Numerical Verification Research Articles

Reconstruction Mechanism of Surface Integrity for Laser Additive Manufactured 316 L Stainless Steel Subjected to Ultrasonic Surface Rolling Process: Numerical Simulation and Experimental Verification

Reconstruction Mechanism of Surface Integrity for Laser Additive Manufactured 316 L Stainless Steel Subjected to Ultrasonic Surface Rolling Process: Numerical Simulation and Experimental Verification

Research and Validation of CF/PEEK-Based Truss Rod Crimping and Pultruding Process for On-Orbit Isoform Forming.

A crimping and pultruding forming process for truss rods using Carbon Fiber (CF)/Polyether-Ether-Ketone (PEEK) prepreg tape as the raw material is proposed to address the problem of continuous manufacturing of space trusses on orbit. The proposed process provides material rods for continuous truss manufacturing. Through numerical simulation and experimental verification, the effects of relevant parameters on the forming process are determined, an efficient method of rod curl pultrusion, in-rail, equal material forming is proposed, and the structural configuration of the rod curl pultrusion forming mold is determined. The equivalent macroscopic mechanical properties of unidirectional CF/PEEK prepreg strips are considered, and the rod-forming process is investigated. Rod samples with different process parameters are prepared, and several tests are conducted on them. The results show that the forming load pull is negatively correlated with the temperature at the same forming speed, and forming speed is positively correlated with the forming load pull at a certain temperature. Temperature and speed affect the surface quality of the rod, the density of the material filling, and the mechanical properties of the rod. The optimal forming process parameters are determined through numerical simulation and experimental verification. The developed molding technology has the advantages of high efficiency, low energy consumption, and high integration. It reduces manufacturing costs and improves manufacturing efficiency, so it can serve as a new and effective solution for the manufacturing of high-performance truss rods in the aerospace field.

Experimental study and numerical simulation verification of the macro- and micromechanical properties of the sandstone–concrete interface under freeze–thaw cycles

In cold-region tunnel engineering, the bonding surface between concrete and surrounding rock is highly susceptible to engineering disasters such as the cracking of support structures under the influence of freeze-thaw cycles, which severely affects the stability of tunnel engineering. This study investigates the macroscopic and microscopic mechanical properties of the sandstone–concrete interface under freeze–thaw cycles and reveals the microdamage and fracture evolutionary laws during the freeze–thaw loading process via the coupled expansion of water–ice particle phase changes via particle flow numerical simulation methods, aiming to provide theoretical support for the design and construction of rock–soil and tunnel engineering in high-altitude frozen soil areas. The results indicate that the interface strength characteristics of the sandstone–concrete specimens exhibit a stable decreasing trend with an increase in the number of freeze-thaw cycles and a decrease in roughness. Taking the most unfavorable condition as an example, the exacerbation of freeze-thaw deterioration resulted in shear strength reductions of 16.53%, 27.01%, and 37.17% for specimens (JRC=3.727), while an increase in roughness led to shear strength increases of 11.00% and 15.14% for specimens (NT=60 cycles). The acoustic emission characteristics during the loading process of the sandstone–concrete interface specimens reflect the microcracking evolutionary activity of the specimens quite well, and setting 1.0 as the recommended value for the precursor determination of the b-value and CV(k) index is most reasonable. Under freeze-thaw cycles, cracks first initiate partial microcracks at the interface and on the outer side of the specimen, primarily dominated by tensile cracks and evolving with a "slow–fast" trend toward both sides of the interface. Under shear stress, particles at the interface first undergo slip dislocation due to their lower bonding strength, generating cracks, subsequently inducing significant displacement of particles on both sides of the interface, resulting in crack propagation toward both sides of the interface, ultimately penetrating and forming shear bands leading to macroscopic failure.

Guided wave localization of small defects based on stochastic resonance characteristics of Duffing systems

To improve the location accuracy of small defects in anti-corrosion pipelines by using ultrasonic guided wave, this study developed a guided wave location method for small defects based on stochastic resonance (SR) characteristics of a time-moving Duffing system. Firstly, it solved the shortcomings of the selection of the key parameters of the system, which depended on human subjectivity and lacked interaction correlation in the previous research. By using the stochastic resonance characteristics of the Duffing system, the best fit parameter group of the system was determined synchronously and coordinately. Secondly, with the conjoint analysis of the key parameters of the system and the numerical simulation verification method, found that part of the energy of the noise signal would be transferred to the system output response, leading to the system output response was strengthened. Finally, A time-moving window function was introduced in the experimental verification, and the enhanced system output response in the window was analyzed using power spectral density (PSD), which could realize the location of guided waves with small defects. The experimental result showed that the small defect guided wave with a cross-section loss rate of at least 6 % could be effectively located.

Accurate and robust linear representation for containership stability conditions with ballast water

Stowage planning involves optimizing the placement of cargo on a ship while ensuring the ship's stability conditions are met. This optimization problem is typically formulated as a mixed-integer linear programming problem. However, a challenge arises in representing stability conditions as linear constraints since these conditions have non-linear relationships to the decision variables. Although there are methods for linearizing these stability conditions, they lack a systematic modeling approach and numerical verification of accuracy and reliability. In particular, the complex and diverse nature of ballast water contributes to significant non-linearity, posing a considerable challenge in developing an accurate linear approximation. This study proposes linear prediction methods that incorporate ballast water to address major stability conditions such as trim, drafts, shear force, bending moment, torsion, and transverse metacentric height. We introduce a comprehensive training and testing methodology for prediction, and validate the proposed method by comparing it with true values on two ships of different capacities, demonstrating its accuracy and scalability.

Numerical investigation and experimental verification of liquid water dynamic transfer characteristics in the flow field of PEMFC with dead-ended anode during gas purging

Water accumulation in the anode during the operation of a proton exchange membrane fuel cell with the dead-ended anode (DEA) has a significant impact on its performance. In this study, numerical simulation and experimental verification were combined to investigate the water accumulation and water dynamic transfer characteristics in the anode flow field during dead-ended operation and gas purging, respectively. The effects of placement orientation, surface wettability, and purge time on the water dynamic transfer characteristics are investigated. The results show that the placement orientation has significant effects on the water distribution characteristics and drainage for PEMFC. When placed vertically and with a purging time of 50 ms, the liquid water saturation in the channel is 5.52 %, which drains 14.91 % more water than that of horizontal placement. Besides, Water discharge velocity and water removal ratio should be considered comprehensively in the development of the purge strategy, the optimal purging time is 70 ms with the water discharge velocity and water removal rate are 0.39 μl/ms and 97.34 %, respectively. Finally, the transfer process of liquid water in the flow field with DEA mode is observed by visual experiment, and the results of the numerical simulation are verified.

Performance of multi-ribbed composite wall incorporating reactive powder concrete-filled steel tubular columns under axial compression

In this study, axial compression researches of an innovative composite shear wall, named multi-ribbed composite wall incorporating reactive powder concrete-filled steel tubular columns, were conducted using theoretical analyses as well as experimental and numerical investigations. This precast hybrid system embedded reactive powder concrete-filled steel tubular columns as boundary elements of multi-ribbed composite wall. A novel approach, namely the unified strength theory, was adopted in consideration of various materials diversity. The outcomes of unified strength theory were utilized to predict the ultimate compressive capacity of multi-ribbed composite wall equipped with reactive powder concrete-filled steel tubular columns. The proposed theoretical formulas were validated against the experimental results reported in this paper. Despite the fact that the calculated formula with b= 0 was obtained to predict the closest capacity value of the test specimen infilling ordinary concrete. The calculations with different values of b clearly indicated that the intermediate principal stress effect should be rationally considered. Experimental observations suggested that the frame column significantly contributed to improving the compressive performance throughout the entire process and maintained the wall integrity. Meanwhile, finite element models were developed using the ABAQUS program, followed by the elaboration of its numerical implementation. The numerical predictions of ten shear wall specimens infilling reactive powder concrete were found to be reasonably in agreement with the calculated results corresponding to b= 0.5. These findings revealed the characteristics of multiple defensive lines of "block-ribbed column-frame column" under axial compression. Following the successful validation of finite element models, parametric studies were carried out to evaluate the influences of the filled block compressive strength, steel tube wall thickness and height-width ratio. The results show that the axial compression capacity of multi-ribbed composite wall incorporating reactive powder concrete-filled steel tubular columns can be noticeably improved with an increase in block strength and tube thickness. The proposed composite wall demonstrates favorable cooperative working performance and desirable displacement ductility. Subsequently, the primary objective of this pilot study aimed at developing a reliable theoretical calculation formula and conducting numerical simulation verification of the innovative composite wall. The aforementioned conclusions are intended to provide insights for the guidance and optimization of engineering structures.

Numerical Prediction and Experimental Verification of Inherent Defect Influences on Frequencies of Adhesively Bonded Joint

The vibrational response of adhesively bonded joints with and without defects in the adhesive layer is predicted by simulation for the different overlapping lengths in this work. The eigenvalue extraction method (Block Lanczo’s) is employed within the finite element analysis (FEA) framework to predict the modal values of adhesively bonded joints. The numerical analysis has adopted a solid 20-node quadratic brick elements with reduced integration (C3D20R) to predict the realistic values. The predicted eigenvalues of adhesively bonded joints using an FEA solution are compared with published data and verified the accuracy of the FEA model through experimentation considering defective and non-defective joints. Additionally, simulation solutions are predicted for different overlap lengths (i.e., 25, 30, 35 and 40 mm) by changing the boundary conditions, adhesive bond thickness aspect ratio, adherend thickness ratio, defect position, and defect aspect ratio. The geometries of the adhesive and adherend significantly affect vibration responses through the dampening effect and structural weight, enhancing the stiffness. Defect position and geometry have negligible impact on the natural frequency values for all overlapping lengths except when located around the overlapping edges.

Numerical Simulation and Experimental Verification of Hot Roll Bonding of 7000 Series Aluminum Alloy Laminated Materials

In the present study, the hot roll bonding process of 7000 series aluminum alloy laminated materials was numerically simulated and investigated using the finite element method, and the process parameters were experimentally verified by properties testing and microstructure analysis after hot roll bonding. In the roll bonding process of aluminum alloy laminated materials, the effects of the intermediate layer, pass reduction ratio, rolling speed and thickness ratio of component layers were studied. The results of finite element simulations showed that the addition of a 701 intermediate layer in the hot roll bonding process could effectively coordinate the deformation of the 705 layer and 706 layer and prevented the warping of the laminated material during hot rolling. It is recommended to use a multi-pass rolling process with small deformation and high speed, and the recommended rolling reduction ratio is 20%~30%, the hot rolling speed is 1.5~2.5 m/s and the thickness ratio of the 705 layer and 706 layer is about 1:5. Based on the above numerical results, five-layer and seven-layer 7000 series aluminum alloy laminated materials were prepared by the hot roll bonding process. The results showed that metallurgical bonding was realized between each component layer, and no delamination was observed from the tensile fracture between the interfaces of component layers. The tensile strength of the prepared laminated materials decreased with the increase in the thickness ratio of the 705 layer, and the bonding strengths of the laminated materials were in the range of 88–99 MPa. The experimental results verified the rationality of the process parameters recommended by the numerical simulations in terms of warping and delamination prevention.

Study on the dynamic response characteristics of lining structures in large-section tunnel blasting using JH-2 model analysis

The lining structures of tunnels are typically constructed using sprayed or cast concrete materials, and their performance and quality during tunnel excavation and blasting are crucial for the stability and safety of tunnels. Therefore, the safe distance between the lining structure and blasting source should be determined to avoid concrete damage caused by blasting vibrations. In this study, taking the subway tunnel of Danshan Station in Qingdao as an example, the JH-2 model is introduced as the constitutive model of the tunnel blasting simulation, and the JH-2 model parameters of the local surrounding rock are obtained by experiments, and finally the numerical simulation and theoretical verification are carried out to study the safety distance of shotcrete under various safety judgment standards. The results indicate that the JH-2 model can effectively simulate the propagation of stress waves under different media conditions, and the closer the strength parameters and pressure constant of the lining structure are to those of the surrounding rock, the safer the concrete–rock bonding interface. During tunnel blasting construction using the ring blasting method, the peak particle velocity (PPV) of the lining structure increases with an increase in the arch angle. Based on the numerical simulation results, we recommend that concrete lining be constructed at a distance of at least 62 m from the blasting source to avoid damage caused by vibrations. The effect of concrete tensile failure caused by longitudinal stress is much smaller than the damage to the bonding interface caused by the PPV and can be neglected.

Analytical prediction and numerical verification of stress concentration profile around an in-situ tow break in resin-impregnated filament-wound composites

A new empirical analytical approach is developed for predicting the stress concentration profile around an in-situ tow break in filament-wound composites. A shear-lag analysis is firstly performed to solve for the perturbational axial displacement of the broken tow and resultant debonding lengths. Solution of stress field caused by tangential load on the surface of an elastic half space is then utilized in combination with superposition principle to obtain the overload magnitudes in the neighboring tows. Subsequently, high-fidelity finite element analysis on a representative uni-directional laminate model under different stress states is performed, and excellent overall agreement is observed between analytical and numerical predictions. The proposed method takes into account essential aspects such as transversely isotropic material properties, in-situ stress states and their effect on the interfacial frictional forces in the debonded interfaces, and thus provides a convenient way to evaluate the stress concentration factors in damaged filament-wound composites. In addition, this approach can be applied to yield auxiliary failure evaluation criteria for statistical strength prediction or finite element modeling of filament-wound composites or similar structures.

Matched Stochastic Resonance Enhanced Underwater Passive Sonar Detection under Non-Gaussian Impulsive Background Noise.

Remote passive sonar detection with low-frequency band spectral lines has attracted much attention, while complex low-frequency non-Gaussian impulsive noisy environments would strongly affect the detection performance. This is a challenging problem in weak signal detection, especially for the high false alarm rate caused by heavy-tailed impulsive noise. In this paper, a novel matched stochastic resonance (MSR)-based weak signal detection model is established, and two MSR-based detectors named MSR-PED and MSR-PSNR are proposed based on a theoretical analysis of the MSR output response. Comprehensive detection performance analyses in both Gasussian and non-Gaussian impulsive noise conditions are presented, which revealed the superior performance of our proposed detector under non-Gasussian impulsive noise. Numerical analysis and application verification have revealed the superior detection performance with the proposed MSR-PSNR detector compared with energy-based detection methods, which can break through the high false alarm rate problem caused by heavy-tailed impulsive noise. For a typical non-Gasussian impulsive noise assumption with α=1.5, the proposed MSR-PED and MSR-PSNR can achieve approximately 16 dB and 22 dB improvements, respectively, in the detection performance compared to the classical PED method. For stronger, non-Gaussian impulsive noise conditions corresponding to α=1, the improvement in detection performance can be more significant. Our proposed MSR-PSNR methods can overcome the challenging problem of a high false alarm rate caused by heavy-tailed impulsive noise. This work can lay a solid foundation for breaking through the challenges of underwater passive sonar detection under non-Gaussian impulsive background noise, and can provide important guidance for future research work.

Investigation of the single-phase immersion cold plate amid PAO-4 and Noah@3000A – An experimental approach and its numerical verification

This study investigates improving traditional immersion cooling systems by employing cold plates in single-phase immersion cooling with dielectric fluids (Noah@3000 A and PAO-4). Experimental and CFD methods explore various cold plate structures in a 1 U server with a TTV heat source. Flow rates range from 1 to 3 LPM, and configurations include side-open, fully enclosed, and dual-open designs. Results show that incorporating cold plates reduces fluid bypass, enhancing thermal performance. High-viscosity dielectric oil as a coolant yields substantial improvements (36.1% and 41.6% at low and high flow rates) compared to traditional systems. Thermal resistance decreases with higher flow rates, more notably for Noah@3000A. Immersing the cold plate in liquid enhances convective heat transfer, reducing thermal resistances by 7.2% and 9.4% for Noah@3000A and PAO-4 at low flow rates. Smaller fin pitch consistently lowers resistance by eliminating bypass. Outlet configuration significantly influences thermal resistance, with Enclosed cold plates showing the least performance for PAO-4 and dual-open cold plate yields the worst performance with Noah@3000A. Differences in heat transfer behavior between PAO-4 and Noah@3000A are linked to laminar and turbulent flow characteristics. These findings offer insights into optimizing immersion cooling systems, emphasizing the impact of fluid choice and cold plate design on thermal performance.

Bandgap tunability and programmability of four-leaf clover shaped elastic metastructures

This paper studies the propagation of elastic waves in a four-leaf clover shaped elastic metastructure (EM), which consists of periodically distributed solid blocks connected by slender beams. The bandgap structure and vibrational transmittance of four-leaf clover shaped EM plates were examined using two-dimensional (2D) and three-dimensional (3D) solid elements. The comparison of elastic wave propagation experiments and numerical transmittance attenuation analysis shows excellent consistency and efficient wave regulation. Based on the experimentally validated model, the effect of structural parameters on the bandgap distribution is explored. It is found that the bandgap frequency can be lowered by up to 50 % and widened by 22 % by adjusting structural parameters, providing useful guidance for parameter settings to lower or widen the low-frequency bandgap. Finally, a programmable EM plate capable of guiding elastic wave propagation is proposed, which has the advantages of convenient adjustment and reliable structure, altering the bandgap from ‘‘on’’ to ‘‘off’’ by adjusting the distribution of the local resonators in the unit cell. Numerical demonstrations and experimental verifications are further carried out, illustrating that the proposed EM plate is capable of highly tuning elastic wave propagation. The results of the study indicate that the four-leaf clover shaped EM has a lower and wider bandgap adjustment range, which can realize waveguide control in a broadband range. The current findings provide important insights for the design of alternative devices such as vibration isolators, beams, and plates.

Hull form optimization research based on multi‐precision back‐propagation neural network approximation model

AbstractIn order to shorten the optimization cycle of ship design optimization and solve the time‐consuming problem of computational fluid dynamics (CFD) numerical calculation, this paper proposes a multi‐precision back‐propagation neural network (MP‐BP) approximation technology. Fewer high‐precision ship samples and more low‐precision ship samples were used to construct an approximate model, back‐propagation (BP) neural network was used to train multi‐precision samples. So that the approximate model is as close as possible to the real model, and achieving the effect of high‐precision approximation model. Subsequently, numerical verification and typical hull form verification are given. Based on CFD and Rankine theory, the multi‐objective design optimization framework for ship comprehensive navigation performance is constructed. The multi‐objective approximation model of KCS ship is constructed by MP‐BP approximation technology, and optimized by particle swarm optimization (PSO) algorithm. The results show that the multi‐objective optimization design framework using the MP‐BP approximation model can capture the global optimal solution and improve the efficiency of the entire hull form design optimization. It can provide a certain degree of technical support for green ship and low‐carbon shipping.

Formation mechanism and improved remedy of thermal property of cold shut surface defects in Vortex Flow Meters: Numerical simulation and experimental verification in investment casting of 316 L stainless steel

The purpose of this study aims to investigate the leading causes of CS (Cold Shut) defects in VFM (Vortex Flow Meters) of intricate geometric configuration and propose improvement strategies to leverage the thermal property in the vicinity of thin-walled regions, such as insulation-enhanced uniformly distributed temperature via ceramic core embedment. First, penetrant testing reveals whether the defect is a penetrating-type defect. Second, several extensive material characterization techniques such as optical microscopy (OM), energy-dispersive X-ray spectroscopy (EDS) analysis, and charge-coupled device (CCD) were employed to provide deeper insights into the formation and morphology of defects. Third, numerical simulations and experimental verifications were utilized to further analyze the causes of CS defects in vortex flowmeters. Fourth, effective preventive measures were designed after identifying the causes of defects, which involved using ceramic cores to replace the shell at deep and thin-walled locations. A virtual thermo-dynamic sensor (VTDS) was used to analyze the temperature distribution in the area before and after the installation of ceramic cores. The results indicate that the temperature in the defect area increased by >40 degrees during the filling period from 2.5 s to 5 s. Additionally, adequate thermal uniformity was achieved through the high thermal conductivity of the ceramic material, thereby reducing the cooling rate and the coefficient of kinematic viscosity in that area, leading to improved fluidity of the molten iron. Ultimately, the occurrence rate of CS defects decreased from 42.6 % to 0 %.

Numerical Verification of the Solution to the Problem of Empty Cavity Collapse in a Viscous Fluid

Numerical Verification of the Solution to the Problem of Empty Cavity Collapse in a Viscous Fluid

A Novel Intuitionistic Fuzzy Set-Based Risk Priority Number Method for Solving Chemical Experiment Risk Evaluation

Scientific experiments cover a wide range of fields—from basic to applied scientific research. Chemical experiments are the basis for cultivating chemical knowledge in scientific experiments and are an important way to cultivate scientific thinking and methods. However, due to the toxicity or flammability of the chemical substances in the experiments, hazardous events often lead to personal injuries and environmental damage. Exactly assessing risk factors and reducing the risk of hazards to protect the experimenters and ensure environmental safety are crucial in chemical experiments. However, while the traditional risk evaluation method cannot consider the weight of risk evaluation criteria, it also cannot effectively address problems through hierarchical analysis, as well as imprecise and ambiguous information inherent in human cognition. Therefore, this paper proposed an approach based on failure mode and effects analysis (FMEA) to assess the risk of chemical experiments in a fuzzy information environment. The approach combines the typical analytic hierarchy process (AHP), the risk priority number (RPN) of FMEA, and the intuitionistic fuzzy set (IFS) methods to evaluate risks associated with chemical experiments and consider the damage recovery in chemical experiments. This study applied the case of a university chemistry experiment, “preparation of hydrogels”, to validate the reasonableness and correctness of the proposed approach and compare its numerical verification results with those from the typical RPN, the AHP-RPN, and the AHP-fuzzy risk priority number (AHP-FRPN) methods. The finding demonstrates that the proposed method can more effectively address risk evaluation problems in chemical experiments than the other methods. This result serves as an important reference for reducing chemical experiment risk occurrences.

Numerical generation and verification of a two-dimensional virtual asphalt mixture

This paper aims at finding a robust method to generate a two-dimensional virtual asphalt mixture and to verify the suitability of the generated virtual mixture. First, three methods namely stereological method, Walraven formula and phase separation method are adopted to convert the actual three-dimensional gradation curves into two-dimensional ones. Then, an approach called semi whole scale cross section (SWSCS) method is developed to verify the results obtained and to determine the most robust procedure to follow. Third, the numerical two-dimensional geometry shape data library (GSDL) of different aggregates and voids and a robust method to assemble representative volume elements (RVEs) are developed using Matlab. Finally, a gradation curve from the literature is considered to generate a virtual asphalt mixture specimen, which is then imported in the finite element (FE) software Abaqus to simulate the dynamic modulus test. The virtual test results are further verified using available literature and another homogenization numerical prediction method based on the Mori-Tanaka's approach. The results show that the phase separation method is effective to convert the three-dimensional gradation curve to a two-dimensional one. The simulation results of the virtual asphalt mixture developed in this study turn out to be in good agreement with both previously presented literature data and Mori-Tanaka's theory.

Numerical Simulation and Experimental Verification of Quality Detection of Grouting in Pre-Stressed Pipelines Based on Transmission Wave Method

The quality of grouting in pre-stressed pipelines plays a critical role in ensuring the safety and durability of pre-stressed concrete bridges. In this study, the transmission wave method was proposed as a means to assess the quality of grouting in pre-stressed pipelines. The ABAQUS finite element simulation (FE simulation) method was used to study the propagation of hammer stress waves in pre-stressed pipes. A full-scale test was conducted to verify the numerical simulation using the AGI-BWG instrument system developed to detect the quality of grouting. The results show that the propagation speed of transmitted waves increases and the frequency shifts towards higher frequencies with an increase in void length within pre-stressed pipelines. This research suggests that the propagation velocity of elastic waves in pre-stressed pipelines serves as a key indicator of grouting quality. The transmission wave method, based on hammer signals, proves to be an effective tool for detecting the quality of grouting in pre-stressed pipelines.