Mechanical Finite Element Analysis Research Articles

Review of Biomechanical Studies and Finite Element Modeling of Sternal Closure Using Bio-Active Adhesives.

The most common complication of median sternotomy surgery is sternum re-separation after sternal fixation, which leads to high rates of morbidity and mortality. The adhered sternal fixation technique comprises the wiring fixation technique and the use of bio-adhesives. Adhered sternal fixation techniques have not been extensively studied using finite element analysis, so mechanical testing studies and finite element analysis of sternal fixation will be presented in this review to find the optimum techniques for simulating sternal fixation with adhesives. The optimal wiring technique should enhance bone stability and limit sternal displacement. Bio-adhesives have been proposed to support sternal fixation, as wiring is prone to failure in cases of post-operative problems. The aim of this paper is to review and present the existing numerical and biomechanical sternal fixation studies by reviewing common sternal closure techniques, adhesives for sternal closure, biomechanical modeling of sternal fixation, and finite element modeling of sternal fixation systems. Investigating the physical behavior of 3D sternal fixation models by finite element analysis (FEA) will lower the expense of conducting clinical trials. This indicates that FEA studies of sternal fixation with adhesives are needed to analyze the efficiency of this sternal closure technique virtually.

Highly stretchable organic electrochemical transistors with strain-resistant performance.

Realizing fully stretchable electronic materials is central to advancing new types of mechanically agile and skin-integrable optoelectronic device technologies. Here we demonstrate a materials design concept combining an organic semiconductor film with a honeycomb porous structure with biaxially prestretched platform that enables high-performance organic electrochemical transistors with a charge transport stability over 30-140% tensional strain, limited only by metal contact fatigue. The prestretched honeycomb semiconductor channel of donor-acceptor polymer poly(2,5-bis(2-octyldodecyl)-3,6-di(thiophen-2-yl)-2,5-diketo-pyrrolopyrrole-alt-2,5-bis(3-triethyleneglycoloxy-thiophen-2-yl) exhibits high ion uptake and completely stable electrochemical and mechanical properties over 1,500 redox cycles with 104 stretching cycles under 30% strain. Invariant electrocardiogram recording cycles and synapse responses under varying strains, along with mechanical finite element analysis, underscore that the present stretchable organic electrochemical transistor design strategy is suitable for diverse applications requiring stable signal output under deformation with low power dissipation and mechanical robustness.

Determinants of fracture type in the proximal femur: Biomechanical study of fresh frozen cadavers and finite element models.

Proximal femur fractures are usually categorized as either a cervical or trochanteric fracture, but the relationship between fracture type and fall direction is not clear. By cadaveric mechanical testing and finite element analysis (FEA), the aims of this research were to verify the factors that define the proximal femur fracture type and to clarify the change in stress distribution based on fall direction. From fresh frozen cadavers, we obtained 26 proximal femora including ten pairs of 20 femora. We conducted quasi-static compression tests in two fall patterns (lateral and posterolateral), and identified the fracture type. We then examined the relationship between fracture type and the following explanatory variables: age, sex, neck shaft angle, femoral neck length, bone mineral density (cervical and trochanteric), and fall direction. In addition, for the ten pairs of femurs, the effect of fall direction on fracture type was examined by comparing the left and right sides. In addition, we generated the proximal femur finite element (FE) models from computed tomography data to simulate and verify the change of external force in different fall directions. In mechanical tests, only fall direction was found to have a significant relationship with fracture type (p=0.0227). The posterolateral fall group had a significantly higher incidence of trochanteric fractures than lateral fall group (p=0.0325). According to FEA, the equivalent stress in the lateral fall was found to be more concentrated in the cervical area than in the posterolateral fall. In proximal femur fractures, fall direction was significantly associated with fracture type; in particular, trochanteric fractures were more likely to occur following a posterolateral fall than a lateral fall.

Performance comparison of carbon fiber reinforced polyaryletherketone and epoxy composites: Mechanical properties, failure modes, cryo‐thermal behavior, and finite element analysis

AbstractHigh‐performance thermoplastic composites are gaining attention as potential replacement for thermoset composites in high‐end structural applications owing to their superior fracture toughness and recyclability. In this study, polyaryletherketone (PAEK) and carbon fabric (CF) reinforced PAEK are compared with epoxy and epoxy‐CF composites. PAEK‐CF composites are prepared by film stacking method followed by compression molding while hand lay‐up technique was used for epoxy‐CF composites. PAEK and PAEK‐CF composites possess superior tensile properties, flexural strength and fracture toughness compared to those prepared from epoxy. The incorporation of CF improved the wear resistance in both PAEK and epoxy and PAEK‐CF exhibited the lowest wear rate. The investigation of interlaminar shear strength of the composites was conducted and the highest value observed for PAEK‐CF composite. Wear and fracture surface analysis suggested ductile failure for PAEK and PAEK‐CF composites and brittle failure in epoxy composites, as indicated by interfacial bonding/debonding and fiber pullout, at the fracture surface. Cryo‐thermal cycling effects on the tensile properties, fracture toughness and fracture surface morphology of the composites are studied. The failure behavior obtained from experimental studies was corroborated with finite element method‐based simulation models of fracture toughness response in single edge notch bend test using Abaqus/Explicit.

Mechanical Characterization and Finite Element Analysis of Hierarchical Sandwich Structures with PLA 3D-Printed Core and Composite Maize Starch Biodegradable Skins

The objective of this research is the fabrication of biodegradable starch-based sandwich materials. The investigated sandwich structures consist of maize starch-based films as skins and biodegradable 3D-printed polylactic filaments (PLA) as the core. To investigate the tensile properties of the skins, conventional and nanocomposite films were prepared by a solution mixing procedure with maize starch and glycerol as the plasticizer, and they were reinforced with sodium montmorillonite clay, cellulose fibers and fiberglass fabric, with different combinations. Test results indicated a significant improvement in the mechanical and morphological properties of composite films prepared with sodium montmorillonite clay in addition with cellulose fibers and fiberglass fabric, with 20 wt% of glycerol. The morphology of the skins was also examined by scanning electron microscopy (SEM). Three orders of hierarchical honeycombs were designed for the 3D-printed core. To investigate how the skin material and the design of the core affect the mechanical properties of the starch-based sandwich, specimens were tested under a three-point bending regime. The test results have shown that the flexural strength of the biodegradable sandwich structure increased with the use of a second order hierarchy core and starch-based skins improved the strength and stiffness of the neat PLA-based honeycomb core. The bending behavior of the hierarchical honeycombs was also assessed with finite element analysis (FEA) in combination with experimental findings. Flexural properties demonstrated that the use of starch-based films and a PLA honeycomb core is a suitable solution for biodegradable sandwich structures.

How can medial support for proximal humeral fractures be achieved when positioning of regular calcar screws is challenging? Slotting and off-axis fixation strategies.

Achieving medial support for proximal humeral fractures (PHFs) by regular calcar screw positioning is challenging when the humeral head is small or locking plates are placed distally, as there are unable inserted calcar screws into the humeral head. We aimed to investigate the suitability of the 2 strategies, slotting calcar screw (SCS) and off-axis calcar screw (OCS), to achieve medial support for PHFs. Regular calcar screw (RCS), SCS, OCS, and noncalcar screw (NCS) were tested via mechanical experiments and finite element analysis (FEA), using synthetic bones for biomechanical comparisons. All PHFs treated in our hospital from March 2017 to March 2019 were reviewed. The patients were divided into 3 groups based on the calcar screw fixation: RCS, SCS, and OCS. The postoperative varus collapse (neck-shaft angle changed to less than 120°) and Disabilities of the Arm, Shoulder and Hand (DASH) scores were recorded. The properties of RCS, SCS, and OCS against the torsion and varus force were superior to those of NCS, whereas the stiffness of SCS, OCS, and RCS were similar. FEA predicted lower peri-screw strains in the OCS and SCS than in the RCS, indicating a lower risk of cut-out. Patients (n = 125; 75 female, 50 male) aged 55.9 ± 13.0 years were evaluated. Compared with the RCS (5/55), varus collapse incidences were not significantly higher following SCS (0/29, P = .094) or OCS (3/41, P = .756), and neither were DASH scores (P = .867 and .736, respectively). This study is a preliminary study demonstrating that the SCS and OCS fixation strategies could be useful alternatives when regular calcar fixation is not possible using the plate at hand.

Custom design and biomechanical clinical trials of 3D‐printed polyether ether ketone femoral shaft prosthesis

During the surgical resection and reconstruction of a pathological femoral fracture, the removal of the femoral tumor leaves a large bone defect. Thus, it is necessary to reconstruct the defect and perform internal fixation. Polyether ether ketone (PEEK) has been widely used in spinal fusion and cranioplasty given its excellent biomechanical properties, biocompatibility, and stability. The typical design method of femoral prosthesis is based on the contralateral mirror image model (M-model), and we propose a novel method for designing femoral prosthesis, which is based on the cross section and centerline of the mirrored femur (C-model). In this study, the femoral shaft prostheses based on two models were manufactured using fused deposition modeling technology, and we use mechanical test and finite element analysis (FEA) to reveal the differences in mechanical properties of the two models. The mechanical results showed that the maximum loading force and yield strength were increased by 3% and 6% in the C-model prosthesis compared with the M-model prosthesis, respectively. In FEA, the results indicate that the C-model prosthesis could reduce the stress concentration by 5.4%-10.9% compared to the M-model prosthesis. Finally, the 3D-printed PEEK femoral shaft prosthesis based on C-model was implanted, no early complications occurred. Postoperative radiological examination indicated that the prosthesis and the femoral osteotomy end were closely matched and fixed well.

ANSYS Simulation of the Thermomechanical Behavior of a Large-Sized Composite Mandrel with Consideration of Viscoelasticity

The article addresses the modeling of the process of manufacturing a large-sized shell, given the thermomechanical behavior and viscoelasticity of the composite mandrel. The results of the experimental identification of viscoelasticity parameters of the examined material are presented. A numerical algorithm for adapting the experimental data for the ANSYS Mechanical APDL finite element analysis package is proposed. A Prony series expansion of the relaxation kernel is used as a model for describing the material behavior. The effect of temperature on the rate of relaxation processes is taken into account through the application of a temperature-time analogy according to the Williams–Landel–Ferry formula. The selected model with the calculated parameters was implanted into the commercial package of ANSYS Mechanical APDL. Simulation of two process steps of manufacturing a large-sized product was performed: winding and heat treatment of the shell. For this purpose, the quasistatic problem of mechanics and unsteady thermal conduction under conditions of convective heat transfer were solved by the finite element method. The influence of thermomechanical behavior of the mandrel material on the normal pressure acting on the mandrel surface as a function of temperature and force factors was estimated quantitatively and qualitatively. It was found that with respect to the nonlinear behavior of the composite material, the pressure level decreases by 50% compared to the case of using models of elastic behavior. This result justifies the importance of using complex models of material behavior in studying long-term technological processes, especially those associated with high-temperature effects.

Performance of liquid crystalline polyester composite burn-in board connectors under cyclic high-temperature condition

The performances of connectors for burn-in tests made of various glass fibre/liquid crystalline polyester composites were analysed using mechanical testing and finite element analyses. Three different composites (E6006L, E6007LHF, and E6808UHF) were evaluated, containing one of two fibre types (chopped or milled) at different contents by weight. Material characterisations of the composites were accomplished by static tensile and fatigue testing under three temperature conditions (23 °C, 160 °C, and 220 °C). The tensile strength, failure strain, and S–N curves of the materials were identified and applied in finite element analyses of the connector structure. The structural integrity of each connector subjected to cyclic high temperature condition was then evaluated using stress and fatigue analyses, and the fatigue life was calculated according to material. Finally, the 40 wt% milled glass fibre/liquid crystalline polyester composite was identified as the most appropriate material for the burn-in test board connector structure.

Finite element simulation on mechanical properties of zeolite as a potential cellular structure

The mechanical properties of the zeolite model with cellular structure as a unit cell were studied via simulation. Four zeolite models were selected, and the mechanical properties of zeolite and traditional cellular structure were compared by mechanical finite element analysis. The results demonstrate that the zeolite structures possess better mechanical behavior under loading, accompany with uniform distribution of structural stress and less stress concentration. In addition, the effect of porosity on mechanical properties of zeolite model was studied. The results demonstrate that both yield strength and elastic modulus for zeolite decrease with the increase of porosity.

Superior Flexibility in Oxide Ceramic Crystal Nanofibers.

Oxide crystal ceramics are commonly hard and brittle, when they are bent they typically fracture. Such mechanical response limits the use of these materials in emerging fields like wearable electronics. Here, a polymer-induced assembly strategy is reported to construct orderly assembled TiO2 crystals into continuous nanofibers that are stretchable, bendable, and even knottable. Ball-milling the spinning sol and curved-drafting the electrospun nanofibers significantly improve the molecular structural order and reduce pore defects in the precursor nanofibers. Using this method, continuous TiO2 nanofibers, in which orderly assembled TiO2 nanocrystals (brick) are connected by twin grain boundaries or an amorphous region (mortar), are formed after sintering. Mechanical measurements and finite element analysis simulation indicate that the dislocation slip of "bricks" and the elastic deformation of "mortar" render the nanofibers with a small bending rigidity of ≈22 mN and a small elastic modulus of ≈20.8 Gpa, thus displaying properties associated with both soft and hard matter. More importantly, the reported approach can be easily extended to synthesize a wide range of soft, yet tough ceramic membranes, such as ZrO2 and SiO2 .

Theoretical and Experimental Investigation of Warpage Evolution of Flip Chip Package on Packaging during Fabrication.

This study attempts to investigate the warpage behavior of a flip chip package-on-package (FCPoP) assembly during fabrication process. A process simulation framework that integrates thermal and mechanical finite element analysis (FEA), effective modeling and ANSYS element death-birth technique is introduced for effectively predicting the process-induced warpage. The mechanical FEA takes into account the viscoelastic behavior and cure shrinkage of the epoxy molding compound. In order to enhance the computational and modeling efficiency and retain the prediction accuracy at the same time, this study proposes a novel effective approach that combines the trace mapping method, rule of mixture and FEA to estimate the effective orthotropic elastic properties of the coreless substrate and core interposer. The study begins with experimental measurement of the temperature-dependent elastic and viscoelastic properties of the components in the assembly, followed by the prediction of the effective elastic properties of the orthotropic interposer and substrate. The predicted effective results are compared against the results of the ROM/analytical estimate and the FEA-based effective approach. Moreover, the warpages obtained from the proposed process simulation framework are validated by the in-line measurement data, and good agreement is presented. Finally, key factors that may influence process-induced warpage are examined via parametric analysis.

Thermo-Mechanical Coupled Analysis-Based Design of Ventilated Brake Disc Using Genetic Algorithm and Particle Swarm Optimization

The brake discs are subjected to thermal load due to sliding by the brake pad and fluctuating loads because of the braking load. This combined loading problem requires simulation using coupled thermo-mechanical analysis for design evaluation. This work presents a combined thermal and mechanical finite element analysis and evolutionary optimization-based novel approach for estimating the optimal design parameters of the ventilated brake disc. Five parameters controlling the design: Inboard plate thickness, outboard plate thickness, vane height, effective offset, and center hole radius were considered, and simulation runs were planned. 27 brake disc designs with design parameters as recommended by the Taguchi method (L27) were modeled using SOLIDWORKS, and the FEA simulation runs were carried out using ANSYS thermal & structural analysis tool. The fatigue life results were analyzed using a 3D surface plot for the effect of the design parameters on the response, contour plots for the determination of maximum response, and statistical regression analysis for model interpretation and predictive modeling. Finally, the two most accurate and widely used evolutionary optimization algorithms: genetic algorithm (GA) and particle swarm optimization (PSO) were applied to determine the optimal design parameters for the ventilated brake disc. The brake disc of design parameters predicted by GA and (PSO), gives 12.74% higher fatigue life compared to parametric analysis. These results have shown that the developed approach can be utilized effectively and reliably for solving, design ventilated brake disc problem in the industry.

Eccentricity Effects on NVH Performance of Interior Permanent Magnets Machines for Hybrid and Electric Vehicles

For the hybrid electric vehicles (HEVs) and electric vehicles (EVs) applications, the electric machine drive unit system provides the main noise source, especially in the presence of faults. Eccentricity is one of the most common faults, which is mainly caused by the motors' package design and assembling process. There are four main types of eccentricity for motors: static offset, dynamic offset, static tilt and dynamic tilt, which are presented and analyzed. Both two-dimensional (2D) and 3-dimentional (3D) finite element analysis (FEA) are utilized in the electromagnetic field analysis for an Interior Permanent Magnet (IPM) motor. The corresponding methodologies for the mesh and force mapping to the mechanical FEA for the NVH analysis are presented. The NVH test shows that both 2D and 3D FEA can provide reasonable accuracy for the motor eccentricity fault analysis. The 2D FEA is the most common method used in the design optimization and early performance prediction for electrical. For the 3D FEA, due to the high requirement for the computer hardware and computation capability, it is usually used in the final validation for electrical machines' performance. The sensitivity of motor performance versus the airgap heights and eccentricities are studied.

Numerical investigation of irradiation induced degradation in a welded core shroud assembly

Most of reactor vessel internals (RVIs) have been constructed by austenitic stainless steels (ASSs) to support and protect core from high temperature coolant and radiation particles. However, if they are operated in the harsh environment for a long time, ASS materials may undergo significant changes in micro-structural features, macroscopic deformation and strengths due to age-related degradation mechanisms (ARDMs). In this study, user subroutines were developed based on material constitutive models of recently revised technical reports to reflect irradiation embrittlement, irradiation enhanced creep and void swelling behaviors. Benchmark analyses for a simple rod and detailed numerical analyses for a RVI sub-components assembly with welds were conducted via coupling the subroutines. With regard to the latter analyses, not only typical normal operating sequences but also three fuel cycles associated with specific core loading patterns were taken into account with a constant initial weld residual stress distribution. Adequacy of the subroutines was verified through analytical solutions generated from temperature and radiation damage dependent equations. Complex neutron dose, temperature and pressure profiles of the assembly were successfully determined from thermal and mechanical finite element analyses. Structural integrity assessment in terms of the ductility, embrittlement and irradiation assisted stress corrosion cracking susceptibility ratio after 40-years of operation led to acceptable in spite of the ARDMs. Contributions of factors and interaction effects were further quantified and discussed via design of experiment approach.

Research on Biomechanical Compatibility for the Artificial Anal Sphincter Based on Improved Actuator

Abstract Anal incontinence, also known as fecal incontinence, refers to the loss of the body's ability to accumulate and control the liquid, solid, and gas contents in the rectum, increasing the frequency of bowel movements. It is a symptom of defecation disorders. The artificial anal sphincter provides a new solution for clinical treatment. In this paper, in order to solve the problem of biomechanical compatibility of the actuator of the artificial anal sphincter system, the original actuator was improved. The model of the rectum and the actuator was constructed by ANSYS. The mechanical finite element analysis of the clamping mechanism was carried out by simulating sphincter behavior, and the displacement cloud diagram and stress cloud diagram of the clamping rectum were obtained. in vitro experiments were carried out using pig intestine to simulate the rectum, which verified the effectiveness of the actuator. The results of the experiment show that the successful rate of holding the rectum reached 96% under the condition of ensuring the normal blood supply to the rectum. It fully proves that the actuator has good biomechanical compatibility.

Design of Internal Supports for Double-Walled Liquefied Natural Gas Road Tanker

Transport and storage of liquefied natural gas (LNG) requires special double-walled cryogenic tanks. To provide a liquid state of LNG throughout entire storage time a temperature inside the tank should be equal −160 °C under the pressure of around 7 bar. Maintaining these parameters requires a vacuum insulation system and internal supports designed to minimize heat leakage into the tank. Additionally, the internal supports must be able to transfer complex mechanical loads that may occur during the operation of the tanker. Combinations and values of directional mechanical loads and thermal loads, to be accepted in designing mobile cryogenic tanks, are determined by proper vessels standards. In this article, we proposed the construction of internal supports for 25 m3 road tanker, which structure allows to reduce heat leakage into the internal tank, while transferring the complex mechanical loads. Tests of the presented solutions were carried out applying both mechanical and thermal finite element analysis using ANSYS software.

Design Study of a Round Window Piezoelectric Transducer for Active Middle Ear Implants.

This report describes the design of a new piezoelectric transducer for round window (RW)-driven middle ear implants. The transducer consists of a piezoelectric element, gold-coated copper bellows, silicone elastomer (polydimethylsiloxane, PDMS), metal cylinder (tungsten), and titanium housing. The piezoelectric element is fixed to the titanium housing and mechanical resonance is generated by the interaction of the bellows, PDMS, and tungsten cylinder. The dimensions of PDMS and the tungsten cylinder with output characteristics suitable for compensation of sensorineural hearing loss were derived by mechanical vibrational analysis (equivalent mechanical model and finite element analysis (FEA)). Based on the results of FEA, the RW piezoelectric transducer was implemented, and bench tests were performed under no-load conditions to confirm the output characteristics. The transducer generates an average displacement of 219.6 nm in the flat band (0.1–1 kHz); the resonance frequency is 2.3 kHz. To evaluate the output characteristics, the response was compared to that of an earlier transducer. When driven by the same voltage (6 Vp), the flat band displacement averaged 30 nm larger than that of the other transducer, and no anti-resonance was noted. Therefore, we expect that the new transducer can serve as an output device for hearing aids, and that it will improve speech recognition and treat high-frequency sensorineural hearing loss more effectively.

Loading comparison of two structures in the moving tube of a non-invasive prosthesis.

The treatment of adolescent patients with distal femoral cancer has always been a concern. The limb-salvage, regarded as a mainstream treatment, had been developed in recent years, but its application in children still remains challenging. This is because it can lead to potential limb-length discrepancy from the continued normal growth of the contralateral lower body. The extendable prosthesis could solve this problem. The principle is that it can artificially control the length of the prosthesis, making it consistent with the length of the side of the lower limbs. However, this prosthesis has some complications. The extendable prosthesis is classified into invasive and minimally invasive, which extends the prosthesis with each operation. We designed a new non-invasive prosthesis that can be extended in the body. Based on the non-invasive and extendable characteristics, we need to verify the supporting performance of this prosthesis. We carried out a mechanical testing method and finite element analysis simulation. The support performance and non-invasively extension of this prosthesis were verified.

Effects of freezing and thawing on retaining wall with changes in groundwater level

Freezing and thawing of pore water within backfill can affect the stability of retaining wall as the phase change of pore water causes changes in the mechanical characteristics of backfill material. In this study, the effects of freezing and thawing on the mechanical performance of retaining wall with granular backfill were investigated for various temperature and groundwater level (GWL) conditions. The thermal and mechanical finite element analyses were performed by assigning the coefficient of lateral earth pressure according to phase change of soil for at-rest, active and passive stress states. For the at-rest condition, the mobilized lateral stress and overturning moment changed markedly during freezing and thawing. Active-state displacements for the thawed condition were larger than for the unfrozen condition whereas the effect of freezing and thawing was small for the passive condition. GWL affected significantly the lateral force and overturning moment (Mo) acting on the wall during freezing and thawing, indicating that the reduction of safety margin and wall collapse due to freezing and thawing can occur in sudden, unexpected patterns. The beneficial effect of an insulation layer between the retaining wall and the backfill in reducing the heat conduction from the wall face was also investigated and presented.