Finite Element Tool Research Articles

Predictive residual stress analysis in gear units: an artificial intelligence approach based on finite element data

Determining residual stresses is essential for ensuring the safety and longevity of gear components. Traditional methods, such as analytical, numerical, and experimental approaches, are often costly, time-consuming, and sometimes destructive. This study proposes a new method to predict residual stresses in gear units using artificial intelligence based on data from finite element analysis. To achieve this, a commercial finite element tool models the heat treatment and carburization processes, grounded in thermomechanical metallurgical physics. The residual stresses obtained from finite element analysis are then compared to the ones from experiment using deep hole drilling approach. This is followed by a sensitivity analysis. Next, a specific class of gearbox component geometries and the computed stress fields are utilized to train artificial neural networks. The performance of the artificial neural networks approach is compared to that of two different machine learning regression methods. It has been concluded that this technique successfully anticipates residual stresses in components with scaled geometries and similar heat treatment steps, outperforming the two regression models in accuracy and efficiency. Importantly, it achieves this with incomparable, significantly less computation time compared to standard finite element analysis.

Enhancing understanding of the rotating magnetic field in electric machines through active learning and visualization

AbstractThis paper presents a method aimed at improving comprehension of AC electric machine principles by facilitating the learning of the Rotating Magnetic Field (RMF) through visualization tools provided by Finite Element Method (FEM) software. First, traditional methods used in textbooks to explain RMF in electric machines are reviewed, with an analysis of various instructional strategies. Acknowledging the limitations of these conventional approaches and the inherent complexity of RMF comprehension, a novel visualization method is proposed. Understanding RMFs in electric machines is fundamental for electrical engineers due to their crucial role in electric machine design and optimization. While textbooks typically rely on mathematical explanations and simple sketches, advancements in computer and software technology offer opportunities to utilize finite element tools for enhanced comprehension. Through dynamic animations and interactive simulations, emphasis is placed on prioritizing conceptual understanding over mathematical descriptions. Furthermore, this paper explores the development of pre‐simulation models in FEM tools to facilitate RMF learning in AC electric machines, and the process of creating a model to teach rotating magnetic fields in electric machines is carefully outlined. This approach holds promise for engineers seeking a deeper understanding of electric machines and can also be utilized by educators to enhance their teaching methodologies.

Computational modeling and uncertainty prediction of hyperelastic constitutive responses of damaged brain tissue under different temperature and strain rates.

The effect of strain rate and temperature on the hyperelastic material stress-strain characteristics of the damaged porcine brain tissue is evaluated in this present work. The desired constitutive responses are obtained using the commercially available finite element (FE) tool ABAQUS, utilizing 8-noded brick elements. The model's accuracy has been verified by comparing the results from the previously published literature. Further, the stress-strain behavior of the brain tissue is evaluated by varying the damages at various strain rates and temperatures (13, 20, 27, and 37°C) under compression test. Additionally, the sensitivity analysis of the model is computed to check the effect of input parameters, that is, the temperature, strain rate, and damages on the material properties (shear modulus). The modeling and discussion sections enumerate the inclusive features and model capabilities.

Numerical analysis of an all-fiber plasmonic polarization filter using dual elliptical gold thin layers deposited photonic crystal fiber

In order to solve the problems of high performance and small size incompatibility, as well as limited bandwidth, of traditional polarization filters in optical communication systems, this work presents an all-fiber polarization filter using dual elliptical gold layer deposited photonic crystal fiber by the finite element tool. The gold layers are plated on the inside of the two elliptical holes to create surface plasmon resonance effect, which cause the signal intensity in x-polarized direction to be much greater than that in y-polarized direction. The simulation results illustrate that when hole-to-hole pitch Λ is 2.0 μm, cladding hole diameter d 1 is 2.0 μm, two inner-holes’ diameter d 2 is 0.3 μm, spacing between two inner-holes d s is 0.755 μm, the major axis length of elliptical holes a is 2.0 μm, the minor axis length of elliptical holes b is 0.97 μm, the gold thin layer t is 100 nm, the proposed PCF filter exhibits good filtering performance at the communication wavelength of 1.55 μm, where the confinement loss in x- and y-polarized direction are 303.91 dB cm−1 and 0.06 dB cm−1, respectively. The crosstalk and operating bandwidth improve with the increment of device’s length, the 800 μm-long PCF filter possesses the maximum crosstalk of −211.14 dB and the bandwidth of 600 nm. Finally, the experimental scheme is also discussed. We believe that this photonic filter can play a significant role in optical communication, optical sensing, spectral analysis, and other related fields.

Modeling and Design of Induction Heating Systems

This thesis is based on a specific industrial application of induction heating technology: induction hardening. The main objective is to create a simulation model that predicts the whole heating process, combining the electrical simulation with the electromagnetic-thermal analysis, employing electrical simulation software and finite element tools, respectively. This proposed model will be called as dynamic model in the following lines.

Chemical Kinetics and Thermal Properties of Ablator Pyrolysis Products During Atmospheric Entry

Legacy and modern-day ablation codes typically assume equilibrium pyrolysis gas chemistry. Yet, experimental data suggest that speciation from resin decomposition is far from equilibrium. A thermal and chemical kinetic study was performed on pyrolysis gas advection through a porous char, using the Theoretical Ablative Composite for Open Testing (TACOT) as a demonstrator material. The finite-element tool SIERRA/Aria simulated the ablation of TACOT under various conditions. Temperature and phenolic decomposition rates generated from Aria were applied as inputs to a simulated network of perfectly stirred reactors (PSRs) in the chemical solver Cantera. A high-fidelity combustion mechanism computed the gas composition and thermal properties of the advecting pyrolyzate. The results indicate that pyrolysis gases do not rapidly achieve chemical equilibrium while traveling through the simulated material. Instead, a highly chemically reactive zone exists in the ablator between 1400 and 2500 K, wherein the modeled pyrolysis gases transition from a chemically frozen state to chemical equilibrium. These finite-rate results demonstrate a significant departure in computed pyrolysis gas properties from those derived from equilibrium solvers. Under the same conditions, finite-rate-derived gas is estimated to provide up to 50% less heat absorption than equilibrium-derived gas. This discrepancy suggests that nonequilibrium pyrolysis gas chemistry could substantially impact ablator material response models.

Modelling the mechanics of 32 T REBCO superconductor magnet using numerical simulation

High-temperature REBCO superconducting tapes are very promising for high-field magnets. With high magnetic field applications there are high electromechanical forces, and thus a concern for mechanical damage. Due to the presence of large screening currents and the composite structure of the tape, the mechanical design of these magnets is not straightforward. In addition, many contemporary designs use insulated winding. In this work, we develop a novel two-dimensional axi-symmetric finite element tool programmed in MATLAB that assumes the displacement field to be within a linear elastic range. The stack of pancakes and the large number of REBCO tape turns are approximated as an anisotropic bulk hollow cylinder. Our results agree with uni-axial stress experiments in the literature, validating the bulk approximation. Here, we study the following configuration. The current is first ramped up to below the critical current and we calculate the screening currents and the forces that they cause using the minimum electromagnetic entropy production method (MEMEP) model. This electromagnetic model can now take insulated magnets into account. As a case study, a 32 T REBCO superconductor magnet is simulated numerically. We perform a complete mechanical analysis of the magnet by including the axial and shear mechanical quantities for each pancake, unlike in previous work where only radial and circumferential quantities were focused on. The effect on mechanical quantities without the screening current is also calculated and compared. It is shown that including the screening current-induced field strongly affects the mechanical quantities, especially the shear stress. The latter may be a critical quantity for certain magnet configurations. Additionally, in order to overcome high stresses, a stiff overbanding of different materials is considered and numerically modelled, which significantly reduces the mechanical stresses. The finite element-based model developed is efficient in calculating the mechanical behaviour of any general superconductor magnet and its devices.

Research on microcracks detection of metal plate based on nonlinear ultrasound

Abstract In recent years, phased array ultrasonic non-destructive testing technology has been increasingly applied in the field of non-destructive testing. However, current phased array ultrasonic testing is based on traditional linear ultrasound and is not sensitive to defects such as microcracks in materials. This article proposes a nonlinear ultrasonic phased array detection technology—fundamental amplitude difference. Nonlinear components are obtained by subtracting the transmission of even and odd elements from the transmission of all elements in a phased array. First, to improve the detection effect, MATLAB software is used to simulate and study probes with different parameters. Under the premise of meeting the probe design standards, the various parameters of the probes are determined. Then, an experimental model was established using the finite element tool Abaqus. The relationship between microcracks of different lengths and nonlinear components was calculated by constructing multiple microcrack damage models. The final simulation results show that as the size of microcracks increases, the corresponding nonlinear components also gradually increase, which can more accurately detect nonlinear components and improve detection accuracy.

Design and simulation of a compact plasmonic photonic crystal fiber filter with wide band and high extinction ratio

In order to realize the performance optimization and function expansion of modern all-optical systems, this work presents a compact plasmonic photonic crystal fiber (PCF) filter, using finite element tool. The deposited gold and graphene layers within the elliptical pores interact with the transmitted light, creating surface plasmon resonance (SPR) effect that amplifies the energy difference between x- and y-polarized light greatly. The simulation results indicate that the structural parameters are configured with the cladding holes' diameter of 0.6 μm, the large-holes’ diameter of 1.2 μm, the inner small-holes’ diameter of 0.2 μm, the lattice constant of 2.0 μm, the elliptical holes' minor axis length of 0.45 μm, the elliptical holes' major axis length of 1.30 μm, the gold layer thickness of 50 nm, and the graphene layer thickness of 20 nm, the central wavelength of the proposed PCF filter is 1.56 μm. When the length of this PCF filter is 1 mm, a maximum extinction ratio (ER) of 133 dB, an operating bandwidth exceeding 800 nm, covering two common communication windows of 1.31 μm and 1.55 μm, as well as a low insertion loss (IL) of 0.59 dB can be achieved. What's more, the feasibility of fabricating the device is also examined. This filter with compactness, broadband and high-extinction demonstrates promising applications in optical communication, optical sensing, optical computing, and various other fields.

Experimental validation of a UAS at engine ingestion conditions: Part I Experiments

In recent years, uncrewed aircraft systems (UASs) have greatly increased in popularity and accessibility to the public. This dramatic increase has led to a substantial risk of a midair collision between a UAS and a commercial aircraft, and these collisions need to be analyzed to understand the dangers associated with them. Soft body (i.e., birds or ice) impacts have been happening since the early days of flight and have been studied thoroughly. In contrast, there has been significantly less research on hard body impacts, with most of the currently published research not using experimentally validated models at the conditions expected to be seen in an engine ingestion. The purpose of this work is to discuss the design and execution of experiments to improve and validate a UAS model for high speed impacts for future engine ingestion studies. The overall effort consisted of first conducting physical tests that represent specific high speed ingestion scenarios. Then simulating these tests using a high fidelity finite element tool. Then finally updating the model as necessary. The design of the experiments, experimental test setup, instrumentation and experimental results are highlighted in Part I of this work. The computational model update and validation of the UAS at conditions seen in an engine ingestion are done in Part II of this work.

Effect of Water-added-mass on Modal Behavior of Shaft-line of Large Hydroelectric Generator Unit

The water-added-mass to a hydro turbine-shaft-line can significantly affect its modal behavior including the vibration modes and their natural frequencies. So it is of great significance to consider the effect of added water mass on the modal behavior of a hydro turbine to assure the safe and efficient operation of the hydro turbine-shaft-line system. In this investigation, the effect of water-added-mass on the shaft-line of one large prototype hydroelectric generator unit has been investigated in detail via the finite element tool. First, a CAD model of the shaft-line was created based on actual dimensions. Then a finite element model of the entire shaft-line was generated with high-quality hexahedral and tetrahedral cells. A first round of finite element simulation of the shaft-line in the air was performed without considering the effect of surrounding water, but the results were not realistic. On this basis, a finite element-based water-structure coupling simulation was carried out to analyze the effect of water-added-mass on the modal behavior of the shaft-line of the large hydroelectric generator unit. The result is more realistic to reality than that in the air. The results of this study show that when the water surrounding the turbine runner is added to the hydro-turbine shaft-line, it increases the overall mass of the shaft-line system, thereby reducing the natural frequencies of the system. The decrease in natural frequencies can cause the shaft-line to approach its critical speed during operation, vibrate at higher amplitudes than usual, and even lead to potential damage to the shaft-line system. According to the results calculated with the finite element water-structure coupling method, the countermeasures to improve the evaluation of the water-added-mass effect on the structural modal behavior of the shaft-line for the hydroelectric generator units have been provided. The conclusion can also apply to other hydraulic turbine and pump units.

Biomechanical response of decompression alone in lower grade lumbar degenerative spondylolisthesis--A finite element analysis.

Previous studies have demonstrated the clinical efficacy of decompression alone in lower-grade spondylolisthesis. A higher rate of surgical revision and a lower rate of back pain relief was also observed. However, there is a lack of relevant biomechanical evidence after decompression alone for lower-grade spondylolisthesis. Evaluating the biomechanical characteristics of total laminectomy, hemilaminectomy, and facetectomy for lower-grade spondylolisthesis by analyzing the range of motion (ROM), intradiscal pressure (IDP), annulus fibrosus stress (AFS), facet joints contact force (FJCF), and isthmus stress (IS). Firstly, we utilized finite element tools to develop a normal lumbar model and subsequently constructed a spondylolisthesis model based on the normal model. We then performed total laminectomy, hemilaminectomy, and one-third facetectomy in the normal model and spondylolisthesis model, respectively. Finally, we analyzed parameters, such as ROM, IDP, AFS, FJCF, and IS, for all the models under the same concentrate force and moment. The intact spondylolisthesis model showed a significant increase in the relative parameters, including ROM, AFS, FJCF, and IS, compared to the intact normal lumbar model. Hemilaminectomy and one-third facetectomy in both spondylolisthesis and normal lumbar models did not result in an obvious change in ROM, IDP, AFS, FJCF, and IS compared to the pre-operative state. Moreover, there was no significant difference in the degree of parameter changes between the spondylolisthesis and normal lumbar models after undergoing the same surgical procedures. However, total laminectomy significantly increased ROM, AFS, and IS and decreased the FJCF in both normal lumbar models and spondylolisthesis models. Hemilaminectomy and one-third facetectomy did not have a significant impact on the segment stability of lower-grade spondylolisthesis; however, patients with LDS undergoing hemilaminectomy and one-third facetectomy may experience higher isthmus stress on the surgical side during rotation. In addition, total laminectomy changes the biomechanics in both normal lumbar models and spondylolisthesis models.

A large deformation gradient theory for glassy polymers by means of micromorphic regularization

AbstractCold forming of polycarbonate films results in the formation of shear bands in the necking zone. The numerical results obtained from standard viscoplastic material models exhibit mesh size dependency, requiring mathematical regularization. For this purpose, we present in this work a large deformation gradient theory for a viscoplastic isotropic material model published before. We extend our model to a micromorphic model by introducing a new micromorphic variable as an additional degree of freedom along with its first gradient. This variable represents a microequivalent plastic strain. The relation between the macroequivalent plastic strain and the micromorphic variable is accomplished by a micromorphic coupling modulus. This coupling forces proximity between the macro- and microvariables, leading to the targeted regularization effect. The micromorphic model is implemented as a three-dimensional initial boundary value problem in an in-house finite element tool. The analysis is performed for both uniaxial and biaxial specimens. The provided numerical examples show the ability of our model to regularize shear bands within the specimens and address the issue of localization.

Wavelength multiplexing system based on ring resonators

Wavelength Division Multiplexing, WDM, is a technology developed for applications in telecommunications with the purpose of combining numerous wavelength signals into one single fibre. The aim of this research is the characterization of WDM systems of ring resonators with planar optical waveguides. The optical responses for different configurations, dimensions, and materials are analysed by doing a parametric study both considering analytical expressions and a Finite Element Tool. The results are from add-drop topologies with one, two and three rings. The main difference between topologies with the same parameters is the number of resonance wavelengths, which is higher due to the increase in the number of ring-shaped waveguides. It is concluded that adjusting the rings’ dimensions, the resonant wavelengths are tuned. Furthermore, the higher the rings’ radius the lower is the free spectral range, that can take values from 40 nm to 90 nm. Then, the number of resonant peaks in a wavelength range may change. Also, 1500–5000 describes the values computed for the quality factor, whereas the full width at half maximum varies within some units of nanometres. For models with different core materials, the higher transmittances decrease with lower core refractive indexes and the resonance width increases. These are new degrees of freedom to tune the response of the device that can definitely work as optical wavelength multiplexer, having losses from 20% to 40% considering the transmitted optical power.

Temperature and strain rate effects on ultra‐high‐molecular‐weight‐polyethylene compression: An experimental and modeling approach

AbstractThis study aims to predict the compression behavior of ultra‐high molecular weight polyethylene (UHMWPE) at various temperatures (25, 40, and 55°C) and strain rates (~10−4/s and ~10−2/s) using a single set of three‐network (TN) viscoplastic model parameters. The TN model is made up of three parallel networks: networks A and B use nonlinear springs and dashpots to control the responses of the crystalline phase and confined amorphous phases, respectively, while network C captures the macromolecular amorphous networks using a single nonlinear spring. A single set of TN model parameters captures the yield and post‐yield hardening responses of the stress–strain curves at experimental temperatures and strain rates. When these TN model calibrated parameters are used as material property in a commercial finite element tool to simulate UHMWPE compression, the predicted and simulated results match well, showing the model's fidelity. Additionally, the model predicts experiments conducted at 40 and 70°C with loading rates of ~10−3/s and ~10−2/s, respectively. The study also correlates the deformations of UHMWPE's crystalline structure and macromolecular amorphous networks with its global stress versus strain response by extracting stresses from individual networks of the TN model at different strain rates and temperatures.Highlights UHMWPE's mechanical behavior predicted by a single set of TN model parameters TN model predicts mechanical response at various strain rates and temperatures. TN model explains microstructural crystalline and amorphous phase deformations.

Prediction of shape distortions in thermosetting composite parts using neural network interfaced visco-elastic constitutive model

The work aims to enhance the capabilities of a Finite Element tool, specifically related to a rheological thermo-chemo-viscoelastic constitutive model. This enhancement is intended to improve the tool’s ability to predict the distortions in composite parts caused by the polymerization of the thermoset composite matrix. These distortions occur due to internal residual stress generated by the inherent anisotropic properties of the thermoset composite material, including coefficients of thermal expansion and chemical shrinkage. The research work’s improvement is tied to the precise modelling of curing behaviour, which literature acknowledges as having a significant impact on manufacturing defects. In order to accommodate the influence of curing behaviour on various process variables—specifically, different thermal loading rates—a neural network model is implemented as an alternative to a standard diffusion cure-kinetics model. The neural network model is trained using Differential Scanning Calorimetry data and is integrated with the classical visco-elastic constitutive model to more accurately predict the progression of distinct thermoset resin states. This transition between cure states is assessed using two cure state variables: the degree of cure and the glass transition temperature. The enhanced predictions of state transitions lead to accurate assessments of internal residual stresses, especially when dealing with thick components subjected to thermal fluctuations. The anisotropic properties of thermoset composites, crucial for numerical analysis, are captured at various stages of cure. Ultimately, this methodology is employed to compare process-induced defects in the case study of the Z-shaped carbon/epoxy woven part, and the defects closely align with experimental measurements.

Finite element analysis of JCO-E fabrication process and its influence on the collapse capacity of offshore pipelines

In the present work, the JCO-E fabrication process is numerically simulated using advanced finite element tools for the case of a thick-walled 30-inch-diameter pipe, which is candidate for deep water installation. Subsequently, the structural performance of the line pipe under external pressure is investigated in a unified approach. Uniaxial tests are performed to obtain the material properties used in the finite element model, which are representative of the loading history that the plate is subjected during the process. The finite element model is validated with geometric measurements from the actual pipe fabricated in the pipe mill. The effect of the expansion level on the properties of the final product is investigated through extensive numerical studies. The results have shown that there exists an optimum expansion range for achieving the minimization of the geometric imperfections of the final product and the maximization of the collapse capacity of the pipe.

DESIGN AND STATIC THERMAL ANALYSIS OF PRESSURE VESSELS WITH VARIOUS MATERIALS USING FEM

Stress assessments are required for a great deal of plant components, including the pressure vessel. A pressure vessel is a container designed to store liquids or gases at pressures much higher than the surrounding air. The finite element analysis of pressure vessels with various types of heads that maintain the same cylindrical volume and thickness is the focus of this project. The intended pressure vessel is made for 8 bar of pressure and 24 lit of volume in accordance with ASME standard section VIII, division I. In order to identify the source of the stress concentration zone in each kind of pressure vessel head at the same volume and reasonable pressure, certain end connections are evaluated under FEA. The project's goal is to use Ansys software to analyse various designs and static and thermal data. It finds that elliptical and flat head pressure vessels have lower distributed stresses than other types of heads, making them the preferred choice for most applications. It displays the fundamental construction and uses finite element modelling to analyse pressure vessels made of various materials, such as Nimonic 80A and SA516 Gr70, and with several types of heads under high stress conditions. In this project, we use the Finite Element tool to compute the estimated stresses that occur in cylindrical pressure vessels supported by two saddles under various end connection types. In order to determine the appropriate design and material, static structural analysis and thermal analysis are performed to compute the stresses in the vessel.

A geometry-based finite element tool for evaluating mitral valve biomechanics.

Mitral valve function depends on its complex geometry and tissue health, with alterations in shape and tissue response affecting the long-term restorarion of function. Previous computational frameworks for biomechanical assessment are mostly based on patient-specific geometries; however, these are not flexible enough to yield a variety of models and assess mitral closure for individually tuned morphological parameters or material property representations. This study details the finite element approach implemented in our previously developed toolbox to assess mitral valve biomechanics and showcases its flexibility through the generation and biomechanical evaluation of different models. A healthy valve geometry was generated and its computational predictions for biomechanics validated against data in the literature. Moreover, two mitral valve models including geometric alterations associated with disease were generated and analysed. The healthy mitral valve model yielded biomechanical predictions in terms of valve closure dynamics, leaflet stresses and papillary muscle and chordae forces comparable to previous computational and experimental studies. Mitral valve function was compromised in geometries representing disease, expressed by the presence of regurgitating areas, elevated stress on the leaflets and unbalanced subvalvular apparatus forces. This showcases the flexibility of the toolbox concerning the generation of a range of mitral valve models with varying geometric definitions and material properties and the evaluation of their biomechanics.

Prediction of slab track settlement using an innovative 3D train-track numerical tool: Full-Scale laboratory validation

The growth of slab track construction in recent years is mainly due to its high stability performance and low deterioration rates when subjected to high-demand railway traffic. Nevertheless, when required, slab track maintenance, such as track geometry correction, can be extensively expensive, time consuming and may involve rail service interruptions. Therefore, the development of tools that are able to analyse the performance and predict the behaviour of slab tracks over time can bring significant economic benefits to the railway industry. This work presents slab track settlement studies using a novel hybrid 3D finite-element tool (HI-Track), which is coupled with mechanistic empirical design, that is able to analyse the track behaviour over millions of train passages. The paper presents a case study of long-term experimental measurements conducted in a full scale test rig using the Bögl slab track system subjected to over 3 million load cycles emulating train operation over a long period of time. The HI-Track tool is used to investigate the long-term performance of the slab track laboratory test case, where simulations are compared and checked in a validation process. The main findings substantiate the reliability of the numerical tool to accurately predict track settlement within specified soil compressive strength of 70–100 kPa and a soil stiffness ranging between 100 and 400 MPa.