Detailed Finite Element Analysis Research Articles

Mechanical behavior analysis of sandwich composite structures with different core geometries under three-point bending

This study presents a comprehensive investigation into the mechanical behavior of sandwich composite structures featuring six distinct core geometries under three-point bending conditions. Through detailed finite element analysis (FEA), the research examines the performance characteristics of I-shaped, traditional honeycomb (NIDA), O-shaped, X-shaped, semi-circular, and modified core geometries. The analysis focused on stress distribution patterns, displacement responses, and overall structural integrity. Results demonstrate that the semi-circular core geometry exhibits superior mechanical properties, achieving an 84.66% improvement in positive stress resistance and 74.79% enhancement in negative stress resistance compared to the traditional honeycomb reference model. The study revealed consistent linear elastic behavior across all models within the tested displacement range, with the semi-circular configuration showing optimal stress distribution and minimal core deformation. Using aluminum for facings and core materials, the research evaluated mechanical responses through displacement-controlled loading conditions, measuring stress concentrations at critical points and analyzing deformation patterns. This research provides valuable insights into the relationship between core geometry and mechanical performance, offering practical implications for engineering applications requiring high strength-to-weight ratios and enhanced flexural resistance in modern structural design.

Numerical investigation of thermal influence on debonding behavior in composite structures through a friction and cohesive coupled model

AbstractThis study conducts an in-depth numerical analysis of debonding behavior in composite structures, with a particular focus on the critical role of thermal effects. Utilizing a frictional contact cohesive zone model, the research characterizes the debonding process while sequentially integrating thermal analysis to assess the impact of thermal loading. A thermomechanical coupled model is developed and implemented using the finite element software ABAQUS. The model's accuracy is validated through the Double Cantilever Beam (DCB) test, ensuring reliable results. The methodology involves a detailed finite element analysis, where thermal loads are applied to composite specimens, followed by mechanical loading to simulate debonding. The frictional contact cohesive zone model accurately captures the interface behavior under varying thermal conditions. Quantitative results indicate that thermal loading significantly affects the debonding process, with a noticeable increase in debonding initiation and propagation rates, highlighting the critical influence of thermal effects on structural integrity.

Simulated and measured performance of the ISIS TS-1 Project target

A new design of spallation target has been installed and operated at the first target station of the ISIS Neutron and Muon Source (ISIS TS-1), as part of the recently completed “TS-1 Project”. Detailed Finite Element Analysis (FEA) simulations were used to guide the design process and predict target performance. Since the TS-1 Project target began operation in November 2022, operating data has been collected and used to validate the target simulation approach. Measured temperatures of 9 out of 10 target plates showed good agreement with FEA simulations of both steady-state and transient behaviour. However, the front target plate temperature was elevated compared to predictions. Because the installed target was now too radioactive to permit hands-on inspection, FEA simulations became an indispensable tool to understand the possible causes and safety implications of this anomalous behaviour. The anomalous elevated temperature appears to be highly localised; a combination of simulations and experiments indicates the mostly likely cause is poor thermal contact between the thermocouple and the bulk of the target plate. In all other respects the target is operating as predicted, and is running reliably at up to 120 kW.

Numerical investigation of knee prosthesis stresses in daily activities: Insight into knee rehabilitation and Creation of a new optimal model

Total knee arthroplasty (TKA) is a cornerstone in addressing knee joint disorders, significantly enhancing patients' quality of life. However, despite technological advancements, a comprehensive understanding of the dynamic stresses experienced by knee prostheses during daily activities, particularly under rehabilitation interventions, remains elusive. This study aims to bridge this gap by employing numerical simulations and finite element analysis to elucidate these dynamic stresses and their interaction with rehabilitation protocols.A real-life knee replacement prosthesis model was meticulously constructed through coordinate measuring and 3D scanning, facilitating detailed finite element analysis in ANSYS Workbench version 17.1. Two distinct boundary conditions and loading scenarios were applied, with comparisons made between linear and nonlinear material assumptions. The simulation results using these different boundary condition methods revealed minimal differences. Specifically, at a knee angle of 0°, the relative stress error rate between the two boundary condition types was approximately 1 % (1.11 MPa and 1.099 MPa, respectively). At 15° and 90°, the error rates were 1.9 % and 0.56 %, respectively (10.275 MPa and 10.078 MPa at 15°; 10.275 MPa and 10.078 MPa at 90°). Given these minimal differences, the first type of boundary condition was adopted for the subsequent scenarios to enhance convergence efficiency in the analysis.Moreover, comparative analyses between linear and nonlinear material behaviors demonstrated acceptable agreement, offering insights into potential efficiency gains in simulation methodologies. Building on this foundation, an optimized tibial model was proposed, incorporating geometric alterations to the tray. Quantitative assessments revealed significant reductions, with von Mises stress decreasing by 23.35 % and equivalent strain by 17 % at a knee angle of 140°. Further evaluations at varying angles, including 60°, consistently showed positive influences on stress and strain. These quantitative findings not only contribute valuable insights into the mechanical behavior of knee prostheses but also provide tangible evidence for the efficacy of linear material behavior assumptions. The proposed optimized model exhibits promising potential for enhancing the design and performance of knee prostheses, particularly under critical loading conditions.In conclusion, these results underscore the importance of a nuanced understanding of knee prosthesis behavior during rehabilitation, offering a quantitative foundation for refining existing designs and informing the development of next-generation prostheses.

Performance enhancements of HTS power cables by minimizing the electric field enhancements for electric transport applications

Abstract Design innovations to manage the electric field enhancements and successful use of cryogenic epoxy EP37 as electrical insulation for high temperature superconducting (HTS) cables for electric aircraft applications are reported. Detailed finite element analysis (FEA) of the electric field distribution shows that the highest electric field is at the interface of the ground and electrical insulation layers. The FEA led to the design, fabrication, and experimental characterization of four model cables with stress cones and a direct bond of the ground and insulation layers. Enhanced partial discharge inception voltage (PDIV) was achieved in the model cables by minimizing the electric field enhancements at the ground layer interface. Using a helium gas mixture with 4 mol% H2, with higher intrinsic dielectric strength than pure helium, further enhanced the PDIV. The results warrant further studies on long HTS cables with EP37 as electrical insulation with a direct bond between the insulation and ground layers.

An experimental and numerical analysis of slit plate as replaceable fuse in moment resisting frame

This study contributes to the ongoing progress in developing cost-effective structural fuse solutions for steel structures, emphasizing enhanced strength, ductility, and energy dissipation capacity. These fuses are strategically placed to coincide with plastic hinge locations under lateral load. During minor seismic events, they provide substantial rotational stiffness, while during medium to large earthquakes, they leverage their post-yield strength for effective energy dissipation. Three varieties of beam-column sub-assemblages viz. single oval slit damper fuse (SOSDF), dual oval slit damper fuse (DOSDF) and single elliptical slit damper fuse (SESDF), featuring advanced replaceable fuses were evaluated using both experimental and numerical analyses under quasi-static loading conditions. The seismic performance of these specimens was comprehensively assessed, focusing on characteristics such as moment-carrying capacity concerning rotation, energy dissipation, ductility, and failure modes. The findings indicate that all specimens exhibited stable hysteresis, with connections utilizing SESDF and DOSDF showing slightly higher moment carrying capacities (19 % and 10 %, respectively) compared to those employing SOSDF. According to AISC 2016 standards, all three connections were classified as full-strength connections. Moreover, the ductility of specimens incorporating SESDF was notably higher as 3.5, marking a 28 % and 26 % increase over the ductility of SOSDF and DOSDF connections, respectively. In major seismic events, damage was confined solely to the fuse components, with no damage observed in the beam and column. Detailed finite element analysis using ABAQUS CAE further corroborated these findings, demonstrating good alignment between experimental and simulated results.

Effects of carbon-fibre Z-pins on the through-thickness tensile strength of curved composite laminates under four-point bending

This study investigates the influence of discrete through-thickness reinforcement, i.e. Z-pins, on the through-thickness tensile strength (TTS) of curved laminates through four-point bending experiments. Three types of samples are considered: unpinned, and Z-pinned with 0.27 % and 0.54 % areal densities. HexPly® IM7/8552 carbon/epoxy unidirectional prepreg with 0/±45 layup and 0.28 mm diameter T300/BMI pins were employed to manufacture the specimens. The Z-pinned laminates have comparable TTS with the unpinned samples in terms of the first observable load-drop. However, the TTS corresponding to the ultimate load-drop for low-density and high-density Z-pinned samples are 29 % and 38 % lower than for the unpinned ones, respectively. Z-pinned samples show less scatter than unpinned ones in terms of the ultimate TTS values. All specimens failed suddenly, i.e. with no evident damage progression. This implies that Z-pins were not able to form a progressive bridging zone to dissipate mechanical energy. Through a detailed meso-scale finite element analysis (FEA), it was found that the high through-thickness tensile residual stress in the Z-pin neighbourhood generated from the cool-down stage of cure is an important factor in causing the reduction in TTS of Z-pinned laminates. CT scan images of tested Z-pinned specimens show that the carbon-fibre pins experience fracture inside the laminates.

On the Shear Force Redistribution in Composite Steel and Concrete Beams with Web Openings

As far as research into the field of composite steel and concrete beams with web openings has shown, the initiation of a complex stress state due to the introduction of web openings is, unfortunately, inevitable. As a logical consequence, estimation of the resistance becomes complex as well. Aiming to provide a more convenient approach, especially for evaluation of the bending resistance to the Vierendeel effect with the presence of high shear forces, a marked simplification with respect to quantification of the shear force redistribution between T-sections is presented. This novel approach stands on strong fundamentals of experimental evidence and parametric finite element (FE) investigation. Concretely, within the experimental part of this investigation, the load response of four composite beam samples was recorded and profoundly analyzed. Subsequently, a detailed FE analysis in the software ANSYS 2024 R1 (ANSYS Inc., Canonsburg, PA, USA), exploiting its parametric design language (APDL), was conducted. Finally, concise data compilation and their comprehensible interpretation were enabled by employing the software MATLAB 2024a (The MathWorks, Inc., Natick, MA, USA). In view of this treatment, a cornerstone for successive assessment of the obtained data was laid. Attempting to identify the key factors influencing the shear force proportion between the tees, integration of the shear stresses along the vertical sections with regular spacing along the FE beam models was conducted. By virtue of this concept, not only the magnitudes of the shear forces for the tees were obtained but also the leading importance of the opening depth was demonstrated. Furthermore, a complete picture of the shear force behavior along the composite perforated beams was derived. On this basis, a novel method representing a simpler and more accurate form of estimation of the shear force proportion for T-sections was proposed.

Compressive load capacity of CHS X-joints: The Efficacy of doubler plates

This study explores the effects of doubler plates and alterations in joint configuration, on the static characteristics of X-joints made from circular hollow sections (CHS) with slender walls, concentrating on how they withstand compressive forces applied to the braces. A detailed finite element analysis (FEA) was launched. Its accuracy verified through experimental tests carried out by the research team and by comparing it with existing studies. The investigation included an extensive parametric analysis (by generating 204 models) to evaluate changes in initial stiffness, load capacity, and modes of failure, with a focus on the importance of interactions between the chord and plates and the impact of geometric and material nonlinearities. Findings revealed that the doubler plates significantly improve the maximum load bearing capacity and failure modes under various joint geometrical scenarios. While the benefits of doubler plates in enhancing the durability of X-joints are clear, their effectiveness under axial load was not studied. Based on these insights, the research introduces a new theoretical design equation, based on yield volume theory and nonlinear regression, to accurately forecast the ultimate load capacity of the joints.

Experimental and analytical investigation of opening effects on the in-plane capacity of unreinforced masonry wall

A test programme consisting of four half-scale URM walls was conducted under quasi-static cyclic loading to evaluate the negative influence of openings. Test results showed that the masonry adjacent to the opening experienced significant damage, and the specimens with a door opening was found to have complete detachment of the masonry pier, resulting in a reduction in the capacity of more than 25%. Furthermore, a detailed parametric nonlinear finite element analysis was performed to assess the influence of parameters affecting the in-plane load capacity of the URM wall. Numerical results showed that depending upon the size and location of openings and the material and geometric properties of walls, the in-plane load capacity was reduced by 6–82%. Considering the results of available experimental studies and present numerical analyses, a simplified equation was proposed to estimate the reduction in the in-plane load capacity of the specimen with different types of openings. The analytical study demonstrated that the proposed equation effectively provided reliable and consistent predictions of the strength reduction factor for walls with different types of openings.

Ultra‐fast finite element analysis of coreless axial flux permanent magnet synchronous machines

AbstractLarge‐scale design optimisation techniques enable the design of high‐performance electric machines. Electromagnetic 3D finite element analysis (FEA) is typically employed in optimisation studies for accurate analysis of axial flux permanent magnet (AFPM) machines, which require extensive computational resources. To reduce the computational burden, a FEA‐based mathematical method relying on the geometric and magnetic symmetry of coreless AFPM machines is proposed to estimate the machine performance indicators using the least number of FEA solutions, thereby significantly lowering the running time. This method is generally applicable to AFPM machines with low saturation effects and cogging torque as exemplified for a printed circuit board (PCB) stator coreless AFPM machine. To further reduce the computation time, a systematically simplified equivalent 3D FEA model for planar PCB coils integrated with this machine is also proposed. The practical implementation of the introduced method is elaborated based on an example optimisation study, and an analytical method for fast design scaling is also discussed. The results of the proposed approach are compared with detailed transient FEA results, and a prototype 26‐pole PCB stator coreless AFPM machine was also used to validate the results experimentally.

Numerical studies of pull-through failures in cold-formed steel battens at sub-zero temperatures

Cold-formed steel (CFS) roof and wall cladding systems comprising thin, high strength steel battens and claddings are popularly used in the building industry worldwide. These cladding systems have been observed to encounter failures under combined snow and strong wind actions during blizzards. Significant damage is caused by the disengagement of the entire roof/wall cladding when localised pull-through failures occur in thin-walled steel battens at the batten to truss/rafter screw connections due to a splitting mechanism around the screw head. This study uses detailed finite element analyses of the pull-through failures of a range of batten configurations under combined wind and sub-zero temperature conditions. Suitable finite element models capable of simulating the pull-through failures of battens were developed and validated using experimental results, followed by detailed numerical parametric studies. The main outcomes of this study are accurate design equations and capacity reduction factors essential for predicting the pull-through capacities of CFS battens at sub-zero temperatures.

Bond-Damaged Prestressed AASHTO Type III Girder-Deck System with Retrofits: Parametric Study

This research describes an in-depth analysis of the flexural strength of a strengthened AASHTO Type III girder-deck system with debonding-damaged strands based on the finite element software ABAQUS 6.17. To investigate the stand-debonding impact and retrofit, two strengthening techniques by the separate use of carbon fiber-reinforced polymer (CFRP) and steel plate (SP) were proposed. A detailed finite element analysis (FEA) model considering strand debonding, material deterioration, and retrofitting systems was developed and verified against relevant experimental data obtained by other researchers. The proposed FEA model and the experimental data were in good agreement. The sensitivity of the numerical model to the mesh size, element type, dilation angle and coefficient of friction was also investigated. Based on the verified FEA model, 156 girder-deck systems were studied, considering the following variables: (1) debonding level, (2) span-to-depth ratio (L/d), (3) strengthening type, and (4) strengthening material amount. The results indicated that the debonding level and span-to-depth ratio had a major effect on both load–deflection behaviors and the ultimate strength. The relationships between the enhancement of the ultimate strength and the thickness of the strengthening material were obtained through regression equations with respect to the CFRP- and SP-strengthened specimens. The coefficient of determination (R2) was 0.9928 for the CFRP group and 0.9968 for the SP group.

Unraveling the complexity of vascular tone regulation: a multiscale computational approach to integrating chemo-mechano-biological pathways with cardiovascular biomechanics

Vascular tone regulation is a crucial aspect of cardiovascular physiology, with significant implications for overall cardiovascular health. However, the precise physiological mechanisms governing smooth muscle cell contraction and relaxation remain uncertain. The complexity of vascular tone regulation stems from its multiscale and multifactorial nature, involving global hemodynamics, local flow conditions, tissue mechanics, and biochemical pathways. Bridging this knowledge gap and translating it into clinical practice presents a challenge. In this paper, a computational model is presented to integrate chemo-mechano-biological pathways with cardiovascular biomechanics, aiming to unravel the intricacies of vascular tone regulation. The computational framework combines an algebraic description of global hemodynamics with detailed finite element analyses at the scale of vascular segments for describing their passive and active mechanical response, as well as the molecular transport problem linked with chemo-biological pathways triggered by wall shear stresses. Their coupling is accounted for by considering a two-way interaction. Specifically, the focus is on the role of nitric oxide-related molecular pathways, which play a critical role in modulating smooth muscle contraction and relaxation to maintain vascular tone. The computational framework is employed to examine the interplay between localized alterations in the biomechanical response of a specific vessel segment—such as those induced by calcifications or endothelial dysfunction–and the broader global hemodynamic conditions—both under basal and altered states. The proposed approach aims to advance our understanding of vascular tone regulation and its impact on cardiovascular health. By incorporating chemo-mechano-biological mechanisms into in silico models, this study allows us to investigate cardiovascular responses to multifactorial stimuli and incorporate the role of adaptive homeostasis in computational biomechanics frameworks.

A Finite-Element-Analysis-Based Feasibility Study for Optimizing Pantograph Performance Using Aluminum Metal Matrix Composites

A pantograph is a key component on the tops of trains that allows them to efficiently tap electricity from power lines and propel them. This study investigates the possibility of using metal matrix composites (MMCs), specifically aluminum MMCs, as a material for making pantograph parts regarding the dynamics of the train’s movement and external meteorological conditions. In this study, a computer-aided design (CAD) model is created using PTC Creo design software and moves to detailed finite element analysis (FEA) simulations executed by the ANSYS software suite. These simulations are important in examining how the dynamic performance of pantographs can vary. The incorporation of Al MMC materials into the structure of the pantograph resulted in significant improvements in structural robustness, with equal stress reduced by up to 0.18%. Similarly, aluminum MMC materials reduced the strain energy by 0.063 millijoules. The outcomes not only give a new perspective to the implementation of modern materials but also provide a breakthrough concept to improve efficiency and increase the service life of pantographs. This study marks a significant milestone in the theoretical development of essential train systems, furnishing eminent perspectives toward the tactical development of transportation infrastructure by suggesting new avenues for the smooth incorporation of smart materials in railway transportation, which would contribute to a more sustainable and reliable future.

Performance Comparison and Optimization of a PMSM Based on Hybrid-Type Permanent Magnet with Two Kinds of Rotor Topology

This study focuses on designing and optimizing Permanent Magnet Synchronous Motors (PMSMs) using hybrid rare earth and ferrite materials. Two distinctive rotor topologies of the Hybrid-Type Permanent Magnet Motor (HTPMM) are proposed: series and parallel magnetic circuits. Initially, the rotor topology and magnetic circuit principles of both the prototype and the designed HTPMM are introduced. Subsequently, a multi-objective genetic algorithm is employed to optimize the two HTPMMs, determining the final optimized parameters. Thise study further analyzes the cost advantage of HTPMMs from the perspective of permanent magnet materials, and detailed finite element analysis is conducted to evaluate the electromagnetic performance, including the air-gap flux density, no-load back electromotive force, cogging torque, load torque characteristics, and demagnetization properties. A comparative analysis of the prototype and two designed motors reveals that the HTPMM exhibits similar performance to the prototype, effectively reducing the usage of rare earth materials and significantly lowering the manufacturing costs. This research validates the feasibility of reducing rare earth material usage while maintaining a similar performance and provides a new perspective for the design of permanent magnet motors.

Evaluation of human-induced vibration in floors of modular hospitals

Construction of modular hospitals has gained significant attention since the global pandemic. One important design requirement for hospitals that is critical for their safe operation is to control floor vibration. Floors in modular buildings are often more prone to vibration because they are lightweight and less restrained. This study first presents a standardized design layout for modular hospitals developed based on Canadian code requirements. Then, the human-induced vibration of various floor systems designed for this sample modular hospital is investigated using different analysis methods including a new method developed by the authors. It is found that conventional floor designs may not be suitable for modular hospitals considering the strict vibration limits for hospitals and the need for lightweight construction. Using detailed finite element analysis, it is shown that the proposed method can accurately predict the vibration response of various floors including those that have frequencies well beyond the application range of existing design methods.

Seismic behaviour of self-centring hybrid steel frames equipped with SMA plates under mainshock–aftershock sequences

This paper focuses on the mechanical behaviour, seismic application in steel frame connections and steel structure of shape memory alloy (SMA) plates. This study commenced by examining the hysteretic response of SMA plates subjected to cyclic tension tests, considering two different loading paths. Subsequently, a self-centring steel frame connection equipped with SMA plates and washers (SC-PW) was examined via quasi-static cyclic loading tests, and comparatively satisfactory self-centring behaviour was observed. However, the degradation of the initial stiffness of the SC-PW due to an initial imperfection was observed. An improvement strategy was proposed to overcome the degradation of the hysteretic behaviour (e.g., initial stiffness) of the SC-PW. Disc springs with a larger stiffness and preloads were introduced to overcome the degradation of the initial stiffness of the SC-PW, and the validation was confirmed via detailed finite element (FE) analyses. To improve the computation efficiency, a simplified FE model was developed to reproduce the hysteretic responses of the connection. Based on the simplified FE model, a six-storey prototype structure, i.e., a self-centring hybrid steel frame (SCHSF), equipped with the improved connection was developed, and the structural dynamic responses were investigated via nonlinear response history analyses, where mainshock–aftershock sequences were considered. The influence of the SMA material properties on the seismic behaviour of the prototype structure was investigated.

Qualification of thermal barrier coating for semi-cryogenic engine thrust chamber through strain-controlled fatigue tests

The combustion chamber of semi-cryogenic engines experiences elevated temperatures which are beyond the capability of most structural materials. To solve this issue, an effective cooling mechanism to be implemented. In one of the developmental launch vehicles of Indian Space Research Organisation, the wall temperature in the combustion chamber is reduced by means of employing regenerative cooling along with thermal barrier coating applied on the inner wall made of special grade copper alloy. This special coating made of layers of Nickel and Nickel-Chromium also protect the thrust chamber from oxidation. The coating forms an integral part of the inner wall and are subject to a complex pattern of loads involving both thermal and pressure loads. This paper presents details about the qualification process used to evaluate integrity of the coating. Firstly, the stresses and strains on the inner wall during the engine operating conditions are arrived at based on detailed finite element analysis. Test specimens are fabricated from copper alloy and the thermal barrier coating as in the actual thrust chamber is applied on it. The specimens are tested under tensile and compressive loading that will induce the expected strains obtained from finite element analysis. The tests are done by means of strain-controlled fatigue tests at elevated temperature in tensile and compressive strain conditions. The integrity of the coating is assessed by means of Non-Destructive Test after each cycle of test and based on these, modifications were made for better performance. The modified coating was again tested for the same loading conditions and evaluated the coating integrity.

ITER ECH Transmission Line System Design and Status

The electron cyclotron (EC) heating & current drive (H&CD) system on ITER provides plasma heating by generating, transmitting, and launching high-intensity, high-frequency (170 GHz) electromagnetic wave energy steerable across the plasma cross-section. The transmission line (TL) subsystem connects the Matching Optics Unit (MOU) on each of the 24 gyrotrons to the 32 feed points in the four upper launchers and the 24 feed points in the equatorial launcher. Each TL must be able to operate at up to 1.2 MW of input power for up to 1 hour pulse lengths. The TL system contains 50 mm water-cooled corrugated waveguide, 90o miter bends, 140o miter bends, polarizer miter bend pairs, switches, expansion units, pumpouts, DC breaks, MOU-TL adapters, Radio Frequency (RF) loads, and isolation shutter valves. A detailed finite element analysis has been used to verify the thermo-mechanical performance of each component. The microwave performance has been analyzed using a 2-D electromagnetic code combined with a Monte Carlo code. This approach allows the impact of manufacturing and installation tolerances to be assessed and optimized to provide a high probability of achieving the system performance requirements. Prototypes of the waveguide and TL components have been fabricated and tested at high-power. Production contracts are now being issued for fabrication and delivery of the waveguide and components to ITER.