Finite Element Analysis Results Research Articles

Flexible pressure sensor based on CNTs/CB/PDMS sponge with porous and microdome structures for sitting posture discrimination

The application fields of flexible pressure sensors are constantly expanding benefiting from their characteristics of being lightweight, flexible, easy to install, etc. Various structures have been developed for the purpose of improving the sensing performances of these sensors. However, the traditional structure designs typically enhance only a single aspect of performance. In this study, a flexible pressure sensor based on carbon nanotubes (CNTs)/carbon black (CB)/polydimethylsiloxane (PDMS) conductive sponge (CCPS) with both porous and microdome dual microstructures is prepared through the double template and swelling ultrasound methods. The introduction of two microstructures leads to the synergistic effect of dual sensing mechanisms, and the dual sensing mechanisms have been discussed according to the changes in microstructure morphology and finite element analysis results. Thanks to the synergistic effect of dual sensing mechanisms, CCPS exhibits comprehensive pressure sensing performances including a wide pressure sensing range of more than 350 kPa, high sensitivity under low pressure (7.10 kPa−1 over 0–25 kPa, 2.96 kPa−1 over 25–135 kPa, 1.09 kPa−1 over 135 kPa), and satisfactory long-term using performance of over 2000 cycles. CCPS is finally demonstrated for applications such as human motion detection, Morse code, and sitting position discrimination, indicating its broad application possibilities.

Investigation on the cyclic buckling and plastic overstrength characteristics of steel shear links utilizing corrugated panels

This paper established and validated the finite element model (FEM) for novel steel shear links utilizing corrugated panels (CSSL), analyzed the stress and strain distributions of CSSL, and summarized the buckling characteristics and determination criteria for CSSL. Utilizing the FEM, the influence of CSSL configuration parameters on its buckling deformation capacity and plastic overstrength characteristics were analyzed. The analysis results indicated that: the decrease in the corrugated panel's sub-panel slenderness a/tw could significantly improve the buckling deformation capacity of CSSL, but had little influence on pre-buckling plastic overstrength characteristics; the decrease in sub-panel aspect ratio h/a and web aspect ratio e/h, as well as the increase in web corrugation angle θ was beneficial for the buckling deformation capacity of CSSL, but might decrease the plastic overstrength characteristics; the decrease in the equivalent links length coefficient eVp/Mp and the increase in structural steel strain-hardening value α had a slight influence on the buckling deformation capacity, but could significantly improve the plastic overstrength characteristics. Based on the analysis result, a theoretical prediction approach for the buckling deformation capacity and plastic overstrength characteristics was proposed, and the load-deformation skeleton curve model was also established, which was validated to exhibit good accuracy with compassion to experimental and finite element analysis results.

Research on the Technology of a Compact Double-Layer Multispectral Filter-Wheel Mechanism Driven by a Single Motor

Spatial multispectral imaging technology can selectively image in specific spectral bands, and the filter wheel is a core component for multispectral selection. At present, there are relatively few types of spectral bands for the filter wheel under limited space/weight constraints. Addressing the challenges presented by this issue, this paper introduces an innovative design approach for the development of a double-layer or even multi-layer filter wheel that is operated by a solitary motor in conjunction with a differential gear mechanism, enabling a vast array of spectral segment combinations within a highly compact layout. A detailed design is implemented for the double-layer filter wheel, including comprehensive modal and dynamic analyses. The results of the modal analysis attested to the structural stability of the component, and the outcomes of the dynamic analysis validated the component’s timely and reliable switching capabilities. A prototype was meticulously crafted and subjected to rigorous testing. The switching functionality was validated during these tests, concurrently affirming the accuracy of the finite element analysis results. Additionally, spectral and application testing confirmed the number of spectral segments and the practical utility of the components. The research presented in this article introduces an innovative design concept for multispectral imaging filter-wheel mechanisms, providing a valuable reference and profound insights for the design and arrangement of a double-layer or even multi-layer filter wheel.

Assessing running safety of high-speed trains on long-span cable-stayed bridges based on in-situ monitoring data

This paper presents a new method for assessing the running safety of high-speed trains passing through long-span cable-stayed bridges based on in-situ monitoring data. The monitoring data include the girder vertical deflection and girder-end rotation of bridges. Vertical deformation is utilized to derive the vertical acceleration formula of high-speed trains, and girder-end rotation is utilized to judge the arrival time of the train. According to the specified vertical acceleration limit of the train, the vertical deflection threshold of the bridge is derived from the vertical acceleration formula. The first derivative of the sinusoidal half-wave function of the side-span is utilized to obtain the girder-end rotation threshold, and the safety threshold system is established. The bridge deformation safety threshold system is then used to assess the running safety of the bridge. To verify the presented method, the bridge deformation thresholds calculated using the proposed method are compared with finite element analysis results. The proposed method avoids complex train-bridge coupling numerical simulation in acquiring the dynamic response of high-speed trains, largely improving computation efficiency and enabling real-time assessment of train safety.

A burst capacity model for pipelines containing pinhole-in-corrosion defects

This study develops a practical burst capacity model for oil and gas pipelines containing pinhole-in-corrosion (PIC) defects based on results of extensive parametric three-dimensional finite element analyses (FEA) that are validated by full-scale burst tests of corroded pipe specimens reported in the literature. The PIC defect considered in this study contains a cylindrical-shaped pinhole located inside a cuboidal-shaped general corrosion. The proposed model takes the form of the well-known PCORRC model for the burst capacity of the general corrosion plus a correction term taking into account the impact of the pinhole, whereby the correction term is evaluated as a function of the depth and length of the general corrosion as well as the depth and relative position of the pinhole using the Gaussian process regression based on the results of parametric FEA. The accuracy of the proposed PIC model is demonstrated using 16 FEA cases and shown to be higher than that of the well-known RSTRENG model and a burst capacity model for complex-shaped corrosion defects reported in the recent literature.

Line Scanning Thermography for Rail Base Defect Detection

Rail base defects present significant maintenance challenges within the railway industry, as they are difficult to detect before they lead to failure. While various in-motion nondestructive evaluation (NDE) methods exist for inspecting rail, none of the existing NDE methods can inspect the rail base area reliably and efficiently. This paper presents finite element analysis (FEA) and experimental results applying a line scanning thermography (LST) approach developed for rail base area inspection. This work demonstrates the LST approach for dynamic inspection of thick steel components containing surface and subsurface anomalies. Initially, FEA was used to help design the experimental setup, then to compare trends in surface temperature variations with those from experimental trials. Through motorized testing, test specimens were moved through a region heated by three stationary line heaters, utilizing LST to capture temperature variations on the surface of each sample. The results have shown that subsurface features 6.3 mm in diameter and with aspect ratios greater than 1.5 were detectable in all specimens. This is a promising development that warrants further study.

Dynamic optimization design of thin plate structure based on surrogate model

Abstract To enhance dynamic optimization efficiency in traditional thin plate structures, surrogate models are integrated for structural dynamic size optimization, reducing dependence on high-precision finite element simulations. This paper focuses on optimizing the aluminum alloy sheet as the subject of research. The parameters of the specimen are optimized through sensitivity analysis, based on the comparison between the free mode Finite Element Analysis (FEA) and Experimental Modal Analysis (EMA) results. The modified specimen undergoes validation under a four-edge clamped boundary condition. Subsequently, random vibration analysis is conducted to determine the root mean square (RMS) value of the acceleration response. Employing surrogate model technology, four models are constructed using parametric modeling and experimental design methods. These models are then compared for their fitting effectiveness. The results indicate that the RBF model exhibits the highest accuracy in fitting each response, effectively replacing dynamic simulation. Finally, the RBF combined with the NSGA-II method, optimizes the specimen’s structural size, resulting in a 21.6% reduction in mass and an 18.60% decrease in acceleration response. These outcomes demonstrate satisfactory optimization results, ensuring accuracy while enhancing the dynamic characteristics of the specimen structure. This research offers valuable insights for related engineering applications.

Biomechanical analysis of different techniques for residual bone defect from tibial plateau bone cyst in total knee arthroplasty.

In patients with tibial plateau bone cysts undergoing total knee arthroplasty (TKA), bone defects commonly occur following tibial plateau resection. Current strategies for addressing these defects include bone grafting, bone cement filling, and the cement-screw technique. However, there remains no consensus on the optimal approach to achieve the best surgical outcomes. This study aims to evaluate the most effective repair method for residual bone defects following tibial plateau bone cyst repair during TKA from a biomechanical perspective. The treatment options for tibial plateau bone defects were classified into four categories: no treatment, cancellous bone filling, bone cement filling, and the cement-screw technique. Finite-element analysis (FEA) was employed to evaluate stress distribution and displacement across the models for each treatment group. In addition, static compression mechanical tests were used to assess the displacement of the models within each group. FEA results indicate that when employing the cement-screw technique to repair tibial plateau bone defects, the maximum stress on the prosthesis and the cement below the prosthesis is minimized, while the maximum stress on the cancellous bone is maximized. And the displacement of each component is minimized. Biomechanical tests results further demonstrate that the displacement of the model is minimized when utilizing the cement-screw technique for tibial plateau bone defects. Using cement-screw technique in treating residual tibial bone defects due to bone cysts in TKA offers optimal biomechanical advantages.

Wireless vibration testing and bridge deck damage identification using underneath maintenance walkway

Bridges will inevitably experience structural damage during long-term operation, which will decrease their structural load bearing capacity and durability. The vibration characteristics of bridge structures can be used as evaluation indicators for accurately diagnosing their deterioration. This study aimed at developing a vibration testing method for identifying bridge deck damage that does not affect traffic and is easy to implement. The vibration tests on the in-service bridge revealed it was mainly subjected to vertical vibrations, with the accelerations in the vertical direction about twice those in the horizontal direction. Based on fast Fourier transform analysis, the dominant vertical vibration frequencies were 2.34 Hz, 4.10 Hz, 10.30 Hz, 14.45 Hz and 18.75 Hz. A series of 0.1–0.3 Hz bandpass filters were used with those frequencies at the centers for modal analysis. The experimental results were then compared to the finite element analysis results. This study proposed a vibration-based damage identification method based on the differences between the bridge deck and both main steel girders. The study confirmed the convenience and effectiveness of using underneath maintenance walkways for wireless vibration testing.

Axial compressive properties of round bamboo-fiber reinforced phosphogypsum composite short columns

Bamboo is an ideal green building material with excellent mechanical properties. Phosphogypsum (PG) is a kind of solid waste residue which is in urgent need of resource utilization and has been used as construction material. In this paper, a kind of round bamboo-fiber reinforced phosphogypsum composite short column was proposed. Axial compression tests of pure bamboo columns, bamboo columns filled with phosphogypsum inside, bamboo columns with phosphogypsum outside and bamboo columns with phosphogypsum inside and outside were carried out to explore the failure mode and mechanical properties of the short columns. The effects of the parameters include bamboo node, hose hoops, size of the bamboo tube and the strength of phosphogypsum on the mechanical properties of the short columns were analyzed, and the theoretical calculation method of the bearing capacity of the short columns was put forward. The results show that the bamboo nodes and hose hoops can improve the bearing capacity, initial stiffness and ductility of the column. The larger the size of the bamboo tube, the better the mechanical properties of the short column. The bearing capacity of round bamboo—phosphogypsum composite short column is higher than that of pure bamboo column. The ductility of bamboo columns with phosphogypsum outside is obviously higher than that of pure bamboo columns. The finite element analysis results are in good agreement with the test results. The theoretical calculation method of the bearing capacity of columns considering the strength reduction coefficient, the bamboo node effect coefficient and the constraint effect in this paper has high accuracy.

Experimental and numerical investigation of novel triangular headed one-sided bolted T-stub connections

The reliable one-sided bolts constitute a vital component of fully bolted joints in demountable steel structures. In this study, an innovative triangular headed one-sided bolt (THOB) based on the traditional hexagon headed bolt (HHB) was proposed, and the tensile performance of T-stubs using the THOBs has been investigated through experimental and numerical approaches. Monotonic tensile tests were performed on 25 THOB bolted T-stubs to analyze the failure modes and load-carrying performance of the specimens. The test results disclosed that, beyond the three typical failure modes stipulated in the Eurocode 3, the specimens exhibited a characteristic failure mode, namely, limit groove pull-off failure. Finite element models, validated by the test results, were employed for the parametric analysis to compare the load-carrying performance of THOB bolted T-stubs with that of HHB bolted T-stubs. The finite element analysis results indicated that the average ratio of the plastic load-carrying capacity of THOB bolted T-stubs to HHB bolted T-stubs was close to 0.88. Furthermore, the load-carrying capacity of THOB bolted T-stubs was evaluated using existing specifications for comparison with the experimental and numerical results, and Eurocode 3 calculations for the plastic load-carrying capacities of THOB bolted T-stubs demonstrated a commendable level of precision. Finally design recommendations were put forward based on the test and finite element analysis results.

Single missing molar with wide mesiodistal length restored using a single or double implant-supported crown: A self-controlled case report and 3D finite element analysis.

Based on a self-controlled case, this study evaluated the finite element analysis (FEA) results of a single missing molar with wide mesiodistal length (MDL) restored by a single or double implant-supported crown. A case of a missing bilateral mandibular first molar with wide MDL was restored using a single or double implant-supported crown. The implant survival and peri-implant bone were compared. FEA was conducted in coordination with the case using eight models with different MDLs (12, 13, 14, and 15 mm). Von Mises stress was calculated in the FEA to evaluate the biomechanical responses of the implants under increasing vertical and lateral loading, including the stress values of the implant, abutment, screw, crown, and cortical bone. The restorations on the left and right sides supported by double implants have been used for 6 and 12 years, respectively, and so far have shown excellent osseointegration radiographically.The von Mises stress calculated in the FEA showed that when the MDL was >14 mm, both the bone and prosthetic components bore more stress in the single implant-supported strategy. The strength was 188.62-201.37 MPa and 201.85-215.9 MPa when the MDL was 14 mm and 15 mm, respectively, which significantly exceeded the allowable yield stress (180 MPa). Compared with the single implant-supported crown, the double implant-supported crown reduced peri-implant bone stress and produced a more appropriate stress transfer model at the implant-bone interface when the MDL of the single missing molar was ≥14 mm.

A single-cell 3D dynamic volume control system for chondrocytes.

In articular cartilage, zone-specific cellular morphology is a typical characteristic of cartilage tissue, which is related with chondrocyte function, inflammation and osteoarthritis (OA). Chondrocyte hypertrophic phenotype is a criticle physiological process which indicates a hallmark of chondrocyte terminal differentiation and bone formation. Thus, developing a in vitro cell culture system for dynamic regulation of single chondrocyte volume at a three-dimensional (3D) level is particularly necessary for understanding how physical cues of matrix microenvironment regulate chondrocyte fate and the degeneration of articular cartilage. Here, based on the soft lithography techniques, we have constructed well-defined single-cell 3D dynamic volume control system to recapitulate the physiological matrix microenvironment of single chondrocyte niche. The results of finite element analysis indicated that the stress and strain distribution in the cell culture region is homogeneous during the stretching process. Additionally, 3D dynamic volume expansion and compression of single cells in physiological or hyperphysiological can be realized in this cell culture system. Our device for single-cell 3D dynamic culture provides a microphysiological culture system for chondrocytes to explore the mechanisms of cartilage hypertrophy, as well as develops a new paradigm for functional cartilage tissue engineering and regenerative medicine.

3D bi-directional auxetic square metastructure with programmable thermal expansion and Poisson's ratio

Multifunctional integration research on metastructures has become the current development trend and hotspot, especially satellite platforms and hypersonic aircraft in the aerospace field. A 3D bi-directional auxetic square metastructure (BASM) with the programmable coefficient of thermal expansion (CTE) and Poisson's ratio (PR) is designed through the combination of re-entrant hexagonal structures and bi-material triangles. Specimens in the form of the 1*2 array are designed and fabricated through 3D printing. The correctness of the results of finite element analysis (FEA) of the BASM is verified by uniaxial compression experiments. Additionally, FEA is adopted to investigate the effective mechanical properties of the BASM with the form of the 2*3 array, and deformation mechanisms are further explored. Results indicate that the CTE, PR, and stiffness of the BASM depend on material combinations and geometric parameters. Under thermal and mechanical loads, the BASM achieves bi-directional regulation of the CTE and PR, encompassing both axial and circumferential deformations. Notably, the deformation mechanisms and critical conditions of the BASM are explored under the thermo-mechanical load. A novel strategy for programming the PR of the BASM is proposed in addition to changing the geometric parameters and the material combinations.

Ultimate strength assessment of randomly pitted stiffened panels considering stiffener corrosion

Stiffened panels are renowned for their exceptional load-bearing capabilities due to their high strength-to-weight ratio and are extensively utilized in ship and marine structures. Nevertheless, they are susceptible to failure under compression, particularly in marine environments where corrosion leads to material and structural degradation. Stiffener corrosion was not involved adequately in current studies, with an unclear synergistic effect of corrosion damage with structural configurations. This paper introduces a numerical modeling approach to develop finite element (FE) models of panels with random pitting corrosion, considering both corrosion on the plating and stiffeners. These FE models are validated against existing experiments and empirical formulae and employed to investigate the effect of random pitting damage on the ultimate strength of panels. The study examines the impact of various structural parameters, such as plate aspect ratio, plate slenderness ratio, stiffener slenderness ratio, and the height-to-thickness ratio of stiffener web, on ultimate strength under different levels of pitting damage. Additionally, the load-bearing behavior and failure modes of damaged panels are analyzed. An artificial neural network (ANN) is developed to predict the ultimate strength of pitted panels. The findings indicate that the ultimate strength of panels with stiffener corrosion in the form of random pitting corrosion leads to a more significant reduction by about 17.7% than that without stiffener corrosion, potentially altering the failure mode. The proposed ANN model accurately predicts the ultimate strength of pitted panels with and without stiffener corrosion, with a mean relative error of approximately 1.1% compared to FE analysis results.

Quantitative mechanism of abnormal hardening behavior of Ti6Al4V alloy strengthened by ultrasonic surface rolling

In general, the outermost region of a metallic material has the highest hardness after surface mechanical strengthening. However, an abnormal surface hardening behavior was observed in Ti6Al4V alloy after the ultrasonic surface rolling process (USRP) in this work. The region with the highest surface hardening was not at the top surface but at the subsurface. By analyzing the distribution of grain size, dislocation density, texture, and kernel average misorientation (KAM) at different depths from the surface, and combining these findings with finite element analysis (FEA), the microstructural evolution underlying this abnormal surface hardening was elucidated. The microstructural characterization and FEA results indicate that the subsurface region underwent the most significant deformation. Subsequently, through the application of theoretical analysis, the potential mechanism of abnormal hardening of USRP treatment is described quantitatively for the first time. The results demonstrated that the hardening effect resulting from grain refinement was less pronounced, whereas the hardening effect resulting from dislocation pile-up was more prevalent. At the subsurface region of the USRP sample, a large number of interfaces resulted in the highest accumulation of dislocations in this area. Consequently, the subsurface region exhibited the highest microhardness, leading to the abnormal surface hardening phenomenon.

Aircraft Structural Assessments in Data-Limited Environments: A Validated FE Method

Aircraft operators often modify aircraft configurations, install new equipment, and alter airframes to accommodate this equipment, leading to operations in flight envelopes different from original design profile. These modifications necessitate airframe structural assessments, which typically require comprehensive aircraft design data, often unavailable to operators. This study aims to develop and validate a practical method for finite element analysis (FEA) of aircraft structures in the absence of this detailed design data. Focusing on a case study involving structural analysis of an aircraft wing, this study presents assumptions and idealizations used to develop 2.5D finite element (FE) model of the wing. Fidelity of this model is established by comparing FE analysis results with experimental data. Key validation metrics include reaction forces, load distribution at wing-fuselage attachments, and deformation at reference points on the wing under design load. Comparison between FE analysis and experimental results is carried out to substantiates accuracy of these geometric simplifications and idealizations of load-carrying behaviour of structural members. Therefore, practicality of these idealizations in absence of design data is demonstrated. This study offers a novel approach for structural assessments of aircraft without relying on proprietary design data. The validated method enhances capability of aircraft operators to perform effective structural analyses, thereby extending service life of aircraft with continued airworthiness.

Flow behaviors of various metals under tensile load

Abstract The influence of flow behaviors on the results of finite element (FE) analyses of metal-forming processes is dominant, even though it varies with strain hardening and softening phenomena. However, obtaining a flow curve with sufficient accuracy is not easy, particularly at large strains. Among various well-known methods of obtaining flow curves, tensile testing-based method is effective to obtain flow curves at large strains at room temperature. It is believed that the strain hardening behavior at large strains during the tensile test was not fully known. In this study, the flow curves, previously obtained using the combined tensile test and finite element method (FEM) approach, are classified as four categories, including monotonic strain hardening function, double-curvature strain hardening function, strain hardening-perfectly-plastic function, and perfectly-plastic-strain softening function. The tensile test characteristics of each type are investigated using its FE predictions, revealing that the specific type of a material can be identified by the tensile test.

Simplified modeling study of the forward fuselage structure based on the overall structural rapid design software for civil aircraft

Abstract In order to solve the problems of poor weight estimation accuracy and difficult layout design trade-offs in the concept demonstration and overall program definition stage of civil aircraft, Aircraft Layout, a civil aircraft overall program structure rapid design software, is used to establish a numerical calculation-based layout program rapid design simulation platform. Based on the forward fuselage structure, this paper gives the results of rapid modeling and finite element simulation and analysis of the forward fuselage isotropic section of a certain type of aircraft, which provides a reference for the optimization design of the structural components of the forward fuselage section of a certain type of aircraft in the conceptual scheme design stage.

Exploring FEA Techniques for Bending Rectangular Glass Plates into Parabolic Shapes

Abstract: A structural Finite Element Analysis (FEA) was conducted, incorporating both linear and nonlinear analysis. The investigation considered geometric nonlinearity, material nonlinearity, and boundary nonlinearity, also known as contact analysis. All boundary conditions, loadings, and material properties used in the analysis were based on real-world conditions. Experimental validations were performed to confirm the accuracy of the FEA results, providing strong confidence in the investigation's findings.