High-fidelity Finite Element Model Research Articles

Failure mechanisms of hybrid metal–composite joints with different protrusion densities under a tensile load

The mechanical behaviors of hybrid metal–composite joints with different protrusion densities were investigated by combining numerical and experimental methods. High-fidelity finite element models that considered the failure modes of all components were developed, and specimens based on metal additive manufacturing technology were tested under quasi-static tensile load to verify the numerical calculations. The results showed that the load capacity and the dominant fracture mode of joints were significantly affected by the metal protrusion density. The failure mechanisms of joints under different protrusion conditions exhibited a clear difference, which proved the possibility of an optimal and functional joint design.

Evaluation of post-storm soil stiffness degradation effects on the performance of monopile-supported offshore wind turbines in clay

Over their lifetime, offshore wind turbines (OWTs) will experience large storm surges that may negatively affect their structural performance. Current design codes do not provide sufficient guidance on tackling this problem. To address it, this study aims to provide a guideline on how shear stiffness degrades around monopiles in normally consolidated clays after a storm surge. High-fidelity finite element models of monopile-supported OWTs are built and validated with 5.5e-05 mean square error against centrifuge tests. Parametric analysis of 108 scenarios is conducted, considering different pile diameters, lengths, soil strengths, and loading scenarios. Pile toe displacements are recorded and used to define a system that can classify the OWT monopiles as flexible or rigid. Shear stiffness degradation ratios at 1D (pile diameter) depth are utilized to predict the change of natural frequency, given the mudline loads. The data suggest that over 5% or 10% decrease in natural frequency indicates that pile head deformations exceed serviceability or ultimate limit state criterion, respectively. A database of soil strain - stiffness degradation ratio pairs is tabulated along each simulated pile as a reference for degraded p-y curve calibration. The proposed method and database are crucial for safer design and quicker assessment of OWTs.

New aspects of the CISAMR algorithm for meshing domain geometries with sharp edges and corners

Several new algorithmic aspects of the conforming to interface structured adaptive mesh refinement (CISMAR) mesh generation technique are presented for creating high-fidelity finite element models of 3D problems with non-smooth (C0–continuous) geometries. The Stereolithography (STL) file characterizing the domain geometry is first pre-processed to identify its sharp edges and corners, followed by overlaying that on a structured background mesh composed of tetrahedral elements to identify elements cuts by material interfaces/boundaries. Three non-iterative algorithms, namely hierarchical r-adaptivity, element deletion, and Kirigami-inspired sub-tetrahedralization are then introduced to generate a high-quality conforming mesh by relocating background mesh nodes, eliminating degenerate elements, and subdividing non-conforming tetrahedra to match material interfaces and domain boundaries. These algorithms either upgrade or fully replace different phases of the original CISAMR technique, which was limited to modeling problems with smooth interfaces. The example problems provided in this manuscript demonstrate the upgraded CISAMR algorithm to handle domain geometries with complex, non-smooth interfaces.

Structural performance of speed-lock joints with split bolts in steel storage racks

This paper aims to experimentally and numerically investigate the structural performance of speed-lock joints with split bolts in steel storage racks. There are no bolts in the typical speed-lock joint for its ease of installation, and the joint transmits and bears force through interactions of the tabs and upright beam holes. However, the joint under seismic loading shows large looseness and slippage with low stiffness. Also, the energy dissipation capacity is insufficient and the failure of tabs in the joints might lead to brittle behavior. In this study, new detail of the speed-lock joint with bolts is proposed by adding a pair of split bolts in the beam end plate while still preserving its merit of ease of installation. A double-cantilever beam test was designed to test this speed-lock joint with split bolts along with the typical speed-lock joint. Low cyclic loading tests were performed on both types of joints: with split bolts and without split bolts. The results revealed the benefits that the split bolts could bring to significantly enhance the performance of the joint in terms of the maximum bending moment, the initial stiffness, the displacement ductility coefficient, the equivalent viscous damping coefficient, and the energy consumption. In addition, a two-step analysis method was proposed for the high-fidelity finite element model of the joints to overcome the complex contact nonlinearity. The numerical model was then validated with the tests for further numerical studies on the performance of speed lock joints with/without bolts.

Simulated seismic behavior of welded steel tee joints and elbows used in natural gas networks

Welded elbows and tee joints are key components within the natural gas network, hence understanding their seismic behavior is critical to ensure the robust seismic performance of the piping network. This paper summarizes results from an experimental and numerical effort aimed at understanding the cyclic behavior of welded steel tee joints and elbows internally pressurized with air. Specifically, four tee joint and four elbow specimens were tested with a pseudo-static increasing-amplitude cyclic displacement-controlled protocol. Seven specimens exhibited a ductile failure while one specimen observed a brittle failure. High fidelity finite element models of each specimen were developed within Abaqus and their material properties were optimized to obtain robust comparison with the experimental results. Notably, the high fidelity finite element models were able to predict the moment-rotation behavior and the deformed shape of the specimens with significant accuracy for the seven fittings exhibiting a ductile failure.

Large strain zero Poisson’s ratio spring cell metamaterial with critical defect analysis and variable stiffness distributions

This paper presents novel metamaterial skins formed by 3D Spring Cells exhibiting zero Poisson’s ratio in two directions with no stress concentration on joints. Precise CAD models are generated to perform numerical and experiment analysis. High-fidelity Finite element models are developed to assess the homogenisation study of zero Poisson’s ratio. Moreover, the analytical method is also used to present for normalised Young’s modulus. Parametric study for the effect of parameter on normalised Young’s modulus and Poisson’s ratio is demonstrated based on analytical method. Pure shear analysis is demonstrated to show the off-axis loading behaviour. Structural defect analysis is investigated with regarding to its deformation mechanism under tensile strain. Furthermore, variable stiffness distribution of Spring Cell metamaterials is demonstrated while maintaining large strain zero Poisson’s ratio. The frequency and buckling analysis of metamaterials formed by spring cells are investigated and compared with equivalent shell. Moreover, their mechanical behaviours including buckling and frequency are investigated. Experiment analysis is performed to validate the force–displacement, Poisson’s ratio and deformation mechanisms discussed in numerical simulations. Finally, construction material analysis is taking to investigate the relations between metamaterial Poisson’s ratio and Young’s modulus and variety types of construction material.

High-fidelity Modelling Approach for Investigating the Tightening Torque Effect in Thread Connection

Accurate replication of the torque-tightening effect is important when simulating the mechanical behavior of composite joints using the finite element (FE) approach. In this study, a parametric mesh construction strategy was developed to automatically build a high-fidelity 3D FE model with lift angle to simulate bolt thread interactions. An experimental approach was proposed to calibrate the FE model. The relation between tightening torque and the axial force was studied by the FE method, experiment, and engineering algorithm. Results showed that traditional empirical formula overestimate the clamping force. By using the proposed model to calculate the axial force of the bolt, the accuracy of the axial force can be significantly improved when analyzing the composite bolted joints. Finally, parametric simulations were performed to investigate the influence of coefficients of friction at thread interfaces and the nut/washer interfaces. The pre-tightening force was significantly influenced by the frictional coefficients at these interfaces. Results indicated that increasing the coefficient of friction (CoF) at the nut/washer interface from 0.1 to 0.2 can lead up to 28% reduction in the clamping force, while this increase was 23% for the threads interfaces.

고장진단을 위한 영구자석형 동기모터 유한요소 모델 개발

This paper proposes a high-fidelity finite element model of a permanent synchronous motor (PMSM) to predict electromagnetic responses. The proposed method aims to generate electromagnetic responses from the PMSM under various operational conditions-including normal and faulty conditions-by coupling several partial differential equations governing the electromagnetics of a PMSM. The rotor eccentricity is considered to be a representative fault of a PMSM, which has electromagnetic characteristics that differ from the healthy state of a PMSM. Note that eccentricity is the most frequent fault during PMSM operation. Therefore, the proposed model could replicate the defected torque responses of an actual motor system. The effectiveness of the proposed model is validated using measurements from a PMSM test bench. Quantitative comparison reveals that the proposed model could replicate both the transient- and steady-state torque responses of the PMSM of interest at a variety of operational conditions, including a faulty status. The proposed model could be used to generate virtual electromagnetic responses of a PMSM, which could be used for data-driven fault detection methods of electric motor systems.

A multi-fidelity surrogate model for structural health monitoring exploiting model order reduction and artificial neural networks

Stochastic approaches to structural health monitoring (SHM) are often inevitably limited by computational constraints. For instance, for Markov chain Monte Carlo algorithms relying upon computationally expensive finite element models it is almost infeasible to sample the probability distribution of the structural state. To provide instead real-time procedures, this work proposes a non-intrusive surrogate modeling strategy, leveraging model order reduction and artificial neural networks. By relying upon a multi-fidelity (MF) framework, a composition of deep neural networks (DNNs) is devised to map damage and operational parameters onto time-dependent sensor recordings. Such an effective strategy is able to exploit datasets characterized by different fidelity levels without any prior assumption, allowing to blend a small high-fidelity (HF) dataset with a large low-fidelity (LF) dataset, ultimately alleviating the computational burden of supervised training while ensuring the accuracy of the approximated quantities of interest. The resulting surrogate model is made of an LF-DNN, which mimics sensor recordings in the undamaged condition, and of a long short-term memory HF-DNN, which adaptively refines the approximation with the effect of damage. An HF finite element model and an LF reduced order model are adopted offline to generate labeled training data of different fidelity, respectively in the presence or absence of a structural damage. Results relevant to an L-shaped cantilever beam and a portal frame railway bridge prove that the procedure efficiently provides remarkably accurate approximations, outperforming their single-fidelity counterparts. The capability of the MF-DNN to be exploited for SHM purposes is finally shown within an automated Bayesian procedure, aimed at updating the probability distribution of the structural state conditioned on sensor recordings, in the presence of operational variability and measurement noise.

An efficient computational framework for hailstone impacts on composite plates utilizing a semi-empirical viscoplastic contact law

The dynamic response of composite structures under impact loading conditions is a complex problem which is attracting substantial attention. Specifically, the case of hailstone impact introduces additional challenges that are urging to be encountered. Hence, the main goal of this paper is to present the development and validation of a computationally efficient impact model that encompasses a novel semi-empirical viscoplastic contact law for crushable ice impactors together with a new time domain spectral shear plate finite element formulation including nonlinear effects due to large displacements and rotations. The new viscoplastic contact law, which provides the coupling between the hailstone impactor and the targeted composite plate, is derived from analytical expressions and observations based on experiments and high-fidelity finite element simulations which utilize a fully integrated ice failure material model. High-velocity spherical hailstone impact experiments on woven glass/epoxy composite plate target structures are conducted using a high pressure pre-charged gas gun Obtained results are validated against high fidelity finite element models and experimental measurements. The results demonstrate the adequacy of the proposed contact law to capture the impact loading, as well as the accuracy, computational efficiency and additional benefits of the presented computational framework compared to other well-established numerical tools.

Optimal design of thin-layered composites for type IV vessels: Finite element analysis enhanced by ANN

For a type IV hydrogen storage vessel, the complexity of the mechanical system is a result of the increased number of thin-layered composites and geometrical details at dome parts, which significantly prolongs the computation time for traditional numerical analysis and optimal design. In this work, a framework couples machine learning (ML) and finite element (FE) analysis is proposed for a 70 MPa type IV vessel. Providing an approach that allows the winding parameters optimization process to include the corresponded feasible dome geometry. High-fidelity FE models are established and different failure modes are included. The artificial neural network (ANN) is developed and coupled with the FE models, where the irregularity of directional material distribution on both cylindrical and dome regions is adequately considered during the optimization process. Winding parameters extended by practical production modifications such as transition areas and layer ending adjustments are introduced to the modified input layer of ANN, to ensure the integrality of the complex geometrical details. The computational cost is greatly reduced with satisfying accuracy compared to FE analysis, where the optimized lay-up scheme could be obtained with a prediction error of less than 2% on the damage state function. The associated simulation results show an obvious improvement in mechanical response under designed burst pressure. Particularly, the prototypical vessels are further produced to carry out comparative experiments, which indicate that the burst pressure of the type IV vessel has been improved from 145 MPa to 157.74 MPa. This is also consistent with the numerical prediction of burst pressure using Hashin failure criteria and progressive damage analysis.

High-fidelity numerical simulation and experimental validation of a 1600-mm-diameter axial loaded grid stiffened cylindrical shell

Stiffened cylindrical shells are commonly used in the launch vehicle, which are prone to buckling under axial compression load and extremely sensitive to imperfections. Establishing a high-fidelity finite element model is a prerequisite for correctly analyzing buckling load and imperfection sensitivity of stiffened cylindrical shells. This paper proposes a homogenization-based model updating approach for the grid stiffened cylindrical shell with many chamfers, which can establish a high-fidelity shell finite element model that maintains calculation efficiency and accuracy advantages. It uses the equivalent elastic constants of the unit cell as the link to modify the size parameters of the finite element model for the grid stiffened cylindrical shell. Moreover, the axially compressed buckling test of a 1.6-m-diameter orthogrid stiffened cylindrical shell is performed to verify the effectiveness of the proposed method. Through comparison, it could be found that the updated finite element model has a higher analysis accuracy. Specifically, the analysis error of the initial finite element model is −16.85% compared with the test result, while the error of the updated model is only −0.67%. The updated model can be used with full confidence for simulating mechanical performance such as the buckling process and the imperfection sensitivity analysis. Besides, it also indicates the necessity of considering the structural characteristics such as the chamfer in the optimization design process of the grid stiffened cylindrical shell structure.

High-fidelity computational modeling of scratch damage in automotive coatings with machine learning-driven identification of fracture parameters

As one of the key components of a vehicle, automotive coating systems are typical micro-size multilayer composites, which normally suffer from intricate scratch damage. Currently, it is a challenging task to reproduce the complex physical phenomena of automotive coatings with micron thickness using numerical simulations. The purpose of this work is to develop a computational framework for an accurate evaluation of such scratch damage. To achieve this end, a high-fidelity finite element (FE) model is proposed, where a rate-dependent cohesive zone model is developed to account for coating crack behaviors. A reverse identification approach based on the machine learning (ML) method is suggested to determine the rate-dependent cohesive parameters that are difficult to be measured via direct experiments. In the course of recognition, this work develops a two-step regional data augmentation strategy based on the existing single-shot recognition method. The developed strategy is capable of reducing the number of training data samples, while improving identification accuracy and robustness. With the identified cohesive parameters, the proposed finite element model is applied to simulate speed-dependent coating scratch behaviors. The good agreement between numerical and experimental results demonstrates the capacity of our developed computational framework for coating scratch problems.

Bolted steel to laminated timber and glubam connections: Axial behavior and finite-element modeling

This study aims to characterize the axial monotonic and cyclic tensile behavior of bolted steel connections to laminated timber and bamboo, using slotted-in steel plates, and to provide a high-fidelity simulation using finite-element modeling. Forty-eight experimental tests were conducted, including eight different configurations, varying in material (Laminated Veneer Lumber (LVL) and Glued Laminated Bamboo (glubam)), number of bolts, and diameter of bolts, under tension, both monotonic and cyclic (three repetitions). The force and displacement were recorded, and used to define the initial stiffness, yielding strength, ultimate strength, ductility, viscous damping, and energy dissipation. The failure modes of the connections were monitored using Digital Image Correlation (DIC) techniques. A novel high-fidelity finite-element model integrating Hill’s yielding and element removal criteria was proposed to predict the mechanical performance and fracture behavior of the examined connections. The numerical simulation was validated by comparing the experimental load–displacement curves and the strain field measurements obtained with DIC. Finally, theoretical formulas for predicting the stiffness of bolted connections were proposed based on the FEM simulations.

Vibration of prestressed beams: Experimental and finite-element analysis of post–tensioned thin-walled box-girders

In published works, very different explanations are given for the effect of prestressing on the beam dynamics, especially on the relationship between the vibrational effects caused by an external compressive force and those due to a prestressing force. To solve this conflict, free transverse vibrations of a post–tensioned thin-walled steel box-girder were investigated. Its fundamental frequencies were then measured for different values of prestressing. Subsequently, the experimental data were compared with a formula considering shear effects. The experimental data were also compared with two high-fidelity finite-element models assuming geometric nonlinearities. According to the obtained findings, and comparisons with tests reported in literature, the beam dynamics strongly depends on the contact of the cables with the surrounding section. If the tendons are not in contact with the surrounding cross-section, the beam dynamics due to an external compressive force is practically coincident to that caused by a prestressing force for low values of prestressing. In this case, the dynamics of prestressed beams are initially ruled by the compression-softening effect. For high values of prestressing, the beam would behave as a shallow arc with horizontal elastic supports. In this case, an increase of fundamental frequency is observed, but the yield stress would be exceeded. Conversely, in thin-walled steel girder-bridges with tendons in contact with the cross-section or draped with a deviator, the fundamental frequency is practically unaffected by prestressing. Thus, the fundamental frequency cannot be used as indicator for identifying long-term phenomena of prestressing losses, such as anchorage slips, tendon friction and relaxation.

Interdisciplinary design optimization of compressor blades combining low- and high-fidelity models

Multidisciplinary design optimization has great potential to support the turbomachinery development process by improving designs at reduced time and cost. As part of the industrial compressor design process, we seek for a rotor blade geometry that minimizes stresses without impairing the aerodynamic performance. However, the presence of structural mechanics, aerodynamics, and their interdisciplinary coupling poses challenges concerning computational effort and organizational integration. In order to reduce both computation times and the required exchange between disciplinary design teams, we propose an inter- instead of multidisciplinary design optimization approach tailored to the studied optimization problem. This involves a distinction between main and side discipline. The main discipline, structural mechanics, is computed by accurate high-fidelity finite element models. The side discipline, aerodynamics, is represented by efficient low-fidelity models, using Kriging and proper-orthogonal decomposition to approximate constraints and the gas load field as coupling variable. The proposed approach is shown to yield a valid blade design with reasonable computational effort for training the aerodynamic low-fidelity models and significantly reduced optimization times compared to a high-fidelity multidisciplinary design optimization. Especially for expensive side disciplines like aerodynamics, the multi-fidelity interdisciplinary design optimization has the potential to consider the effects of all involved disciplines at little additional cost and organizational complexity, while keeping the focus on the main discipline.

Seismic retrofitting of beam to double-I built-up column moment connections by lateral T-stiffeners: Experimental and numerical study

In the present paper, the retrofitting of welded flange plate moment connections joined to double-I built-up columns is discussed by presenting the design method and details of construction retrofitting. Some of the usual construction problems of this connection include the defective complete joint penetration groove weld at the connection of the flange plate and the column, the large out-of-plane deformations of the column cover plate at the level of the beam-to-column connection, and as a result, its inappropriate seismic performance and the connection's partially restrained behavior. Thus, an attempt is made to evaluate the advantages of strengthening this defective connection with the help of lateral T-stiffeners using analytical and experimental studies. For this purpose, the experimental specimen and the high-fidelity finite element model are considered for both retrofitted and defective connections by evaluating the proposed design method, cyclic behavior of connection, collapse potential of weld fasteners, and failure modes. The results indicate that by using the proposed retrofitting method, the connection is classified in the group of fully restrained connections, while also having the necessary strength and ductility to accept the conditions of the special moment-resisting frames according to AISC seismic provisions. By performing a sensitivity analysis on the T-stiffener, changing its dimensions and examining the damage indices, the accuracy of the proposed design method is proven. The examinations indicate that the aforementioned retrofitting method is a proper method for the introduced defective connection.

High-fidelity simulation of low-velocity impact damage in fiber-reinforced composite laminates using integrated discrete and continuum damage models

A high-fidelity finite element (FE) model based on integrated discrete and continuum damage modeling techniques was developed to predict damage modes, locations, sizes, and damage occurrence sequence in a composite laminate during a low-velocity impact event. Fiber breakage and transverse matrix cracking were captured using the three-dimensional Hashin’s criteria, and delamination was captured by inserting a layer of cohesive elements between every adjacent composite ply. Delamination progression from one layer to another was captured by embedding cohesive elements inside each composite ply aligned with the fiber orientation and with a 45° angle to the thickness direction. The refined mesh and intralaminar cohesive elements were only used in the predicted damage region based on an analytical solution. The FE model predicted impact response was validated by drop-weight tests, and the layer-by-layer damage areas were validated and characterized by X-Ray CT inspections on 254 mm by 304.8 mm IM7/977-3 laminates with a stacking sequence of [0/45/90/-45]4s. The absorbed energy, damage areas, maximum deflection, contact time, and peak load were predicted with less than 10% error. The detailed damage occurrence sequence during the impact event was predicted through histories of energies dissipated by different damage modes. The modeling methodology developed in this work highlights the effects of modeling parameters on convergence, solution accuracy and computational efficiency, and provides an effective approach for progressive damage modeling of composite laminates.

Numerical investigations on dynamic responses of subway segmental tunnel lining structures under internal blasts

Numerical simulation of segmental lining tunnel subjected to internal explosive loading is carried out in this paper based on the arbitrary-Lagrangian-Eulerian (ALE) and finite element (FE) coupled algorithms. A high-fidelity FE model considering assembled features of segmental lining structure is established, and the mapping technique is adopted to accurately simulate the explosion process. The calculated overpressure histories and failure modes of the lining structure fit well with field test results of full-scale specimens, indicating the applicability and accuracy of the numerical model. A more comprehensive numerical model considered the practical service state of segmental lining tunnel is further built based on the verified model. Influences of mechanical properties and pressure levels of surrounding soils on dynamic responses of tunnel structure under internal explosion are investigated. Numerical results show that dominated deformation modes of the segmental lining tunnel under the action of internal explosion include opening deformation at the segmental joints of the charged ring and shear deformation between the adjacent rings. The modest explosion caused by terrorist bombing attacks may severely harm the shield tunnel structure and impair its service performance, especially if the tunnel is buried in soft soil at a shallow depth

Predicting of Punching Shear Capacity of Corroded Reinforced Concrete Slab-column Joints Using Artificial Intelligence Techniques

Rebars in reinforced concrete (RC) slab-column structures may corrodeunder unfavourable conditions, making slab-column joints (SCJs) more susceptibleto punching shear (PS) failure. Moreover, PS failure is a common brittle failure,which makes it more difficult to evaluate slab column systems' functioning andfailure probability. Thus, the prediction of PS resistance and the related reliabilityanalysis are key factors for building RC slab-column systems. In this study, a highfidelity finite-element model was created using Abaqus. A comprehensiveexperimental record is compiled for corroded RC slab-column joints subjected topunching shear loading. Then, effective parameters are established by applying