Explicit Finite Element Method Research Articles

Computational prediction of impact sound insulation of a timber floor excited by an ISO standard tapping machine

During the last decades, researchers have actively developed procedures to predict impact sound insulation of timber slabs and floors using the finite element method (FEM). Since the simulations have mainly been performed in the low frequencies, a full understanding of their suitability for research and development (R&D) purposes has not yet been created. The object of the study reported in this paper was to determine the applicability of a modern FEM simulation procedure for predicting the normalised impact sound pressure level Ln of a full timber floor, when information provided by material manufacturers is used as input data. Force excitation caused by the ISO standard tapping machine was determined utilizing explicit time integration and FEM. The modelling of sound radiation itself was performed in a frequency domain FEM analysis. The models of a timber floor in its construction stages were constructed before the laboratory measurements of impact sound insulation so that the set-up corresponded to a simulated R&D task. Based on the prediction results, the applied procedure was considered suitable for R&D purposes and needs for further studies were identified.

Ballistic resistance of ceramic and metal target plates impacted against different projectile’s nose shape: A numerical investigation

Layered ceramic/metal plates are investigated for ballistic impact against projectiles with different nose shapes. Explicit finite element method is used to model the target and projectile. This study examines the effect of nose shapes on the ballistic performance of target. This includes replacing the metallic layer with a ceramic plate of the same thickness to identify the best ceramic-to-target plate ratio for maximum BLV. Ballistic performance is compared between two different configurations having equal total thickness of ceramic and metallic layer. Increased ceramic layer thickness upto certain thickness-ratio may significantly improve the target plate’s ballistic resistance for all bullet types.

A digital-twin driven Split Hopkinson bar layout for the tensile characterization of thin, low impedance, sheet-like materials

The Split Hopkinson or Kolsky bar is one of the most popular devices when it comes to the mechanical characterization of material samples under high strain-rates. While testing of high impedance materials, such as metal alloys, is relatively straight forward, samples with low impedance pose certain challenges. The present work focuses on the detailed implementation of a high strain-rate tensile testing method for thin, low impedance, sheet-like materials by using the Split Hopkinson test principle. In order to find a suitable Split Hopkinson setup a digital twin was created using explicit finite element methods. With the help of the digital twin, the design of the transmission bar and the sample holders including the friction liners were explored. The numerical model indicated, that a hollow transmission bar with a moderate tapering (hollow bar 1.0) is suited for the characterization of low impedance materials over a wide strain-rate range. Furthermore, this setup has to be combined with an asymmetrical sample holder configuration (heavier on the incident side and lighter on the transmission side) and aluminum friction liners to return accurate results. This numerically derived setup was validated against experimental tests on paper, representative of low impedance, sheet-like materials.

On the application of RHT model and SPG algorithm for the analysis of rock cutting process

The linear cutting process in rock poses challenges for verification in field experiments, laboratory investigations, or numerical simulations. This study aims to analyze the rock cutting process and disc cutter force estimation when using linear cutting mode. Three-dimensional numerical simulations using the explicit dynamic finite element method (LS-DYNA software) are conducted to characterize the cutting process. In this regard, two computational algorithms (Lagrangian and Smoothed Particle Hydrodynamics (SPH)) and two material models (Johnson-Holmquist Concrete (JHC) and Riedel-Hiermaier-Thoma (RHT)) are compared, with SPH and RHT identified as more suitable for rock cutting simulation. The results of comparative analyses show that the Lagrangian computational algorithm is highly dependent on the erosion value, hence this method is not suitable for the simulation of the rock-cutting process. Comparing to the RHT material constitutive model, the Johnson-Holmquist model does not well model the post-failure softening strain behavior, which leads to a reduction in the width of the failure area. The comparative analyses also show that the normal and rolling forces predicted by the JHC model are well over 30% higher than the actual experimental results, while the RHT model shows a good agreement between the predictions and the actual results. Overall, the RHT material model with the use of the SPH computational algorithm shows a very good combination in rock cutting process simulation.

Prediction of wear of short glass fiber reinforced polyamide 66 composite sprocket

The wear of a polymer composite sprocket primarily depends on contact pressure and sliding velocity that vary significantly during service. The sliding distance and contact pressure at the sprocket/roller interface were estimated for a pristine polymer composite sprocket engaged with a standard and a 3% extended steel chain by employing the explicit finite element method. A set of experiments was executed to find the friction and wear coefficients of sprocket material using polyamide 66 composite pins and standard steel disc at sliding speeds of 1, 2, and 3 m/s and normal loads of 10, 20, 30, and 40 N. The wear depth is estimated after getting friction and wear coefficients experimentally, and contact pressure and sliding distance numerically. Archard wear model was executed using the UMESHMOTION subroutine with the Arbitrary Lagrangian-Eulerian technique in ABAQUS. The peak contact pressure on the sprocket is increased approximately by 1.5 times as the chain elongates from 0% to 3%. A pristine sprocket engaging a 3% extended chain after one lakh cycles experienced an approximate wear depth of 90 µm.

A Failure Analysis of the Long-Term Overturning Stability of Concrete Continuous Single-Column Pier Bridges Considering Creep and Overloaded Vehicles

Several single-column pier girder bridges have been involved in overturning accidents, resulting in significant economic losses and casualties, thus necessitating a risk assessment of the overturning stability. To date, the effect of structural degradation due to concrete creep on the long-term stability of bridges has not been demonstrated. In this study, a full-scale nonlinear analysis of the lateral overturning process of a collapsed concrete box girder based on the explicit dynamic finite element method (EFEM) was conducted to verify the reliability of the numerical method. An EFEM model incorporating concrete creep was developed to demonstrate the effect of structural degradation on the long-term stability of bridges. The synthesis overturning axis method (SOAM) was proposed to evaluate the long-term overturning stability of concrete continuous bridges, aiming to address the deficiencies in existing methods, particularly for curved bridges, and was compared with conventional methods. The results show that the variations in bearing reaction forces between curved and straight bridges under creep and self-weight are minimal, staying within 2%. An increase in the creep terminal coefficient results in the opposite trend in the ultimate vehicle weight of curved bridges and straight bridges, but fluctuations remain within 2%, indicating that long-term creep has a limited effect on the overall overturning stability. A failure analysis of 20 single-column pier bridges reveals significant differences in the ultimate vehicle weight between the rigid overturning axis method (ROAM) and folded overturning axis method (FOAM), with error ranges of −14.2% to 567.4% and −99.1% to −32.1%, respectively. The SOAM results have the smallest error range compared to those of the EFEM, with an error range of −38.8% to 33.9%. Despite these errors, the SOAM demonstrates a significant improvement in characterizing the trend and assessment accuracy of the overall overturning stability of single-column pier bridges.

Explicit finite element simulations of dynamic low adhesion behavior between wheel and rail in the presence of high-frequency vibrations

PurposeDynamic low adhesion (DLA) has become an urgent problem for the high-speed wheel-rail system because of continuous decrease of adhesion redundancy in the past decades. This article aims to provide a simulation method to reveal the mechanism of DLA under high-frequency vibrations.Design/methodology/approachA transient wheel-rail rolling contact model is developed for a typical Chinese high-speed railway system using the explicit finite element (FE) method. Instantaneous adhesion exploitation levels are studied in the time domain, for which driving cases over corrugated rails are taken as an example. A speed up to 500 km/h is considered together with different traction coefficients and corrugation dimensions. DLA is expected when the instantaneous adhesion exploitation level reaches 1.0, that is adhesion saturates and full sliding contact occurs.FindingsThe instantaneous adhesion exploitation level can be very high in the presence of corrugation, even at low traction coefficients. DLA is found to occur as great vertical unloading takes place and causes a significant increase of creepage. An approach is further developed to determine the critical depth of corrugation over which DLA occurs.Originality/valueThis study employs the transient wheel-rail rolling contact model to predict the instantaneous adhesion exploitation level under high-frequency vibrations. The presented results reveal a mechanism of DLA being beneficial to guidelines for future railway practice.

Численное исследование задачи низкоскоростного столкновения стального шара с ледяной плитой

In this paper, the dynamic deformation process during the low-speed collision was investigated. The full 3D dynamic contact problem was simulated in the Abaqus software, based on the explicit finite-element method on structured meshes. Two basic mechanical models (linear isotropic elastic and elastoplastic) are considered. The obtained results showed the possibility of the experimental data, available in the open literature for different striker velocities, reproduction. The better understanding of the ice deformation process can be useful for different applied problems, like the ice impact on the aircraft wings estimation and the ice-water contact reflected waves filtration during the seismic survey in the Arctic region.

Micromechanical modeling for longitudinal tensile property of unidirectional CFRP considering dispersion of fiber properties

Longitudinal tensile failure prediction has always been the focus of research on unidirectional (UD) Carbon Fiber Reinforced Polymer (CFRP). In this paper, the longitudinal tensile tests of unidirectional T800 grade carbon fiber reinforced epoxy resin composite were carried out first. The experimental stress–strain curves show that there are obvious progressive damages before the final failures of the specimens. However, this phenomenon is usually neglected in most of the existing investigations and tests to only obtain elastic modulus and ultimate strength. Thus, a Representative Volume Element (RVE) model based on micromechanics was established using finite element method, considering the randomness of fiber spatial distribution and fiber strength. The tensile strength of fiber monofilaments was assumed to follow a statistical two-parameter Weibull distribution. The failure process of UD composite under longitudinal tensile load was simulated by explicit finite element method. The stress–strain curves obtained by simulation are in good agreement with the experimental results. Finally, the influence of different boundary conditions on the calculation of the RVE was studied. It is found that the final failure strengths of the RVE with uniform displacement boundary conditions are similar to the case of periodic boundary conditions, while the former has higher computational efficiency.

Investigation of frictional rolling contact behavior in a switch panel considering traction load

The dynamic effects involved in wheel-rail interactions can be increased by the traction force potentially causing rapid degradation of turnout rails. A precise stress/strain analysis is essential for wheel-rail frictional rolling contact and the related degradation. Therefore, an explicit finite element method is established considering dynamic effects related to the contact. Furthermore, the frictional rolling contact solutions and related degradation with different traction coefficient in turnout are investigated. The results indicate that the effect of asymmetric excitation caused by traction force and geometric irregularities will lead to yaw motion of wheelset. The width of running band on the switch rail is increased as the top surface width of the switch rail increases. In addition, the contact patch on the switch rail will gradually shift forward compared to that on the stock rail, leading to excessive shear stress and increase of microslip. Meanwhile, the adhesion-slip distribution, uneven wear and severe plastic deformation during transition are recognized.

Direct spatio-temporal stress field determination combining full-field deformation measurements and explicit finite element method: Concept verification

High strain rate loading of materials with spatially heterogeneous properties produces non-homogeneous and transient stress-strain states. Such stress-strain states are atypical of classical split Hopkinson pressure bar (SHPB) analysis that assumes homogeneous deformation and dynamic force equilibrium. To determine spatio-temporal stress fields in heterogeneous materials, a novel concept combining digital image correlation (DIC) full-field deformation measurements and explicit dynamic finite element method (EFEM) is described in this paper. The concept utilizes measured boundary forces and DIC measurements including both displacements and accelerations as input. The measured input is used to calculate internal forces, and hence the stress fields, within each continuum finite element by solving the governing equations of motion using the framework of EFEM. The DIC+EFEM concept procedure is verified using simulated synthetic data considering one-dimensional stress wave propagation in a bar. The reconstructed axial stress fields match identically with the exact EFEM solution for both homogeneous and heterogeneous materials that are elastic or elastic-plastic. The influence of DIC measurement noise on the reconstructed stresses is also studied.

On the development of a high strain-rate tensile testing method for thin low-impedance materials

This work deals with the high strain-rate characterization of paper under uniaxial tension using a Split Hopkinson test bench. An aluminum bar system featuring a highly sensitive hollow transmission bar was used. Paper tests were performed in a strain-rate range between approximately 60 s−1 and 210 s−1. The experimental tests showed that the breaking strength appears to decrease with increasing strain-rate. To verify these results, a digital twin of both the paper specimen and the entire test rig was created in an explicit Finite Element method environment. The numerical model was then used to perform a parameter study with different types of transmission bars. It was shown that the system is quite sensitive to additional masses caused by the specimen fixtures, as well as to drastic reductions in the cross section of the transmission bar. As a result, the transmitted measuring signal can be distorted and may need to be corrected using the digital twin.

Energy dissipation mechanism and ballistic characteristic optimization in foam sandwich panels against spherical projectile impact

This study systematically examines the energy dissipation mechanisms and ballistic characteristics of foam sandwich panels (FSP) under high-velocity impact using the explicit non-linear finite element method. Based on the geometric topology of the FSP system, three FSP configurations with the same areal density are derived, namely multi-layer, gradient core and asymmetric face sheet, and three key structural parameters are identified: core thickness (tc), face sheet thickness (tf) and overlap face/core number (no). The ballistic performance of the FSP system is comprehensively evaluated in terms of the ballistic limit velocity (BLV), deformation modes, energy dissipation mechanism, and specific penetration energy (SPE). The results show that the FSP system exhibits a significant configuration dependence, whose ballistic performance ranking is: asymmetric face sheet > gradient core > multi-layer. The mass distribution of the top and bottom face sheets plays a critical role in the ballistic resistance of the FSP system. Both BLV and SPE increase with tf, while the raising tc or no leads to an increase in BLV but a decrease in SPE. Further, a face-core synchronous enhancement mechanism is discovered by the energy dissipation analysis, based on which the ballistic optimization procedure is also conducted and a design chart is established. This study shed light on the anti-penetration mechanism of the FSP system and might provide a theoretical basis for its engineering application.

Folding, stowage, and deployment of composite thin-walled lenticular tubes

Composite thin-walled lenticular tube (CTLT) is a lightweight foldable and deployable structural material that enables large-scale deployable mechanisms for various space missions. A key step toward the structural design of CTLT is to understand its folding, stowage, and deployment behaviors. This work presents an integrated experimental and numerical investigation of the dynamic deployment behavior of CTLT that wraps around a central hub, with emphasis on the effect of long-term storage. A two-meter-long CTLT prototype was manufactured, and a gravity compensation system was designed and built for the on-ground dynamic deployment experiments. The deployment experiments were performed on the CTLT prototype both before and after it had been stowed for extended storage periods. The results indicate that after being stowed for 6 and 10.5 months the CTLT is deployed slower and the deployment time increases by 8.2% and 15.0%, respectively. Furthermore, a high-fidelity numerical model was constructed using the explicit dynamic finite element method, where the CTLT was modeled as a deformable part and the folding/deployment mechanisms were modeled as rigid bodies to perform the folding, stowage, and deployment simulations. The long-term storage effect was accounted for in the numerical analyses with the use of a viscoelastic fiber-reinforced composite material model, and a good agreement has been achieved between the experimental and numerical results.

Numerical Investigation of Elastic Layer Effects in Wheel–Rail Rolling Contact

In railway systems, layered structures could be induced in wheel–rail contact interfaces due to several causes, such as head hardening, work hardening, plastic deformation, and mechanical or thermal excursion-induced phase transformation. This study proposes an explicit finite element (FE) method for investigating elastic layer effects in wheel–rail rolling contact. The proposed method is first validated by comparing its solution with that of Kalker’s boundary element method (BEM) when the layer is not present, with a focus on the tractive rolling contact. To investigate general layer effects, the rail is assumed to consist of two layers, i.e., the top layer and the matrix material. The top layer is assumed to have different elastic moduli from the matrix material and then the top elastic layer effects on contact characteristics such as contact stress, contact patch, and subsurface stress are investigated. Different layer thicknesses are also considered. It is observed that a harder layer tends to introduce larger contact pressure and surface shear stress, but a smaller contact patch. A harder layer also produces larger subsurface stresses. A thicker layer may intensify these effects. The results suggest that in engineering applications, the analysis of wheel–rail rolling contact consequences such as wear and rolling contact fatigue (RCF) may need to consider the layered structures using appropriate methods.

Numerical study on crushing damage and energy absorption of multi-cell glass fibre-reinforced composite panel: Application to the crash absorber design of tsunami lifeboat

Abstract During an evacuation, the tsunami lifeboat should be able to withstand the possible external loads that might be occurred, such as collisions, violent crashes, and capsizing events. Special structural reinforcement and improvement, such as a crash absorber, are attached to prevent damage due to the impact load. Therefore, this article focuses on the crushing behaviour of the tsunami lifeboat crash absorber made of the multi-cell glass fibre-reinforced composite panel. The effect of the cross-section geometry design of the cell on the damage mechanism and energy absorption behaviour was investigated. The explicit dynamic finite element method was used to identify the multi-cell configuration’s crashworthiness performance. Experimental studies such as tensile and three-point bending tests were conducted to define the material properties and validation of the FE model. The simulation results showed that the explicit dynamic finite element method has effectively estimated the crash absorber crushing damage. The circular cross-section has shown the most significant crash absorption capability compared to the others, namely the honeycomb, the square, and the triangular cell. Furthermore, the 4CSM laminate type has revealed a lower energy absorption than the 4WRC45 and 4WRC laminates. Otherwise, the study exhibits that the cross-sectional geometry and the laminate type significantly influence the crash absorber performance for improving the tsunami lifeboat crashworthiness.

Numerical predictions of intralaminar and interlaminar damage in thin composite shells subjected to impact loads

This paper investigates the impact dynamics of thin semicylindrical woven composite laminate shells, with a particular focus on understanding the influence of thickness. Utilizing the finite element (FE) method, the study evaluates both intralaminar and interlaminar damage associated with the impact response. The findings show that the implementation of the explicit FE method, along with a continuum damage mechanics model, for the intralaminar damage, and a surface-based cohesive model, for the interlaminar damage, may be used to correctly predict the load histories, as well as the maximum impact force, maximum displacement, contact time and impact bending stiffness (IBS). The numerical predictions reproduce well the linear response of the maximum impact force and maximum displacement to the thickness variation, as well as the 2nd order polynomial curve of the IBS, with errors ranging from 2.7% to 15.9%. Moreover, the damage areas and the effect of thickness on the damage severity were accurately replicated. These results’ validation enables the prediction of the energy histories and the ensuing energy dissipation forms. According to the findings, the intralaminar damage is around 5 times more significant than the other energy dissipation forms. The accuracy of the simulation creates the possibility for more impact investigations using a similar numerical approach, reducing the expenditures of experimental testing.

Design and verification of continuous forming process of ultra-long thin-walled Lenticular Deployable Composite Boom

Ultra-long thin-walled deployable composite structures with high-strain ability are of considerable interest and increasingly used in large-size deployable spacecraft structures due to their high folding-storage ratio function. This paper seeks to investigate continuous curing technology of an ultra-long thin-walled Lenticular Deployable Composite Boom (LDCB) made of high strain carbon-fiber-reinforced-plastics. The equipment for continuous curing of thin-walled boom is designed. The continuous forming process including flattening, traction and coiling are simulated by explicit finite element method for determining the length of the transition zone of the equipment, the gap of the flattening roll, and the radius of the reeling roller.

Spherical cavity expansion method dependent on strain, strain rate, and temperature

This paper presents a spherical cavity expansion method based on the self-similar field considering dynamic hardening, which includes plastic strain, plastic strain rate, and temperature for an infinite compressible medium under J2 plasticity. This study proposes an approach based on the gradients of plastic strain and temperature under self-similarity transformation to deal with dynamic hardening models such as the Johnson-Cook (JC) and the modified Johnson-Cook (mJC) models. A theoretical model shows that the effective and radial stresses are reduced near the cavity surface and increased away from the cavity under the mutual influence of hardening and thermal softening. The JC hardening model is used to analyze the behavior of the cavity expansion for AISI 4340 steel. The proposed theoretical model was validated by comparing the result of the explicit finite element method (FEM). This study discusses the behavior of the expanding cavity problem for thermal softening and strain rate sensitivities. In addition, rigid penetration problems are simulated to analyze the application of the presented method. FEM and the proposed cavity expansion method were compared with the penetration depth of AA6061-T651 target using the mJC hardening model for a hemispherical-nosed penetrator. A comparison is made for the performance of the penetration depth with an ogive-nose projectile for AA7075-T651 and AA6061-T651 materials using the mJC hardening model. This study concludes that the proposed method can be applied without modifying the hardening models to spherical cavity expansion problems that involve dynamic hardening models dependent on strain, strain rate, and temperature under adiabatic heat.

Optimization of a temporary road traffic steel barrier using explicit finite element method and laboratory testing

Over a million people die in road crashes and tens of millions result injured or disabled each year, globally. Hence, there is a constant concern for improving the safety of the roads to protect road users, and those at the most risk, the road workers. Construction, maintenance, and utility work are constantly needed to ensure safety and functionality of roads and highways. Temporary road traffic barriers are used to separate passing traffic from the workspace and protect the workspace from an errant vehicle intrusion. Steel barriers are light, and their major advantage is rapid installation. These barriers are not anchored to the ground, and their behavior relies on the base-pavement friction, mass inertia, and stiffness of the system. The paper describes a methodology that was successfully applied for the development of a temporary road traffic steel barrier in compliance with the European specification EN 1317. The study included a simplified theoretical analysis of 178 barriers, static laboratory tests of three types of barrier connectors, development of explicit finite element models (EFEMs) of four selected barrier designs, and a full-scale crash test of the final barrier design. It is shown that static laboratory tests of complex connector systems can help to improve the design process and reduce the cost. The analysis and use of EFEMs was enough so that just a single full-scale crash test was sufficient for certification of the barrier design for use in Europe. The final barrier is compliant with the EN 1317–2 requirements for T1/W1 (TB21) containment level, which was confirmed by a full-scale crash test.