Finite Element Analysis Model Research Articles

Programming the deformation of the temperature driven spiral structure in 4D printing

Abstract Achieving shape programming of 4D printed actuators by varying the manufacturing process parameters. In this study, the effect of different path combinations on structural deformation was investigated. By altering the driving layer, passive layer, and grid angle, the spiral deformation direction of the double-layer structure was precisely controlled. Additionally, a finite element analysis model was established to predict the deformation behavior of PLA-based spiral structures. Furthermore, the influence of printing speed, nozzle temperature, line width, layer height, and plate temperature on the spiral curvature of the structure was examined. The results show that increasing printing speed and plate temperature can improve the spiral behavior of the structure, whereas increasing line width, layer height, and nozzle temperature have opposite effects. A multiple linear regression analysis was conducted on the five printing parameters to predict their influence on the spiral curvature of the structure, and a predictive model for the spiral deformation was developed. The structure was partitioned for design purposes, aiming to achieve diverse deformations of the actuator under the same geometric configuration. A loop-shaped actuator was designed to capture objects. The results showed that the path combination determined the spiral direction of the actuator, while the forming parameters effectively controlled the spiral curvature of the actuator.

Optimizing the Sewing Position of Flexible Piezoelectric Energy Harvesters on a Three-Dimensional Deforming Heart: An Integrated Approach Using Finite Element Analysis, Deep Learning, and Theoretical Modeling

Abstract Flexible piezoelectric energy harvesters (FPEHs) have attracted tremendous attention due to their potential applications in the field of biomedicine, such as powering implantable devices. Despite observations in numerous in vivo experiments that the electrical output of FPEHs varies considerably with sewing positions during energy harvesting from heartbeats, optimal sewing positions have not been thoroughly investigated. In this article, an approach that integrates finite element analysis (FEA), long short-term memory (LSTM) deep learning method, and theoretical modeling was proposed to investigate the impact of the sewing position on the harvest performance of the FPEH, utilizing real three-dimensional heart deformation data as the end-to-end displacement load for the FPEH. The results reveal that the sewing positions have a significant influence on the electric output performance of the FPEH. The optimal sewing position was identified near the posterior interventricular groove on the upper part of the left ventricle, with a corresponding optimal resistance value of 8 MΩ and an output power of 122.9 nW. Additionally, five suggested sewing positions across different regions of the heart's surface were provided for clinical application. The methodology that integrates FEA, deep learning approach, and theoretical modeling in this article can be extended to determine the optimal position for the flexible devices patching on other irregular and deforming surfaces.

Multidepth quantitative analysis of liver cell viscoelastic properties: Fusion of nanoindentation and finite element modeling techniques.

Liver cells are the basic functional unit of the liver. However, repeated or sustained injury leads to structural disorders of liver lobules, proliferation of fibrous tissue and changes in structure, thus increasing scar tissue. Cellular fibrosis affects tissue stiffness, shear force, and other cellular mechanical forces. Mechanical force characteristics can serve as important indicators of cell damage and cirrhosis. Atomic force microscopy (AFM) has been widely used to study cell surface mechanics. However, characterization of the deep mechanical properties inside liver cells remains an underdeveloped field. In this work, cell nanoindentation was combined with finite element analysis to simulate and analyze the mechanical responses of liver cells at different depths in vitro and their internal responses and stress diffusion distributions after being subjected to normal stress. The sensitivities of the visco-hyperelastic parameters of the finite element model to the effects of the peak force and equilibrium force were compared. The force curves of alcohol-damaged liver cells at different depths were measured and compared with those of undamaged liver cells. The inverse analysis method was used to simulate the finite element model in vitro. Changes in the parameters of the cell model after injury were explored and analyzed, and their potential for characterizing hepatocellular injury and related treatments was evaluated. RESEARCH HIGHLIGHTS: This study aims to establish an in vitro hyperelastic model of liver cells and analyze the mechanical changes of cells in vitro. An analysis method combining finite element analysis model and nanoindentation was used to obtain the key parameters of the model. The multi-depth mechanical differences and internal structural changes of injured liver cells were analyzed.

Numerical study on flexural behaviour of sulphate corroded RC beams strengthened with ultra-high-performance concrete

Ultra-high-performance concrete (UHPC) has found extensive application in the strengthening of existing reinforced concrete (RC) structures; however, limited knowledge exists regarding its use in RC structures exposed to sulphate attacks. This study developed a non-linear finite element analysis (FEA) model to predict the flexural behaviour of sulphate corroded RC beams strengthened with UHPC jackets. The FEA model, validated with experimental results, was extended to examine UHPC configurations and thicknesses. Evaluation included ultimate load capacity, serviceability state, and stiffness. Crack patterns, load-deflection behaviour, and strain distribution were analysed for strengthened beams at their respective ultimate loads along the mid-span cross-section height. FEA results showed diverse configurations significantly enhanced the load-carrying capacity of sulphate corroded RC beams by 54.5-88.6%. Strengthened beams exhibited a 64% increase in flexural moment capacity, with notable improvements in cracking and post-cracking stiffness. Strain distribution analysis revealed UHPC strengthening increased strain values, emphasising UHPC jackets’ substantial role in resisting stresses and enhancing flexural behaviour. As expected, the three-sided UHPC configuration outperformed two-sided and bottom-side ones. Increasing UHPC thickness proved most effective in bottom-side strengthening, followed by three-sided, with a lesser effect in two-sided strengthening. Theoretical predictions from the suggested flexural moment capacity calculation aligned well with FEA results.

Development and experimental verification of an advanced 3D elastoplastic progressive damage model for composite materials

This study develops a sophisticated three-dimensional elastoplastic progressive damage finite element analysis (FEA) model for stiffened composite materials under axial compression. The model integrates the Hashin and Ye criteria to capture the inception of damage within the composite and introduces a cohesive zone model (CZM) to simulate debonding between stiffeners and panels. Furthermore, damage evolution based on energy release rate and plastic flow rules grounded in Hill’s criteria are employed to thoroughly explore the progressive failure behavior of stiffened composite materials. Implemented within Abaqus/Explicit through user-defined ‘VUMAT’ subroutines, the model ensures computational accuracy and reliability. Comparative evaluations against standard linear elastic progressive damage models demonstrate a statistically significant improvement of at least 5% in predicting ultimate load capacities. Additionally, this model accurately captures different failure modes, providing a nuanced understanding of stiffened composite material failure under compressive loads.

Effect of Sclerosis Bands in Femoral Head Necrosis on Non-Vascularized Fibular Grafting-A Finite Element Study.

Femoral head necrosis is a challenging condition in orthopaedics, and the occurrence of collapse is an important factor affecting the prognosis of femoral head necrosis. Sclerosis bands are known to influence the collapse of the femoral head, yet there is a lack of research on the biomechanical role of sclerosis bands in non-vascularized fibular grafting surgery. This study aims to evaluate the biomechanical impact of sclerosis bands in femoral head necrosis and their role in non-vascularized fibular grafting surgery (NVFG) using finite element analysis. We constructed 11 finite element models based on CT scan data of a normal hip joint, simulating different sclerosis band thicknesses and defect scenarios. The models were analyzed for changes in femoral head displacement and von Mises stress. We constructed a hip joint model based on CT data from a normal hip joint, and after reconstruction, assembly, and optimization using 3-matic. We created five groups consisting of 11 finite element analysis models of the hip joint. Mesh partitioning and mechanical parameter settings were performed in ANSYS. The changes and differences in femoral head displacement and von Mises stress of these models were analyzed. Increasing sclerosis band thickness led to reduced peak displacement of the femoral head by 28.6%, 42.9%, and 47.6%, and increased surface von Mises stress by 28.3%, 13.8%, and 13.0%, respectively. Post-surgery, peak displacement decreased in all groups compared to pre-surgery levels. Increasing sclerosis band thickness post-surgery resulted in decreased maximum von Mises stress of the femoral head by 13.9%, 3.0%, and 8.1%. Defect volume in the defect groups correlated with increased peak displacement of the femoral head by 10.0%, 30.0%, and 100.0%, and increased surface maximum von Mises stress of the femoral head by 9.3%, 14.0%, and 15.1%. Sclerosis band formation exacerbates von Mises stress concentration on the femoral head surface. However, thicker sclerosis bands improve post-NVFG stability and mechanical performance. Larger anterior lateral sclerosis band defects significantly compromise postoperative stability, increasing the risk of collapse. Protecting the anterior lateral sclerosis band during NVFG surgery is crucial.

Efficiency enhancement of bicycle anti-lock braking systems (ABS): Design and optimization of solenoid actuators through finite element analysis and performance simulation

The rising popularity of cycling underscores the need for enhanced safety, particularly under challenging braking conditions. This study introduces a novel high-power switch valve designed explicitly for Bicycle Hydraulic Disc Brakes (BHDBs), incorporating Hydraulic Anti-lock Braking Systems (ABS). Comprehensive Finite Element Analysis (FEA) modeling and subsequent optimization of an existing solenoid valve’s internal geometry were performed through 2D and 3D simulations to evaluate magnetic flux. The improved design achieved a maximum output force of 280 N with a linear stroke of approximately 3.5 mm. Notably, the enhanced system exhibited a 28% reduction in required current, from 5.0 to 3.6 A, a result validated through LabVIEW-equipped custom tests, which stress the credibility of the research. This study underscores significant advancements in high-power switch valves for BHDBs, promising enhanced braking efficiency and safety in high-performance, battery-powered bicycles. These findings not only promise enhanced safety for cyclists but also suggest the potential for broader application in energy-efficient and sustainable bicycle ABS technology, contributing to improved cyclist safety without compromising the environmental and health benefits of cycling. The potential impact of this research extends beyond the immediate context, offering insights that could be applied to other areas of technology and safety.

Comparative Biomechanical Study of Different Screw Fixation Methods For Minimally Invasive Hallux Valgus Surgery: A Finite Element Analysis

BackgroundThere are different screw configurations utilised for minimally invasive hallux valgus (HV) deformity despite limited biomechanical data assessing the stability and strength of each construct. We aimed to compare the strength of various screw configurations for minimally invasive HV surgery using finite element analysis (FEA). MethodsA FEA model was developed from a CT of a female with moderate HV deformity. Five screw configurations utilizing one or two bicortical or intramedullary screws were tested. Stress analysis considered osteotomy displacement, maximum and minimum principal stresses, and von Mises stress for both implants and bone for each screw configuration. ResultsFixation with two screws (one bicortical and one intramedullary) demonstrated the lowest values for osteotomy displacement, minimum and maximum total stress, and equivalent von Mises stress on the bone and screws in both loading conditions. ConclusionThe optimal configuration when performing minimally invasive surgery for moderate HV is one bicortical and one intramedullary screw. Level of evidenceLevel III

Computer Modelling Study of Volume Kinetics in Intraocular Segments Following Airbag Impact Using Finite Element Analysis.

We have previously studied the physiological and mechanical responses of the eye to blunt trauma in various situations using finite element analysis (FEA). In this study, we evaluated the volume kinetics of an airbag impact on the eye using FEA to sequentially determine the volume change rates of intraocular segments at various airbag deployment velocities. The human eye model we created was used in simulations with the FEA program PAM-GENERISTM (Nihon ESI, Tokyo, Japan). Different airbag deployment velocities, 30, 40, 50, 60 and 70 m/s, were applied in the forward direction. The volume of the deformed eye impacted by the airbag was calculated as the integrated value of all meshes in each segment, and the decrease rate was calculated as the ratio of the decreased volume of each segment at particular timepoints to the value before the airbag impact. The minimum volume of the anterior chamber was 63%, 69% and 50% at 50, 60 and 70 m/s airbag impact velocity, respectively, showing a curve with a sharp decline followed by gradual recovery. In contrast to the anterior chamber, the volume of the lens recovered promptly, reaching 80-90% at the end of observation, except for the case of 60 m/s. Following the decrease, the volume increased to more than that of baseline at 60 m/s. The rate of volume change of the vitreous was distributed in a narrow range, 99.2-100.4%. In this study, we found a large, prolonged decrease of volume in the anterior chamber, a similar large decrease followed by prompt recovery of volume in the lens, and a time-lag in the volume decrease between these tissues. These novel findings may provide an important insight into the pathophysiological mechanism of airbag ocular injuries through this further evaluation, employing a refined FEA model representing cuboidal deformation, to develop a more safe airbag system.

Bispherical metal augment improved biomechanical stability in severe acetabular deficiency reconstruction: a comparative finite element analysis

BackgroundThis study used finite element analysis (FEA) to compare the biomechanical stability of bispherical metal augment (BA) and wedge-shaped trabecular-metal augment (TA) in different acetabular defect reconstruction models, thereby explaining the application value of this novel bispherical augment in complex hip revision.MethodsThree different acetabular defect pelvis models originating from three representative patients with different types of severe acetabular defects (Paprosky IIC, IIIA, and IIIB) were constructed and reconstruction with BA and TA technique was simulated. Based on the FEA models, the displacement of reconstruction implants, relative displacement of bone implants, and hemi-pelvic von Mises stress were investigated under static loads.ResultsBA acquired smaller reconstruction system displacement, less relative displacement of bone implants, and lower pelvic von Mises stress than TA in all Paprosky IIC, IIIA, and IIIB defect reconstructions.ConclusionThe FEA results show that BA could acquire favourable biomechanical stability in severe acetabular defect reconstruction. This technique is a reliable method in complex hip revision.

Analytical model for flexural-torsional coupling behavior of prestressed corrugated steel-concrete composite girders

Prestressed corrugated steel-concrete (PCSC) composite girders are often subjected to combined bending and torsion in practice, but the existing theoretical models have mainly focused on pure torsional behavior. Thus, this paper proposed a modified combined action softened truss model (MCA-STM) to predict the flexural-torsional coupling behavior and failure modes of PCSC composite girders. The equivalent loading and nonlinear equations were modified, and the convergence criteria of flexural and torsional failure were established, considering the structural characteristics of PCSC composite girders. A new optimized algorithm was employed to solve the MCA-STM, providing a more efficient and numerically stable solution procedure. A 3D finite element analysis (FEA) model of the PCSC composite girder was established, which was verified by comparing the available test results. A parametric study was carried out based on the verified FEA model to get more datasets with various parameters, and the results were compared to the proposed analytical model. The curves obtained by the FEA and MCA-STM are in good agreement, indicating that the proposed analytical model can predict the full flexural-torsional coupling behavior and failure modes of the PCSC composite girders.

Experimental and Numerical Study on the Blast Resistant Performance of Geopolymer Concrete

Geopolymer, with its notable benefit of low carbon dioxide emissions, holds the potential to substantially curtail environmental pollution. According to the existing related research on geopolymer materials, it is obvious that it has great development potential in many engineering application fields, and it is a new generation of green and environmentally friendly recycled materials. Nowadays, there is a growing concern regarding explosion protection. Explosions near buildings can cause catastrophic damages on the building external and internal structure, and the most important thing is that can cause injuries and loss of life to the occupants of these buildings. This study investigates the mechanical performance of the fiber-reinforced geopolymer concrete under explosive testing. Furthermore, the finite element analysis models have been established through LS-DYNA software to simulate the explosive testing using Structure-Arbitrary Lagrangian Eulerian Method (S-ALE). The model is used to assess the dynamic mechanical behavior of geopolymer materials.

Experimental and numerical study on behavior of demountable T-shaped bolt shear connectors in sustainable composite beams

This paper proposed a new type of demountable T-bolt shear connector to improve the disassembly efficiency of composite beams and realize the sustainable of the structure components. The shear behavior of nine groups of push-out specimens was experimentally investigated through monotonic loading push-out tests. The finite element analysis (FEA) models were validated against the test results, specifically in terms of the load-slip responses and failure modes of the T-bolt shear connectors in these push-out specimens. The obtained results show that all the specimens have no obvious deformation and cracks in the steel beam and RC slab. The separation between the slab and the steel beam is no more than 1 mm, indicating that the anti-lifting ability is excellent. Moreover, parametric analysis demonstrates that increasing the bolt pretension of the T-shaped shear connector and the friction coefficient between the bridge gasket and the steel beam significantly enhances the initial stiffness and ultimate strength of the shear connectors. However, the shear behavior is relatively insensitive to variations in the channel thickness and bolt grade. Based on regression analysis, a load-slip mechanical model has been proposed. This model accurately describes the mechanical properties of this type of shear connector, providing a theoretical foundation for the application of demountable composite beams.

Statistical analysis of adhesive rod-tube joints under tensile stress for structural applications

Adhesive bonding has been replacing traditional joining methods such as welding, bolting, and riveting in the design of mechanical structures in the automotive, aerospace and aeronautic industries. This joining method has several advantages over traditional methods such as ease of manufacture, lower costs, ease of joining different materials, higher fatigue resistance, and high corrosion resistance. Although tubular adhesive joints have varying applications, such as in truss structures and vehicles, machine axles, and piping, different joint configurations exist, such as rod-tube joints (RTJ), which are not conveniently addressed in the literature. This work compares the tensile performance of adhesively bonded RTJ between aluminium alloy components (AW6082-T651), considering the variation of the main geometric parameters: overlap length (LO), tube thickness (tS), rod diameter (d), adhesive fillet angle (f), and type of adhesive. The Taguchi’s method was employed in the elaboration of the applied design of experiments (DoE). To compare the RTJ behaviour, a numerical analysis was carried out through finite element analysis (FEA) and cohesive zone modelling (CZM). Peel (σy) and shear (τxy) stresses in the adhesive layer were initially obtained by applying purely elastic models. CZM modelling made possible to obtain the damage evolution in the adhesive layer, the maximum load (Pm) and dissipated energy (U) at Pm of the adhesive joints. As a result of applying the Taguchi method, the adhesive joint that showed the best overall performance used the adhesive Araldite® AV138, LO = 40 mm, d = 20, and tS = 3 mm.

Transient Shutdown Cooling Simulation of a Gas Turbine Test Rig Configuration Under Ventilated Natural Convection

Abstract A transient simulation of shutdown cooling for a gas turbine test rig configuration under ventilated natural convection has been successfully demonstrated using a coupled aero-thermal approach. Large eddy simulation (LES) and finite element analysis (FEA) were employed for fluid domain computational fluid dynamics (CFD) and solid component thermal conduction simulation, respectively. Coupling between LES and FEA was achieved through a plugin communicator. The buoyancy-induced chimney effect under the axially ventilated natural convection is correctly reproduced. The hotter turbulent flow in the upper part of the annular path and the colder laminar-type air movement in the lower part of the annulus are appropriately captured. The heat transfer features in the annular passage are also faithfully replicated, with heat flux of the inner cylinder reaching its maximum and minimum at the bottom dead centre (BDC) and the top dead centre (TDC), respectively. Agreement with experimental measurements is good in terms of both temperature and heat flux, and the result of the transient simulation for the shutdown cooling is encouraging too. In addition, radiation is simulated in the FEA model based on the usual grey body assumptions and Lambert?s law for the coupled computation. It has been shown that at the high power (HP) condition, the radiation for the inner cylinder is approximately 11% of its convective heat flux counterpart. The importance of radiation is thus clearly revealed even for the present rig test case with a scaled-down temperature setup.

A deformation procedure using position-based dynamics to optimize the geometric model of woven fabrics

Generating realistic three-dimensional (3D) yarn-level models for fabrics has become a significant research topic due to the complexity of fabric structures and the requirement for high-quality models with no interpenetration between yarns. The generation process of idealized geometric models leads to inaccurate descriptions of yarn contact, specifically the interpenetrations and spurious voids between yarns. A geometric optimization procedure was developed to address the defects in the idealized models, involving a series of geometry-driven operations, such as the shrinking and expansion of yarn volume and the straightening of the yarn centerline, to obtain accurate and consistent fabric models for Finite Element Analysis. During the geometric optimization, a method for yarn deformation based on position-based dynamics (PBD) was applied to simulate the real deformation during yarn interweaving, ensuring no interpenetrations between yarns while preserving yarn volume. The accuracy of the model is validated by comparison with the real fabric images. Although the methods involved in the procedure are all geometric, their deformation results have realistic physical effects. In addition, the procedure can be applied to various woven fabric structures.

A Comprehensive Model to Compute Roll Gap Profile for a Rolling Mill Including Bearing and Mill Housing Deflections

Abstract Obtaining the desired strip profile is of paramount importance in cold rolling. The final strip profile depends on several parameters of the plants including crown and taper profiles and segmented backup roll positions. This paper aims to present a newly developed combined finite element–analytical model of the rolling mill able to model not only the roll cluster but also the mill housing and backup bearings deformations. This makes the proposed model especially suitable to simulate cluster-type rolling mills. The model exploits a modified elastic foundation formulation for a precise computation of the contact forces between rolls, taking into account rolls’ crown and taper. A reduced stiffness matrix approach is implemented for accurate mill housing modeling. A full 3D finite element model of the rolling mill and experimental data are used for the validation of the presented model. By exploiting the validated model, the paper shows that the deformation of supporting bearings and mill housing plays a crucial role in the strip profile calculation and should be included in any cluster-type roll mill model.

Fatigue Life Prediction of a Rubber Mount Considering the Self-Heating by the Hysteresis Loss of the Rubber Material Subjected to Cyclic Loadings

Failure analysis and fatigue life prediction are important steps in the design procedure of industrial products to assure the safety and reliability of their components. A model to calculate the heat generation by the hysteresis loss in natural rubber subjected to cyclic loads in a uniaxial direction was introduced and the fatigue life prediction model of the rubber was established based on the theory of continuum damage mechanics (CDM). Dynamic mechanical analysis (DMA) was used to measure the viscoelasticity of the rubber material. The heat generation in the rubber material was calculated using a subroutine with the programming software C++ and the temperature rise in the rubber material was analyzed by a thermal finite element analysis (FEA) method. Then static mechanical FEA models of a rubber mount were established and the strain contours of the rubber mounts at various loads were calculated. The total principal strain was used as the fatigue parameter to predict the fatigue life of the rubber mount. Finally, the fatigue lives of the rubber mounts at various loads were measured on a test rig to validate the accuracy of the prediction method. The test results indicated that the fatigue lives predicted considering the temperature rise agreed better with the test results compared with those not considering the temperature rise and we suggest our fatigue prediction method should be applicable to both rubber and other types of components.

Investigation of the effect of residual waviness formed by rail profile milling of reshaped surface on wheel-rail contact stresses and low cyclic fatigue

The rail profile milling process allows considerable thickness to be removed in a single pass. However, the residual waviness formation law after milling and its subsequent effect on rail performance remains uncertain. In this paper, the wavelength and wave height of the residual waviness are identified as the key characteristics. The relationship between milling speed and residual waviness is determined, and a numerical model of the residual waviness formed on the surface after milling is established based on the commonly used three milling speeds of 300, 600, and 1000 m/h, and its accuracy is verified using the parameters of the residual waviness detected by the milling experiments. A three-dimensional finite element analysis model of wheel-rail contact was employed to analyze the contact stresses and low fatigue cycles at a wheel load of 11.5 tons with no residual waviness on the rail profile surface and with three types of residual waviness, respectively. The results show that the residual waviness changes the wheel-rail contact position and the morphology of the contact area, reduces the maximum contact stress and increases the strain fatigue cycles. The application of elevated milling speeds reduces the wheel-rail contact stresses after milling, thereby increasing the low fatigue cycles.

Fatigue performance of a steel truss web-concrete external joint in railway composite continuous girder bridges

ABSTRACT This study conducted fatigue tests on two 1:3 steel truss web-concrete external joints to investigate their fatigue performance. The fatigue failure mode of the external joints and the stress distribution of each component were investigated. In addition, a finite element analysis (FEA) model was established, and parametric analysis was carried out to discuss the influence of gusset plate thickness, stiffening plate layout, and gusset plate structural form on fatigue performance. The results show that the fatigue life of the external joints under the design load amplitude is 3.75 million times (187.5 years). Fatigue cracks appear in the junction area between the gusset plate and the end of the stiffening plate, which is a weak fatigue detail of the external joint. The fatigue cracks cause local stress redistribution of the gusset plate. The stress at the junction (GN3) between the gusset plate and the stiffening plate N3 can be reduced by up to 37%, 61%, and 21% by altering the above three factors. Furthermore, the fatigue life of the optimized joint is increased by 1.4 times, indicating that the fatigue performance can be significantly enhanced by improving the stiffening plate layout and the gusset plate structural form.