia and alumina, with KI0/KIC equal to approximately 0.8. On the other hand, they also showed lower fracture toughness than Ni-3YSZ, with Ni-BCZY442 and Ni-BCZY27 having a fracture toughness of respectively 1.74 and 3.04 MPa*m1/2 for porosities equal to 25.8% and 19.1% respectively, compared to Ni-3YSZ reported in previous work with similar Ni content and porosity of approximately 30% having a fracture toughness equal to 3.4 MPa*m1/2. Furthermore, the analysis of samples presenting extensive barium depletion indicated fast fracture propagation upon application of loads significantly lower than the critical fracture load.

Symmetrical wrinkling of compressed composite SSCF facings of a rectangular sandwich plate

Results of the study of symmetrical facing wrinkling of compressed rectangular composite sandwich plates with orthotropic faces and core are presented in the paper. Two parallel edges of the plate facings are simply supported, one edge is clamped, and another edge is free (SSCF). The wrinkling problem is solved using the Ritz method in which the total energy functional of plate faces and core is obtained based on the original model, considering nonlinear variation of the transverse displacement of the core material from the value of facing’s deflection to zero. Application of the Ritz method yields formulas for the calculation of critical compressive load. The critical load is found using a minimization with respect to the parameter of the wrinkling waves evolution and the parameter characterizing the rate of fading of the transverse displacement. Based on the derived formulas, the effects of facing and core thicknesses, and modulus elasticity of core material on the critical wrinkling load are studied. The results of calculations are verified using a finite element analysis. It is shown that the value of critical load calculated based on the proposed model is more accurate compared to that calculated using the Winkler-Pasternak model, particularly for the sandwich plates with thin faces and thick core.

Progressive failure analysis of z-pin reinforced composite pi joints

A finite element model of a z-pin reinforced composite pi joint has been developed and correlated against experimental results. A smeared cohesive zone modeling approach was implemented to represent the effect of z-pinning in an efficient and scalable manner. In the smeared approach, cohesive properties governing the traction–separation response of the z-pin reinforced areas were defined to account for the effective fracture toughness caused by z-pinning in an averaged sense. The crack band method was used to account for diffuse damage and failure in the weave of the pi preform. The damage in the preform developed due to delamination suppression caused by the z-pinning. The numerical model was calibrated using experimental data from pristine and defective z-pinned pi joints subjected to pull-off and side-bend loading. Comparisons of experimental and numerical results show good agreement in terms of structural response, critical loads, and failure modes.

A robust microgrid formation method for risk-resistant service restoration considering subsequent contingency

Service restoration (SR) is essential for resilience enhancement of distribution systems (DSs) when natural disasters occur. However, a restored DS may face potential outage risks caused by subsequent contingency during the prolonged event. To improve the risk-resistance of SR strategies, this paper proposes a microgrid-based SR method to continuously supply critical loads when considering subsequent contingency. The microgrids are proactively formed to mitigate the influence of subsequent contingencies, which can effectively reduce the load shedding and wind power curtailment during the SR process. To deal with uncertainties of subsequent contingency and wind power, a two-stage robust model is established. Moreover, an improved uncertainty set is established to further reduce the conservatism of robust optimization. Specially, the line interruption probability is considered when constructing the Shannon entropy-based uncertainty set of subsequent contingencies, and the spatial–temporal correlations of wind power is considered when formulating the budget-constrained uncertainty set. Then, the robust model is solved by column-and-constraint generation algorithm efficiently. Numerical results demonstrate that the proposed SR method can effectively enhance the risk-resistance of SR strategy and reduce the conservatism while ensuring the robustness of solutions.

Contact stiffness of the multi-indenter contact interface

Mechanical contact plays a pivotal role in both industrial and daily life applications. Contact stiffness of a multi-indenter contact interface fundamentally determines force–deformation relations. However, the understanding of the overall contact stiffness from the historical perspective is limited owing to inherent difficulties in precisely characterizing the interaction in multi-indenter contacts. In this study, the mechanical strong interaction among indenters is pinpointed. A theoretical model for accurately determining the contact stiffness of multi-indenter contact interface is developed. The physical mechanism of the contact stiffness of multi-indenter contact interface is revealed. The theoretical model is solidly validated by experiment and simulation. More importantly, the present theoretical model can predict the contact stiffness of contact interfaces with complex and irregular configurations, which may be filled up with indenters of hierarchical structures. The critical load is determined to guarantee the finished product rate during transfer printing. This is experimentally evidenced by the transfer printing of silicon wafers with complexly customized patterns. The present study provides a profound guidance for various engineering applications such as fabrication and integration of micro- and nano-electronic chips as well as electronic devices.

Influence of HTS tape arrangement on the transverse compression performance of copper former CORC cables

CORC cables are subject to large transverse compression electromagnetic forces in fusion projects. Unfortunately, the electromagnetic force exceeding its critical transverse compression load will cause an irreversible decrease in its critical current. Therefore, it is particularly important to enhance the critical transverse compression load to ensure that the critical current does not decrease during operation. The winding method of high temperature superconducting (HTS) tape on the central former is variable. So the experimental study on how to increase the critical transverse compression load of CORC cable by changing the winding method of HTS tape is carried out in this paper. Firstly, the influence law of parameters of the number of HTS tapes per layer and the number of HTS tape layers on their transverse compression performance are analysed independently. The results indicate that increasing the number of HTS tapes per layer and the number of HTS tape layers can both improve the transverse compression performance of CORC cables. Whereas, in the case of a cable with a certain critical current demand (the same total number of HTS tapes), increasing the number of HTS tape layers necessarily reduces the number of HTS tapes per layer. Therefore, in order to compare the degree of influence of the above two parameters, we conducted transverse compression experiments on multiple groups of CORC cables with different winding methods (more layers with few tapes per layer or few layers with more tapes per layer) under the same critical current demand. The results show that under the same critical current demand, choosing the winding method that reduces the number of HTS tape layers and increases the number HTS tapes per layer can effectively improve the transverse compression performance of CORC cables. A 3D multilayer CORC cable transverse compression finite element model is also established to explain the inherent reasons for the differences in transverse compression performance of CORC cables under different HTS tape winding methods.

A model for the response of unreinforced and z-pin reinforced composite pi joints

Experimental data obtained from Narrow Element and Wide Element pi joints was used to motivate the development of a mechanics-based model to predict the quasi-static response of non-reinforced and z-pin reinforced composite pi joints. The progressive failure modeling approach used a novel cohesive formulation to include intra- and inter-laminar damage modes and their interactions. A smeared cohesive zone modeling approach was implemented in which effective fracture toughness and cohesive strength values were defined in the areas corresponding to the z-pin fields in the reinforced joints. Properties defining the cohesive responses were calibrated at the narrow element level and subsequently used in the wide element model to establish blind predictions prior to experimental testing. Unreinforced (unpinned) and z-pin reinforced pi joint specimens were tested in pull-off loading. Experimental and numerical comparisons were made in terms of load–displacement response, critical loads, damage modes, and failure progression. Comparisons between the experimental results and blind predictions for the unpinned joints were found to be in good agreement; however, discrepancies for the z-pin reinforced joint emphasize the challenges associated with physics-based simplified modeling techniques intended to capture complex z-pin behavior.

Concept of combined strain-stress state control of long span structures

Purpose: Argumentation of necessity of special protective system design to protect structures in seismic zones and remote areas from specific loads. Such protective system combines seismic isolation and internal force control systems.Research findings: Restrictions of long-span structures construction are reviewed. Such restrictions are caused by building conditions embodied in National Building Codes and Standards. Combined and separate use of seismic isolation and internal force control systems is a critical specific load protection. Present inventions and experience in the field of seismic isolation and internal force control systems are reviewed.Value: The article determines problems of protective system design based on the control for combined strain-stress state.

A Resilient Approach to a Test Rig Setup in the Qualification of a Tilt Rotor Carbon Fiber-Reinforced Polymer (CFRP) Wing

The evolution of aircraft wing development has seen significant progress since the early days of aviation, with static testing emerging as a crucial aspect for ensuring safety and reliability. This study focused specifically on the engineering phase of static testing for the Clean Sky 2 T-WING project, which is dedicated to testing the innovative composite wing of the Next-Generation Civil Tiltrotor Technology Demonstrator. During the design phase, critical load cases were identified through shear force/bending moment (SFBM) and failure mode analyses. To qualify the wing, an engineering team designed a dedicated test rig equipped with hydraulic jacks to mirror the SFBM diagrams. Adhering to specifications and geometric constraints due to several factors, the jacks aimed to minimize the errors (within 5%) in replicating the diagrams. An effective algorithm, spanning five phases, was employed to pinpoint the optimal configuration. This involved analyzing significant components, conducting least square linear optimizations, selecting solutions that met the directional constraints, analyzing the Pareto front solutions, and evaluating the external jack forces. The outcome was a test rig setup with a viable set of hydraulic jack forces, achieving precise SFBM replication on the wing with minimal jacks and overall applied forces.

Energy Storage Systems: Technologies and High-Power Applications

Energy storage systems are essential in modern energy infrastructure, addressing efficiency, power quality, and reliability challenges in DC/AC power systems. Recognized for their indispensable role in ensuring grid stability and seamless integration with renewable energy sources. These storage systems prove crucial for aircraft, shipboard systems, and electric vehicles, addressing peak load demands economically while enhancing overall system reliability and efficiency. Recent advancements and research have focused on high-power storage technologies, including supercapacitors, superconducting magnetic energy storage, and flywheels, characterized by high-power density and rapid response, ideally suited for applications requiring rapid charging and discharging. Hybrid energy storage systems and multiple energy storage devices represent enhanced flexibility and resilience, making them increasingly attractive for diverse applications, including critical loads. This paper provides a comprehensive overview of recent technological advancements in high-power storage devices, including lithium-ion batteries, recognized for their high energy density. In addition, a summary of hybrid energy storage system applications in microgrids and scenarios involving critical and pulse loads is provided. The research further discusses power, energy, cost, life, and performance technologies.

Characterization of cosputtered (TiZrHfY)Nx films

Medium-entropy TiZrHfY alloy films and corresponding nitride (TiZrHfY)Nx films were fabricated through cosputtering. The Ti0.24Zr0.23Hf0.27Y0.26 film had the form of a hexagonal close-packed (HCP) solid solution with a mixing enthalpy of 9.09 kJ/mol, mixing entropy of 11.50 J/mol·K (1.38 R), atomic size difference of 7.72 %, and valence electron concentration of 3.73. Moreover, this film had a hardness of 6.0 GPa and an elastic modulus of 106 GPa. (TiZrHfY)Nx films with various stoichiometric ratios (x) were fabricated by adjusting the reactive gas flow ratio fN2 [N2/(N2 + Ar)] in the range 0.1–0.7. Adding N to the TiZrHfY matrix resulted in a change of phase from an HCP structure to a face-centered cubic phase. The (Ti0.23Zr0.18Hf0.24Y0.35)N0.71 film (with fN2 = 0.2) exhibited the most favorable mechanical properties, having a hardness of 19.1 GPa and an elastic modulus of 244 GPa. Moreover, the film had the highest critical loads (LC3 = 46.6 N) among the films analyzed in the scratch test. The anticorrosive properties of the TiZrHfY and (TiZrHfY)Nx films were evaluated using potentiodynamic polarization curves, obtained in 3.5 wt% NaCl aqueous solution. High polarization resistance of 1.1 × 106 Ω·cm2 was obtained for the (Ti0.23Zr0.18Hf0.24Y0.35)N0.71 film, which was 145 times higher than that of the bare SUS420 substrate. The (Ti0.23Zr0.18Hf0.24Y0.35)N0.71 film had the most favorable mechanical and anticorrosive properties of the surveyed (TiZrHfY)Nx films.