Multi-physical Field Coupling Research Articles

Low Noise Optimization Design of Integrated Permanent Magnet Synchronous Motor Based on Multi-Physical Field Coupling

Low Noise Optimization Design of Integrated Permanent Magnet Synchronous Motor Based on Multi-Physical Field Coupling

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.

Multi-granularity negotiation correction method for satellite digital twin model

Affected by uncertainty, there are errors between the digital twin model and the real system, which need to be corrected and the uncertainty of the model quantitatively evaluated as the basis for selecting the model when using it. However, the satellite digital twin model has the characteristics of multi-dynamic, multi-spatial scale, and multi-physical field coupling. The rigidity problem of differential equations and the multi-scale problem of partial differential equations will appear during numerical solution. If many telemetry parameters are corrected at the system level at the same time, the results will not converge. A multi-granularity negotiation correction framework for satellite digital twin models is proposed. The parameters are grouped by analyzing the correlation and frequency domain characteristics of telemetry parameters. Models of different granularities of satellite subsystems and components are established, and multi-granularity digital twin models are constructed on demand. The coupling relationship between different levels of satellite components is studied, and a negotiation correction method is proposed. The framework is verified using real on-orbit telemetry data. The research results show that the negotiation correction method proposed in this paper improves the RMSE accuracy by more than that of the unused one , and the correction results are more systematic and complete.

Laser-Induced Self-Limiting Welding of Ag Nanowires with High Mechanical and Electrical Performance.

The high-efficiency and high-precision welding technology of Ag nanowires is of great engineering significance for the integration of new-generation micro- and nanodevices, and the mechanical behavior of its interconnect joints is also essential for their reliable application, especially for some flexible device. In this paper, based on the nano-focusing and localized plasma enhancement properties of Ag nanowires under laser irradiation, Ag nanowire self-limiting joints with mechanical and electrical properties comparable to those of the base material are obtained. At the same time, the local plasma enhancement characteristics of Ag nanowire joints are scanned and analyzed with nanoscale resolution by using cathodoluminescence technology, and the local multi-physical field coupling regulation mechanism of Ag nanowire joints induced by different laser parameters is systematically investigated by combining theoretical simulations. Meanwhile, based on the in situ laser welding and nanomechanical tensile experiments, the mechanical properties of single Ag nanowires and their welded joints are systematically analyzed, and the characteristics of the interfacial atomic behaviors and the evolution process during the welding and tensile processes are investigated.

Reliability Simulation of IGBT Module with Different Solders Based on the Finite Element Method

The interconnecting solder is a key control factor for the reliability of electronic power packaging because it highly affects the junction temperature of insulated-gate bipolar transistor (IGBT) modules and is prone to plasticity, creep, and other failure behaviors under temperature-change environments. In this paper, the interconnecting performance and fatigue life of five different kinds of solders such as SAC305, sintered silver, Au80Sn20, sintered copper, and pure In under direct current (DC), power cycle, and electro-thermal coupling complex environments were studied based on electro-thermal multi-physical field coupling finite element simulation method, respectively. Results show that the sintered silver owns the most outstanding thermal reliability and the DC operating junction temperature of the IGBT module after utilizing sintered silver solder is only 90.2 °C, which is nearly 15 °C lower than that of the IGBT module utilizing SAC305 solder. Furthermore, in the power cycle reliability test, the fatigue life of Au80Sn20 solder reaches a maximum of 3.26 × 107 cycles while the life of indium presents only 5.85 × 103 cycles, a difference of nearly four orders of magnitude. Finally, under the complex environment of electro-thermal coupling, the fatigue life of Au80Sn20 solder is also the largest at 1.9 × 106 cycles, while the smallest life of solder becomes SAC305 solder at 4.44 × 102 cycles. The results of this paper can provide a theoretical basis for solder selection and life prediction of the IGBT module, which is of great significance in improving the reliability of power electronic packaging.

Study on the effect of Lorentz force on the nuclear reactor core melt stratification in electromagnetic cold crucible

To understand the effect of the Lorentz force on core melt stratification during experiments, a multi-physical field coupling model of electromagnetic induction, non-isothermal flow, and two-phase flow is established in this paper. The evolution of the layered core melt in the electromagnetic cold crucible is studied for different relative densities and phase volume fraction ratios between metal and oxide. The calculation results show that the coupling model can accurately describe the structural evolution of core melt. The Lorentz force cannot change the relative positions of the metal and oxide, but it can significantly affect the morphology of the core melt. If the density of the metal is less than that of the oxide, the Lorentz force causes the light metal with a small phase volume fraction to form a hemispherical shape in the top center of the crucible. As the phase volume fraction increases, the Lorentz force become weaker than those of gravity and buoyancy. The light metal is then flat. When the metal density is greater than the oxide density, the Lorentz force causes the heavy metal with a small phase volume fraction to appear as a hemisphere, but causes the heavy metal with a large phase volume fraction to appear as an ellipsoid in the lower part of the crucible.

Numerical Investigation of coupling hazard zone of coal spontaneous combustion and gas in gob for high-gas mines

As coal mining operations continue to deepen, the frequency of coal spontaneous combustion (CSC) and gas explosion disasters in high-gas mines is increasing. Understanding the distribution patterns of CSC and gas compound disaster zones in the gob during the extraction process is crucial for reducing the risks of combustion and explosion. This study focuses on the 201 working face of the Shuanglong Coal Mine, where a multi-physical field coupling model of pressure, temperature, gas seepage, and diffusion was established to investigate the evolution characteristics of compound disaster zones and propose corresponding prevention and control measures. The results demonstrate that the area with the most severe composite hazard is mainly located at the return roadway side, extending to the middle of the gob. With increased ventilation volume and advance rate, the area of the CSC and gas coupling hazard zone expands continuously. By implementing measures such as brattice cloth and nitrogen injection, the areas of spontaneous combustion and CH4 explosion zones were reduced by 53.6 % and 49.5 %, respectively, effectively controlling the extent of the compound disaster zone and eliminating the risk of gas explosions.

Gap compensation control method for robotic electrochemical milling machining based on multi-physics field coupling

Gap compensation control method for robotic electrochemical milling machining based on multi-physics field coupling

Research on the high-performance computing method for the neutron diffusion spatiotemporal kinetics equation based on the convolutional neural network

Due to the uncertainty of computational results and the lack of interpretability of models in solving physical field equations in current deep learning, this paper designs a convolutional neural network that can be used to solve the neutron diffusion spatiotemporal kinetics equation in polar and cylindrical coordinate systems. This algorithm directly utilizes the macroscopic cross-section of the material without using the lattice homogenization method, replaces the finite volume method with the extended matrices, and solves the extended matrices using the convolutional kernels instead of the iterative algorithms. Taking the simplified Tsinghua High Flux Reactor (THFR) as an example, the feasibility of the algorithm is verified on the PyTorch platform and compared with the calculation results of the source iteration method running on the GPU. The calculation results show that when the number of grids in the radial and axial sections of the simplified THFR model is 804,600 and 3,576,000, respectively, and the algorithm is iterated 3000 times, the normalized power of the convolutional neural network and the source iteration method converges to 10−10, and the maximum point by point error of the neutron flux density of the above two algorithms converges to 10−5. The computational time consumed by the convolutional neural network is approximately 880.64 s and 3729.62 s, which reduces the computational time by 4.66% and 5.05% compared to the GPU parallel accelerated source iteration method, and the former consumes 43.75% less memory compared to the latter. The convolutional neural network is mainly used as the virtual physics engine for the THFR digital twin system, in addition to solving the neutron diffusion spatiotemporal kinetics equation and further improving computational speed. The algorithm directly utilizes the neutron macroscopic cross-section of the material to calculate the neutron flux density distribution without using the lattice homogenization, providing theoretical guidance and algorithm support for developing the high-precision multi-physical field coupling model.

Study on heat and mass transfer behavior of coupled electrochemical reaction in porous structure of proton exchange membrane fuel cell

Proton exchange membrane fuel cell (PEMFC) is widely used in transportation, aviation and energy storage due to its unique advantages. Improving the performance of fuel cells depends largely on effective hydrothermal management. In this work, a multi-physical field coupling model based on the lattice Boltzmann method (LBM) is established to analyze the oxygen transport, liquid water transport, heat transfer and electrochemical reaction, mainly considering the difference between the overpotential of the cell and the surface wettability of the structure. The results show that the overpotential is closely related to the reaction process. The rate of water production is significantly accelerated by increasing the overpotential, and the breakage and merging of water clusters are observed. The increase of overpotential will lead to more energy loss in the form of heat, thus increasing the heat production. Enhancing the hydrophobicity of the structure has a positive effect on the performance of the fuel cell, and the possibility of local hot spots in the low-hydrophobic structure is greater. It is feasible to improve water management and fuel cell performance through wettability design.

Influence of Immersion Orientation on Microstructural Evolution and Deformation Behavior of 40Cr Steel Automobile Front Axle during Oil Quenching.

This study employs the finite element method to investigate the microstructural evolution and deformation behavior of a 40Cr steel automobile front axle during the quenching process. By establishing a multi-physics field coupling model, the study elucidates the variation patterns of the microstructure field in the quenching process of the front axle under different immersion orientations. It is found that along the length direction, the bainite and martensite structures decrease from the center to the edge region, while the ferrite structure shows an increasing trend. Additionally, the influence of immersion orientation on the hardness of the front axle's microstructure and deformation behavior is thoroughly discussed. The results indicate that, firstly, when quenched horizontally, the hardness difference among different regions of the front axle is approximately 8.2 HRC, whereas it reaches 10.3 HRC when quenched vertically. Considering the uniformity of the microstructure, the horizontal immersion method is preferable. Secondly, due to the different immersion sequences in different regions of the front axle leading to varying heat transfer rates, as well as the different amounts of martensite structures obtained in different regions, the deformation decreases along the length direction from the center to the edge region. Horizontal immersion quenching, compared to vertical immersion, results in a reduction of approximately 56.2% and 48.9% in deformation on the representative central cross-section (A-A) and the total length of the front axle, respectively. Therefore, considering aspects such as microstructure uniformity and deformation, the horizontal immersion quenching orientation is more favorable.

Experimental study and life prediction for aero-engine turbine blade considering creep-fatigue interaction effect

As an important failure form of the turbine blade, creep-fatigue interaction damage affects the safe operation and maintenance strategy of aero-engine, and has been the focus of scientific research and the academic community. Firstly, based on the Kachanov-Rabotnov-Lemaitre continuum damage mechanics theory and the nonlinear symmetry of creep damage and fatigue damage, a creep-fatigue life prediction model is constructed considering the interaction effect in this paper. Then, based on the thermal-fluid–solid multi-physical field coupling numerical simulation of the turbine blade, the equivalent method of creep-fatigue load spectrum was explored according to the equal damage criterion and linear damage rule, and the creep-fatigue interaction test of smooth samples of the blade material was conducted to analyze the creep-fatigue fracture morphology. Finally, the stress term in the creep-fatigue life prediction model of blade material is modified by the correction factor α, and the modified creep-fatigue life prediction model of the turbine blade is constructed considering the interaction effect. The results show that the modified creep-fatigue life prediction model considering the interaction effect has a high life prediction ability with an error of 3.9%. The above research has important scientific research value for the life extension design of turbine blades and the improvement of aero-engine maintenance strategy.

Multi-physical Field Coupling Analysis of Flat Wire Motor

Multi-physical Field Coupling Analysis of Flat Wire Motor

Optimization method for geometric shape of DC GIL insulators based on electric thermal multi-physics field coupling model

Optimization method for geometric shape of DC GIL insulators based on electric thermal multi-physics field coupling model

Analysis and Optimization of Multi-Physical Field Coupling in Boom Flow Channel of Excavator Multiway Valves

The multiway valve is the core control element of the hydraulic system in construction machinery, such as excavators. Its complex internal structure, especially the flow channels, significantly impacts the machine’s efficiency and reliability. This study focuses on the boom flow channel of excavator multiway valves and establishes a multi-physical field coupling simulation model. We propose six key flow channel structural parameters and analyze changes in the valve’s flow field, temperature field, and structural field using orthogonal test simulation data. The range analysis method identifies the primary and secondary influences of structural parameters on pressure loss, temperature, stress, and strain. A multi-objective optimization model was developed using a neural network and the Non-dominated Sorting Genetic Algorithm II(NSGA-II), with pressure loss and maximum stress as the optimization objectives. The Pareto front solution set for key flow channel parameters was calculated. The optimization results showed a 9.0% reduction in pressure loss and a 40.7% reduction in maximum stress. A test bench verified the simulation model, achieving prediction accuracies of 94.8% for pressure loss in the inlet area and 92.3% in the return area. This method can provide a reference for the optimal design of the dynamic characteristics of high-pressure multiway valves.

The impact of various curing methods on the curing process of polymer-fiber composites analyzed using analytical approach

Ti/Gf/Cf represents a novel form of hybrid fiber metal laminates (HFMLs) that successfully blend the benefits of titanium alloy, glass fiber reinforced plastic (GFRP), and carbon fiber reinforced plastic (CFRP). These materials have garnered attention in the field of engineering due to their exceptional levels of stiffness, strength, and shear resistance. The quality of HFMLs during the curing process was significantly impacted by the chosen curing method. Moreover, the use of multiple types of fibers complicated the optimization of curing parameters in HFMLs. A comprehensive study was conducted using a multi-physics field coupling finite element method to investigate the impact of various curing methods on the development of temperature distribution, curing degree, and curing stress in HFMLs during the curing process. By integrating thermal transmission equations, curing kinetics, and viscoelastic mechanical models, a detailed curing simulation model was established. Increasing the cooling rate from 1 °C to 5 °C was shown to raise the maximum curing stress by 4.7 MPa. Additionally, higher curing temperatures were found to induce internal curing stress due to variations in thermal properties. Insufficient insulation times were observed to exacerbate non-uniform temperature distribution and curing degree fields in HFMLs, potentially leading to increased internal stress. To mitigate the generation of large residual stress, it is recommended to lower the heating and cooling rates, reduce curing temperatures, and extend the insulation time appropriately during the curing process of HFMLs. The primary goal of this research was to accurately predict the evolution of curing parameters in HFMLs under different curing regimes, which were impacted by the chosen curing method. The results of the study demonstrated that rapid changes in temperature during heating and cooling stages can lead to uneven curing, resulting in the accumulation of residual stress within the laminates.

Multi-physics field coupling analysis of in-situ laser-assisted micro-imprinting of micro tapered holes

Micro tapered holes find extensive use in various domains including detection, infusion, lighting, etc. This study has investigated the deformation behavior and machining quality of micro-tapered holes generated by in-situ laser-assisted micro-imprinting (In-LAI) using a diamond indenter. The effects of in-situ laser-assisted action on the edge bulge at the inlet, residual stress at the outlet, and microcracks at outlet of a micro tapered hole have been analyzed by using a coupled optical-thermal-force multiphysics field model. Replacing conventional Gaussian heat sources with laser light intensity distributions obtained from optical-thermal coupling model analysis. Compared to ambient temperature, Laser intensity at the tip of the diamond indenter under operating conditions decreased by 11.59 %. The in-situ laser-assisted action has reduced the force by 13 %, reduced the edge bulge at the inlet of the micro tapered hole by 57.3 %, increased the residual compressive stress at the outlet by 47.6 %, and suppressed the generation of microcracks at the outlet. The results show that In-LAI is an effective technique for micro-tapered hole machining, and the multi-physical field coupling research method also provides implications for other in-situ laser-assisted machining (In-LAM) techniques.

Multi-scale FE analysis of coupled load-moisture mechanical behavior of saturated asphalt pavements considering transversely isotropic permeability

Assessing the collective impacts of external loading and void pressure on the mechanical behavior of porous media presents a significant challenge due to its inherent heterogeneity and complex multi-physical field coupling mechanisms. This study addresses this challenge by developing a novel multiscale hydraulic-mechanical modeling framework to investigate the structural response of water-saturated asphalt pavement under sequential coupling hydro-mechanical loading. The framework comprises three key components. Firstly, incorporating an upscaling homogenization approach to establish the linkage of material properties between different scales; secondly, developing a downscaling transfer procedure to transfer the structural response across scales for insight into its multiphysics mechanisms; and finally, proposing a new sequential coupling algorithm in multiscale simulations for comprehensive multi-field coupling calculations. The primary outcomes of this study demonstrate that asphalt concrete (AC)-graded pavements are susceptible to “down-top” cracks under hydro-mechanical loading, while open graded friction course (OGFC)-graded pavements have the potential to develop both “top-down” and “down-top” cracks. In AC-graded pavements, increasing the hydraulic head reduces stress concentrations, while in OGFC-graded pavements, changes in the permeability coefficient have a lesser impact on mechanical response. At the mesoscopic level, tensile stress concentrations in the asphalt mortar decrease significantly at higher temperatures. Furthermore, the OGFC-graded RVE model exhibits higher tensile stresses in the asphalt mortar compared to the AC-graded RVE model.

Multi-physics field coupling interface lubrication contact analysis for gear transmission under various finishing processes

Surface integrity is crucial for the load-bearing capacity, transmission performance, and service life of gears. Finishing processes can effectively improve surface quality and are widely used in gear manufacturing processes to enhance surface integrity and improve the service performance of gears. Five precision machining tests of form grinding, vibratory finishing, barrel finishing, honing, and abrasive flow machining were conducted on spur gears. High-precision surface integrity characterization methods were used to analyze the surface integrity parameters of the finished gear surfaces, including surface roughness, surface microtopography, residual stress, texture aspect ratio, roughness peak curvature radius. The finishing processes uniformity and effectiveness of the tooth profile surface were also evaluated. By using the finished rough surfaces as inputs and considering the impact of thermal elasto hydrodynamic lubrication on the gear surface, a multi-field coupling contact analysis model encompassing solid, liquid, and thermal fields at the gear meshing interface was established. Lubrication performance parameters such as oil film pressure, oil film thickness, oil film temperature rise, and friction coefficient under various finishing surfaces were compared and analyzed. Experimental results indicate that barrel finishing can simultaneously improve various parameters, such as surface roughness, texture aspect ratio, and compressive residual stress. Finishing processes can effectively reduce surface roughness, improve lubrication performance and reduce the risk of scuffing failure. This approach provided an effective method for the comprehensive evaluation of the effects of various finishing processes. The developed program offers theoretical guidance and data support for the selection and optimization design of gear surface finishing processes.

A study on the uniformity of hot air drying quality for stacked flake materials based on multi-physical coupling fields

To improve the uniformity of the hot air drying quality for stacked flake materials, a heat and mass transfer study of stacked flake materials drying process based on multi-physical field coupling is carried out. A numerical simulation model of the stacked flake materials is developed based on the multi-physical field coupling theory, and the accuracy of the numerical simulation model is verified by the bidirectional alternating hot air drying test bed. The segmented hot air drying method is used to analyze the influence mechanism of single airflow direction and alternate airflow direction on the heat and mass transfer for stacked flake materials, and the optimization of drying parameters is studied. The results indicate that a single airflow direction may cause excessive drying, and the uneven stacking density significantly affects the drying quality. The increase of air flow direction change number will lead to the improvement of drying uniformity and moisture content of drying results, and at the same time, the flake material absorbs moisture significantly after changing the air flow direction. By adopting the down-down-up-up airflow direction and optimizing the parameters, the moisture content uniformity of the drying results is improved by 19%, while energy consumption is reduced.