Finite Element Analysis Methodology Research Articles

Mechanical Design, Manufacturing, and Testing of a Soft Pneumatic Actuator with a Reconfigurable Modular Reinforcement

Soft actuators have enabled the growth of soft robotics, overcoming several drawbacks of rigid robotics by providing devices with many degrees of freedom and the ability to grasp, bend, move, jump, and more. The reconfiguration of the workspace is still a limitation of these actuators. Indeed, once the actuator is designed and developed, it is used for a specific task. This work presents a reconfigurable soft pneumatic actuator with a novel reconfigurable modular reinforcement. The latter is wrapped around an inner tube in silicone rubber and is made of components whose assembly can be configured based on the task. A formulation is identified by a hybrid approach based on finite element analysis and response surface methodology for predicting and designing the behavior of the actuator. The prototyping revealed the ease of fabrication and reconfigurability as the strength of this new actuator. The experimental tests demonstrated the feasibility of adopting the actuator as a finger in a gripper for handling and moving objects of different shapes, masses, and stiffness. Furthermore, the evaluated performance shows a good trade-off between mass, developed force, implementation time, easy reconfigurability, and cost-effectiveness.

Comparative analysis of internal fixation modalities for PER type IV ankle fractures: a finite element study

BackgroundThere are many options for the surgical treatment of pronation external rotation (PER) type IV ankle fractures, including the use of fibular plates and screws, the aim of this study was to investigate the biomechanical stability and safety of different internal fixation methods for PER type IV ankle fractures via finite element analysis.MethodsA three-dimensional finite element model of the ankle joint and the whole foot of a healthy 26-years-old adult male was established and validated based on computed tomography images of his lower limb, and a computer-aided design was used to produce a PER type IV ankle fracture and plate and screw model. Four different internal fixation modes were simulated, including a (all ankle fixation—utilizing a fibular plate and screws for comprehensive stabilization of the ankle), b (inferior tibiofibular joint fixation + all ankle fixation), c (inferior tibiofibular joint fixation + unfixed anterior ankle), and d (inferior tibiofibular joint fixation + unfixed anterior and posterior ankles). The results of the four different fixation methods were compared via finite element analysis, and the von Mises stresses. The displacements of the four different fixation methods were analyzed as the output indices.ResultsThere were no significant differences between the results of using fibular plates and screws and the displacement of fracture breaks among the four internal fixation modalities. The von Mises stress in the tibiotalar joint, median ankle, posterior ankle, and anterior ankle was minimized in the working condition of d, d, b, and d respectively. The von Mises stress in the fibular plate and screws was minimized in the working condition of a. The von Mises stress in the distal fibula was minimized in the working condition of a. However, the stress was mainly concentrated at the attachment point of the inferior tibiofibular anterior ligament, and in the working condition with inferior tibiofibular joint fixation, the stress was significantly concentrated in the inferior tibiofibular joint screw in all the fibular plates and screws.ConclusionsThe results of this study demonstrate the feasibility of using finite element analysis to compare the biomechanical stability and safety of four configurations of fibular plates and screws for treating PER type IV ankle fractures. All four modalities provided comparable biomechanical stability and safety, showing no significant differences. However, the current limitations of the finite element analysis methodology preclude specific clinical inferences. Further refinement of the methodology in future studies is necessary to enable reliable clinical applications.

Prediction of defects in deep drawn rectangular parts using Finite Element Analysis (FEA) and Response Surface Methodology (RSM)

Abstract Deep drawing defects such as thinning and earing present challenges to sheet metal forming industry while designers tend to favour the usage of new materials and production processes. The present work introduces an integrated approach using Design of Experiment, FEA experimentation and RSM to study the effect of deep drawing process parameters and resulting defects associated with sheet metal forming processes such as thinning and earing particularly in deep drawing of non-circular parts. The Design of Experiment (DoE) is used to generate a series of experiments for different process parameters in deep drawn rectangular products which are then simulated using Simulia 2022, a finite element package. The results are then fed to statistical analysis software, Design Expert 12.0, to develop regression equations that predict minimum sheet thickness and earing defects using RSM. FE models for deep drawing of different products have been built and results have been verified through comparisons with published data. Critical process parameters were selected for investigation in the present work. Based on the results of these experiments, a two-level design of experiment is conduct to generate 64 FE experiments. The relationships between these parameters and minimum sheet thickness after drawing and earing defects are then obtained using RSM. Optimum values of different parameters are obtained for maximum sheet thickness after drawing and minimum earing.

A study on end mill tool geometry parameters for end milling of 316L: finite element analysis and response surface methodology optimization based on resultant cutting force

A study on end mill tool geometry parameters for end milling of 316L: finite element analysis and response surface methodology optimization based on resultant cutting force

Optimizing functionally graded tibial components for total knee replacements: a finite element analysis and multi-objective optimization study

The optimal design of complex engineering systems requires tracing precise mathematical modeling of the system’s behavior as a function of a set of design variables to achieve the desired design. Despite the success of current tibial components of knee implants, the limited lifespan remains the main concern of these complex systems. The mismatch between the properties of engineered biomaterials and those of biological materials leads to inadequate bonding with bone and the stress-shielding effect. Exploiting a functionally graded material for the stem of the tibial component of knee implants is attractive because the properties can be designed to vary in a certain pattern, meeting the desired requirements at different regions of the knee joint system. Therefore, in this study, a Ti6Al4V/Hydroxyapatite functionally graded stem with a laminated structure underwent simulation-based multi-objective design optimization for a tibial component of the knee implant. Employing finite element analysis and response surface methodology, three material design variables (stem’s central diameter, gradient factor, and number of layers) were optimized for seven objective functions related to stress-shielding and micro-motion (including Maximum stress on the cancellous bone, maximum and mean stresses on predefined paths, the standard deviation of mean stress on paths, maximum and mean micro-motions at the bone-implant interface and the standard deviation of mean micro-motion). Then, the optimized functionally graded stem with 6 layers, a central diameter of 5.59 mm, and a gradient factor of 1.31, was compared with a Ti6Al4V stem for various responses. In stress analysis, the optimal stem demonstrated a 1.92% improvement in cancellous bone stress while it had no considerable influence on the maximum, mean, and standard deviation of stresses on paths. In micro-motion analysis, the maximum, mean, and standard deviation of mean micro-motion at the interface were enhanced by 24.31%, 39.53%, and 19.77%, respectively.

Finite Element Analysis of Manufacturing Deformation in Polymer Matrix Composites.

This paper introduces a unique finite element analysis (FEA) technique designed to predict elastic response in polymer matrix composites (PMCs). Extensive research has been conducted to model the manufacturing process of multiple 'L'-shaped components, fabricated from SPRINTTM materials (GLP 43 and GLP 96) at two thicknesses (15 mm and 25 mm). Three distinct FEA methodologies were utilised to determine the impact of thermal loads and rigid fixtures. An error deviation of 3.23% was recorded when comparing simulation results to experimental data, thereby validating the effectiveness of the FEA methodology.

The osteoclastic activity in apical distal region of molar mesial roots affects orthodontic tooth movement and root resorption in rats

The utilization of optimal orthodontic force is crucial to prevent undesirable side effects and ensure efficient tooth movement during orthodontic treatment. However, the sensitivity of existing detection techniques is not sufficient, and the criteria for evaluating optimal force have not been yet established. Here, by employing 3D finite element analysis methodology, we found that the apical distal region (A-D region) of mesial roots is particularly sensitive to orthodontic force in rats. Tartrate-resistant acidic phosphatase (TRAP)-positive osteoclasts began accumulating in the A-D region under the force of 40 grams (g), leading to alveolar bone resorption and tooth movement. When the force reached 80 g, TRAP-positive osteoclasts started appearing on the root surface in the A-D region. Additionally, micro-computed tomography revealed a significant root resorption at 80 g. Notably, the A-D region was identified as a major contributor to whole root resorption. It was determined that 40 g is the minimum effective force for tooth movement with minimal side effects according to the analysis of tooth movement, inclination, and hyalinization. These findings suggest that the A-D region with its changes on the root surface is an important consideration and sensitive indicator when evaluating orthodontic forces for a rat model. Collectively, our investigations into this region would aid in offering valuable implications for preventing and minimizing root resorption during patients’ orthodontic treatment.

Impact behavior of spark plasma sintered Ti–Al–Mo/TiN composites: a finite element analysis approach using Abaqus CAE

BackgroundThe utilization of Finite Element Analysis (FEA) has emerged as a crucial methodology in the field of structural and elasticity analysis, facilitating researchers in their understanding of material responses to diverse thermal or structural loads. This study investigates the utilization of FEA to simulate the Impact characteristics of titanium composites, with specific emphasis on the Charpy impact test. The research utilizes the Abaqus Explicit software, which is widely recognized for its explicit dynamic analysis functionalities, to simulate high-speed and short-duration events such as impacts. The primary objective of this study is to examine the impact behavior of Ti–7Al–1mo/TiN composites fabricated through the spark plasma sintering technique. The impact behavior is simulated using FEA, wherein the shear failure model is utilized to replicate fracture phenomena. This paper examines the methodology employed in the FEA approach, with a particular focus on various factors including boundary conditions, explicit dynamic analysis settings, and material properties.ResultsThe outcomes and analyses involve the examination of the von Mises stress distribution, displacement magnitude, and energy behavior of the models that were tested. Reinforcement of Ti–Al–Mo ternary alloy with TiN led to a progressive increase in maximum von Mises stress, reaching a peak at 3 wt% TiN. Conversely, displacement magnitude decreased with increasing TiN content, with CP-Ti and the unreinforced alloy exhibiting the highest values. Absorbed energy also declined with higher TiN levels. While models containing 5 and 7 wt% TiN displayed limited plastic deformation before fracture, composites with ≤ 3 wt% TiN maintained acceptable ductility despite enhanced strength and stiffness.ConclusionThe FEA methodology effectively simulates the Charpy impact characteristics of Ti–7Al–1Mo/TiN composites, thereby offering significant contributions to understanding their mechanical behaviors. These findings suggest that TiN reinforcement up to 3 wt% presents a promising strategy for improving the mechanical performance of Ti–Al–Mo alloys while minimizing the trade-off in toughness. This research emphasizes the inherent trade-off between toughness and strength/stiffness, suggesting the possibility of optimizing the composition of materials to suit particular applications. This study makes a valuable contribution to the expanding field of impact behavior research, demonstrating the potential of FEA, specifically utilizing Abaqus Explicit software, for enhancing material design and evaluation.

Analysis of Lathe Machine Tumbler Gear Mechanism Using Finite Element Methodology

Gear is the special division of Mechanical Engineering concerned with the transmission of power and motion between the rotating shafts. In this study, a lathe machine tumbler gear mechanism used for threading purpose is taken and applied finite element analysis methodology on each metallic spur gears. Main purpose of this study is to compare FEA stresses of metallic spur gears with the AGMA standard stress. Modelling of gears is done in PRO-ENGINEERING and analysis is done using ANSYS workbench v11.

Novel numerical approach for reliability-assurance of ceramics by combining self-crack-healing with proof testing

Ceramics exhibit stochastic fracture behavior due to internal and surface defects, thereby limiting their practical use. To address this issue, a combined method of ‘self-crack-healing’ and ‘proof testing’ has been proposed. However, to efficiently implement the method, a numerical analysis is required for preliminary investigation. This study establishes a finite element analysis methodology that enables the prediction of both strength recovery due to crack healing and the scatter of strength due to microstructural features. We determine the dependence of the scatter of the three-point bending strength on the healing conditions using the Weibull distribution and demonstrate the applicability of the proposed analysis method to proof tests. Results revealed that the proposed methodology can estimate the healing conditions and proof stresses by obtaining the microstructural information and oxidation kinetics parameters of the ceramic components in advance.

An Analysis of Mechanical and Thermal Stresses, Temperature and Displacement within the Transparent Cylinder and Piston Top of a Small Direct-Injection Spark-Ignition Optical Engine

Two- and three-wheeled vehicles account for a significant portion of the automobile market in several countries worldwide. In order to advance the capabilities of these vehicles, the integration of direct-injection (DI) technology is essential, given its potential benefits such as high thermal efficiency and low engine-out emissions. Direct injection in small-bore engines, however, further complicates the challenges involved (of DI technology) like fuel impingement and mixture inhomogeneity inside the engine cylinder, driving the need for an in-depth exploration of in-cylinder processes. Consequently, the necessity arises to develop a small-bore direct-injection spark-ignition (DISI) optical engine that incorporates a transparent cylinder and piston top. In this scenario, these transparent components are required to endure a combination of intricate loads and boundary conditions, hence the potential to result in failures. This work aims to assess numerically the effects of these loads and boundary conditions on the transparent components and optimize their thicknesses. For this purpose, a computer-aided design model of a small-bore DISI optical engine (displacement volume of 200 cm3) is developed. The mechanical and thermal loads are extracted from the experimental data and validated computational fluid dynamics model of the same engine configuration. A coupled temperature-displacement finite element analysis methodology is developed in ABAQUS/CAE, and simulations are performed under both steady and transient conditions. Temperature and combined stress distributions within the transparent cylinder and piston top are obtained and analyzed to find their optimum thicknesses. Knowing thermal gradients, combined stresses and displacements under actual conditions helped design the small optical engine with an improved factor of safety.

Ballistic response of additively manufactured AA6061/AA7075 multistack plate for armor-piercing projectile

The current ballistics research study focuses heavily on substituting heavy metals with lightweight materials to make mobility more accessible and effective for all armor applications. To do so, the researchers found that aluminum alloys are the better alternative to substitute steel armor due to their high strength-to-weight ratio. Therefore, this research conducted ballistic studies on aluminum alloys using the Finite Element Analysis (FEM) methodologies and associated mathematical analysis. This Research primarily focuses on the damage factor, ballistic limit, and residual velocity of the bullet following penetration of target plates. In this investigation, the Johnson-Cook fracture and Recht-Ipson models were implemented on materials AA6061-T6 and AA7075-T6. The main objective of these models is to establish the damage factor and verify whether it is less than unity; if the factor is less than unity, it is eligible to study the residual velocity of the bullet after penetration into the target armor plate. The target plate was impacted with a 7.62 mm armor-piercing projectile with an impact velocity of 500 m/s. Monolithic plates of 18 mm thickness were evaluated initially. After that, the multilayered stack of each 3 mm thick plate was analyzed, and studied the effectiveness of using a multilayered stack armor plate.

Investigating the impact of roller position on pressure tube-end fitting rolled joint performance using 3D explicit finite element analysis

Pressurized Heavy Water Reactors (PHWRs) utilize Zr-2.5 Nb pressure tubes that are connected to SS-403 end fittings through rolled joints. These rolled joints are made using a rolling tool equipped with five rollers and a tapered mandrel. The action of the rollers induces plastic deformation on the inner surface of the tube. The tapered mandrel promotes rotation and axial advancement of the rollers into the pressure tube through friction. However, prolonged usage of this rolling tool can lead to the wearing down of both the mandrel and the rollers. Consequently, this wear and tear can cause the rollers to deviate from their intended position within the rolled joint. Such misalignment can lead to excessive rolling of the pressure tube into the entry taper section of the end fitting. This, in turn, generates higher residual stresses than initially anticipated. This issue may also arise from accumulated tolerances within the rolling tool or positioning errors made by operators during the rolling operation. The overextension of the rollers can significantly increase tensile residual stresses within the pressure tube, and management of these stresses is critical to prevent failure of the pressure tube due to Delayed Hydrogen Cracking.The primary objective of the present investigation is to explore the effects of the overextension of rollers on the residual tensile stresses in the transition region of the rolled joint. This objective is achieved by employing a three-dimensional explicit finite element analysis methodology. In order to ensure the reliability and authenticity of the finite element model, the computational results are cross-validated with the experimental findings documented in the existing literature. The current investigation involves the examination of two distinct configurations of pressure tube to end fitting rolled joints, which are typically found in PHWRs. The results of the present inquiry reveal an optimal roller position that minimizes residual tensile stresses within the transition region of a rolled joint. Furthermore, it is observed that any deviations in the roller position within a range of 5 mm, beyond the optimal position, result in a negligible increase in residual tensile stress.

Multi-response Design optimization of Cardiovascular Catheters with Lasercut Hypotubes using Finite Element Analysis and Response Surface Methodology

Multi-response Design optimization of Cardiovascular Catheters with Lasercut Hypotubes using Finite Element Analysis and Response Surface Methodology

Fracture Energy Measurement in Different Concrete Grades

Fracture energy is regarded as an intrinsic (material) properties that dominates crack mechanisms and associated crack growth in concrete damage under applied stress. In recent times, significant advancements in computing technology have driven the adoption of finite element analysis (FEA) methodologies that necessitate the integration of constitutive models, includingthe traction-separation relationship derived from cutting-edge fracture mechanics. A physically-based model requires fracture energy values; therefore, a properly measured fracture energy value is essential to exhibit better structure response within FEA models. There are large arrays of parameters involved during the concrete mixture, such as beam size effect, aggregate size, and concrete grade, that affect the flexural resistance of the concrete. The fracture and failure in concrete ahead of the crack tip are represented by fracture energy values where micro-damage events such as interfacial failure, fiber-bridging, and matrix cracking occurred.This study aims to determinethe fracture energy of concrete specimens with combination of notch depth aoat mid-span, design concrete strength as specified in the testing series. Independent compression strength, fcand measured load-displacement profiles underathree-point bendingtest were used to determine fracture energy by incorporating three available fracture energy expressions such as Bazant, Hillerborg,and CEB-FIP models.

A Finite-Element Method for Enhancement Issues of Frame of Battery Operated Ridge Planter with Drip Line Installer

Using distinct partial differential equations, complicated structures breaks down into small elements using the computational approach known as finite element analysis (FEA). Engineers in agriculture can investigate the behavior of numerous input products using numerical simulation based on the FEA technique in order to enhance the design of any machine without constructing a prototype. The current study employed the FEA technique to develop and simulate the frame of a battery-operated ridge planter with a drip line installer. A static structural test was performed through using the FEA technique in the ANSYS version 15.0 workbench software, and a 3D-CAD model of the frame of a battery-operated ridge planter with drip line installer was made using the Solid Works software. To determine the force necessary in the universal testing machine and the applied forces, respectively, on the frame, a specific fixture has been generated.
 Total deformation was measured at 23313 mm, and the simulation revealed that the maximum shear stress, equivalent stress, normal stress, stress intensity, and strain energy were, respectively, 8.40 MPa, 16.68 MPa, 16.4 MPa, 16.8 MPa, and 3.55 MPa at 1817.5 N of total load acting on the frame.
 The stress values are within the material's yield strength, it was also observed. The FEA methodology was discovered to be a way for creating and simulating the frame of a battery-operated ridge planter with drip line installer that is very effective and scientific.

Optimization of Design and Performance of Medical Implants using FEA

In recent years, the optimization of medical implants to enhance their safety and functionality has emerged as a paramount concern in the biomedical field. This study elucidates a comprehensive approach to optimizing the design and performance of medical implants using Finite Element Analysis (FEA). The primary objective was to discern potential areas of stress concentration and deformation, consequently proposing modifications to existing designs. Various implant materials and geometries were explored, encompassing orthopaedic, dental, and cardiovascular applications. The research successfully employed a multi-phased FEA methodology that commenced with the development of an accurate model, followed by the application of realistic boundary conditions and subsequent simulation under physiological loads. Results consistently indicated that by leveraging FEA insights, it was possible to predict potential failure points and areas of undue stress, thereby guiding design modifications. Moreover, it was observed that the iterative design process, supplemented by FEA, led to implants that exhibited enhanced biocompatibility, reduced patient discomfort, and extended longevity. This paper underscores the potency of FEA as an indispensable tool for the evolution of medical implant designs, fostering a future where implant failures become a rarity rather than a risk.

Design and Analysis of the Wing Functioning as a Ramp for a Spitfire Flight Simulator

This paper designed and analysed the wing for a Spitfire Mk9 Flight Simulator using three-dimensional modeling, finite element analysis and fatigue analysis methodologies with 3D EXPERIENCE, ABAQUS/FE-SAFE software. The results demonstrated that by using the wing structure as the access ramp to the cockpit simulator, the accessibility, safety and structural integrity could be improved vastly in comparison with the existing Spitfire flight simulators.

Finite Element Analysis Methodology for Additive Manufactured Tooling Components

Fused deposition modeling (FDM) for additive manufacturing is constantly growing as an innovative process across the industry in areas of prototyping, tooling, and production parts across most manufacturing industry verticals such as Aerospace, Automotive, Agricultural, Healthcare, etc. One such application that is widely used is for tooling on the shop floor e.g. for pick-off tools, assembly fixtures etc. For tooling applications printing the solid fill component with +45/- 45 raster is common practice. There is a requirement for finite element analysis to validate the strength of 3D printed components for some specific applications in tooling, but due to the anisotropic behavior of 3D printed parts and the unavailability of all mechanical properties FE analysis of 3D printed parts is sometimes challenging. Advance approaches like multiscale modeling approach requires specialized & costly analytical tools. So, to understand the behavior of additively manufactured parts the team has conducted a few tests and compared the results. In this work, solid-filled dog-bone tensile test and three-point bending test specimens were printed with +45/-45 raster orientation and tested in the lab. Tensile test specimens were built with flat, on-edge, and up-right orientations and tested to determine the directional properties of young’s modulus. Using mechanical properties from the tension test 3 points bending test is simulated in FE software- ANSYS. The FE modeling was done in two ways, in first model orthotropic properties were assigned to the specimen, and for second model isotropic properties were assigned. For isotropic modeling least value of young’s modulus is used. Simulation results of three-point bending test shows that in the linear region of force-deflection curve, deformation values from FE model with both orthotropic and isotropic modeling are in good agreement with the experimental results. Also, the difference in stress results between isotropic and orthotropic FE model is almost negligible. To support this observation, study is performed for various conditions. The specimens were printed with ABS material on Ultimaker® and ASA material on Stratasys® Fortus 360mc™ machine with T12, T16 and T20 nozzle settings. Study shows, for tooling applications if the 3D printed solid-filled components are designed with a certain factor of safety then validating its strength with isotropic material properties will give acceptable results. The advantage of this approach is getting the isotropic mechanical properties is easy and modeling with FE modeling will be simple.

Finite element analysis of fracture behavior in ceramics: Competition between artificial notch and internal defects under three-point bending

Evaluation of the nonlinear relationship between the surface defect size and fracture strength of ceramics is important for engineering applications. In this study, we aim to predict the apparent nonlinear relationship between the defect size and fracture strength of single-edge notched beams (SENBs) using the finite element method. Specifically, we applied the methodology for predicting fracture strength from microstructure distribution data (relative density, pore size, aspect ratio, and grain size) to a finite element analysis (FEA) model in which the shape and size of the initial defects are defined at notch locations. By reproducing the apparent nonlinearity caused by the competition between the surface and internal defects within the framework of linear elastic fracture mechanics, the effectiveness of the FEA methodology for the evaluation of strength scatter and allowable crack size in ceramics was demonstrated.