Finite Element Analysis Research Articles

An improved approach to compensating for cure‐induced deformation to manufacture composite aircraft skin accurately

AbstractThe purpose of this paper is to compensate for the cure‐induced deformation to manufacture composite aircraft skin with variable curvature accurately. Firstly, a finite element analysis (FEA) method appropriate for curing simulation was described. Then, the discrete curvature‐based displacement adjustment (DC‐DA) method for mold surface compensation was proposed. The DC‐DA method utilizes the discrete curvature of the section points to obtain a smooth compensated curve. Finally, a skin part was selected to prove its effectiveness. The experimental results showed that after the mold's surface was modified by the DC‐DA method with the FEA‐predicting deformation as input, the forming shape could meet the requirement of the part accuracy in one cycle. The DC‐DA method was also compared with the displacement adjustment (DA) method and proved to be more efficient for the compensation of composite skin with variable curvature.Highlights The FEA is appropriate for the calculation of the skin's curing deformation. The DC‐DA method is efficient for compensating for the skin's deformation. The shape of the case part could meet the requirement of accuracy in one cycle.

Real-scale tests on bundle-bar-filled circular hollow sections (BBFC) under eccentric compression

The escalating demand for innovative, multifunctional, and advanced composite structures stems from the pressing concerns related to cost efficiency and environmental impact, alongside interest in the prefabrication methods within the construction industry. This paper advances a pioneering approach by proposing the utilization of high-strength bundle-bar-filled circular hollow sections (BBFC) as columns. In this method, a bundle comprising high-strength reinforcing bars with an impressive yield strength of 670 N/mm² is strategically placed within a steel tube, varying in related-slenderness values from 0.86 to 2.44. Subsequent to this arrangement, the bundle undergoes grouting with mortar, resulting in the formation of the BBFCs. The composition of the bundle is a critical aspect, with different configurations featuring 1, 3, 7, and 19 high-strength bars. Given the intricacies involved in the fabrication process, this paper meticulously outlines the unique techniques employed to successfully manufacture the BBFCs. To comprehensively evaluate the performance of these innovative columns, a series of ten real-scale tests were conducted. These tests look at various aspects, including capacity, flexural stiffness, deflection, and strain response. In addition to experimental validation, finite element analysis was applied, not only to corroborate the empirical findings but also to lay the foundation for future parametric studies. These subsequent investigations aim to explore and understand the influence of different geometric and material features on the structural behaviour of this innovative composite column, thereby contributing to the advancement of knowledge in the field.

Decoding the mechanical characteristics of the human anterior cruciate ligament entheses through graduated mineralization interfaces

The anterior cruciate ligament is anchored to the femur and tibia via specialized interfaces known as entheses. These play a critical role in ligament homeostasis and joint stability by transferring forces, varying in magnitude and direction between structurally and functionally dissimilar tissues. However, the precise structural and mechanical characteristics underlying the femoral and tibial entheses and their intricate interplay remain elusive. In this study, two thin-graduated mineralization regions in the femoral enthesis (~21 μm) and tibial enthesis (~14 μm) are identified, both exhibiting distinct biomolecular compositions and mineral assembly patterns. Notably, the femoral enthesis interface exhibits progressively maturing hydroxyapatites, whereas the mineral at the tibial enthesis interface region transitions from amorphous calcium phosphate to hydroxyapatites with increasing crystallinity. Proteomics results reveal that Matrix Gla protein uniquely enriched at the tibial enthesis interface, may stabilize amorphous calcium phosphate, while C-type lectin domain containing 11 A, enriched at the femoral enthesis interface, could facilitate the interface mineralization. Moreover, the finite element analysis indicates that the femoral enthesis model exhibited higher resistance to shearing, whereas the tibial enthesis model contributes to tensile resistance, suggesting that the discrepancy in biomolecular expression and the corresponding mineral assembly heterogeneities collectively contribute to the superior mechanical properties of both the femoral enthesis and tibial enthesis models. These findings provide novel perspectives on the structure-function relationships of anterior cruciate ligament entheses, paving the way for improved management of anterior cruciate ligament injury and regeneration.

Shaking Table Test and Numerical Modeling of Seismic Behavior of Rectangular Tunnel Structures Embedded in Soft Clay

In this paper, a series of 1-g shaking table model tests were carried out to investigate the seismic behavior of a relatively stiff rectangular tunnel structure installed in soft clay bed, accounting for different ground motions with varying peak accelerations. Using a validated numerical analysis procedure, a suite of three-dimensional (3D) finite element (FE) analyses was performed to systematically study the factors of tunnel burial depth, seismic intensity, flexural rigidity of the middle column and tunnel wall thickness on the seismic response of rectangular tunnel structures installed in clayey ground. It was found that, with the increasing burial depth, the seismic response of rectangular tunnel structure became more intense due to the increased inertial force arising from the overlying clay; in terms of improving the seismic performance of tunnel structure, increasing tunnel wall thickness seemed more effective than increasing flexural rigidity of the middle column. Furthermore, it was found that the existing simplified approaches generally tended to overestimate the earthquake-induced racking distortions of rectangular tunnels installed in clayey ground. A new semi-empirical relationship was derived for better correlating the racking ratio with flexibility ratio for rectangular tunnels embedded in soft clays, which could provide a useful reference for the seismic design and risk assessment of similar clay-tunnel systems.

Probabilistic Modeling Geometric Tolerance and Low Cycle Fatigue Life of Gas Turbine Compressor Blade

Abstract This paper presents a probabilistic low cycle fatigue (LCF) assessment for geometric tolerances on high load contact surfaces of gas turbine compressor blades. The typical patterns of the geometric deviations for the root contact flank of the compressor blades are identified and characterized according to coordinate measurement machine (CMM) measurements of the blade root. These typical patterns are closely related to the root form manufacture tools and process. Finite element (FE) models for the typical geometric deviation patterns are created based on nodal coordinates transformation of the surface nodes on the blade root contact flanks and radius. An optimized blade root profile tolerance is established, which enables significant cost saving. The elastic-plastic FE analysis with nonlinear contact model, material strain-life test, response surface, and constrained Monte Carlo simulation are used to create a probabilistic LCF life model for the optimized tolerance. The model quantifies the effect of the geometric deviations, blade mass, and material property on the blade LCF life. The result shows that with the optimized tolerance, the probability of blade LCF failure is very low and acceptable. It is also shown that the strain life material property is the most critical factor for the LCF failure. The root profile tolerance and blade mass are seen to have a much weaker effect on the blade LCF life.

The Influence of Material Properties and Wall Thickness on Predicted Wall Stress in Ascending Aortic Aneurysms: A Finite Element Study.

Finite element analysis (FEA) has been used to predict wall stress in ascending thoracic aortic aneurysm (ATAA) in order to evaluate risk of dissection or rupture. Patient-specific FEA requires detailed information on ATAA geometry, loading conditions, material properties, and wall thickness. Unfortunately, measuring aortic wall thickness and mechanical properties non-invasively poses a significant challenge, necessitating the use of non-patient-specific data in most FE simulations. This study aimed to assess the impact of employing non-patient-specific material properties and wall thickness on ATAA wall stress predictions. FE simulations were performed on 13 ATAA geometries reconstructed from computed tomography angiography (CTA) images. Patient-specific material properties and wall thicknesses were made available from a previous study where uniaxial tensile testing was performed on tissue samples obtained from the same patients. The ATAA wall models were discretised with hexahedral elements and prestressed. For each ATAA model, FE simulations were conducted using patient-specific material properties and wall thicknesses, and group-mean values derived from all tissue samples included in the same experimental study. Literature-based material property and wall thickness were also obtained from the literature and applied to 4 representative cases. Additional FE simulations were performed on these 4 cases by employing group-mean and literature-based wall thicknesses. FE simulations using the group-mean material property produced peak wall stresses comparable to those obtained using patient-specific material properties, with a mean deviation of 7.8%. Peak wall stresses differed by 20.8% and 18.7% in patients with exceptionally stiff or compliant walls, respectively. Comparison to results using literature-based material properties revealed larger discrepancies, ranging from 5.4% to 28.0% (mean 20.1%). Bland-Altman analysis showed significant discrepancies in areas of high wall stress, where wall stress obtained using patient-specific and literature-based properties differed by up to 674kPa, compared to 227kPa between patient-specific and group-mean properties. Regarding wall thickness, using the literature-based value resulted in even larger discrepancies in predicted peak stress, ranging from 24.2% to 30.0% (mean 27.3%). Again, using the group-mean wall thickness offered better predictions with a difference less than 5% in three out of four cases. While peak wall stresses were most affected by the choice of mechanical properties or wall thickness, the overall distribution of wall stress hardly changed. Our study demonstrated the importance of incorporating patient-specific material properties and wall thickness in FEA for risk prediction of aortic dissection or rupture. Our future efforts will focus on developing inverse methods for non-invasive determination of patient-specific wall material parameters and wall thickness.

Zirconia endocrown with intracanal extension and zirconia posts on maxillary molars: in silicio study.

The study aims to evaluate the stress distribution on tooth and restoration of zirconia endocrowns with pulp chamber or intracanal extension and zirconia post performed maxillary first molar using finite element analysis. Three three-dimensional endodontically treated maxillary molars were modeled. Cortical bone and cementum were modeled 2 mm and 200 μm in thickness. Periodontal ligament at 250 μm thickness was constructed. Zirconia endocrown with pulp chamber extension of 2 mm (Model E+PCE), zirconia endocrown with intracanal extension of 4 mm (Model E+ICE), and zirconia post of 4 mm and crown (ZP) were modeled using software. All restoration models were placed on the maxillary molars. Models were subjected to 400 N loading from the three occlusal contact points. Von Mises stress was recorded. Expectingly, points where the stress was applied showed high stress compared to other regions of the models. The stress did not occur at the trifurcation in any of the models. For the stresses occurring in the restoration material, there were 14.67 MPa, 57.79 MPa, and 155.56 MPa, in Models E+PCE, E+ICE, and ZP, respectively. At the remaining dentin, these values were 47.04 MPa, 32.85 MPa, and 33.42 MPa in Models E+PCE, E+ICE, and ZP, respectively. Within the limitation of the study, zirconia endocrowns with intracanal extension exhibit more favorable stress distribution in both restoration material and dentin compared to zirconia posts and pulpal extension endocrowns. These findings suggest that endocrown with intracanal extension may be a better restorative option for reducing stress.

Structural performance of split orthogonal beam joints in continuous beam‐type circular concrete‐filled steel tubular beam‐to‐column connections

AbstractA continuous beam‐type connection has been proposed as a new type of concrete‐filled steel tubular beam‐to‐column connection without a diaphragm exhibits good seismic performance. However, in a 2‐way configuration, the performance of the connection in a direction orthogonal to the continuous beam may be suboptimal due to beam splitting. In this study, a new detail of a split orthogonal beam joint was proposed and 4 specimens were constructed and tested under quasi‐static conditions. All the specimens attained the full‐plastic flexural strength for the beams and exhibited a stable inelastic behavior. The specimen in which the depth of the orthogonal continuous beam was 100 mm greater than that of the split beam exhibited good inelastic cyclic behavior, whereas two other specimens with a split beam exhibited slipping and pinching. Minor fractures were observed in the tube wall; however, the strength and stiffness did not deteriorate significantly, though a slight pinched hysteresis was observed. In addition, a finite element analysis was conducted. The split beam was largely rotationally constrained by the bearing pressure of the concrete above and/or below the beam flange. If the split beam's flange was sufficiently inserted into the connection panel, the stiffness and strength were ensured.

Nondestructive differential eddy current testing for corrosion detection on coated aluminium alloys

PurposeThe objective of this study is to use non-destructive testing of corrosion on coated aluminium alloys using differential eddy current detection (DECD), with the aim of elucidating the relationship between the characteristics of corrosion defects and the detection signal.Design/methodology/approachPitting corrosion defects of varying geometrical dimensions were fabricated on the surface of aluminium alloy plates, and their impedance signals were detected using DECD to investigate the influence of defect diameter, depth, corrosion products and coating thickness on the detection signals. Furthermore, finite element analysis was used to ascertain the eddy current distributions and detection signals under different parameters.FindingsThe size of the defect is positively correlated with the strength of the detection signal, with the defect affecting the latter by modifying the distribution and magnitude of the eddy current. An increase in the diameter and depth of corrosion defects will enhance the eddy current detection (ECD) signal. The presence of corrosion products in the corrosion defects has no significant effect on the eddy current signal. The presence of a coating results in a decrease in the ECD signal, with the magnitude of this decrease increasing with the thickness of the coating.Originality/valueThe objective is to provide experimental and theoretical references for the design of eddy current non-destructive testing equipment and eddy current testing applications.

A multi‐layer approach for additive manufacturing of continuous fiber composites

AbstractAdditive manufacturing (AM) of continuous fiber reinforced polymer composites (cFRPCs) requires innovative tool‐pathing strategies that account for the anisotropic properties of the continuous fibers and ensure their continuous deposition as reinforcement along the designed structure, reducing fibers bending and cutting. Existing 3D printing slicing software, designed for isotropic materials like neat polymers, has been adapted for 3D printing of continuous fiber composites, resulting in a layer‐by‐layer approach that necessitates filament cutting after each layer deposition. This method introduces discontinuities, weakening the material and underutilizing continuous fibers strength. In this research, we propose a novel tool‐pathing strategy designed to address these challenges through (1) Ensuring fiber continuity across layers by allowing overlapping filaments and (2) Strategically positioning fiber cut points based on stress distribution, modeled using finite element analysis. A Multi‐Layer Continuous Fiber Path (ML‐CFP) approach was introduced and validated on a simple bracket structure featuring two load‐application inserts. 3D printed brackets using different tool paths were tested to failure under tension and compression after compression molding to improve interlayer adhesion. Mechanical investigations confirmed that the ML‐CFP approach enhances fiber utilization, improving tensile strength and work to fracture by up to 46% and 100% through promoting failure in fibers rather than at cut points.Highlights Introduced the multi‐layer continuous fiber path method (ML‐CFP) in AM of cFRPCs. Introduced the strategic cut point placement (SCPP) based on stress distribution. Maintaining fiber continuity and reduce fiber bending by allowing filament overlap. Mechanical testing to compare the ML‐CFP with conventional slicing methods. Enhanced tensile strength by up to 46% and work to fracture by 100%.

Comparative study of a femoral amputated limb with and without implant

The contact pressure at the socket–residual limb interface is the most critical parameter for evaluating the comfort of a leg prosthesis. Experimental studies have analyzed this parameter for typical postures and during walking on a flat surface of an amputee; however, experimental tests require a real socket prototype equipped with transducers. To optimize socket design, this work presents a virtual approach based on a digital avatar of a patient wearing a lower limb prosthesis. Our study integrates two different types of simulations: the first concerns the femur with an implant, the second without an implant, and includes the evaluation of pressure at the socket–residual limb interface using finite element analyses (FEA). The objective of this study is to understand the distribution of loads and stresses at the interface between the residual limb and the prosthesis. The lower contact pressure is represented by CPRESS, while CSHEAR1 is the frictional shear stress component in the first local tangent direction, and CSHEAR2 is the frictional shear stress component in the second local tangent direction.

Equivalent spring model and efficient numerical strategy for simulating mechanical performance of seam-clip connections in aluminum alloy high-vertical standing seam metal cladding systems

The equivalent spring model has been validated as effective in simulating the mechanical performance of seam-clip connections in typical steel high-vertical standing seam metal cladding systems (SSMCSs). To enhance its applicability, this study further refines the equivalent spring model by developing thickness-related stiffness calibration models and an efficient numerical strategy for seam-clip connections in the aluminum alloy SSMCSs. Tensile tests are initially conducted to analyze the material properties of specimens with three commonly used thicknesses. Subsequently, the mechanical performance of the aluminum alloy seam-clip connections with different thicknesses is systematically studied, followed by the development of thickness-related stiffness calibration models. The tensile test results reveal notable nonlinearities and variability in the mechanical performance. To simulate this mechanical performance equivalently in the finite element (FE) model using data from tensile tests, an efficient numerical strategy is developed. This strategy involves methods for implementing simplified connections to establish the equivalent spring model and techniques for efficiently creating these simplified connections. It is found that both connectors and spring connections with calibrated parameters from tensile tests can effectively replicate the mechanical performance of seam-clip connections. To further validate the effectiveness of the equivalent spring model and the efficient numerical simulation strategy, a comparison of structural responses of the double-span sheet module (DSSM) obtained from tests and FE analysis is performed. The results reveal that all simulated structural responses on the DSSM with three common sheet widths align well with the corresponding experimental results. This highlights the feasibility and efficacy of the equivalent spring model and efficient numerical strategy in simulating the mechanical performance of seam-clip connections and delving deeper into the structural responses of the aluminum alloy high-vertical SSMCSs.

Finite element study of stress distribution in medial UKA under varied lower limb alignment

Knee osteoarthritis (KOA) has a high incidence among the elderly, significantly impacting their quality of life and overall health. Medial unicompartmental knee arthroplasty (UKA) is an excellent choice for treating knee single-compartment lesions, and lower limb alignment has a profound impact on medial UKA. To explore the influence of different lower limb alignments on medial UKA. In this study, we selected MR and CT data of healthy adult male knee joints to establish a complete finite element analysis (FEA) model of the knee joint. After validation, we established a finite element model of medial UKA. Subsequently, we created 60 sets of FEA models with different lower limb alignments to analyze the impact of different lower limb alignments on medial UKA. A vertical load of 1000 N was applied to the FEA models with different lower limb alignments. During the process of shifting the Mikulicz line from the midpoint of the knee joint towards the medial side, the lower limb load was primarily concentrated on the medial compartment. The stress values of the lateral meniscus, tibial cartilage, and femoral cartilage gradually decreased. ROI (region of interest) 1 and ROI 2 showed the maximum principal strain changes, while ROI 3 and ROI 4 exhibited less pronounced fluctuations, with the maximum principal strain roughly proportionally increased. During the process of shifting the Mikulicz line towards the lateral side from the midpoint of the knee joint, the stress on the lateral compartment increased observably. ROI 1, ROI 2, ROI 3, and ROI 4 showed decreased maximum principal strains, approximately inversely proportional changes, but the overall reduction was relatively small. Different lower limb alignments have a profound impact on the short- and long-term joint function after UKA. When the Mikulicz line is 10 mm inside the midpoint of the knee joint or slightly outside, there is a relatively lower risk of tibial component fractures, lower stress on the lateral compartment, and lower load on the prosthesis. During medial UKA, measures such as bone resection and prosthesis selection should be taken to ensure that the Mikulicz line is in the ideal position.

Vibration suppression of balls in different contact states during mirror milling of curved thin-walled parts based on magnetic follow-up support fixture

Milling of curved thin-walled parts is a critical step in the manufacturing of aircraft skins or rocket storage tanks. During the process of milling thin-walled parts using magnetic follow-up support fixture, the complex situation that the fixture balls in different contact states with the surface of the thin-walled parts occurs, leading to changes in the dynamic characteristics of the thin-walled parts, thereby causing machining vibration and even chatter, ultimately affecting machining quality. To this end, this paper focuses on the vibration of thin-walled parts under balls in different contact states. Firstly, the structure and function of the magnetic follow-up support fixture are illustrated. Then, a dynamical model of a mirror milling system that accurately reflects balls in different contact states is established using finite element technology, in order to explore the changing law of dynamic characteristics at milling points of thin-walled parts under balls in different contact states. To further investigate chatter under balls in different contact states of thin-walled parts, after obtaining modal parameters of the thin-walled parts through impact tests, three-dimensional stability lobe diagrams (3D-SLDs) of thin-walled parts under balls in different contact states are plotted using the full-discretization method, and chatter-free parameters are selected. Finally, the rationality of finite element analysis and stability analysis, as well as the practicality of the fixture, are verified through milling experiments. The experimental results show that after the fixture is applied, the dominant frequency of curved thin-walled parts can be increased by up to 6 times, its amplitude can be reduced by over 60 %, and the surface roughness can be reduced by up to 57.98 %.

Strain and Deformation Analysis Using 3D Geological Finite Element Modeling with Comparison to Extensometer and Tiltmeter Observations

This study verifies the practicality of using finite element analysis for strain and deformation analysis in regions with sparse GNSS stations. A digital 3D terrain model is constructed using DEM data, and regional rock mass properties are integrated to simulate geological structures, resulting in the development of a 3D geological finite element model (FEM) using the ANSYS Workbench module. Gravity load and thermal constraints are applied to derive directional strain and deformation solutions, and the model results are compared to actual strain and tilt measurements from the Jiujiang Seismic Station (JSS). The results show that temperature variations significantly affect strain and deformation, particularly due to the elevation difference between the mountain base and summit. Higher temperatures increase thermal strain, causing tensile effects, while lower temperatures reduce thermal strain, leading to compressive effects. Strain and deformation patterns are strongly influenced by geological structures, gravity, and topography, with valleys experiencing tensile strain and ridges undergoing compression. The deformation trend indicates a southwestward movement across the study area. A comparison of FEM results with ten years of strain and tiltmeter data from JSS reveals a strong correlation between the model predictions and actual measurements, with correlation coefficients of 0.6 and 0.75 for strain in the NS and EW directions, and 0.8 and 0.9 for deformation in the NS and EW directions, respectively. These findings confirm that the 3D geological FEM is applicable for regional strain and deformation analysis, providing a feasible alternative in areas with limited GNSS monitoring. This method provides valuable insights into crustal deformation in regions with sparse strain and deformation measurement data.

Finite element analysis of 2.5D packaging processes based on multi-physics field coupling for predicting the reliability of IC components

The 2.5D packaging technology is a high–performance method for electronic packaging. This study addresses the reliability issues of 2.5D packaging during the manufacturing process. A multi–physics field coupling Finite Element Method (FEM) has been developed, combined with sub–modeling techniques, to investigate the curing of underfill adhesive, the curing of Epoxy Molding Compound (EMC), and the reflow soldering between the interposer and substrate in a 2.5D packaging entity during various manufacturing procedures. The focus is on the thermo–mechanical–chemical behavior of viscoelastic components within the packaging structure, as well as the viscoplastic characteristics of the micro solder balls and microbumps. A systematic analysis is conducted on the warpage deformation and stress distribution of the 2.5D packaging at crucial time points. The results demonstrate that after curing, the overall warpage of the packaging exhibits a ‘concave’ warpage profile. Additionally, as the thickness of the EMC above the chip increases, the warpage value of the packaging also increases. The warpage value defined by linear elasticity is larger than that defined by viscoelasticity. The maximum Von Mises stress value in the key areas of the submodel is greater than the maximum Von Mises stress value in the corresponding key areas of the global model. After reflow soldering, the stress concentration in the micro solder balls occurs at the edge of the micro solder ball array. The maximum stress values for each component of the packaging are observed in the interface areas between the components. Packaging components that undergo the curing process have notably higher warpage and Von Mises stress values than those that do not undergo the curing process. The simulation method established in this study can accurately predict the warpage deformation and stress distribution state of 2.5D packaging, providing significant engineering application value for process optimization and reliability enhancement of 2.5D packaging in the production process.

Thermal model to investigate temperature distribution with a hollow notched K-wire for bone drilling

K-wire drilling is commonly used in orthopedic surgeries, generating significant heat that can lead to bone thermal osteonecrosis. To understand the heat propagation and thermal damage region, a mathematical model of the negative rake angle on the hollow notched K-wire was established. Subsequently, a theoretical model of the shear angle for this negative rake angle was proposed. Based on these models, a comprehensive theoretical model of the heat flux was derived. The accurate heat flux was determined using the theoretical values, and experimental temperature data through inverse heat transfer method (IHTM). This heat flux was then applied in a finite element analysis to simulate the heat transfer process and identify thermal damage regions under different drilling conditions. Results showed that the thermal damage region of bone with a solid K-wire, hollow notched K-wire without cooling, with air cooling, and with water cooling were approximately 6.4 mm, 3.2 mm, 2.6 mm, and 4.8 mm in width, respectively, and 6.79 mm, 6.45 mm, 6.39 mm, and 6.58 mm in depth, respectively. This study demonstrates that the hollow notched K-wire with air cooling is a potential solution to reduce the thermal damage region, thereby accelerating patient recovery.

Design and Simulation Study of Structural Parameters of Bionic Cutters for Tea Harvest Imitating Aeolesthes induta Newman

The cutter of the hand-held tea picker is the key cutting component in the efficient tea harvesting process. In order to solve the problems of large cutting resistance and uneven incision during tea picking, this study fully applied the bionics principle to combine the excellent cutting performance of Aeolesthes induta Newman’s mandibles with the tea cutter, which extracted and fitted the tooth profile structure curve of the upper edge of the Aeolesthes induta Newman’s mandibles. The trapezoidal teeth on the reciprocating cutter of ordinary hand-held tea-picking harvesters were optimized by the fitted curve, and a new tea cutter with the shape of Aeolesthes induta Newman teeth was obtained, which included four kinds of bionic tea-harvesting cutters. The multi-body system software ADAMS 2020 and finite element analysis software ANSYS 2024R1 were used to compare the kinematics, statics and explicit dynamics of cutting properties of the four bionic cutters and common cutters with ordinary trapezoidal teeth and saw teeth. The simulation results showed that the maximum equivalent elastic strain and the maximum cutting force during the cutting operation were reduced by 36.7% and 42.89%, respectively, for the cutting teeth of the bionic tea-harvesting cutter #4 compared with that of the cutter with ordinary trapezoidal teeth. The bionic tea-harvesting cutter designed in this study has better cutting performance than the cutter with traditional cutting teeth, which can effectively reduce the cutting force and improve the flatness and cutting quality of the cutting surface.

Finite element analysis of sliding wear on the borided AISI 316L stainless steel

This work implements a 3D finite element to analyze wear in borided AISI 316 L stainless steel. The 3D model was validated through sliding wear test under a ball-on-flat configuration, following the ASTM G133 standard procedures. ABAQUS software was used with an Arbitrary Lagrangian-Eulerian (ALE) remeshing technique alongside the UMESHMOTION subroutine to apply an elemental level Archard’s equation. The artificial roughening of the worn surfaces due to discretization in finite element sizes was controlled by relating the maximum increment time on each wear step to the element size and the stroke. The study also described the evolution of the stress field and the behavior of the contact area. The maximum stress was estimated after the first indentation, decreasing as the contact area increased, reaching a minimum at the last wear step. The results revealed a good correlation between the experimental and modeled data, with a maximum error of 8.34% in the contact stress and a maximum error of 22% in the wear depth.

High stability enhanced ultrasonic microfluidic structure with flexible tip coupled bubbles

Ultrasonic microfluidic technology is a technique that couples high-frequency ultrasonic excitation to microfluidic chips. To improve the issues of poor disturbance effects with flexible tip structures and the susceptibility of bubbles to thermal deformation, we propose an enhanced ultrasonic microchannel structure that couples flexible tips with bubbles aiming to improve the disturbance effects and the stability duration. Firstly, we used finite element analysis to simulate the flow field distribution characteristics of the flexible tip, the bubble, and the coupling structure and obtained the steady-state distribution characteristics of the velocity field. Next, we fabricated ultrasonic microfluidic chips based on these three structures, employing 2.8 μm polystyrene microspheres as tracers to analyze the disturbance characteristics of the flow field. Additionally, we analyzed the bubble size and growth rate within the adhering bubbles and coupling structures. Finally, we verified the applicability of the coupling structure for biological samples using human red blood cells (RBCs). Experimental results indicated that, compared to the flexible tip and adhering bubble structures, the flow field disturbance range of the coupling structure increased by 439.53% and 133.48%, respectively; the bubble growth rate reduced from 14.4% to 3.3%. The enhanced ultrasonic microfluidic structure proposed in this study shows great potential for widespread applications in micro-scale flow field disturbance and particle manipulation.