Finite Element Simulation Research Articles

Finite Element Simulation and Parameter Optimization of SWRH82B Wire Rod in Stelmor Cooling Process

Finite Element Simulation and Parameter Optimization of SWRH82B Wire Rod in Stelmor Cooling Process

Flexural performance of reinforced concrete beams repaired with BFRP grid-TSUHDC

Due to the influence of time, load, and external environmental factors, many reinforced concrete beams have been damaged and require repair. Tailings are waste generated during mineral production, resulting in substantial environmental pollution and economic losses due to the excessive generation of tailings and low comprehensive utilization. In the UHDC, tailings replaced quartz sand, while BFRP grids itself is an environmentally friendly material. Two repair methods were evaluated in this study, Tailings Sand Ultra-High Ductile Concrete (TSUHDC) and Basalt Fiber Reinforced Polymer (BFRP) grid-TSUHDC, grounded in the principles of green and sustainable development. Five reinforced concrete beam specimens were designed and fabricated for bending performance tests and finite element simulations. The effects of different repair methods and levels of damage on the flexural performance of reinforced concrete beams were investigated. The results reveal that, compared to untreated reinforced concrete beams, both TSUHDC and BFRP grid-TSUHDC repair methods enhanced bending load-bearing capacity. However, the stiffness of specimens repaired with TSUHDC decreased when subjected to 80 % of the pre-applied failure load. When the pre-applied failure load is less than 80 %, the recommended repair approach is the use of TSUHDC for repair. For cases where the pre-applied failure load exceeds 80 %, BFRP grid-TSUHDC is the preferable option. The flexural bearing capacity formula for this type of repair method was derived by improving existing formulas, yielding prediction results in close alignment with the experimental results.

Thermo-Structural Coupled Finite Element Analysis of Repair Process for Steam Turbine Blade Using Laser-Directed Energy Deposition Method

AbstractThis study presents a numerical additive manufacturing simulation aimed at simulating the shape recovery process of a steam turbine blade damaged by corrosion, using laser-directed energy deposition (LDED). The simulation integrates the finite element (FE) method with heat conduction and thermo-elastoplastic constitutive equations, incorporating phase transformation. The additive manufacturing process by LDED was modeled using the death-birth algorithm, wherein a deposition layer is defined as a virtual element. Its stiffness and thermal properties activated when the laser irradiation regions overlapped. In this study, the shape of the virtual element was determined based on the cross-sectional shape of the deposition layer manufactured under various laser conditions. To validate the numerical simulation results, additive manufacturing was conducted for one pass deposition in the width direction at the center of a cantilever-supported plate made of SUS304 steel, and the changes in displacement at the free edges with respect to the process time were compared. The obtained FE results are in good agreement with the experimental results. Finally, an FE simulation was performed for the shape recovery of a steam turbine blade thinned due to corrosion damage. The results revealed that the residual stress component becomes more compressive as the laser output decreases and scanning speed increases, which is advantageous for improving the fatigue strength of steam turbine blades.

Uncovering Pattern-Transformable Soft Granular Crystals Induced by Microscopic Instability

Abstract Upon compression, some soft granular crystals undergo pattern transformation. Recent studies have unveiled that the underlying mechanism of this transformation is closely tied to microscopic instability, resulting in symmetry breaking. This intriguing phenomenon gives rise to unconventional mechanical properties in the granular crystals, paving the way for potential metamaterial application. However, no consistent approach has been reported for studying other unexplored transformable granular crystals. In this study, we present a systematic approach to identify a new set of pattern-transformable diatomic granular crystals induced by microscopic instability. After identifying the kinematic constraints for diatomic soft granular crystals, we have generated a list of feasible particle arrangements for instability-induced pattern transformation under compression. Instead of computationally intensive finite element models (FEMs) with continuum elements, we adopt a simplified mass-spring model derived from granular contact networks to efficiently evaluate these feasible particle arrangements for pattern transformation. Our numerical analysis encompasses quasi-static analysis and microscopic/macroscopic instability analyses within the framework of linear perturbation. Subsequently, the pattern transformation of the identified particle arrangements is confirmed through quasi-static analyses employing detailed finite element (FE) simulations with continuum elements. Additional numerical simulations with continuum elements reveal that the pattern transformations of particle arrangements are significantly influenced by the initial void volume and some transformed granular crystals may exhibit strong low-frequency directional phononic band-gaps, which were not observed in the initial granular crystals.

Thermo-micromechanical finite element modelling of tyre–pavement interaction under UAE environmental conditions

ABSTRACT This work presents a finite element model of the thermo-mechanical behaviour of tyre–pavement interaction, focusing on the effects of temperature variations in the UAE on skid resistance under various tyre operating conditions. The pavement is modelled as multiple layers to account for the stiffness contribution of each layer. The top asphalt layer is modelled at a microscale level to consider its various constituents such as air voids, aggregates and binder. Moreover, the model accounts for the viscoelastic properties of tyre and pavement, considering their dependence on time and temperature. The finite element simulations of a rolling tyre over the pavement have been carried out under different tyre operating conditions and various temperature cases reflecting the winter, spring, and summer seasons in the UAE. The simulation results show that the maximum level of skid resistance occurs during the winter season and thereafter drops by a significant amount during the summer. This research provides good insights about the seasonal variation of skid resistance in the UAE, which enhances road safety.

Building Chemical Interface Layers in Functionalized Graphene Oxide/Rubber Composites to Achieve Enhanced Mechanical Properties and Thermal Control Capability of Tires

With the rapid development of the transport industry, there is a higher demand for environmental friendliness, durability, and stability of tires. Rubber composites with excellent mechanical properties, abrasion resistance, and low heat generation are very important for the preparation of green tires. In this study, the all-aqueous phase process was initially employed to prepare 2-Amino-5-mercapto-1,3,4-thiadiazole (AZT) functionalized graphene oxide (AGO). Subsequently, modified graphene oxide/silica/natural rubber (AGO/SiO2/NR) composites were obtained through latex blending and hot press vulcanization processes. This method was environmentally friendly and exhibited high modification efficiency. Benefiting from the good dispersion of AGO in the latex and the cross-linking reaction between AGO and NR, AGO/SiO2/NR composites with good dispersion and enhanced interfacial interaction were finally obtained. AGO/SiO2/NR composites showed significantly improved overall performance. Compared to GO/SiO2/NR composites, the tensile strength (28.1 MPa) and tear strength (75.3 N/mm) of the AGO/SiO2/NR composites were significantly increased, while the heat build-up value (10.4 °C) and DIN abrasion volume (74.9 mm3) were significantly reduced. In addition, the steady-state temperature field distribution inside the tire was visualized by ANSYS finite element simulation. The maximum temperature of the prepared AGO/SiO2/NR was reduced by 18.2% compared to that of the GO/SiO2/NR tires. This strategy is expected to provide a new approach for the development of low energy consumption, environmentally friendly, and long-life rubber for tires.

Effect of plastic deformation of particle and substrate on metallurgical bonding during cold spraying

The metallurgical bonding of cold spraying is investigated from the perspective of plastic deformation. The individual Al particle was deposited on the surface of Ni substrate by low-pressure cold spraying technology. Direct observation of the Al/Ni interface from the cross-sectional morphology shows that metallurgical bonding occurs only at the partial Al/Ni interface. The finite element simulation considering the presence of oxide layer confirms that the metallurgical bonding is located in front of the maximum plastic deformation area. In the maximum plastic deformation area, the relative displacement between Al particle and Ni substrate exists from the beginning of contact to the end of deposition, which makes the metallurgical bonding discontinuous and gradually disappear.

Pre-stress effect of metal bars in low-stress separation technology

This paper proposes a low-stress separation technology based on pre-stress effect. It connects notching and loading to take advantage of the rotating bending fatigue to achieve the cropping of metal bars. The real-time positions of the notching tool and loading hammer are calculated based on energy equivalence theory. Compared to the conventional notching method, it achieves 25.1 % reduction of cutting force in the case of AISI1045 steel bars. A testing platform is set up and the loading curve is designed to meet the requirements of deflection law and fatigue cyclic loading law. The bending stress for the minimum cutting force, crack angle and deviation under different notch parameters, and the reasonable pre-loading of different materials are determined through cropping tests and finite element simulation. Cropping results indicate that the optimized notch angle and depth are 60° and 1.5 mm, respectively.

Fine grains, dispersed phases and strong crystal defect interactions inducing excellent strength-ductility synergy in powder sintered Cu–18Sn-0.3Ti alloy via hot extrusion and solution treatment

In order to prepare the Cu–18Sn-0.3Ti alloy with excellent mechanical properties to realize the favorable collaborative deformation of Cu–18Sn-0.3Ti alloy and Nb in the preparation process of Nb3Sn superconducting wires by bronze method, the hot extrusion process of the Cu–18Sn-0.3Ti alloy prepared by Direct Current assisted Hot Pressed sintering based on micron atomized spherical alloy powders was systematically investigated by the combination of experiments and finite element simulation in this work. The ultimate tensile strength, yield strength and elongation can reach 683.5 MPa, 414.3 MPa and 33.3 %, respectively, through the optimization of hot extrusion parameters and subsequent solution treatment. The results show that hot extrusion with high strain rate induced the formation of fine α grains and dispersed δ phases. Especially, strong dislocations-annealing twins (ATs) interaction occurred, which was manifested as the pile-up of dislocations at twin boundaries of ATs, slippage of dislocations in multiple directions inside ATs and storage of dislocations inside ATs. Meanwhile, the high strain rate induced the formation of deformation twins inside partial grains. The grain refinement of α matrix, formation of dispersed δ phases and strong interactions of crystal defects were the main reasons for the strength-ductility enhancement of hot extruded samples, and laid an excellent microstructure foundation for further improving the mechanical properties of alloy by subsequent solution treatment. The results not only describe a feasible method for simultaneously enhancing the strength and ductility of Cu–18Sn-0.3Ti alloy, but also provide a theoretical guidance for the strength-ductility enhancement of multicomponent alloys.

Dynamic phase change materials with extended surfaces

Phase change materials (PCMs) present opportunities for efficient thermal management due to their high latent heat of melting. However, a fundamental challenge for PCM cooling is the presence of a growing liquid layer of relatively low thermal conductivity melted PCM that limits heat transfer. Dynamic phase change material (dynPCM) uses an applied pressure to pump away the melt layer and achieve a thin liquid layer, ensuring high heat transfer for extended periods. This paper investigates heat transfer during dynPCM cooling when the heated surface has extended features made from high thermal conductivity copper (Cu). Using experiments and finite element simulations, we investigate the heat transfer performance of dynPCM paraffin wax on finned Cu surfaces. A total of 102 transient temperature measurements characterize the performance of dynPCM with extended surfaces and compare the performance with other cooling methods including hybrid PCM and air cooling. The study examines the effects of fin geometry, applied power (20–65 W), and pressure (0.97–12.5 kPa). For dynPCM on a finned surface and a heating power of 65 W, the thermal conductance is 0.45 W/cm2-K, compared to 0.22 W/cm2-K for dynPCM on a flat surface and 0.10 W/cm2-K for hybrid PCM. The heat transfer is highest at the fin tips where the melt layer is thinnest, providing valuable design guidelines for future high performance dynPCM cooling technologies.

Metaheuristic algorithm inspired by enterprise development for global optimization and structural engineering problems with frequency constraints

In this study, a novel metaheuristic optimization algorithm inspired by the enterprise development (ED) process was developed. This process encompasses tasks, structure, technology, and human interactions. A mechanism for switching activities was utilized to determine each step by updating the searched solutions. The ED optimizer underwent evaluation against 50 mathematical functions and 54 IEEE Congress on Evolutionary Computation (CEC) functions, and it was compared with six up-to-date algorithms, three winners of CEC 2020 in real-world single-objective constrained optimization, and ten well-known algorithms. The evaluation results revealed that the ED optimizer outperformed the algorithms in mathematical tests. Using finite element simulation, this novel method was applied to minimize steel structure component weights under various frequency constraints. The engineering designs included a 37-bar planar truss, a 52-bar dome, a 72-bar space truss, a 600-bar dome, and a 1,410-bar dome. Optimization results for these structures showed that the developed ED optimizer yielded the optimal solution and required fewer function evaluations. In conclusion, the ED optimizer is a superior metaheuristic algorithm that can effectively solve complex structural design problems.

Numerical Simulation Study of Wall Thickness Change Rule of Single Point Progressive Molding of Al5083

With the development and progress of science and technology, the application of single-point progressive molding is more and more extensive, but single-point progressive molding still exists the problem of excessive thinning of wall thickness of molded parts, which seriously affects the quality of molded parts. The article takes Al5083 plate forming cone as the research object, uses Abaqus finite element simulation software, according to the principle of single variable, respectively explores the influence of process parameters such as tool head diameter, layer spacing, feed rate and residual height on the average wall thickness reduction rate and the maximum wall thickness reduction rate of the molded parts. The results show that: increasing the tool head diameter, the average wall thickness reduction rate increases and the maximum wall thickness reduction rate decreases; the average wall thickness reduction rate and the maximum wall thickness reduction rate increase with the increase of ply spacing; the average wall thickness reduction rate and the maximum wall thickness reduction rate increase with the increase of the tool feed rate; the average wall thickness reduction rate decreases and the maximum wall thickness reduction rate increases with the increase of the residual height.

REVERSE ENGINEERING MODELING PROCESSING AND FABRICATION OF VORONOI PERFORATED ANKLE-FOOT ORTHOSIS

The ankle may not function optimally because of an ankle foot injury due to torn ligaments or foot drop, a post-stroke effect of hemiplegia. One treatment that can be done for sufferers of ankle foot injury and foot drop is using an ankle foot orthosis (AFO). Reverse engineering (RE) and additive manufacturing (AM) technologies can be utilized within the medical domain, specifically for producing prosthetic devices and orthoses that include optimal fit, lightweight characteristics, and cost-effectiveness. This study aims to create an optimized design for an ankle-foot orthosis by utilizing reverse engineering techniques, followed by an analysis of its performance using finite element simulation. The research process involved several key steps, namely 3D Scanning, CAD modeling, model analysis, and 3D printing. The findings of the model study after the implementation of Voronoi ventilation holes indicated that the highest equivalent stress observed in the model, with a shell element thickness of 1.4 mm, amounted to 21.12 MPa. This result represented an elevation of 11.74% compared to the model before introducing Voronoi ventilation holes. Nevertheless, there was a reduction in the model's mass by 20.3%, specifically from an initial weight of 400.86 grams to a final weight of 319.51 grams. On the contrary, despite a fall in the safety factor, it continues to be considered safe, with a value of 2.84.

Cutting-Based Manufacturing and Surface Wettability of Microtextures on Pure Titanium

Pure titanium is a preferred material for medical applications due to its outstanding properties, and the fabrication of its surface microtexture proves to be an effective method for further improving its surface-related functional properties, albeit imposing high demands on the processing accuracy of surface microtexture. Currently, we investigate the fabrication of precise microtextures on pure titanium surfaces with different grid depths using precision-cutting methods, as well as assess its impact on surface wettability through a combination of experiments and finite element simulations. Specifically, a finite element model is established for pure titanium precision cutting, which can predict the surface formation behavior during the cutting process and further reveal its dependence on cutting parameters. Based on this, precision-cutting experiments were performed to explore the effect of cutting parameters on the morphology of microtextured pure titanium with which optimized cutting parameters for high-precision microtextures and uniform feature size were obtained. Subsequent surface wettability measurement experiments demonstrated from a macroscopic perspective that the increase in the grid depth of the microtexture increases the surface roughness, thereby enhancing the hydrophilicity. Corresponding fluid–solid coupling finite-element simulation is carried out to demonstrate from a microscopic perspective that the increase in the grid depth of the microtexture decreases the cohesive force inside the droplet, thereby enhancing the hydrophilicity.

Safety evaluation of electromagnetic exposure for compact wireless charging stations of electric vehicles

ABSTRACT The spatial electromagnetic field of electric vehicle (EV) wireless charging stations may experience a superposition effect, which will increase the electromagnetic radiation. To assess the safety of electromagnetic exposure from wireless charging stations, this study employs a finite element simulation software to construct an electromagnetic environment model for a compact wireless charging station. The model is utilized to compute the superposition effect of spatial electromagnetic fields resulting from the simultaneous charging of multiple wireless chargers. Furthermore, the model assesses the levels of electromagnetic exposure on human models at eight observation points situated within the charging station. Results indicate that the volume average values of spatial magnetic induction strength ( B ) and electric field strength ( E ) are higher when multiple EVs are charged simultaneously than when a single EV is charged, and the electromagnetic radiation received by a human standing between two vehicles is greater than that near one vehicle. At the 22 kW charging power level, the maximum values of B , E and current density at the eight observation points of the charging station are all below the International Commission on Non-Ionizing Radiation Protection limit, demonstrating that the human body is safe in compact wireless charging stations at this power level.

Model for the Failure Prediction Mechanism of In-Service Pipelines Based on IoT Technology

With the rapid increase in pipeline mileage in China, the accurate prediction of corrosion issues in in-service pipelines has become crucial for ensuring safe pipeline operation. Traditional pipeline leakage monitoring methods are significantly limited by human factors and equipment precision, making it challenging to predict and identify leakage points accurately. Therefore, aligned with the trend of intelligent pipeline development, this study aims to construct a failure pressure prediction mechanism model for corroded pipelines based on IoT technology. This model leverages intelligent sensing and prediction to assess the safety status of corroded pipeline sections. Ultrasonic phased array technology detects specific corrosion points and detailed defect parameters within pipeline sections. The parameters are then utilized in the Simdroid domestic finite element analysis model to simulate the ultimate burst pressure of the pipeline. A single-variable approach is employed to analyze the sensitivity of different parameters to the pipeline’s ultimate burst pressure, with the minimum burst pressure point of multi-point corroded sections selected as the overall segment failure pressure. Finite element simulation data are integrated into a neural network database to predict the pipeline failure pressure. The real-time operational data of the pipeline are monitored using negative-pressure wave sensing. The operational pressure of the corroded points is compared with the algorithm-predicted failure pressure; if the values approach a critical threshold, an alarm is triggered. Moreover, the remote control terminals evaluate the pipeline’s self-rescue time, providing a buffer for pipeline leakage self-rescue. The failure prediction mechanism model for in-service pipelines was applied to the Fujian–Guangdong branch of the West–East Gas Pipeline III to verify its accuracy and feasibility. The research results offer technical support for the maintenance and emergency repair of pipeline leakage scenarios, leveraging intelligent pipeline technology to reduce costs and increase the efficiency of pipeline operations, thereby supporting the sustainable development of China’s oil and gas pipelines with theoretical and technical backing.

Advanced Mechanical Transfer of Micro-LEDs Enabled by Structurally Modified Wide Sapphire Nanomembranes through Thermal Reflow of Photoresist.

Micro light-emitting diodes (micro-LEDs) are pivotal in next-generation display technologies, driven by the need for high pixel density. This study introduces a novel methodology utilizing wide sapphire nanomembranes (W-SNM) as a dual-purpose template for high-quality epitaxial growth and the mechanical lift-off of individual micro-LEDs. Micro-LEDs grow individually on W-SNM, obviating the chip singulation process. By employing mechanical fracturing of the thin W-SNM, our method facilitates the transfer of micro-LEDs without the conventional laser lift-off (LLO) process. Previously introduced sapphire nanomembranes (SNM) have shown promise in enhancing epitaxial layer quality; however, they encountered challenges in managing micro-LED size variation and achieving efficient mechanical transfer. Here, we apply simple yet effective adjustments to the SNM structure, specifically, its elevation and widening. This strategic modification allows micro-LEDs to endure applied forces without incurring cracks or defects, ensuring that only the targeted W-SNM are selectively fractured. The mechanically transferred vertical 15 × 15 μm2 micro-LED device operates at an optimal turn-on voltage of 3.3 V. Finite element simulations validate the mechanical strain distribution between the W-SNM and GaN when pressure is applied, confirming the efficacy of our design approach. This pioneering methodology offers a streamlined, efficient pathway for the production and mechanical transfer of micro-LEDs, presenting new avenues for their integration into next-generation, high-performance displays.

Entropy‐based method considering nonlinear hardening effect to predict the crack propagation life of superalloy GH4169 at elevated temperature

AbstractThis paper aims to determine the relationship between thermodynamic entropy generation and fatigue crack propagation life of superalloy GH4169 at 300–650°C. The entire specimen was considered as the thermodynamic system. The plastic energy dissipation in the crack tip was obtained by finite element simulation utilizing the Chaboche nonlinear hardening model. Then the cyclic entropy generation rate (CEGR) and the accumulated entropy generation are calculated by combining simulation and experimental methods. Results show that the CEGR is a power function of the stress intensity factor range, and it is almost a constant at fatigue failure. The fatigue fracture entropy (FFE) increases as fatigue cycles at failure increase at constant temperature, but it first decreases and then increases when temperature increases from 300 to 650°C. A fatigue life prediction model based on the thermodynamic damage parameter is established and verified by comparison with experimental results and available data in the literature.

Revealing the mechanisms of electrocaloric effects by simultaneously direct measuring local electrocaloric and electrostrain under ambient conditions

Electrocaloric solid-state refrigeration is a primary candidate for the next-generation cooling method for microelectronic systems. However, the mechanisms of electrocaloric effect remain unclear due to the lack of direct correlation evidence, especially for novel negative electrocaloric (NEC) effect. In this work, we develop a high-accuracy direct measurement method for simultaneously measuring local electrocaloric and electrostrain responses under ambient conditions, providing the accompanying electrostrain evidence during electrocaloric effect. Combined with experiments, thermodynamic analyses and finite element simulations, it is found that the electrostrain is very large when NEC and large positive electrocaloric (PEC) responses occur, and NEC effect is caused by ferroelectric-ferroelectric phase transition, while large PEC response originates from paraelectric-ferroelectric phase transition. Results also indicate that NEC temperature change does not increase with electric field, and shows the maximum temperature change at phase transition critical electric field, different from PEC temperature change increasing with electric field. The developed method provides an alternative and sensitive pathway to investigating electrocaloric effect.

Constructing alkaline microenvironment on catalyst surface for enhanced electrocatalytic synthesis of hydrogen peroxide in a neutral electrolyte

The direct electrochemical synthesis of H2O2 via a two-electron oxygen reduction reaction (2e− ORR) offers a feasible alternative to the energy-intensive anthraquinone oxidation process. Compared to alkaline electrolytes, challenges remain in achieving high 2e− ORR selectivity and activity for electrosynthesis of H2O2 in neutral electrolytes due to the low concentration of OH−, which hinders the effective binding of key intermediate OOH*. Here, we introduced Lewis acid TiO2 to modify carbon black catalyst for adsorbing in-situ generated OH− and created a local alkaline microenvironment for enhancing the 2e− ORR activity and selectivity in neutral electrolytes. H2O2 productivity of TiO2 modified carbon black catalyst (52.5 mmol L−1 h−1) in a neutral electrolyte (0.5 M Na2SO4) at 0.2 V vs. RHE was 1.6 times as much as that of pristine carbon black (33 mmol L−1 h−1), which was similar with that of pristine carbon black (58.4 mmol L−1 h−1) in an alkaline electrolyte (0.1 M KOH). The finite-element method simulations and experiments indicated that TiO2 could enhance local alkalinity to increase the current density for facilitating 2e− ORR. The density functional theory calculations indicated that the introducing of TiO2 into the CB structure could promote the adsorption of O2, facilitate the adsorption of *OOH and reduce the overpotential, resulting in high activity towards 2e− ORR to H2O2. This work proposes a new strategy for optimizing electrode–electrolyte interface to enhance 2e− ORR performance in neutral electrolytes.