Finite Element Model Analysis Research Articles

Finite element simulation and experiment of residual stress evolution in MEMS structures

The MEMS device structure is usually formed by the combination of thick film and thin film deposition of many different materials, and the residual stress generated in the process of integration/superposition of different materials has a significant impact on the performance and reliability of the device.In this study, a test structure of a multilayer thin film was designed and processed. Based on this, finite element modeling analysis and reliability experiment, analyze the evolution of residual stress and construct the corresponding theoretical analysis model. The finite element modeling analysis can characterize the evolution and distribution laws of residual stress. The reliability experiment is mainly by carrying out the temperature shock experiment, and measuring the resistance value, resonance frequency and the surface morphology of the device, so as to better reflect the change of residual stress. Through this study, the resonant frequency and surface morphology of the device can reflect the residual stress of the device, which provides help for the test and analysis of the residual stress. To a certain extent, it can help reduce the harm caused by the residual stress in the design and manufacturing process, and improve the performance and reliability of MEMS devices.

Researching the force absorption system for the front of the passenger car to secure the driver

Protecting the safety of drivers in the bus is very important and necessary in front collisions. This research on the system shock absorber and absorption of force bus head in front collisions. This design will protect bus heads not violations in safe spaces and protect drivers in front collisions. The finite element model and safety analysis simulation of the system shock absorber and absorption of force by LS – DYNA and MADYMO software. The study’s results show shock absorber structure ensures durability. The head part index is down 35%. The neck part index is down 28%. Drivers are protected more safely. Injury values of driver satisfy safety ECE R94 standard in bus front collision. Keywords: ECE R94 standard, MADYMO software, LS - DYNA software, collision, injury.

Milling of additively manufactured AlSi10Mg with microstructural porosity defects, finite element modeling and experimental analysis

Metal additive manufacturing finds its applications in various sectors, especially the automotive and aerospace industries, wherein weight reduction of components is of paramount importance with respect to performance and fuel consumption. However, additively manufactured metallic components usually undergo post-processing steps to make them ready for end use application. One of these steps is finish machining that is employed to overcome the surface irregularities and poor tolerances produced as a result of additive manufacturing (AM). These finish machining processes involve turning, milling, drilling, reaming, or grinding. This paper presents a three-dimensional (3D) finite element (FE) model to simulate the chip formation during the milling of an AM aluminum alloy AlSi10Mg, while taking microstructural porosity defects into consideration. The material was chosen for its significance in the aerospace and automotive industries. The proposed numerical model was developed using ABAQUS™ and is capable of predicting the cutting forces during the milling of AM AlSi10Mg. The Johnson-Cook strength and fracture models were utilized to simulate the deformation mechanics of the workpiece material subjected to high strains, high strain rates, and high temperatures caused by machining. Two algorithms have been proposed and discussed to model the microstructural defects in the AM metal. Machining tests were performed on an AM AlSi10Mg specimen block to validate the proposed finite element model. To further demonstrate the capability of the proposed model in capturing the influence of porosity on cutting forces, a study has been conducted revolving around the impact of different pore sizes. The chips produced during the machining tests were also collected to compare the morphologies between the numerically simulated chips and the ones obtained experimentally, to further strengthen the validity of the proposed model.

Finite element model analysis of long-term performance of composite anchorage based on double-material parameters

Carbon fibre-reinforced polymer (CFRP) tendons demonstrate the advantages of light weight, high strength, and superior corrosion resistance and have broad application prospects for long-span cable structures. However, given the low transverse shear strength of CFRP tendons, how to achieve long-term and reliable anchorage for CFRP tendons is a critical issue. The long-term performance (LTP) of a novel composite anchorage for CFRP tendon was assessed in this study. Then, a finite element model (FEM) with double-material creep parameters was established to reliably model the LTP experiment according to the creep parameters of the bonding medium and CFRP tendon. Finally, the effects of the free section tendon length, pre-tightening force, over-tensioning force, and elastic modulus of the bonding medium were analysed using the established FEM with double-material creep parameters. Results revealed no visible damage to the CFRP tendon and anchorage after the LTP experiment. The maximum tendon slippage was 0.054 mm, and the residual load ratio was 0.826. These phenomena indicate that the novel composite anchorage has excellent LTP. The FEM modelling results based on double-material creep parameters were in good agreement with the experiment results. The residual load ratio calculated by the FEM was 1% lower than the experimental value. Through the parameter analysis, the residual load ratio of the specimen was effectively improved under longer free section tendon condition, but tendon slippage increased to a certain extent. In addition, the LTP of the composite anchorage can be effectively improved by appropriately decreasing pre-tightening force and over-tensioning force. When the over-tensioning force was 1.4 times the test load, the tendon slippage was reduced by 34.2%, and the residual load ratio increased by 4.8%. The greater elastic modulus of the bonding medium in the range of 2.1 GPa–3.1 GPa, the worse the LTP of the composite anchorage.

Novel approach to the derivation of dam breach parameters in 2D hydrodynamic modeling of earthquake induced dam failures

Current methods of dam breach analyses adopt a deterministic approach. Applying these methods to Concrete Faced Rockfill Dams (CFRD) is fraught with huge levels of uncertainty, especially in the context of natural hazards. The frequency and magnitude of rainfall and earthquakes are higher in today's world. In the literature, the complete collapse of dams is modelled on dam breach parameters that define the dam break outflow but are not related to the return periods of natural hazards. As more new dams are constructed to control the floods in intra-plate seismic regions, this study presents a novel approach to the derivation of generalized dam break parameters for CFRD based on the structural analysis of Finite Element Model (FEM) simulations for peak ground accelerations corresponding to 475 and 2475 year return periods. Furthermore, the occurrence of rainfall and earthquake for different return periods are modelled using 2D hydrodynamic simulations. Results show the significance of generalized dam breach parameters for planning and managing CFRDs during earthquakes. The study emphasizes the utilization of structural analysis outputs for the hydraulic modeling of dam breaks, which will result in more specific and accurate dam break parameters. Additionally, the study has shown that the flood risk and the severity will increase with the intensity of earthquake and rainfall magnitudes. Disaster mitigation strategies can be optimized by considering the integrated occurrence of rainfall and earthquakes based on the probability of occurrence, demonstrated using a case-study dam. Another significant outcome of the study is the effect of soil saturation condition during a dam break, which reveals that areas within 40 km of the dam breach location might be worst affected.

Characterizing ABS–copper chemistry-dependent adhesion: From the atomic to macro level

The electroplating of copper layers on acrylonitrile–butadiene–styrene (ABS) polymer surfaces is a common need in industrial applications. The development of new eco-friendly techniques to promote ABS–copper adhesion is crucial due to the harsh and expensive chemicals used in the existing processes. The initial path involves establishing a better understanding on chemistry-dependent ABS–copper adhesion mechanisms. By formulating the material with more functional groups, the adhesion between ABS and the coated copper layer was characterized through a multiscale approach. At the atomic scale, we performed ab initio density functional theory simulations to obtain the variations in the adsorption energy. At the nano and micro scales, we adopted atomic force microscopy to measure the adhesion forces on the bulk polymer surfaces. At the macro scale, we compared these adhesion results with both 90-degree peeling tests and finite element model analyses. This study presents the first comprehensive approach for bridging information gaps across the scales (from nano to macro) with computational and experimental data, facilitating the design of formulated ABS additives.

Finite Element modeling and convergence analysis of a new Biomimetic Branching Structure.

Branching structures are gaining popularity in the field of advanced structures and building design; they offer high performance in terms of strength and lightweight design, along with the flexibility and precision enabled by modern processing technologies like Additive Manufacturing. This paper provides a concise overview of a geometric design procedure for a novel ribbed class of structures which was previously developed by the authors as a biomimetic optimal Micro-architected dome. Hereinafter, linear lattice models are suggested to carry out structural calculations using the finite element method (FEM). The objective is to examine discretization thresholding and strain energy convergence criteria. Results show that convergence is reached for numbers of elements per leg, ranging from 2 to 6, depending on the geometrical configuration of the dome being studied. The strain energy balance also exposes the influence of each internal force on the total mechanical response of the structure, pinpointing bending moment and axial force as the main decisive factors. As a perspective, the study will focus on limit state design calculations and Analysis of how the local geometry influences the overall stability and strength of this new design.

Machine Learning approaches for the design of biomechanically compatible bone tissue engineering scaffolds

Triply-Periodic Minimal Surfaces (TPMS) analytical formulation does not provide a direct correlation between the input parameters (analytical) and the mechanical and morphological properties of the structure. In this work, we created a dataset with more than one thousand TPMS scaffolds for the training of Machine Learning (ML) models able to find such correlation. Finite Element Modeling and image analysis have been used to characterize the scaffolds. In particular, we trained three different ML models, exploring both a linear and non-linear approach, to select the features able to predict the input parameters. Furthermore, the features used for the prediction can be selected in three different modes: i) fully automatic, through a greedy algorithm, ii) arbitrarily, by the user and iii) in a combination of the two above methods: i.e. partially automatic and partially through a user-selection. The latter, coupled with the non-linear ML model, exhibits a median error less than 3% and a determination coefficient higher than 0.89 for each of the selected features, and all of them are accessible during the design phase. This approach has been applied to the design of a hydroxyapatite TPMS scaffolds with prescribed properties obtained from a real trabecular-like hydroxyapatite scaffold. The obtained results demonstrate that the ML model can effectively design a TPMS scaffold with prescribed features on the basis of biomechanical, mechanobiology and technological constraints.

Impact of Sacroiliac Interosseous Ligament Tension and Laxity on the Biomechanics of the Lumbar Spine: A Finite Element Study

ObjectiveTo investigate the influence of sacroiliac interosseous ligament tension and laxity on the biomechanics of the lumbar spine. MethodsA static analysis of a three-dimensional finite element model of the Lumbar-Pelvic (L3-P) is conducted to verify the model's effectiveness. Adjusting the sacroiliac ligament's elasticity modulus under a 10Nm lumbar flexion/extension moment, it simulates ligament tension/laxity to calculate vertebrae displacements, intervertebral disc stress and deformation, nucleus pulposus pressure, facet joint force, and ligament stress. ResultsWith the elastic modulus of the sacroiliac ligament changing by +50%, -50%, and -90%, the angular displacement of vertebra 3 in forward flexion changes by +1.64%, -4.84%, and -42.3%, and the line displacements change by +5.7%, -16.4%, and -144.9%, respectively; and the angular displacements in backward extension change by +0.2%, -0.6%, -5.9%, and the line displacements change by +5.5%, -14.3%, and -125.8%. However, the angular displacement and center distance between adjacent vertebrae do not change, leading to no change in the maximum stress of the intervertebral disc and the maximum pressure in the nucleus pulposus. Flexion and extension directly affect the deformation and stress magnitude and distribution in the lumbar spine. ConclusionWhile sacroiliac interosseous ligament laxity and tension have little effect on disc deformation and stress, and nucleus pulposus pressure, they reduce the stability of the lumbar-sacral vertebrae. In a forward flexion state, the lumbar ligaments bear a large load and are prone to laxity, thereby increasing the risk of lumbar injury.

Modal Analysis of Combustion Chamber Acoustic Resonance to Reduce High-Frequency Combustion Noise in Pre-Chamber Jet Ignition Combustion Engines

<div>The notable increase in combustion noise in the 7–10 kHz band has become an issue in the development of pre-chamber jet ignition combustion gasoline engines that aim for enhanced thermal efficiency. Combustion noise in such a high-frequency band is often an issue in diesel engine development and is known to be due to resonance in the combustion chamber. However, there are few cases of it becoming a serious issue in gasoline engines, and effective countermeasures have not been established. The authors therefore decided to elucidate the mechanism of high-frequency combustion noise generation specific to this engine, and to investigate effective countermeasures. As the first step, in order to analyze the combustion chamber resonance modes of this engine in detail, calculation analysis using a finite element model and experimental modal analysis using an acoustic excitation speaker were conducted. As a result, it was found that there are two combustion chamber resonance modes in the 7–10 kHz band, both of which affect the high-frequency oscillation of the in-cylinder pressure. Both resonant modes have mode shapes that form a single nodal plane in the diametrical direction including the central axis of the cylinder, but the orientations of those nodal planes differ by 90 degrees. In addition, the two resonance frequencies are influenced by not only the bore diameter, temperature, and heat capacity ratio, but also the spatial shape of the combustion chamber. Therefore, when the piston descends and the spatial shape of the combustion chamber changes, the resonance frequencies change as well.</div>

Effect of external magnetic field on electric current-induced fracture of notched thin metallic conductors: Part 2- High magnetic fields

In the companion report (Telpande et al., n.d.), we discussed the impact of a weak external magnetic field (up to 0.4 T) on the electric current-induced fracture of pre-notched thin metallic conductors, revealing a linear decrease in critical current density, jc, necessary for crack propagation. This study extends the investigation to explore the effects of stronger external magnetic fields (0.6–1 T) on the fracture of pre-notched, current-carrying metallic foils. The experimental analysis reveals a substantial, albeit linear, drop (up to 40 %) in jc under stronger magnetic fields. Interestingly, calculations of the dynamic stress intensity factor, KIE,t, which assesses the interplay between applied current density and external magnetic field, indicate crack growth under a strong magnetic field even when KIE,t is below the plane stress critical stress intensity factor, KIC. A remarkable phenomenon emerges: the application of electric current pulses combined with strong external magnetic fields induces observable surface undulations near the notch tip. A comprehensive 3D finite element model, integrating linear and nonlinear buckling analyses under multiphysics stimuli, attributes these undulations to localized buckling near the notch tip. This buckling-induced stress redistribution near the crack tip contributes to an overall reduction in fracture toughness due to mode mixity, leading to the fracture of the Al foil below KIC. This investigation, along with the companion report (Telpande et al., n.d.), significantly advances our understanding of the effects of magnetic fields on the fracture of current-carrying conductors.

A hybrid self-centering seismic damper: Finite element modeling and parametric analysis

This study presents a finite element model for a hybrid self-centering damper considering the rate and temperature effects and explores the effects of different design parameters on the damper response. The damper, called as superelastic friction damper (SFD), consists of superelastic shape memory alloy (SMA) cables and a frictional energy dissipation mechanism. The experimental response of the SMA cables, frictional unit and overall damper at different loading frequencies and temperature are used to develop numerical model of the damper. Once a validated numerical model is obtained, parametric studies are carried out to evaluate force-displacement response of the damper when the design parameters are altered. The effects of damper design parameters on the equivalent stiffness, dissipated energy, equivalent viscous damping and self-centering capabilities of the damper are analyzed. Based on the findings, the recommendations for the design of the damper are presented.

The effect of enhanced structure in the posterior segment of clear aligners during anterior retraction: a three-dimensional finite element and experimental model analysis

BackgroundMesial tipping of posterior teeth occurs frequently during space closure with clear aligners (CAs). In this study, we proposed a new modification of CA by localized thickening of the aligner to form the enhanced structure and investigate its biomechanical effect during anterior retraction.MethodsTwo methods were employed in this study. First, a finite element (FE) model was constructed, which included alveolar bone, the first premolars extracted maxillary dentition, periodontal ligaments (PDL), attachments and aligners. The second method involved an experimental model—a measuring device using multi-axis transducers and vacuum thermoforming aligners. Two groups were formed: (1) The control group used common CAs and (2) the enhanced structure group used partially thickened CAs.ResultsFE model revealed that the enhanced structure improved the biomechanics during anterior retraction. Specifically, the second premolar, which had a smaller PDL area, experienced a smaller protraction force and moment, making it less likely to tip mesially. In the same vein, the molars could resist movement due to their larger PDL area even though they were applied larger forces. The resultant force of the posterior tooth was closer to the center of resistance, reducing the tipping moment. The canine was applied a larger retraction force and moment, resulting in sufficient retraction of anterior teeth. The experimental model demonstrated a similar trend in force variation as the FE model.ConclusionsEnhanced structure allowed force distribution more in accordance with optimal principles of biomechanics during the extraction space closure while permitting less mesial tipping and anchorage loss of posterior teeth and better retraction of anterior teeth. Thus, enhanced structure alleviated the roller coaster effect associated with extraction cases and offered a new possibility for anchorage reinforcement in clear aligner therapy.

Modeling Development of a Diamagnetically Stabilized Magnetically Levitated Gravimeter.

The aim of this work is to create a new type of gravimeter that can function effectively in the challenging conditions of space, specifically on the surfaces of planets and moons. The proposed device, called a diamagnetically stabilized magnetically levitated gravimeter (DSMLG), uses magnetic forces to balance a test mass against the force of gravity, allowing for accurate measurements. A diamagnetically stabilized levitation structure comprises a floating magnet, diamagnetic material, and a lifting magnet. The floating magnet levitates between two diamagnetic plates without the need for external energy input due to the interaction between the magnetic forces of the floating magnet and the stabilizing force of the diamagnetic material. This structure allows for stable levitation of the floating magnet without requiring additional energy. The goal is to design a gravimeter that is lightweight, requires minimal power, can withstand extreme temperatures and shocks, and has a low data rate. The authors envision this gravimeter being used on various robotic spacecraft, such as landers and rovers, to study the interiors of rocky and icy celestial bodies. This paper reports on the results of a finite element model analysis of the DSMLG and the strength of the resulting diamagnetic spring. The findings contribute to the understanding of the levitation characteristics of diamagnetically stabilized structures and provide valuable insights for their practical applications, including in the development of the proposed DSMLG.

Thermal Analysis of Concrete Blocks and Stack-Bond Prisms under Different Boundary Conditions

Fire is a significant threat to human lives and the integrity of buildings. To better understand the complex behavior of masonry exposed to high temperatures, thermal analyses were carried out to evaluate the temperature distribution in concrete blocks and stack-bond prisms exposed to high temperature levels. The effects of distinct specimen boundary conditions (restrict or easy access to air circulation inside the voids of the block and prisms) on the thermal response of the masonry materials were investigated. Thersys 2.0 software was used to implement three-dimensional thermal analysis of distinct finite element models. Four-node tetrahedral elements and full integration were used in all models. The modeling approach was validated by experimental data obtained from thermocouples embedded into masonry components. The results indicated that the boundary conditions significantly affected the time required for homogenization of temperature in blocks and prisms. Easy access to air circulation inside the voids of the prisms provided a faster temperature homogenization. In this scenario, the prism reached temperature ranges of (300 ± 0.5% × 300) °C and (600 ± 0.5% × 600) °C after exposure times of 2 h and 2 h 10 min, respectively. When access to air circulation within the voids of the prisms was limited, the same temperature ranges were achieved after exposure times of 5 h 20 min and 6 h, respectively.

Exteriorization of the uterus reduces fetoscopic cannula-induced stress and strain: A finite element model analysis.

To estimate stresses and strains in the uterine wall and fetal membranes with single/multi-port fetoscopy, simulating either a percutaneous access or via exteriorized uterus. Finite element models based on anatomical dimensions, material properties and boundary conditions were created to simulate stresses, strains and displacements on the uterine wall and fetal membranes during simulated fetal surgery either via exteriorized uterus or percutaneous approach, and with one or three cannulas. Clinically, we measured the anatomical layer thickness and cannula entry point displacement in patients undergoing single port percutaneous fetoscopy. Simulations demonstrate that single port percutaneous fetoscopy increases stress on the fetal membranes (+105%, 128 to 262 kPa) and uterine wall (+115%, 0.89 to 1.9 kPa) compared to exteriorized uterine access. Using three ports increases stress by 110% (148 to 312 kPa) on membranes and 113% (1.08 to 2.3 kPa) on uterine wall. Finite Element Method showed 0.75cm uterine entry point displacementfrom the cutaneous entry, while clinical measurements demonstrated displacement of more than double (1.69±0.58cm), suggesting modeled measurements may be underestimations. The stresses and strains on the fetal membranes and uterus are double as high when entering percutaneously than via an exteriorized uterus. Based on what can be clinically measured, this may be an underestimation.

Tube Mechanism With 3-Axis Rotary Joints Structure to Achieve Variable Stiffness Using Positive Pressure

Studies on soft robotics have explored mechanisms of switching the stiffness of a robot structure. The hybrid soft-rigid approach, which combines soft materials and high-rigidity structures, is the most commonly-used method for the variable stiffness mechanism. The positive-pressurization method, in particular, has attracted significant attention in recent years as it can remove the limit on the driving pressure. Moreover, it can change the shape holding force according to the value of internal pressure. In this study, a variable stiffness mechanism, consisting of 3-axis rotary ball joints and a single chamber, is devised via frictional force using positive pressure. The prototype can change joint angles arbitrarily when not pressurized and can hold joint angles when a positive pressure is applied. By using a theoretical model of the torque required to hold the joint angle, we simulated the holding torque using finite element modeling analysis and measured the holding torque in the pitch and roll directions when internal pressure was applied. Based on the interaction of the theoretical model, measurement, and FEM analysis, it was confirmed that the value of the holding torque in the roll direction was approximately π/2 times larger than that in the pitch direction for each value of the internal pressure. Further, we evaluated the FEM value, theoretical value, and measured value of holding torque by numerical comparison with each other. We believe that our approach will aid the design of effective stiffening mechanisms for soft robotics applications.

Lateral Displacement Behavior of IBS Precast Concrete Elements Reinforced with Dual System

Throughout history, the construction industry has been a significant contributor to construction waste, presenting an ongoing challenge in efficiently managing this waste to mitigate environmental pollution. The Industrialized Building System (IBS) stands out as a construction approach that utilizes prefabricated components made from various waste materials, implemented with machinery and formwork, leading to minimal waste production. The potential failure of IBS blockwork columns under lateral loads is a significant concern, and the deformation of these columns is crucial in assessing overall structural performance against lateral forces. This study focuses on examining the deformation and flexibility of components in IBS blockwork columns when subjected to lateral loads. Using Finite Element Modeling (FEM), a 1:5 scale prototype model of the dual-reinforced system IBS Block Work Column is analyzed. The IBS Block Work Column, comprising four prefabricated components assembled in the form of a crucifix plan to enhance lateral stability, is subjected to FEM analysis and experimental investigations. The study aims to explore the impact of four different shapes of reinforcement on deformation resistance. The findings suggest that employing a dual-reinforced system in the IBS Block Work Column enhances its resistance to lateral loads compared to a column with conventional reinforcement. Moreover, the assembled IBS Block Work Column exhibits greater stiffness than a single prefabricated component when subjected to lateral loads. Doi: 10.28991/CEJ-2024-010-01-020 Full Text: PDF

Numerical and theoretical analysis on soil arching effect of prefabricated piles as deep foundation pit supports

This study presents a detailed investigation into the soil arching effects within deep foundation pits (DFPs), focusing on their mechanical behavior and implications for structural design. Through rigorous 3D finite element modeling and parameter sensitivity analyses, the research explores the formation, geometric characteristics, and spatial distribution of soil arching phenomena. The investigation encompasses the influence of key parameters such as elastic modulus, cohesion, and internal friction angle on the soil arching effect. The findings reveal that soil arching within DFPs exhibits distinct spatial characteristics, with the prominent arch axis shifting as excavation depth progresses. Optimal soil arching is observed when the pile spacing approximates three times the pile diameter, enhancing soil retention and minimizing deformation risks. Sensitivity analyses highlight the significant impact of soil parameters on soil arching behavior, underscoring the critical role of cohesive forces and internal friction angles in shaping arching characteristics. By elucidating the interplay between soil parameters and soil arching effects, the research provides insights for optimizing pile spacing and structural stability.

Design and numerical analysis of new earthquake-resilient semi-rigid joints

A calculation method for the design of a new earthquake-resilient semi-rigid joint was proposed, and its accuracy was verified through cyclic loading tests. Finite element model analysis was performed to investigate the energy dissipation capacity of the new joint. The deformation characteristics, energy dissipation capacity, and stiffness of energy dissipators with different shapes and lengths were compared. Subsequently, the computational method was improved. The parametric analysis results revealed the excellent seismic performance of the joint; the energy dissipator dissipated more than 75% of the energy. Furthermore, we assessed the influence of the area, shape, and length of the energy dissipators on their energy dissipation capacity. Increasing β (the ratio of the flange to web area in the energy-dissipating core area) and γ (the slenderness ratio of the energy-dissipating core area) resulted in an initial rise in the energy dissipation capacity followed by a decrease. The recommended values for β and γ are 0.67 and 7.71–9.21, respectively.