Finite Element Simulation Research Articles

Highly Efficient Acidic Electrosynthesis of Hydrogen Peroxide at Industrial-Level Current Densities Promoted by Alkali Metal Cations.

Acidic H2O2 synthesis through electrocatalytic 2e- oxygen reduction presents a sustainable alternative to the energy-intensive anthraquinone oxidation technology. Nevertheless, acidic H2O2 electrosynthesis suffers from low H2O2 Faradaic efficiencies primarily due to the competing reactions of 4e- oxygen reduction to H2O and hydrogen evolution in environments with high H+ concentrations. Here, we demonstrate the significant effect of alkali metal cations, acting as competing ions with H+, in promoting acidic H2O2 electrosynthesis at industrial-level currents, resulting in an effective current densities of 50‒421 mA cm‒2 with 84‒100% Faradaic efficiency and a production rate of 856‒7842 μmol cm-2 h-1 that far exceeds the performance observed in pure acidic electrolytes or low-current electrolysis. Finite-element simulations indicate that high interfacial pH near the electrode surface formed at high currents is crucial for activating the promotional effect of K+. In situ attenuated total reflection Fourier transform infrared spectroscopy and ab initio molecular dynamics simulations reveal the central role of alkali metal cations in stabilizing the key *OOH intermediate to suppress 4e- oxygen reduction through interacting with coordinated H2O.

A computationally efficient gradient-enhanced healing model for soft biological tissues.

Soft biological tissues, such as arterial tissue, have the ability to grow and remodel in response to damage. Computational method plays a critical role in understanding the underlying mechanisms of tissue damage and healing. However, the existing healing model often requires huge computation time and it is inconvenient to implement finite element simulation. In this paper, we propose a computationally efficient gradient-enhanced healing model that combines the advantages of the gradient-enhanced damage model, the homeostatic-driven turnover remodeling model, and the damage-induced growth model. In the proposed model, the evolution of healing-related parameters can be solved explicitly. Additionally, an adaptive time increment method is used to further reduce computation time. The proposed model can be easily implemented in Abaqus, requiring only a user subroutine UMAT. The effectiveness of proposed model is verified through a semi-analytical example, and the influence of the variables in the proposed model is investigated using uniaxial tension and open-hole plate tests. Finally, the long-term development of aneurysms is simulated to demonstrate the potential applications of the proposed model in real biomechanical problems.

Sandwich-structured SrTiO3/PEI composite films with high-temperature energy storage performance

Dielectric capacitors are widely used in aerospace and power systems due to their non-polluting, high power density and fast charge/discharge rates. Polyetherimide (PEI) exhibits excellent temperature tolerance, high withstand voltage and low dielectric loss. However, its relatively low dielectric constant restricts its energy storage density. In this paper, a sandwich-structured composite film with the outer layer of pure PEI and the middle layer of strontium titanate (SrTiO3)/PEI is prepared by the solution casting method. At room temperature, the composite film with 5 vol% two-dimensional (2D) SrTiO3 plates achieves an outstanding energy storage density of 19.46 J cm−3 and an ultra-high energy storage efficiency of 97.05% under an electric field of 630 MV m−1. Furthermore, this composite film exhibits a maximum energy storage density of 10.34 J cm−3 and an energy storage efficiency of 88.13% at 150 °C. Combined with finite element simulation results, it confirms that the synergistic effect of 2D SrTiO3 plates and sandwich-structured can effectively hinder the development of electric trees. This work presents a sophisticated approach to design and preparation of dielectric composites suitable for the applications of high-temperature energy storage.

Pullout behaviour of strip plate anchors in clay overlying sand

Plate anchors are being increasingly employed to establish mooring systems for offshore floating facilities owing to their notable efficiency and cost-effectiveness. The majority of prior studies have concentrated on plate anchors, examining the vertical to horizontal orientations, particularly when embedded in single layer clay or sand. However, it is common to encounter multiple layers of soil with varying characteristics in practical engineering, leading to inaccurate estimation of pullout capacity when based solely on the properties of a single soil layer. This paper reports pullout behaviours of strip plate anchors in clay overlying sand by adopting two dimensional finite element analysis. To simulate the hardening and subsequent softening behaviour of medium to dense sand, a modified Mohr-Coulomb model is considered. The current Finite Element (FE) results are in good agreement when compared with both previous FE simulations and physical model test data. Then, the soil flow mechanisms (e.g. the accumulated plastic shear strain, the friction angle) surrounding the anchor during pullout out are revealed. Based on a series of FE results, a calculation framework considering the effect of thickness of clay layer is designed to predict the pullout behaviour of plate anchors in clay overlying sand.

Wave‐to‐Wire Model and Output Performance Analysis of a Point Absorption Wave Energy Converter Based on Triboelectric Nanogenerator

Herein, a point absorption wave energy converter (WEC) model combined with a contact–separation mode triboelectric nanogenerator (PAW TENG) is proposed. The model considers the interaction between the hydrodynamic forces captured by a point absorption conversion device of wave energy and the electrostatic force of the TENG. According to the established harmonic oscillation model of the buoy, the buoy's hydrodynamic properties and power generation characteristics are studied using finite element simulation and numerical simulation calculations. The best matching resistor circuit for PAW TENG in regular waves is investigated and analyzed. The electrical characteristics of the PAW TENG in the irregular wave spectrum are also solved. This work will provide design ideas for the experimental design of a novel point absorption WEC.

Multi-objective optimization of membrane cavity curve of diaphragm compressor and its verification

According to the trend of compressor upgrades in hydrogen refueling stations, this article optimizes the single exponential curve of membrane chamber volume and diaphragm stress that performs poorly. First, set the optimization goals as the membrane cavity volume and the arc length of the curve, use the MOPSO algorithm to optimize the curve, and fit the optimization results to obtain a new curve mathematical model. Then, select three curves for comparison. Theoretical calculations and finite element simulations were performed on the membrane cavity volume and diaphragm stress, and the theoretical calculation methods and results were verified with the help of existing experiments. Finally, it was found that the new curve can increase the membrane cavity volume and reduce the diaphragm stress requirement by changing its own parameters, and the new curve has a small amount of cavity volume near the transition point, which has little impact on the membrane cavity volume. Under the same maximum radial stress, the membrane cavity volume of the new curve can be increased by 5.56% compared to the single exponential curve, while under the same membrane cavity volume, the new curve can reduce the maximum stress on the gas side by 8.9% compared with the single exponential curve, and the maximum stress on the oil sides is reduced by 9.8%.

A Soft Supernumerary Robotic Limb with Fiber-Reinforced Actuators

Supernumerary robotic limbs (SRLs) have great potentials to assist human in daily activities and industrial manufacturing by providing extra limbs. However, current SRLs have heavy and rigid structures that may threaten the operator safety; moreover, their limited degrees of freedom and movement modes are not suitable for complicated tasks. Although soft SRLs have exhibited advantages in structure compliance and flexible manipulation to address these problems, it remains challenging to accurately design the geometrical parameters to adapt to specific tasks, and accurate control is also required to realize the expected movement. Inspired by the biological characteristics of the octopus arm muscle fibers, fiber-reinforced actuators (FRAs) are employed to realize various motions, including extension, expansion, bending, and twisting; multiple FRAs are assembled to implement the SRL to achieve complex movement trajectories. The analytic model of the FRA is established to reveal the relationship between its deformation and geometrical parameters as well as input air pressures, which is validated with finite element simulation. Trajectory and payload optimization algorithms are proposed to optimally design the SRL and its control strategy with meeting the prescribed requirement of movement trajectory and payload capacity. Finally, experiments are conducted to validate the proposed robotic system.

Effects of jet grouting on adjacent ground through numerical modelling

When using jet grouting for soil stabilization, effects of the installation process, such as erosion or remolding of the surrounding soil, need to be evaluated. This could be particularly important for applications in challenging ground conditions and low initial ground stability. This study investigates such effects in soft marine clays (undrained shear strength of 20-30 kPa) using numerical finite element simulations for both flat and sloping terrains. Additionally, an analytical solution using the modified Hagen-Poiseuille equation was developed to i) assess the pressure induced by the grout at any installed depth, and ii) illustrate the importance of maintaining a proper amount of return flow to avoid build-up of excessive pressures in the ground during the jet grouting process. Combining the analytical and the finite element (FE) simulations, jet grouting induced soil displacements were determined. For flat terrain, the area affected by jet grouting was approximately three to four times the column radius. By contrast, for the studied slope (inclination of 1:3), the influenced area increased to about 10 times the column radius. The influenced area could increase further for steeper slopes. The obtained displacement magnitude was also considerably larger for sloping terrain than for flat terrain. The reported findings relate to jet-grouting in marine clays (which is not the normal application of this technology) and cannot be extrapolated to other soils.

Enzymatic Reaction Enhanced Diffusion Accelerates Cargo Transport through Micro/Nano-Channels.

Energy conversion and transfer of enzyme-catalyzed reactions at molecular level are an interesting and challenging scientific topic that helps understanding biological processes in nature. In this study, it is demonstrated that enzyme-catalyzed reactions can enhance diffusion of surrounding molecules and thus accelerate cargo transport within 1D micro/nanochannels. Specifically, urease is immobilized on the inner walls of silica micro/nano-tubes to construct bio-catalytically active micro/nanochannels. The catalytic reaction inside the channels drives a variety of cargoes, including small dye molecules, polymers, and rigid nanoparticles (e.g., quantum dots, QDs), to pass through these micro/nanochannels much faster than they will by free diffusion. The enhanced diffusion of molecular species inside the channels is validated by direct observation of the Brownian motion of tracer particles, and further confirmed by significantly enhanced Raman intensity of reporter molecules. Finite element and Brownian dynamics simulations provide a theoretical understanding of these experimental observations. Furthermore, the effect of the channels' size on the diffusion enhancement is examined. The acceleration effect of the cargo transport through these enzymatically active micro/nanochannels can be turned on or off via chemical activators or inhibitors. This study provides valuable insights on the design of biomimetic channels capable of controlled and efficient transmembrane transport.

Self-centering of steel braced frames equipped with Fe-SMA TADAS dampers

Abstract This study proposes a novel triangular added damping and stiffness (TADAS) damper that uses the shape memory effect (SME) of iron-based shape memory alloy (Fe-SMA) to provide a self-centering system to recover the initial shape of a structure after significant inelastic deformation induced by nonlinear response of fused elements, without the need for difficult and expensive replacement procedures of conventional TADAS systems. Unlike most studies which consider simplified uniaxial behavior of Fe-SMAs, the present non-linear finite element simulations cover the full 3D material non-linearity of Fe-SMA component based on the SMA constitutive law to capture both flexural and shear behavior in various coupled thermomechanical loadings, including the mechanical loading/unloading, the heating, and the final cooling (as the recovering process). Simulations performed on a one-bay steel frame for different drift ratios reveal that although the dissipation energy of the new device is at most 10% less than the ordinary one, it enjoys the self-centering property to recover the initial shape of the frame before loading, showing that the proposed damper is an effective alternative to ordinary TADAS yielding dampers to achieve the self-centering characteristics.

Experimental and Finite Element Analyses of Adjustable Foundation Bolts in Transmission Towers

Uneven settlement of transmission tower foundations can result in catastrophic events, such as tower collapse and line failures, disrupting power transmission operations. To address the challenging repairs caused by uneven foundation settlement of transmission towers, we propose an adjustable foundation bolt (AFB). This paper provides a detailed theoretical analysis of the AFB’s stability and load-bearing capacity, including critical buckling force formulas and maximum normal stress expressions. Finite element simulations confirm the precision of our theoretical formulations. Additionally, we introduce a method using baffles to enhance its load-bearing capacity, analyzing the impact of different numbers of baffles through numerical simulations. The experimental results validate the effectiveness of baffles in enhancing structural load-bearing capacity. The device brings convenience and efficiency to the maintenance of transmission towers.

Direct integration of measured viscoelastic relaxation data in time-domain finite element simulations

The current approach to modeling viscoelastic materials in most commercial finite element packages is based on the General Maxwell Model, which views these materials as combinations of spring and dashpot elements. However, the data can be incorporated more directly into a transient finite element study by direct interpolation of the relaxation function. This work explores a linear interpolation scheme to the inclusion of viscoelastic relaxation functions on an example problem. The results show several benefits over the General Maxwell Model for transient studies. Included in the analysis are displacement solutions utilizing both approaches, relaxation function error calculations for both approaches, and parametric runtime studies comparing speed of calculation. The variation in computational flop counts is considered and an argument is made for the preference of the proposed approach.

A new model of thermo-mechanical actuation for twisted and coiled polymer muscles with initial curvature

Abstract The twisted and coiled polymer (TCP) artificial muscle is one type of novel soft actuator for mimicking natural skeletal muscle that can provide large linear and torsional actuation and energy density. Twisting and coiling are the pivotal steps in fabricating TCP muscles. The influence of twisting on the actuation response of TCP muscles has been extensively investigated recently. However, the influence of coiling remains unclear. Based on the finite strain theory, we establish a new thermo-mechanical actuation model for TCP muscles with initial curvature. The theoretical predictions based on the model align well with the finite element simulations, accurately capturing the actuation response of thermally-activated TCP muscles. It is revealed that twisting contributes positively to the actuation, while coiling has a passive effect. Geometrical parameters, such as the helix radius and helix angle, can effectively regulate the actuation performance of TCP muscles. Furthermore, an optimal bias angle is identified that maximizes both the recovery torque and the linear actuation. This study sheds light on the structural optimization design of TCP muscles.

The effect of secondary cutting on the chip breaking in turning with (Ti,W)C cermet cutting tools

This study proposes a secondary cutting technique to address the chip breaking issue of cermet cutting tools. A cemented carbide blade is superimposed to cut off the chips while cutting with (Ti,W)C cermet tools, this approach allows for achieving chip breaking while maintaining excellent machining surface integrity. In this paper, the influence of the distance between the secondary cutting tool and the major cutting edge and the thickness of the tool on the chip breaking is studied, by using the combination of finite element simulation and experimental verification. The results indicate that the secondary cutting technique transforms the chips from long helical chips into dual-C-type chips. The distance between the secondary cutting tool and the major cutting edge is the primary factor affecting chip breaking. The reason is that the free end of the chip is subjected to the reaction force of the secondary cutting tool, which hinders the increase of the chip curl radius, increases the internal strain, and achieves the chip breaking condition. The thickness of the secondary cutting tool is also a significant factor influencing chip breaking, when the thickness reaches the critical value of 1.8 mm, the tool transitions from obstructive action to cutting action. When the cutting material is 45 steel, the cutting speed is 300 m/min, the feed rate is 0.142 mm/r, and the cutting depth is 0.2 mm, the distance between the secondary cutting tool and the major cutting edge is 1.5 mm, and the tool thickness is 1.3 mm, the chip breaking effect is the best, the main types of chips is dual-C type chips, with a chip length of 7.1 mm ± 0.3 mm and a chip fracture curl radius of 1.8 mm ± 0.1 mm. At this point, the surface roughness can be reduced to as low as 0.98 μm, good surface integrity is ensured while chip breaking.

Simulation Study and Optimization Strategies for Vacuum Infusion of GFRP Hoses Based on Resin Time-Viscosity Variables

During the infusion process of a glass-fiber-reinforced thermosetting composite hose, the viscosity of its resin matrix undergoes temporal variations. Consequently, if the impact of resin viscosity changes over time on the internal resin fluidity is not considered during the infusion process, this may result in the incomplete impregnation of the hose, characterized by the presence of numerous voids. This phenomenon adversely affects the quality of the pipe’s curing and forming process. Therefore, based on the characteristic variations in resin viscosity, this paper considers the changes in fluidity caused by the resin’s temporal evolution within the material. We establish a finite element simulation model to calculate and analyze the overall infusion effects of resin viscosity changes during the hose infusion process. Furthermore, based on the predicted analysis, a variable parameter infusion strategy is proposed to increase resin impregnation in the hose, thereby reducing internal void content and subsequently improving the quality of material curing and forming.

Rate-dependent energy dissipation of graded viscoelastic structures fabricated by grayscale vat photopolymerization

A major benefit of additive manufacturing technologies is precise control over structural topologies and material properties, which allows to tailor, for instance, energy absorption and dissipation. While vat photopolymerization is generally restricted to a single material, grayscale masked stereolithography (gMSLA) allows to customize material behavior by grading the light intensity within a structure. This study investigates the impact and opportunities of grayscale grading strategies on the rate-dependent mechanical behavior of structures fabricated by gMSLA. Considering the viscoelastic nature of polymers, rate-dependent energy dissipation is explored, introducing a parametric linear viscoelastic constitutive model for varying grayscales. The investigation includes the comprehensive characterization of mechanical properties, numerical finite element simulation, validation through experimental procedures, and exploration of dissipation energy under different strain rates. In this way, a rational function successfully determines the critical strain rate at which the maximum dissipation occurs. Overall, the research offers a comprehensive investigation of the mechanical dissipation behavior of graded 3D printed structures, laying the foundation for further studies and advancements aimed at optimizing these structures for enhanced energy absorption capabilities.

Thermal-force coupling simulation of carbon fibre-reinforced poly-ether-ether-ketone thermoplastic composites during the laser-assisted automated tape placement process

To reveal the thermal-force coupling characteristics of the laser in-situ consolidation (ISC) of carbon fibre-reinforced poly-ether-ether-ketone (CF/PEEK) composites, a two-dimensional transient thermal-force model of CF/PEEK composites was constructed using COMSOL Multiphysics finite element simulation software to calculate the temperature history and the thermal stress variation of CF/PEEK composites during the laser-assisted automated tape placement (LATP) process. The results show that the temperature field formed on the surface of each layer by the laser spot during LATP is stable, and the temperature gradient at the front of the spot movement direction is higher than that at the back edge. The maximum stresses in the laminate occur on both sides of the first CF/PEEK layer and the stresses are unevenly distributed along the length and thickness directions of the lay-up. The composite material on both sides of the laminate tends to ‘shrink’ compared to its original position.

Effects of core geometry, silica nanoparticles, and polyurethane foam on the mechanical properties of a novel circular-shaped core sandwich panels under compression test: Experimental study

For the first time in this paper, a composite sandwich panel with a novel circular-shaped core reinforced with silica nanoparticles (SNPs) is designed and fabricated using the vacuum-assisted resin transfer molding (VARTM) method. Carbon fibers and epoxy resin are utilized to construct the composite sandwich panels, followed by polyurethane foam injection. After fabrication, the sandwich panels undergo uniform compression testing to examine their mechanical behavior and properties. In this study, the effects of various parameters, such as core length, core height, weight percentage (wt.%) of SNPs, and polyurethane foam, on the compressive strength of the structure are evaluated. To validate the results, a finite element simulation of the sandwich panel compression test is performed using ABAQUS software, and the results obtained are compared with experimental data, showing good agreement. The results of this research demonstrate that adding SNPs within a specific range results in a considerable enhancement of the structural strength. Adding SNPs up to 3% leads to approximately a 19% increase in the compressive strength of the structure. However, adding 4 wt.% SNPs results in a decrease of about 12% in the strength of the sandwich panel. Additionally, the core’s geometry significantly influences the control of compressive strength and rigidity of the sandwich panel. In other words, by increasing the core length, the compressive strength increases by 38%, while increasing the core height decreases compressive strength by about 30%. Also, it is found that adding polyurethane foam to the sandwich panel, despite a slight increase in weight, leads to a significant increase in compressive strength by about 32% and postpones its ultimate failure. Eventually, the hybrid specimen exhibits a strength approximately 57% greater than that of the pure foamless sandwich panel.

Effect of Micro-Cracks on Chloride Ion Diffusion in Concrete Based on Stochastic Aggregate Approach

For concrete structures in offshore areas, chloride ion erosion is one of the main factors affecting durability. It is crucial to evaluate the chloride ion permeability resistance of concrete structures. In this paper, a finite element simulation of the chloride ion diffusion process in concrete is conducted. A mass diffusion finite element model based on a random aggregate approach is established to investigate the influences of an aggregate, the interface transition zone, and micro-cracks on the chloride ion diffusion coefficients in concrete. The results show that the mass diffusion finite element analysis based on the exponential function model and the power function model can effectively simulate the chloride ion diffusion process in concrete. In addition, the data reveal that volume fraction and distribution aggregates considerably affect chloride ion diffusivity in concrete. Also, the interface transition zone significantly accelerates chloride ion diffusion in concrete. Moreover, this acceleration effect exceeds the barrier effect of an aggregate.

Machine Learning Prediction and Evaluation for Structural Damage Comfort of Suspension Footbridge

To investigate the impact of structural damages on the comfort level of suspension footbridges under human-induced vibrations, this study addresses the limitations of traditional manual testing, which often entails significant manpower and material resources. The aim is to achieve rapid estimation and health monitoring of comfort levels during bridge operation. To accomplish this, the study combines finite-element simulation results to establish a data-driven library and introduces three distinct machine learning algorithms. Through comparative analysis, a machine learning-based method is proposed for quick evaluation of bridge comfort levels. Focusing on the Yangjiadong Suspension Bridge, the study evaluates and researches the comfort level of the structure under the influence of human-induced vibrations. The findings revealed a relatively low base frequency and high flexibility. Additionally, when considering the mass of individuals, peak acceleration decreased. The predictive performance of the Artificial Neural Network (ANN) model was found to be superior when accounting for multi-parameter damages, yielding root mean square error (RMSE), mean absolute percentage error (MAPE), and R-squared (R2) values of 0.03, 0.02, and 0.98, respectively. Moreover, the error ratio of the generalization performance analysis was below 5%. Furthermore, the study identified a damage coefficient of 0.13 for the bridge’s main cable, hanger, and steel longitudinal beam. Under a crowd density of 0.5 people per square meter, the predicted peak acceleration was 1.098 m/s2, with a model error of less than 10% compared to the observed value of 1.004 m/s2. These results underscore the model’s effectiveness in swiftly evaluating bridge comfort levels, thereby offering valuable insights for the health monitoring of bridge comfort levels.