Three-dimensional Simulation Model Research Articles

A three-dimensional numerical model for computing the actual voltage induced in a Barkhausen surface coil

This investigation presents a novel three-dimensional simulation model designed for the analysis of Magnetic Barkhausen Noise (MBN). The model’s formulation is directly deduced from Maxwell’s equations, establishing a Boundary Value Problem (BVP) with boundary conditions tailored to a specific configuration involving a lengthy steel rod encased within a solenoid, subjected to sinusoidal current excitation, all contained within an air enclosure. This chosen configuration holds physical equivalence to the majority of setups commonly utilized in Barkhausen experiments. Utilizing the proposed three-dimensional model, it became feasible, for the first time, to computationally assess the voltage induced in the coil by the flux emanating from all spatial directions. The findings indicate that the MBN signal is primarily generated by the flux rate aligned with the direction of the applied field. Nevertheless, simulations confirm additional contributions to the signal originating from magnetic flux in directions significantly deviating from the applied field direction. It is demonstrated that these contributions from lateral flux significantly influence the angular dependence of the Barkhausen signal energy, showcasing a notable alignment between the proposed model and experimental results. The results underscore the capability of the proposed model to facilitate the simulation of Barkhausen Noise.

Numerical study on dynamic flow of flexible extension nozzle in rocket motors

The use of extension nozzles in rocket propulsion systems is one of the effective methods to increase the geometric expansion ratio and thrust of the nozzle. As a new type of extension nozzle, the flexible extension nozzle can achieve continuous changes in nozzle expansion ratio. To explore the characteristics of the flow field structure at the “bulge” structure and the step structure in the actual configuration of the flexible extension nozzle, and the impact on the performance of the nozzle, a three-dimensional numerical simulation model of the flexible extension nozzle was first established to study the flow field at the “bulge” structure, and then a two-dimensional unsteady numerical simulation model was established by using the coupling technology of dynamic grid and overlapping grid to study the flow field at the step structure. The results show that during the unfolding of the nozzle surface, a complex flow structure of “expansion fan-mixing layer-shock-vortex” were formed in the step area at the junction of the fixed section and the moving extension section. The specific impulse loss of the 3D model is larger than that of the 2D model due to the consideration of the “bulge” structure. The flow loss of the “bulge” structure and the step structure to the nozzle is 0.73% and 0.65% respectively.

Use of virtual reality in physical rehabilitation: A narrative review

Virtual reality (VR) has emerged as an innovative technology in various fields. It transforms how we experience and interact with the world, and it has also developed into physical rehabilitation. Rehabilitation has also evolved from mere exercises to using technology while giving exercises to patients. VR is a technology that can enhance treatment and improve outcomes. VR uses computer-generated three-dimensional interactive simulation models, allowing users to engage in environments resembling real-world objects and events. An extensive literature search was conducted on SCOPUS, PubMed, the Web of Science and relevant rehabilitation databases. The keywords ‘virtual reality’, ‘rehabilitation’ and ‘physical therapy’ were employed to identify pertinent studies. The inclusion criteria encompassed research investigating the use of VR in rehabilitating musculoskeletal, neurological and cardiovascular conditions. VR has been used in various rehabilitation domains. It is effectively used in balance and gait training, cognition and memory training, pain management, muscle strengthening, etc. It has also been shown to improve adherence to exercises. VR training in physical therapy represents a transformative advancement in rehabilitation. Integrating VR technology offers many benefits, including enhanced engagement, customised therapy regimens and a safe environment for patients to practice and improve their physical abilities. The evidence from various studies indicates its potential to improve outcomes for individuals with a wide range of physical impairments.

Design, thermal-mechanical coupling analysis, and optimization of polymeric matrix composite sandwiches with a lattice core exposed to a high temperature

This study presents the design of a sandwich structure tailored for post-heat transfer applications subjected to out-of-plane compression. A three-dimensional finite element simulation model was developed to analyze the temperature distribution within the sandwich structure and investigate the effects of high-temperature exposure on its mechanical behaviors. The structure was subjected to a temperature of 300 °C for 400 s, and the temperature distribution at the upper connection point between the top face sheet and the struts of the core was determined. Subsequently, upon returning the sandwich to ambient temperature, a comprehensive calculation of its mechanical properties was conducted and then enhanced by applying different optimization techniques. The results demonstrate that filling the core with Saffil alumina fibers in the presence of a 1.5 mm a thermal barrier coating of Superwool 607 helps increase the mechanical properties of the sandwich structure by around 55%.

Thermal and Mechanical Stress Analysis in Aircraft Hybrid Panels with Multi-Bolt Joints.

This study investigates the thermal stress and bolt load distribution in a hybrid panel structure of an aircraft mechanical joint under extreme temperatures. The hybrid panel structure comprises two aluminum alloy splices, six T-shaped composite stringers, and two composite skins, secured together with 96 bolts. This study analyzed the strain induced by thermal stress on composite materials and metals within the structure across temperatures, employing temperature environment tests ranging from room temperature to -54 °C, alongside a carrying capacity test at -54 °C. Furthermore, a three-dimensional simulation model of the panel structure was developed, incorporating considerations for contact, metal elastoplasticity, and the progressive damage failure of composite materials. This model facilitated the determination of thermal stress and bolt load distribution patterns. The results indicate a strong consistency between the finite element analysis outcomes and the experimental data. Temperature variations exacerbate the uneven distribution of bolt loads, concentrating the load near the edges of the hybrid structure while diminishing it in the center. The bolt load distribution parallel to the mechanical load direction forms an "M" shape, with a maximum load magnitude of approximately 31 kN. Perpendicular to the mechanical load, the bolt load undergoes significant changes, especially at the edges, reaching a maximum of about 20 kN, which warrants attention. The bolt-load distribution of the structure with the increase in mechanical load at -54 °C tends to be consistent with that at room temperature.

Influence of Magnetic Field Configuration in Helicon-Negative Ion Source on Increase of the Efficiency of NNBI Heating System

The influence of the magnetic field configuration on the performance of a helicon-based negative ion source is investigated with simulation experiments. Using COMSOL Multiphysics software, a three-dimensional simulation model for a negative ion source, based on a helicon plasma source, is presented in two magnetic field configurations: uniform and nonuniform configurations. The helicon plasma source employed a Nagoya-type antenna to apply radio-frequency (RF) power at a frequency of 13.56 MHz. The injected gas is hydrogen with a flow of 10 standard cubic centimeters per minute. Using a three-dimensional model, helicon wave propagation in the presence of a magnetic filter and the energy absorption mechanism in the helicon system are investigated. In this context, in the presence of the two magnetic field configurations, the influence of the important parameters’ working pressure and RF power on the optimization of negative ion production under volume mode is studied. Six electromagnetic coils at the same current are used for producing the magnetic field in both cases of uniform and nonuniform configurations. The variation of the electron density and electron temperature, in both regions of driver and expansion, are calculated and represented with respect to the different power and the gas pressure. The simulation results of the negative ion density in the expansion region for the uniform and nonuniform magnetic field configurations are compared. The results indicate that at the same applied current of coils, the negative ion density in the presence of the nonuniform magnetic field is about 1.75 times higher than the negative ion density of the uniform case. Moreover, the results show that the negative ion density is decreased by decreasing the magnetic field of the driver region in the nonuniform cases.

Electric-thermal-mechanics modeling for in-process phenomena during micro resistance spot welding spark plug of Pt and Inconel600

The spark plug is one of the important components in the gasoline engine's combustion chamber. To reduce vehicle emissions, the platinum spark plug is selected due to its good performance. Due to the high productivity of resistance spot welding (RSW), a micro-scale RSW process is employed to assemble the platinum tip to Inconel600 part in the production of spark plugs. In order to understand the electric-thermal-mechanics phenomena during micro resistance spot welding spark plug for controlling the welding quality and saving electric energy, a three-dimensional simulation model and the in-house finite element program JWRIAN-RSW3D were developed. The potential history and upper electrode displacement results were verified with experiments. Numerical case studies were made to investigate the influence magnitude of welding current on the electric-thermal-mechanics phenomena. The developed model reveals inside phenomena to clearly understand the welding mechanism for potential, current density, temperature, electrode displacement and their distribution/history as well as the molten zone. The comprehensive phenomena of maximum temperature distribution on both base metals and Inconel600 were clarified using a top perspective, revealing differences in distribution on the contact surface between horizontal and vertical sections. To achieve a complete welding joint, the molten zone on the contact area is required carefully in order to facilitate the bonding of both base metals. Based on simulation results for three welding conditions, the alternating current at the magnitude of 1.2 kA with the welding time of 0.1 s is recommended to obtain the welded joint with minimized energy consumption in production.

Simulation-Based Thermal Fatigue Validation Test Development for Exhaust Manifold

Abstract Exhaust manifolds in diesel engines undergo continuous thermal cycle loading of varying thermal cycles with different mean, amplitude, and rate of temperature change created by application duty cycles. This makes analysis and testing of the exhaust manifold to meet the thermal mechanical fatigue life expectation of different applications challenging. In this paper, a simulation-based product development approach, which uses application duty cycles, simulation models of different capabilities, including three-dimensional Finite element simulation model, one-dimensional (1D) physis-based damage model to develop an abusive thermal cycle engine test for validating exhaust manifold, is presented.

The influence of hydraulic fracture and reservoir parameters on the storage of CO2 and enhancing CH4 recovery in Yanchang formation

The demand for a clean energy source from shale is growing day-to-day since it is not harmful to the environment like other fossil fuels. Further, shale reservoirs offer long-term geo-carbon dioxide (CO2) storage. Innovations in horizontal drilling and multi-stage hydraulic fracturing have made shale gas extraction and geo-CO2 storage economically viable. A three-dimensional Yanchang shale formation simulation model in Ordos's basin was developed using CMG-GEM, considering adsorption/desorption, diffusion, geomechanics, permeability changes, and non-Darcy flow. Two horizontally drilled wells, each 510 m long, were fractured and positioned 90 m apart. CO2 gas was injected into Well-2, producing methane (CH4) in Well-1. After simulation for 30 years, the cumulative mass of CH4 produced was 1.07×10+5kg, the cumulative mass of CO2 produced was 2.3×10+4kg, which is 1.14% of the mass injected, the cumulative mass of CO2 injected was 2.01×10+6kg and cumulative mass of CO2 gas stored was 1.987×10+6kg which is 98.86% of the injected mass of CO2 gas. The natural fracture system was the dominant factor of enhanced shale gas recovery and CO2 injection in the Yanchang shale formation. A sensitivity analysis was conducted with CMG-CMOST, examining the influence of reservoir and hydraulic fracture parameters in the storage of CO2 and enhancing CH4 recovery. Natural fracture porosity had the most significant impact on CH4 production and CO2 storage, followed by fracture permeability and half-length leading for hydraulic fracture parameters, with fracture conductivity being the least influential parameter. The approach used in this study applies to tight shale oil and gas formations in various sedimentary basins worldwide, enabling a more comprehensive understanding of reservoirs and hydraulic fracture parameters that can enhance oil and natural gas production.

Liquid metal-enhanced thermoelectric generator for high-temperature thermal harvesting

It is a challenge to achieve high output power of the thermoelectric generator (TEG) for high-temperature waste heat recovery due to the working fluids with low thermal conductivity (such as air) or low tolerance of temperature (water or oil). In this paper, the gallium-based liquid metal (LM) with a high boiling point (>1000 ℃) and thermal conductivity (>20 W/mK) are introduced to significantly enhance heat charging and discharging at the hot/cold sides of TEG. We also developed an electromagnetic induction pumping method for the effective LM-driven flow at high temperatures. A three-dimensional coupling multi-parameter optimization simulation model of LM-based TEG was developed to reveal the internal heat transfer and power generation mechanism for clarifying the impact factors of the performance. The results have shown that the power generation capacity can be effectively improved by increasing the inlet temperature (Thot-in). It is worth noting that the temperature difference (ΔT) of the TEG module is severely limited by the thermal resistance (Rcapacity) of the LM heat capacity, such as, when the flow rate of 2 L/min, the Rcapacity accounts for 90.6 % (0.020 ℃/W). It is easier to achieve a larger open circuit voltage by increasing the height of the thermoelectric leg, but the Pmax is constantly weakened. Compared with Xceltherm 600 and Solar salt, LM heat transfer fluid has more obvious advantages in enhancing the power generation performance of the system. The LM-based TEG experiment platform was established to study heat transfer and power generation characteristics. The results have demonstrated that good consistency was proved by comparing experimental and numerical data. And the Pmax of the LM-based TEG system is 0.16 W/cm2 at ΔT of 136 ℃. LM-based TEG can open new perspectives for broad applications in high-temperature waste heat recovery.

Research on the influence and optimization of sunshade effect on radiative cooling performance

Intense solar radiation is the main reason why radiative cooling is difficult to achieve during the daytime, as the radiative heat flux from the sun will offset the heat emitted by the cooler. Most previous studies have focused on providing coolers with high solar reflectance and high mid-infrared spectral emissivity by designing photonic structures. In this study, a macroscopic sunshade device based on the solar visual motion trajectory is proposed to reduces the direct solar radiation received by the cooler surface through setting a blocking on the solar path, while hardly affecting the radiative capacity of the cooler. Here, we built a three-dimensional sunshade device simulation model based on the surface-to-surface radiative heat transfer module in COMSOL Multiphysics® software, which can effectively improve the cooling performance of the cooler. Then, using polished aluminum plates, black paint-coated cooler, and reflective radi-cool film to test the impact of macroscopic sunshade device based on the solar apparent motion trajectory on improving the cooling performance of difference coolers. The results verified the effectiveness of the proposed sunshade devices in improving radiative cooling performance, and the results showed that the maximum temperature reduction could reach 3.35 °C, 26.96 °C, and 3.42 °C, respectively.

A numerical simulation method for solving electromagnetic-mechanical coupling field

A new numerical simulation method based on the finite volume method has been proposed to address the challenges associated with the pseudo-oscillation phenomenon that occurs with an increased Péclet number, as well as determining an appropriate time step for electromagnetic-mechanical coupled physical field calculations. This method utilizes the concept of upwind from Computational Fluid Dynamics (CFD) to solve Maxwell's equations, a finite-volume method for discretizing the electromagnetic diffusion equations. Through computing typical electromagnetic field problems such as TEAM problem 9–1 and comparing the results to the literature, it has been confirmed that this method has sufficient computational accuracy to solve electromagnetic field numerical simulation problems containing moving conductors. Additionally, a three-dimensional simulation model of the electromagnetic coil gun has been established to verify the viability of the proposed method for solving magnetic field problems under the electromagnetic launch (EML) system. The study also examined the change in magnetic field strength and current density of the EML device during the launching process. The results lay the foundation for the technical application of this method.

Optimizing Hydrogen and Ammonia Injection Timing for Enhanced Mixture Formation in Internal Combustion Engines

Hydrogen and ammonia are two carbon-free alternative fuels for engines. They represent some of the most viable pathways toward achieving our objectives of energy conservation and reducing emissions. To research the quality of the hydrogen-ammonia-air mixture formation under different hydrogen/ammonia injection timing, a three-dimensional simulation model for a PFI(Port Fuel Injection) hydrogen internal combustion engine with the inlet, outlet, valves and cylinder was established using Converge software. Research focused on the space distribution characteristics and variation law of velocity field, concentration field and turbulent kinetic energy under different injection timings in order to reveal the influence of these parameters on hydrogen-ammonia-air mixture formation process. The results showed that hydrogen injection should be neither too early nor too late. Backfiring can be initiated too early or too late. Therefore, the optimum starting point for hydrogen/ammonia injection should be 338°CA.

A Discrimination method of three types of defects in insulated cladding components based on the lift-off effect of capacitive imaging (CI) technology

In insulated cladding components, simultaneously detecting and distinguishing surface defects on the insulation layer, hidden defects in the insulation layer, and surface defects on the metal layer of insulated cladding components can help in formulating appropriate maintenance plans and promptly eliminating safety hazards, which is of great significance for ensuring the safety of insulated cladding components in relevant application fields. This paper applies capacitive imaging (CI) to detect three different types of defects. A three-dimensional simulation model of the CI sensor detecting the three types of defects is established using COMSOL software. The corresponding measurement sensitivity distribution (MSD) and volume of influence (VOI) are obtained, and the detection mechanisms of the three different types of defects are analyzed in detail. By analyzing the lift-off height variation, the VOI regions' changing patterns for different types of defects are determined, and the distinguishing mechanisms for the three types of defects are obtained. Based on the monotonicity of the normalized variation ratio (NVR) and the differences in the positions of the intersection points, a comparative distinguishing method for the three types of defects based on the variation of the lift-off height is established. Experimental results demonstrate that the defect comparative distinguishing method based on the lift-off effect can effectively differentiate surface defects on the insulation layer, hidden defects in the insulation layer, and surface defects on the metal layer.

Evaluation of Ground Pressure, Bearing Capacity, and Sinkage in Rigid-Flexible Tracked Vehicles on Characterized Terrain in Laboratory Conditions.

Trafficability gives tracked vehicles adaptability, stability, and propulsion for various purposes, including deep-sea research in rough terrain. Terrain characteristics affect tracked vehicle mobility. This paper investigates the soil mechanical interaction dynamics between rubber-tracked vehicles and sedimental soils through controlled laboratory-simulated experiments. Focusing on Bentonite and Diatom sedimental soils, which possess distinct shear properties from typical land soils, the study employs innovative user-written subroutines to characterize mechanical models linked to the RecurDyn simulation environment. The experiment is centered around a dual-tracked crawler, which in itself represents a fully independent vehicle. A new three-dimensional multi-body dynamic simulation model of the tracked vehicle is developed, integrating the moist terrain's mechanical model. Simulations assess the vehicle's trafficability and performance, revealing optimal slip ratios for maximum traction force. Additionally, a mathematical model evaluates the vehicle's tractive trafficability based on slip ratio and primary design parameters. The study offers valuable insights and a practical simulation modeling approach for assessing trafficability, predicting locomotion, optimizing design, and controlling the motion of tracked vehicles across diverse moist terrain conditions. The focus is on the critical factors influencing the mobility of tracked vehicles, precisely the sinkage speed and its relationship with pressure. The study introduces a rubber-tracked vehicle, pressure, and moisture sensors to monitor pressure sinkage and moisture, evaluating cohesive soils (Bentonite/Diatom) in combination with sand and gravel mixtures. Findings reveal that higher moisture content in Bentonite correlates with increased track slippage and sinkage, contrasting with Diatom's notable compaction and sinkage characteristics. This research enhances precision in terrain assessment, improves tracked vehicle design, and advances terrain mechanics comprehension for off-road exploration, offering valuable insights for vehicle design practices and exploration endeavors.

Design and Optimization of a Robot Dosing Device for Aliquoting of Biological Samples Based on Genetic Algorithms

Aliquoting of biological samples refers to the process of dividing a larger biological sample into smaller, representative portions known as aliquots. This procedure is commonly employed in laboratories, especially in fields like molecular biology, genetics, and clinical research. Currently, manual dosing devices are commonplace in laboratories, but they demand a significant amount of time for their manual operation. The automated dosing devices available are integrated into narrowly focused aliquoting systems and lack versatility as manipulator equipment. Addressing this limitation, a novel technical solution is proposed in this paper for a modular dosing device compatible with robotic manipulators. The paper introduces and details a mathematical model, optimizes its parameters, and constructs a detailed 3D model using the NX environment to demonstrate the engineering feasibility of our concept. It further outlines the development of a three-dimensional dynamic simulation model for the dosing device, comparing analytical calculations with simulation results. The construction of a dosing device prototype is discussed, followed by a comprehensive experimental validation.

Simulation study on arc motion process of 38 A low-voltage AC contactor under AC-4 conditions

In the process of breaking an AC contactor, the ablation of the contact by the arc current is an important factor affecting its electrical life, so the evolution of arc shape in the arc extinguishing chamber has an important influence on its breaking performance. To explore the influence of arc motion characteristics on its breaking characteristics, based on the theory of magnetohydrodynamics and considering the contact motion process, a three-dimensional air arc simulation model is established for the arc extinguishing chamber of an AC contactor with a fixed current of 38 A and the arc motion characteristics of the arc during breaking are analyzed. To verify the accuracy of the simulation model, a test platform was built. Under the same breaking conditions, the arc shape, arc voltage, and arc current were measured, and the experimental results were consistent with the simulation results. On this basis, an optimization scheme of the arc extinguishing component is proposed and its influence on the arc motion process is analyzed.

Radiated emission from DC bus loop of AC induction motor inverter FEM based and experimental evaluation

The paper describes practical method how to analyze locally radiated magnetic field to improve the geometry of printed circuit board (PCB) or busbar structure, select better control method and design electromagnetic interference (EMI) filter. Experimental prototype of three-phase induction motor variable frequency drive has been created and controlled by microcontroller with sinusoidal, namely pulse with modulation (PWM) method. Three-dimensional finite element model simulation of DC bus structure has been created and results has been obtained. Electromagnetic field was measured, practically and results compared with simulation-based ones. Simulation based and experimental results matches thus allowing to conclude method usefulness for cost effective way to test different geometries of DC bus, different modulation methods, EMI filters for variable frequency drive, and other power electronics converters.

Development of an Anatomically Accurate Three-Dimensional Simulation Model for Pediatric Central Line Placement

Abstract Intensive care unit patients can require a central venous catheter (CVC) which medical trainees often place. The purpose of this study was to create a novel three-dimensional (3D) printed model, based on actual patient anatomy from a de-identified computed tomography (CT) scan, with improved anatomy, tactile properties, and realism beyond current task trainers for pediatric CVC placement simulation. Bakken Center researchers converted CT DICOM slices into a 3D model using multiple computer programs and multiple 3D printers. Faculty of various subspecialties at our institution attempted to place a CVC line into the model and then evaluated the model in 5 categories using an anonymous REDCap survey. Fifteen faculty participated and fourteen completed their survey. Feedback, based on a 0–10 scale with 10 being highest, was as follows: the model's size scored an average of 8.4, the model's tactile properties scored a 6.1, the model's anatomy received a 7.1, the model's perceived usefulness for practicing central line placement received a 7.6, and the model received a 7.6 in regard to whether it should be utilized in procedural training curriculums. Additional comments were collected in the survey and participants requested that the model's blood vessels be fully visible on ultrasound and that the model be firmer. In conclusion, creating a 3D simulation model for pediatric CVC placement is possible.

Experimental study and finite element analysis of heavy-duty escalator truss under full load conditions

The performance of the heavy-duty escalator truss greatly affects the stability and service life of the whole escalator system, and the manufacturing cost of truss structure accounts for more than 1/5. Thus, how to design the truss structure reasonably is a pivotal issue drawing the attention of numerous engineers and researchers. In this work, the experimental research of heavy-duty escalators under full load conditions were performed in terms of the end restraints, the docking port clearances, and the deflection. Based on the experimental results, the three-dimensional simulation model of truss structure was created, and the influences of various factors such as the internal chamfer of truss member, the lower deviation of truss member, the dead weight of escalator, and the pretension force of each bolt at the docking port were analyzed and quantified. Finally, the finite element model which can almost completely characterize the actual structure was obtained with slight difference. The conclusions drawn in this work provide the basis for the efficient design, correct simulation, low cost production and rapid installation of the heavy-duty escalator truss.