FEA Software Research Articles

Numerical study on fracture behavior of alkali activated concrete mixes for different beam sizes

The present study considers the use of AAC mixes, since the raw materials that are being used to produce concrete are non-renewable natural resources, particularly Ordinary Portland Cement (OPC). Also, production of OPC contributes a greater amount of CO2 to the environment. Hence, an attempt has been made to study alternative construction materials keeping in mind sustainable development. The present numerical study compares the fracture behaviour and size effect of Alkali Activated Concrete (AAC) mixes with Ordinary Portland Cement Concrete (OPCC) mixes by numerically modelling the beams of AAC and OPCC using FEA software ABAQUS. Three different mixes of AAC, characterized by the variation of percentage volume of water-quenched slag (WQS) as a substitute for Natural sand (RS) and one OPCC mix, were studied. A three-point bending test was performed in ABAQUS for the beams of three different sizes, which are geometrically similar with constant thickness. Numerical simulation is performed under displacement control. Load versus CMOD graphs are plotted from the output data obtained from the numerical modelling. Fracture parameters such as Fracture energy (GF), Brittleness number (B), Characteristic length (lch), and Stress intensity factor (KIC) are then calculated from the obtained data and compared to understand the influence of fracture properties and size effect on the behaviour of structural elements since limited research works are available from the literature. From the results, it is observed that OPCC mixes show superior strength, high resistance to crack propagation, more toughness, and high fracture energy when compared to AAC mixes. AAC-50 concrete mix has shown better performance compared to the other two AAC mixes, i.e., AAC-0 and AAC-100. The results of this work can certainly be used to predict the non-linear behaviour of concrete and can be adopted in the design of structural elements.

Application of finite element analysis to honeycomb sandwich structures: a review

Honeycomb sandwich is really one of the fundamentals to make a composite strong, stiff, very light, safe and have wonderful performance. Honeycomb materials are majorly used where high strength to weight ratio, stiffness to weight ratio is needed. Honeycomb sandwich consist of two face sheet or skin and a light core which can take many shapes, the common is hexagonal shape. The core handles shear load, while the skins resist compression and tension. This paper aims to guide the design of honeycomb sandwich structures done with finite element analysis software. The characteristic of honeycomb at microstructure and unit cell will be discussed Moreover, much demand on light weight honeycomb structures that can withstand heavy loads under different working condition are on high demand. Experimental approach can be time consuming and costly, this created room for massive research using FEA on loading response with various cores and thickness, in order to investigate the mechanical properties. This study will focus on the FEA of honeycomb sandwich done by many researches currently on commercial software’s ANSYS and ABAQUS, this will be a guideline for researches to see what has been done and what is obtainable using FEA software.

ANALYSIS OF MESOSTRUCTURE AND FRACTURE KINETICS OF ELEMENTS OF LATTICE COMPOSITE STRUCTURES UNDER TRANSVERSAL COMPRESSION USING STOCHASTIC FEA MICROMECHANICS

The paper analyses the mesostructure of the structural elements of lattice aircraft shells – ribs consisting of alternating layers of equal thickness and made from unidi-rectional CFRP and pure matrix material. In experimental studies, the elastic characteristics of unidirectional CFRP were obtained under three-point bending and transversal compression. As a result, the longitudinal modulus of elasticity of the layered composite turned out to be 101 GPa, and the shear modulus was 2.95 GPa. Numerical modeling of the meso- and micromechanics of the interaction of the noticed layers under transversal compression has been performed up to failure. The ANSYS FEA software (explicit and implicit formulations) was used. The regular and stochastic stacking of fibres in the cross section under compression is considered. The fiber diameters in the composite element were measured on thin sections using a Zeiss Axio Observer D1m digital microscope and were equal to 5.1 ± 0.8 µm. Layers with a fiber volume fraction of about 60 % alternate with layers of pure epoxy. It is proposed to use only the first principal stress in the matrix as a micromechanical criterion for failure under com-pression and tension. At the first stage of calculations, the problem of transversal compression of a cell with a regular laying of fibres was solved (the error in the value of the transversal modulus of elasticity was less than 2 %). At the second stage, an assessment was made of the strength and accumulation of microdamages under compression in a model of a layered structure with stochastic fibre stacking. The analysis of stress-strain state of a layered mesostructure under compression made it possible to explain the reason that the rib has a trans-verse strength twice lower than that of a homogeneous CFRP. The calculated values of the ultimate strength in transversal compression of a layered rib are in good agreement with the experimental ones.

Investigations on IC Engine Piston Ring made of Composite Materials

This paper is respecting the evaluation of stress distribution on IC engine (four-stroke) piston ring and analysis of finite element by using FEA software. The purpose of this analysis is to calculate strain for SiC reinforced ZrB2, A360, A2618 and deformation resulting through ring elastic pressure and gas pressure. The total deformation and strain on the piston ring have been obtained in this project. The characteristics of such vibrations are analyzed with the help of solid works software and analysis of finite element is performed on the Ansys workbench software. The material used is Silicon Carbide reinforced Zirconium Diboride (SiC reinforced ZrB2), Aluminium alloy (A360), Aluminium alloy (A2618). This is a ceramic matrix composite (CMC) which has good safety factor and lower cost. The experiment is conducted on three types of composites to evaluate the strain on SiC reinforced ZrB2, A360, A2618 resulting from the total deformation and strain. Compressive strength has also been analyzed for the structural model of the piston ring.

Stiffness-Performance-Based Redundant Motion Planning of a Hybrid Machining Robot

Large-scale components usually have complex structures with high local stiffness, and the holes on them are required to be machined with high precision, which makes it important and challenging to study how to efficiently and precisely drill in the large-scale components. This article presents mobile hybrid machining equipment that consists of a five-axis parallel module, a 2-degree-of-freedom (DoF) robotic, arm and an automated guide vehicle (AGV) connected in series. With the ability of wide-range positioning and precise local processing, it has potential advantages in the drilling processing of large-scale components. Stiffness is one of the most important performances for machining equipment, and it’s highly related to the its configuration. For the discussed equipment, the stiffness is determined by the two-stage-positioning hybrid machining robot, which comprises a five-axis parallel module and a two-DoF robotic arm. The redundant motion of the hybrid machining robot makes it possible to optimize its configuration by reasonably planning redundant motion. Therefore, a redundant motion-planning method based on stiffness performance is proposed. A kinematic analysis of the five-axis parallel module, the robotic arm, and the hybrid machining robot is carried out. A hybrid robot usually consists of several subsystems, and to take the compliance of each subsystem into consideration, the stiffness-modeling method for the hybrid robot with n subsystems connected in series is proposed. The stiffness model of the hybrid machining robot is established by using this method, and the variation of the stiffness magnitude has the same trend as that obtained by using FEA software. Stiffness magnitude and isotropy indices are proposed to evaluate the robot’s stiffness performance along the axis of the spindle and in the plane perpendicular to the axis of the spindle. The redundant motion of the hybrid machining robot is planned by maximizing the stiffness magnitude along the spindle axis, with priority to the stiffness isotropy index. Finally, the drilling experiment is carried out, and the results show that the relative error of the hole diameter obtained under the optimal configuration of the hybrid machining robot is 1.63%, which is smaller than those obtained under the other two configurations for comparison with relative errors of 3.75% and 3.50%, respectively. It proves the validity of the redundant motion-planning method. The proposed stiffness-modeling method and the stiffness-performance indices are also applicable to other hybrid machining robots.

Bolt pre-load CAE analysis and validation: FEA simulation of hex bolt tightening torque for IDU assembly of 2-wheeler in MSC Nastran and practical validation

In any machine or automotive product, different nuts, bolts and other types of fasteners are used during assembly of the different parts. It is required to properly define the fastening loads or torques during the fastening application. In certain product assembly being manufactured and assembled by Varroc Engineering ltd, it is required to find out the exact tightening torque of the bolt as it could crack the product if the torque applied beyond certain limit. The product is IDU. In this we have done the bolt preload analysis in MSC FEA (Patran) software. Firstly, we found the allowable clamping force by analytical method. Then we performed bolt pre-load analysis to find the stress and displacement values which could be induced due to the certain tightening torque. Then we tested the part for same into lab and validated the results. Due to this simulation, we have been able to understand the behavior of the part under different bolt tightening torque values and thus it has enabled the designer to finalize the tightening torque values. Same concept of simulation is being applied now for tightening torque problems of different application.

Biological heat and mass transport mechanisms behind nanoparticles migration revealed under microCT image guidance

Background and objectivesBlood perfusion, infusion rate, distribution and heating induced redistribution of magnetic nanoparticles inside tumour interstitium governs the heating protocol designs. This study aims to answer three important questions: Why do magnetic nanoparticles redistributes? What causes their migration? Why it is important to be included in priori-treatment planning simulations? Our aim is to test how the regulation of magnetic nanoparticles affects the temperature distribution and how this temperature change modifies tumour microenvironment. We have tested our hypothesis for two cases: (1) when the nanoparticles are lying in close proximity to the flank position of tumour i.e. near the interface of tumour and healthy tissue and (2) when the nanoparticles are located near the skin surface of tumour. Materials and methodsSAS® and MATLAB programs are used to average micro-CT cross-sectional slices containing three-dimensional clusters of pixels corresponds to nanoparticles as a SAR file and Concentration distribution file import to the COMSOL-Multiphysics® 5.2 FEA software for evaluation of temperature distribution and its resulted collateral thermal damage. The volumetric heat generation rate (qMNH‴) is kept ∼ 0.37 W for infusion rate of 4 μL/min. Pennes bioheat equation is three-way coupled with traditional Arrhenius thermal damage model, modified concentration equation in which heat source term (SAR) varies in a directly proportional relationship with Concentration distribution. All variables i.e. Diffusion coefficient, porosity, blood perfusion, metabolic heat generation are varying as a function of thermal damage for a coupled biophysics problem. ResultsThermal signatures of cell-death were evaluated for two case scenarios. The initial distribution volume is 188.46 mm3. On compare and contrast, 6.24% larger thermal diffusion is seen at outer extremities case than at the interface. However, the treatment times are 12.90% (1.13 fold more) to achieve a Ω ≥ 4.6 with ΔT=10°C for latter case. On evaluation of “Source maps” (before heating) with “Destination maps” (after heating) suggests migration of nanoparticles from the regions of higher concentration to the regions of lower concentration due to cell-necrosis induced enhancement in tumour interstitial space. Thermal-diffusion of nanoparticles suggests an increase in redistribution volumes by 23.44% and 26.30% respectively during 99.6% transformation of cancerous cells. This study precisely elucidate qualitative and quantitative aspects of this issue. One of the possible reasons of nanoparticle migration is that the dead cells release intracellular solution after the rupturing of cell membrane. We speculate that five-fold increase in diffusion coefficient of nanoparticles might have played a significant role in particle migration. ConclusionsCNIDC (Cell necrosis induced diffusivity change) and CNIPE (Cell necrosis induced porosity enhancement) may be the two intricate mechanisms that promotes nanoparticles migration.

3D printed custom gas cam for race bike application using Progrip® lock on grips mod.708

Background: The “drive by wire” mechanism for managing the throttle is not applied to every modern motorcycle, but it is often managed through a steel wire. Here, there is a cam on the throttle control. Its shape allows the throttle opening to be faster or slower and its angle of rotation, required for full opening, to be greater or less. The maximum angle a rider's wrist can withstand depends on numerous musculoskeletal mobility factors, often limited by falls or surgery. Methods: Using a Progrip knob with interchangeable cams allows the customization of a special cam profile, to ensure the best engine response to throttle rotation and ergonomics for the rider. The use of FEA software and lattice structures, allows to realize a lightweight and efficient design, targeted for fabrication with additive manufacturing technologies. Results: The cam was manufactured by exploiting MSLA technology. Finally, a dimensional inspection procedure was performed before assembly. The main result is to have obtained a lighter and cheaper component than the original. Conclusions: This study has allowed the design of a mechanical component consisting of innovative shape, light weight, and ergonomics. Furthermore, it demonstrates the effectiveness in the use of lattice structures to enable weight optimization of a component while minimizing the increase in its compliance.

Numerical investigation of steel-concrete composite (SCC) beam subjected to combined blast-impact loading

Existing literatures on combined effects of blast-impact loadings on steel-concrete composite beams are limited. In this study, behavior of steel-concrete composite beam subjected to combined blast-impact loading was investigated using LS-DYNA nonlinear FEA software program. The accuracy and reliability of developed FEA model was validated using experimental data reported in literature. Parametric studies were performed on impacting speed, concrete strength, various characteristics of H-structural steel, yield strength of studs and steel rebars to get insight into performance of composite beam subjected to combined blast impact loading. FEA results revealed that increase in specified cylindrical compressive strength of concrete, yield stress, flange and web thicknesses of H-type structural steel beam significantly improved dynamic response of a steel-concrete composite beam under combined impact-blast load case whereas yield stress of studs, and reinforcement steel bars showed insignificant contribution. Moreover, increasing impactor’s initial velocity significantly affects dynamic response of a SCC beam under combined blast-impact loading.

Development of Tail and Nose Cone for Underwater Vertical Profiler Using Fused Deposition Modelling Technology

Unmanned underwater vehicle (UUV) research is currently a prominent and quite well-known topic for researchers from various engineering disciplines. A wide number of applications for 3D printing technologies have been explored, including robotics, automotive components, food, healthcare, space, marine, etc. This paper introduces the implementation of additive manufacturing technology (3D printing) into marine applications. The use of various 3D printing processes to create complex, cost-effective profiles have recently gained popularity to test the durability of newly designed products. The subsequent sections will explain the development of 3D printed nose and tail cones for the Underwater vehicles which will be used for underwater exploration. The development process is divided into the design of nose and tail cones using Solidworks, a 3D design software, flow analysis for the estimation and reduction of drag, operational depth of 3D printed parts using FEA software ANSYS, and prototyping using fused deposition modelling technology. The developed tail and nose cone were implemented into the vertical profiler and tested at the NITK swimming pool and successfully profiled the vertical column of the pool.

FEA Approach for Wear and Damage Prediction of Tools for the Progressive Die Stamping of Steel Washers

In progressive die stamping processes, maintenance activities caused by tool damage, and wear represent economic losses for companies. An effective predictive maintenance strategy can only be implemented if maintenance data coming from the operations are correlated to specific process-related information. As a part of a more general data-based predictive maintenance strategy, the main causes of tool damage and wear in a progressive die stamping factory that produces automotive metal washers have been identified by means of FEA simulations. In this study, the progressive die stamping of a dented conical washer is simulated with Transvalor FORGE FEA software by implementing the process parameters used in a real case. In this study, two indicators called FEAwear and FEAdamage are proposed for prediction of die wear and damage for tools with high risk of failure. For validating the accuracy of the FEA simulations, dimension and geometry comparisons are performed between FEA and real washer, and then real and FEA maximum press force comparison is performed. In the end, FEA simulations demonstrated their accuracy in predicting the stamping force of the press and the final part quality, and proposed FEA damage and wear indicators accurately predicted the most critical tools and stations, as confirmed by the real maintenance data. Finally, the simulations also correctly detected potential damage zones of the tools.

Modelling and analysis of ventilated disc Brakes using Creo and FEA software

Abstract: An important part of a car's safety system is the brakes. Brakes are easily worn, leading to unpredictable disasters. To avoid this, ventilated disc brakes are used, which helps the brakes to work well in stressful conditions and high temperatures. The materials used play an important role in determining performance. The main objective of this research work is to analyze the current design and conduct a suitable brake rotor analysis to improve its performance. Existing brake disc designs are modeled in Creo and analyzed with software. The material grades used in this study were performed on stainless steel, grey cast iron, structural steel, and titanium alloy brake discs using the same brake disc design to determine the best grade. Keywords: ventilated disc brake, creo, thermal analysis, static analysis.

Analysis of Composite Beam with Shear Connectors Using FEA Software (ANSYS)

Abstract: The Composite structures made of concrete slabs and rolled steel profiles are widely used components in bridges and High buildings. Composite effects are created by connecting concrete slabs and steel profiles with chemical anchors. In this paper, I analyze three types of shear connectors ( Headstud, T shape, Channel section ) with different grade of concrete M-20, M-30, M-40 based on design strength given by the code book IS: 11384-1985. Based on their performance under static load, find the best connector for a particular composite beam while maintaining the stress and amount of steel in the connector as a common aspect. Keywords: Composite beams, Ansys Software, Shear Connectors

Numerical simulation of a magnetic induction coil for heat treatment of an AISI 4340 gear

In manufacturing industry, heat treatment is a fundamental requirement for improving the material quality of readily manufactured products. Induction heating technology is repeatable and easily controlled by the advantage of having an electronical control unit. Nowadays, numerical methods have gained so much importance that it become as a reference for the induction heating industry. Experimental methods are costly and time demanding procedures. However, making use of finite element method software, induction heating simulations of a steel gear can be performed relatively cost effective and in a short time. In this paper, induction heating simulation of an AISI 4340 steel gear using FEA software is performed. The effect of variation of inductor frequency and gear workpiece-inductor coil distance on the hardening depth of the gear surface is investigated. The temperature profile of the workpiece is obtained. From the temperature distribution on the steel gear workpiece, the regions of the gear at which the austenitizing temperature (Ac3) - responsible for martensite phase formation- are observed. From the numerical results, hardening profile and hardening depth of the gear is interpreted.

Comparative Study on the Behaviour of Steel Reinforced Beam-Column Joint with GFRP Bars

Beam-column joints are the crucial zones in the moment resisting structure and are designed to achieve the desired strength and durability. In extreme weathering conditions, the steel in the reinforced concrete is more susceptible to corrosion. So, the steel should be provided with the precautionary measure like coating, etc, if used in such conditions. This results in the use of Fibre Reinforced Polymer (FRP) bars as an alternative to steel since it is non-corrodible. Several researches were done by using FRP bars as an alternative to steel. It is identified that the flexural strength of the beam reinforced with FRP bars were reduced compared to the beams with steel bars. To increase the flexural strength, the fibres were added to the beam. And the seismic behaviour of the beam-column joint will be studied. In this study, a journal proposed by Mohammed Hasaballa and Ehab El-Salakawy is validated using FEA Software package and the results were compared. The comparison between these results was proposed. The failure study is undertaken and compared with GFRP and Steel.

Tensile Properties of Additively Manufactured Thermoplastic Composites Reinforced with Chopped Carbon Fibre.

3D printing allows controlled deposition of composite components, which the user defines by the modification of the printing parameters. The article demonstrates that all observed printing parameters (infill type, infill orientation) influence the tensile test results of nylon reinforced with chopped carbon fiber. The highest tensile strength obtains specimens with the maximum number of walls around the circumference. The plastic region of the tensile diagram differs significantly with the change of material orientation in the structure, as the specimens with material deposited 45/−45 to the load axis have four times greater tensile strains and 20% higher tensile stresses than 0/90. The assessment of results reveals the significant difference between deformations at break and permanent deformations. In addition, the permanent lateral strain reaches up to 20%. Finally, the article consists of a brief assessment of the printing parameters (printing time, weight) of individual series. The future modelling in FEA software requires additional experiments to verify the viscoelastic properties of the material.

The influence of dental restoration depth, internal cavity angle, and material properties on biomechanical resistance of a treated molar tooth

ObjectivesTo assess the hypotheses that a restored tooth structure for a class II occlusal-distal (OD) cavity can be reinforced by optimizing the cavity geometry and choosing composites with adequate mechanical properties. MethodsA human maxillary molar tooth was scanned, and segmented. The 2D profiles of dentin and enamel were drawn and imported to ABAQUS software. Eighteen restored tooth models with different cavity occlusal depths (OcDs) and internal cavity angles were developed. A semi-circular stone part was used to apply contact loads to the restored tooth model. After setting up the required interactions and boundary conditions, a written Python code was used to automatically assign a wide range of elastic moduli, from 2 GPa to 26 GPa, to the composite restorations, and assign constant material properties to the enamel and dentine.For simplicity, the behaviour of the mechanical material was postulated homogeneous and elastic, while the FE analyses were linearly carried out in this study. Also, the code enabled the FEA software to conduct the stress analyses, determine maximum principal stresses, and record the obtained results. ResultsThe internal cavity angle formed between the mesial wall and the pulpal floor of the cavity significantly changed the peak maximum principal stress both in the enamel and restoration. The peak stress concentrations were observed mostly at the enamel-restoration interface, with an almost perpendicular orientation to this interface. Regarding the effect of occlusal cavity depth (OcD), the model with the shallowest cavity (OcD = 1.5 mm) represented greater resistance to applied loads than the model with deeper cavities (OcD = 2.0 mm and OcD 2.5 mm). The composite modulus (CM) in the range of 10–18 GPa reduced the maximum principal stress concentrations in the enamel. The lowest result for maximum principal stress was observed in the model with OcD = 1.5 mm, CM = 10 GPa and internal cavity angles = 100°, which was the strongest model against contact loads. SignificanceClass II OD cavities with optimal geometry have reduced induced stress levels, thus being able to be more mechanically robust against contact load transmitted by a stone. Cavity geometry designs with obtuse (more than 90°) internal cavity angles were significantly efficient in minimizing peak stress concentrations. The results indicated that for the model with obtuse internal cavity angles, choosing a composite with optimised properties can diminish stress, particularly at the tooth-restoration interface. Furthermore, the shallowest the cavity, the sturdier the restoration was, especially when the interface tooth-restoration laid on enamel and not on dentine.

Numerical study on prequalification and cyclic performance of column-tree connections

Column-tree connections are commonly employed as a shop-welded and field bolted connection in the steel moment resisting frames to ease installation and inspection. The prequalification and cyclic performance of these connections are not completely clear yet. In the present study, using nonlinear finite element analysis by ABAQUS FEA software, the effects of bolted splice location and design method on the prequalification and cyclic behavior of the column-tree connection are investigated. The numerical models are validated based on experimental test results. The numerical analysis results show that the column-tree connection prequalification depends on the stub beam length and bolted splice design method; moreover, the bolted splice configuration influences the monotonic and cyclic behavior, strength, bolts pre-tension loss, stiffness, fracture tendency, ductility, and energy dissipation characteristics of the connection. Also, it is observed that based on the moment strength and rotational stiffness of the bolted splice, the column-tree connection is classified as a rigid or semi-rigid moment connection. This finding needs to be taken into account in the column-tree moment frame design.

Numerical Prediction of Strength of Socket Welded Pipes Taking into Account Computer Simulated Welding Stresses and Deformations.

The paper presents a numerical model based on the finite element method (FEM) to predict deformations and residual stresses in socket welding of different diameter stainless steel pipes made of X5CrNi18-10 steel. The next part of the paper concerns the determination of strength properties of a welded joint in terms of a shear test. A thermo-elastic–plastic numerical model is developed using Abaqus FEA software in order to determine the thermal and mechanical phenomena of the welded joint. This approach requires the implementation of moveable heat source power intensity distribution based on circumferentially moving Goldak’s heat source model. This model is implemented in the additional DFLUX subroutine, written in Fortran programming language. The correctness of the assumed model of thermal phenomena is confirmed by examinations of the shape and size of the melted zone. The strength of the welded joint subjected to shear is verified by performing a compression test of welded pipes as well as computer simulations with validation of the computational model using the Dantec 3D image correlation system.

Mechanical behaviour of 3D monofilament knitted fabrics: Modeling, simulation and validation

Three-dimensionally (3D) knitted technology textiles are expanding into industrial and technical applications of textile composites given their geometric, structural, and functional performance. However, there are many challenges in developing computational tools that allow for physics-based predictions while keeping the related computing cost low. The strong interactions between geometrical and physical elements permit determining the behavior of this type of engineering material. In the aim of understanding the specific mechanical behaviors of knitted textiles, a yarn-level simulation model framework was created to predict the nonlinear orthotropic mechanical behavior of monofilament jersey-knitted textiles. The relative contributions of many computational parameters on the global mechanical behavior of knitted fabrics are investigated, specifically, inter-yarn interactions and the boundary conditions effect. The models are saved in a format that can be read directly by Finite Element Analysis FEA software. Yarns are numerically discretized as nonlinear 3D beam components, while input parameters, such as mechanical characteristics of yarns and geometric dimensions of loops in fabrics are established experimentally. Good agreement was relieved by comparing experimental data to simulation results in a wale-wise direction tensile load.