Analytical Finite Element Analysis Research Articles

FEA analysis and design optimization for a multifunctional piece of furniture

The paper presents an original approach to the integration of computer aided design and finite element analysis for a multifunctional piece of furniture using CATIA Generative Structural Analysis workbench. Finite Element Analysis (FEA) application is an important engineering technique in the furniture industry. FEA is an accurate method for numerical solution of field problems. A major problem of mesh generation today is access to CAD geometry in a efficient and precise manner. Starting with a solid modelling for the creation of the desired piece of multifunctional furniture is used in this case, the automatic generation of the finite element meshes. Getting more accurate results for the mesh refinement process can be made by changing parameters. The article outlines the developed model for analysing the supporting structure of the armchair. This model provides simulating of the different loads and checking the raised stresses and deformation in the structures analysed. The main objective of this research is to evaluate strength of wooden cedar armchair for a person weighing 140 kg and for this the finite element analysis (FEA) has been used. Multifunctional furniture is the answer to the challenges contemporary lifestyle, creativity in design activities that require optimal space utilization and reducing costs.

Comparative Evaluation of Stress developed on Rotary Retreatment Instruments during Retrieval of Gutta-percha

The aim of the study is to compare the maximum stress distribution on the rotary retreatment instruments within the root canal at cervical, middle, and the apical one-third during retreatment of gutta-percha. A human mandibular premolar was scanned, and three-dimensional geometry of the root was reconstructed using finite element analysis (FEA) software package (ANSYS). The basic model was kept unchanged; tooth models were created using the same dimensions and divided into two groups as follows: Group I: ProTaper Universal retreatment system and group II: Mtwo rotary retreatment system. The stress distribution on the surface and within the retreatment files was analyzed numerically in the FEA package (ANSYS). The FEA analysis revealed that the retreatment instruments received the greatest stress in the cervical third, followed by the apical third and the middle third. The stress generated on the ProTaper Universal retreatment system was less when compared with the Mtwo retreatment files. The study concludes that the retreatment instruments undergo higher stress in the cervical third region, and further in vivo and in vitro studies are necessary to evaluate the relationship between instrument designs, stress distribution, residual stresses after use, and the torsional fracture of the retreatment instrument. The stress developed on the rotary retreatment instruments during retrieval of gutta-percha makes the instrument to get separated. There is no instrument system, i.e., suitable for all clinical situations and it is important to understand how the structural characteristics could influence the magnitude of stresses on the instrument to prevent its fracture in use.

A preliminary case study of the effect of shoe-wearing on the biomechanics of a horse’s foot

Horse racing is a multi-billion-dollar industry that has raised welfare concerns due to injured and euthanized animals. Whilst the cause of musculoskeletal injuries that lead to horse morbidity and mortality is multifactorial, pre-existing pathologies, increased speeds and substrate of the racecourse are likely contributors to foot disease. Horse hooves have the ability to naturally deform during locomotion and dissipate locomotor stresses, yet farriery approaches are utilised to increase performance and protect hooves from wear. Previous studies have assessed the effect of different shoe designs on locomotor performance; however, no biomechanical study has hitherto measured the effect of horseshoes on the stresses of the foot skeleton in vivo. This preliminary study introduces a novel methodology combining three-dimensional data from biplanar radiography with inverse dynamics methods and finite element analysis (FEA) to evaluate the effect of a stainless steel shoe on the function of a Thoroughbred horse’s forefoot during walking. Our preliminary results suggest that the stainless steel shoe shifts craniocaudal, mediolateral and vertical GRFs at mid-stance. We document a similar pattern of flexion-extension in the PIP (pastern) and DIP (coffin) joints between the unshod and shod conditions, with slight variation in rotation angles throughout the stance phase. For both conditions, the PIP and DIP joints begin in a flexed posture and extend over the entire stance phase. At mid-stance, small differences in joint angle are observed in the PIP joint, with the shod condition being more extended than the unshod horse, whereas the DIP joint is extended more in the unshod than the shod condition. We also document that the DIP joint extends more than the PIP after mid-stance and until the end of the stance in both conditions. Our FEA analysis, conducted solely on the bones, shows increased von Mises and Maximum principal stresses on the forefoot phalanges in the shod condition at mid-stance, consistent with the tentative conclusion that a steel shoe might increase mechanical loading. However, because of our limited sample size none of these apparent differences have been tested for statistical significance. Our preliminary study illustrates how the shoe may influence the dynamics and mechanics of a Thoroughbred horse’s forefoot during slow walking, but more research is needed to quantify the effect of the shoe on the equine forefoot during the whole stance phase, at faster speeds/gaits and with more individuals as well as with a similar focus on the hind feet. We anticipate that our preliminary analysis using advanced methodological approaches will pave the way for new directions in research on the form/function relationship of the equine foot, with the ultimate goal to minimise foot injuries and improve animal health and welfare.

Determining biosensing modes in SH-SAW device using 3D finite element analysis

Surface acoustic wave (SAW) sensors are electromechanical devices that exploit the piezoelectric effect to induce elastic (acoustic) waves which are sensitive to small perturbations: for example specific binding and recognition of disease biomarkers. Shear horizontal surface acoustic waves (SH-SAWs) are particularly suited to biosample analysis as the wave is not completely radiated and lost into the liquid medium (e.g., blood, saliva) as is the case, for example, in a device implementing Rayleigh waves. Here, using 3D finite element analysis (FEA) the nature of waves launched on a particular quartz device is investigated with respect to the cut of the quartz, the addition of gold guiding layers, and the addition of other linear elastic materials of contrasting acoustic properties. It is demonstrated that 3D FEA analysis showing the device's frequency shift with added guiding layer height reveals a proportional relationship in agreement with the Sauerbrey equation from perturbation theory. It is directly shown, given certain device parameters and a gold guiding layer, that shear horizontally polarized waves are launched on the surface with a dominant mode frequency around 250MHz. This would be an appropriate biosensing mode in Point of Care (POC) testing for the particular properties of certain disease biomarkers delivered via a liquid medium.

FEA simulation and RSM based parametric optimisation of vibrating transmission gearbox housing

Summary The main objective of this research work is optimisation of connecting bolts number using Detuning principle. Connecting bolts are used for constraining transmission system on vehicle frame. The model of transmission system designed for FEA and RSM analysis consists of 5–37 connecting bolts for tightly mounting on vehicle frame. At zero displacement condition when all 37 connecting bolts were constraint, natural frequency reaches in a higher order range of 1650.5–3565.1 Hz. This higher order range of frequency makes the model a conservative design when critical frequency for medium duty vehicle varies from 0 to 100 Hz. Using detuning principle and RSM optimisation technique an optimised number of connecting bolts can be identified. Response surface methodology (RSM) has been used for parametric optimisation and finite element analysis (FEA) was used for calculation of modal frequency and mode shapes. FEA analysis was done using ANSYS 14.5 and solid edge, and Pro-E has been used for geometric modelling.

Axial crush behaviours and energy absorption characteristics of aluminium and E-glass/epoxy over-wrapped aluminium conical frusta under low velocity impact loading

Low velocity axial impact crush behaviours and energy absorption characteristics of thin-walled aluminium conical (AC) and E-glass/epoxy composite over-wrapped aluminium conical hybrid frustrated shells (CWAC) have been studied through experimental and numerical procedures. In this regard, 15°–24° semi-apical angled aluminium and hybrid conical test specimens of required thickness and fibre ply orientations were fabricated through hand layup method. The axial impact tests were performed at different strain rates on each AC and CWAC samples with the help of low velocity impact test setup in order to assess the energy absorption capacity of each specimen against impact loading. The influence of inertia, strain rate, addition of GFRP laminates over aluminium shell and GFRP fibre ply orientation towards the crashworthiness performances of various categories of conical frusta were analyzed. The low velocity impact tests were also simulated with the help of finite element analysis (FEA) techniques of ABAQUS® software in order to predict and compare the crashworthiness of each category of specimen model with experimental results. The obtained crashworthiness test results and collapse behaviours of FEA analysis are found in good agreement with the experimental results.

Effect of Jig Design and Assessment of Stress Distribution in Testing Metal-Ceramic Adhesion.

In testing adhesion using shear bond test, a combination of shear and tensile forces occur at the interface, resulting in complex stresses. The jig designs used for this kind of test show variations in published studies, complicating direct comparison between studies. This study evaluated the effect of different jig designs on metal-ceramic bond strength and assessed the stress distribution at the interface using finite element analysis (FEA). Metal-ceramic (Metal: Ni-Cr, Wiron 99, Bego; Ceramic: Vita Omega 900, Vita) specimens (N = 36) (diameter: 4 mm, veneer thickness: 4 mm; base diameter: 5 mm, thickness: 1 mm) were fabricated and randomly divided into three groups (n = 12 per group) to be tested using one of the following jig designs: (a) chisel (CH) (ISO 11405), (b) steel strip (SS), (c) piston (PI). Metal-ceramic interfaces were loaded under shear until debonding in a universal testing machine (0.5 mm/min). Failure types were evaluated using scanning electron microscopy (SEM). FEA was used to study the stress distribution using different jigs. Metal-ceramic bond strength data (MPa) were analyzed using ANOVA and Tukey's tests (α = 0.05). The jig type significantly affected the bond results (p = 0.0001). PI type of jig presented the highest results (MPa) (p < 0.05) (58.2 ± 14.8), followed by CH (38.7 ± 7.6) and SS jig type (23.3 ± 4.2) (p < 0.05). Failure types were exclusively a combination of cohesive failure in the opaque ceramic and adhesive interface failure. FEA analysis indicated that the SS jig presented slightly more stress formation than with the CH jig. The PI jig presented small stress concentration with more homogeneous force distribution compared to the CH jig where the stress concentrated in the area where the force was applied. Metal-ceramic bond strength was affected by the jig design. Accordingly, the results of in vitro studies on metal-ceramic adhesion should be evaluated with caution. When adhesion of ceramic materials to metals is evaluated in in vitro studies, it should be noted that the loading jig type affects the results. Clinical observations should report on the location and type of ceramic fractures in metal-ceramic reconstructions so that the most relevant test method can be identified.

Estimation of Composite Laminate Design Allowables Using the Statistical Characteristics of Lamina Level Test Data

A methodology for determining the design allowables of composite laminates by using lamina level test data and finite element analysis (FEA) is proposed and verified in this paper. An existing method that yields the laminate design allowables by using the complete test results for laminates was improved to reduce the expensive and time-consuming tests. Input property samples for FEA were generated after considering the statistical distribution characteristics of lamina level test data. , and design allowables were derived from several FEA analyses of laminates. To apply and verify the proposed method, Hexcel 8552 IM7 test data were used. For both un-notched and open-hole laminate configurations, it was found that the design allowables obtained from the analysis correctly predicted the laminate test data within the confidence interval. The potential of the present simulation to substitute the laminate tests was demonstrated well.

Corrosion Fatigue Failure Analysis of a Supporting Pipe Weld in Deaerization Plant

The aim of this work is to reveal the failure mechanism of a supporting pipe weld after 20 years of service in a deaerization plant. The characterization methods included inductively coupled plasma, optical microscopy, scanning electron microscope, X-ray energy dispersive spectrometer, mechanical tests, and finite element analysis (FEA). The results showed that the supporting pipe weld failed by corrosion fatigue cracking. Cracks initiated from the surface pits which were due to corrosion. FEA analysis revealed that stress concentration occurred in the failed weld. This paper brings out the details of the investigation and suggests remedial measures to improve performance of such pipe welds in deaerization plants.

Failure analysis of vessel propeller bolts under fastening stress and cathode protection environment

This paper describes the failure analysis of propeller blade fastening bolts made from martensitic stainless steel 0Cr16Ni5Mo, which was ruptured under service of cathode protection for 5years. The general crack pattern of the bolts, fractographic features, hydrogen content determination and slow tensile test results are all exhibiting the characteristics of hydrogen embrittlement. Accordingly, hydrogen diffusion driven by hydrogen concentration gradient and stress concentration was identified by experiment and finite element analysis (FEA). The morphology of the crack was intergranular of initiation from bolt cap root surface, and quasi-cleavage of propagation. The hydrogen distribution indicated that the hydrogen concentration in the bolt was in gradient distribution, and the region farther away from the sea water contains less hydrogen content. This revealed that hydrogen entered the bolt top surface through sea water under cathodic protection, and diffused from top to cap. The hydrogen content of the cap where crack initiated was 7.0ppm, which was much higher than that in bolt shaft with normal content of 1.1ppm. Results of low tensile test together with fractographic observation showed that the brittleness of the bolt was enhanced by the effect of hydrogen. Stress distribution calculated by FEA analysis indicated that the maximal stress of the bolt was about 1016MPa, located at cap root surface which was consistent with crack initiation sites. The stress drove hydrogen to accumulate at root surface until cracking occurred. In a sum, the failure was attributed to the hydrogen diffusion, local high stress, and the martensitic microstructure susceptible to hydrogen embrittlement. Remedial measures such as avoiding over protection potential, that increase tempering temperature were suggested. Methods to optimize stress distribution of the bolt were also suggested based on FEA calculation.

Droplet formation and settlement of phase-change ink in high resolution electrohydrodynamic (EHD) 3D printing

This paper presents a modeling framework to model the droplet formation and settlement on substrate of phase-change ink in high resolution electrohydrodynamic (EHD) printing process, which can successfully produce sub 10-μm droplet footprints and 3D microstructure. We have used Finite Element Analysis (FEA) to develop the model for droplet formation and droplet settlement. Two important competitive forces in EHD printing, electrostatic force and surface tension force are modeled by FEA. The droplet size is obtained by balancing the electrostatic force and surface tension of the pending droplets at the tip of the meniscus under different printing conditions. With the results from FEA analysis about the charge on a droplet and electrostatic field distribution, the droplets in-flight velocity and impact velocity on the substrate are derived numerically. With the derived impact velocity, the droplet spreading and settlement on the substrate is also modeled by FEA. The results from FEA models are compared with the experimental measured droplet dimensions at different process conditions to validate the developed model, which demonstrate very good agreement between the experimental results and model prediction. We have successfully applied EHD printing process for phase-change wax material, which is widely used in 3D printing or additive manufacturing for supporting and model material, to achieve high resolution sub 10-μm 3D structures.

Simulating bio-composite cycling helmet performance through FEA and CFD approaches

&lt;p&gt;Finite Element Analysis (FEA) and Computational Fluid Dynamics (CFD) analysis were performed in this work in order to obtain the best design for safety and aerodynamic performance of the bicycle cycling helmet. FEA analysis was computed on two different helmet designs to determine the critical area subjected to impact. A pressure load was applied on the helmets’ outer surface to simulate oblique loading. The critical areas of the helmets were then highlighted and identified, enabling design improvements to be made on both designs. CFD analysis was then executed in order to obtain the lowest drag coefficient number in reducing the air resistance induced by both of the helmet designs, inherently increasing cyclist performance and ensuring competition success.&lt;/p&gt;

Compensation of Gravity Induced Heliostat Deflections for Improved Optical Performance

Heliostat optical performance can be affected by both wind and gravity induced deflections in the mirror support structure. These effects can result in decreased energy collection efficiency, depending on the magnitude of structural deflections, heliostat orientation and field position, and sun position. This paper presents a coupled modeling approach to evaluate the effects of gravity loading on heliostat optical performance, considering two heliostat designs: The National Solar Thermal Test Facility (NSTTF) heliostat and the Advanced Thermal Systems (ATS) heliostat. Deflections under gravitational loading were determined using finite element analysis (FEA) in Ansys Mechanical, and the resulting deformed heliostat geometry was analyzed using Breault Apex optical engineering software to evaluate changes in beam size and shape. Optical results were validated against images of actual beams produced by each respective heliostat, measured using the Beam Characterization System (BCS) at Sandia National Laboratories. Simulated structural deflections in both heliostats were found to have visible impacts on beam shape, with small but quantifiable changes in beam power distribution. In this paper, the combined FEA and optical analysis method is described and validated, as well as a method for modeling heliostats subjected to gravitational deflection and canted in-field, for which mirror positions may not be known rigorously. Furthermore, a modified, generalized construction method is proposed and analyzed for the ATS heliostat, which was found to give consistent improvements in beam shape and up to a 4.1% increase in annual incident power weighted intercept (AIPWI).

Strain behaviors of solder bump with underfill for flip chip package under thermal loading condition

Since the introduction of Cu/low-k as the interconnect material, the chip-package interaction (CPI) has become a critical reliability challenge for flip chip packages. Revision of underfill material must be considered, which compromises the life of flip chip interconnect by releasing the stresses transferred to the silicon devices from the solder bumps, and thereby maintain the overall package reliability. Thus, it is important to understand the thermo-mechanical behavior of solder bumps. In this study, the solder bump reliability in flip chip package was investigated through an experimental technique and numerical analysis. For the experimental assessment, thermo-mechanical behavior of solder joints, especially the solder bumps located at the chip corners where most failures usually occur was investigated. Digital image correlation (DIC) technique with optical microscope was utilized to quantify the deformation behavior and strains of cross-sectioned solder bump of flip-chip package subjected to thermal loading from 25°C to 100°C. The results clearly show captured deformations of solder bump under thermal loading. Finally, finite element analysis (FEA) was conducted by simulating the thermal loading applied in the experiments, and validated with experimental results. Then, consistently using the FEA analysis, parametric study for underfill material properties were performed on the reliability of flip chip package, by varying the glass transition temperature (Tg), Young’s modulus (E), and coefficient of thermal expansion (CTE). Averaged plastic work of the corner solder bump and stress at the die side were obtained and used as damage indicators for solder bumps and low-k dielectrics layer, respectively. The results show that high Tg, and E of underfill are generally desirable to improve the reliability of solder interconnects in the flip chip package.

Finite Element Analysis and Design Optimization of a Pneumatically Actuating Silicone Module for Robotic Surgery Applications

The design of a pneumatically actuated silicone module, resembling soft tissue, with three pneumatic chambers is considered and optimized in this study with the aim of using it in a soft robot arm for robotic surgery applications. Three types of silicone materials, Ecoflex 0030 and 0050 and Dragonskin 0030, have been investigated, and a constitutive model has been derived for each of them. Design optimization of the silicone module was based on finite element analysis (FEA) that was validated against experimental data of one-degree bending under one-channel actuation. This was followed by FEA parametric studies for module design optimization to minimize the ballooning effect in one-degree bending as well as reduce the actuation pressure. Modules made from Ecoflex 0030 and Ecoflex 0050 exhibited the same bending shape in FEA, but about three times higher actuation pressure was required for the harder Ecoflex 0050. Design parameters under investigation in the parametric FEA studies included the shape of the pneumatic channel cross section, the ratio of channel length to module length, the distance of channel from the module wall, and the ratio of channel to module cross-sectional area. After FEA design optimization yielded least ballooning for pneumatic chambers of semicircular cross section, an internal dragonskin structure was added internally below the module surface to enable and guide the bending under one-channel pneumatic actuation and further contain the ballooning effect: the benefits of this design were successfully verified under both FEA and experimental analysis.

Development and Modeling of Melt Electrohydrodynamic-Jet Printing of Phase-Change Inks for High-Resolution Additive Manufacturing

This paper presents the development and modeling a high-resolution electrohydrodynamic-jet (EHD-jet) printing process using phase-change ink (i.e., wax), which is capable of producing sub-10 μm footprints (sub-10 fL in volume) for super-resolution additive manufacturing. In this study, we successfully apply EHD-jet printing for phase-change ink (wax), which is widely used as modeling and supporting material for additive manufacturing, to achieve micron-scale features. The resolution for single droplet on substrate is around 5 μm with the thickness in the range of 1–2 μm, which provides great potential in both high-resolution 3D printing and 2D drop-on-demand microfabrication. The droplet formation in EHD printing is modeled by finite element analysis (FEA). Two important forces in EHD printing, electrostatic force and surface tension force, are modeled separately by FEA. The droplet size is obtained by balancing the electrostatic force and surface tension of the pending droplets around meniscus apex. Furthermore, to predict the droplet dimension at different process conditions, a dimensionless scaling law is identified to describe the relationship between dimensionless droplet diameter and modified nondimensional electrical bond number. Finally, the droplets in-flight velocity and impact characteristics (e.g., Reynolds number and Weber number) are modeled using the results from FEA analysis.

Determining fan generated dynamic forces for use in predicting and controlling vibration and structure-borne noise from air handling equipment

Vibration measurements were conducted to determine the dynamic forces imparted by an operating fan to the floor of an existing rooftop mechanical room. The calculated forces where then used as inputs to a Finite Element Analysis (FEA) computer model to predict the vibration and structure-borne noise in a future building with a similar fan. This paper summarizes the vibration measurements, analysis of the measured data, the subsequent FEA analysis of the future building and the recommendations developed to control fan generated noise and vibration in the future building.

Stress-shielding induced bone remodeling in cementless shoulder resurfacing arthroplasty: a finite element analysis and in vivo results

Cementless surface replacement arthroplasty (CSRA) of the shoulder was designed to preserve the individual anatomy and humeral bone stock. A matter of concern in resurfacing implants remains the stress shielding and bone remodeling processes. The bone remodeling processes of two different CSRA fixation designs, conical-crown (Epoca RH) and central-stem (Copeland), were studied by three-dimensional (3-D) finite element analysis (FEA) as well as evaluation of contact radiographs from human CSRA retrievals. FEA included one native humerus model with a normal and one with a reduced bone stock quality. Compressive strains were evaluated before and after virtual CSRA implantation and the results were then compared to the bone remodeling and stress-shielding pattern of eight human CSRA retrievals (Epoca RH n=4 and Copeland n=4). FEA revealed for both bone stock models increased compressive strains at the stem and outer implant rim for both CSRA designs indicating an increased bone formation at those locations. Unloading of the bone was seen for both designs under the central implant shell (conical-crown 50–85%, central-stem 31–93%) indicating high bone resorption. Those effects appeared more pronounced for the reduced than for the normal bone stock model. The assumptions of the FEA were confirmed in the CSRA retrieval analysis which showed bone apposition at the outer implant rim and stems with highly reduced bone stock below the central implant shell. Overall, clear signs of stress shielding were observed for both CSRAs designs in the in vitro FEA and human retrieval analysis. Especially in the central part of both implant designs the bone stock was highly resorbed. The impact of these bone remodeling processes on the clinical outcome as well as long-term stability requires further evaluation.

Magnetic circuit model and finite‐element analysis of a modular switched reluctance machine with E‐core stators and multi‐layer common rotors

This study presents a novel switched reluctance machine (SRM) with modular E-core stators and multi-layer common rotors for high reliability applications. The stator is composed of six independent modular E-cores with the windings wound around the yoke of the E-cores. The rotor consists of three magnetically independent common rotors which are place in the same shaft without any angular shift. The equivalent magnetic circuit (EMC) models of this new SRM at the aligned and unaligned positions are described. To evaluate the motor performance, two types of analysis, namely, approximate simplified two-dimensional (2D) model and 3D model finite-element analysis (FEA) have been utilised. The 2D FEA static and dynamic results are compared with 3D FEA results. Furthermore, comparisons between the novel modular SRM and a conventional 6/4 SRM are made. Finally, a prototype of this modular SRM has been fabricated and tested in the laboratory. Comparison between FEA and EMC analysis for flux linkage are made and compared with measured characteristics. The simulated and measured phase currents and average torque are also presented and compared to verify the analytical and simulation results.

Design Optimization and Finite Element Analysis of 3C-SiC Bio-Sensors Based on Dogbone Resonator

This paper presents the optimized design and Finite Element Analysis (FEA) of a bio sensor based on cubic silicon carbide (3C-SiC) for pathogen detection. Silicon Carbide is chosen due to its excellent material properties and chemical stability compared to silicon in varying environmental conditions. The desired resonance frequency is optimized using matlab and the finite element analysis is carried out using COMSOL and Intellisuite software’s. The effect of the residual stress on the desired mode of resonant frequency and the fabrication feasibility of the proposed resonator fabrication are studied using FEA analysis. The mathematical modeling of thermally actuation and piezoresistive sensing for the design resonator bio sensors are illuminated. The close agreement between the analytical model and finite element analysis verify the design of proposed bio sensors.