Investigation of anode shaping process during co-rotating electrochemical machining of convex structure on inner surface

A novel co-rotating electrochemical machining method is proposed for fabricating convex structures on the inner surface of a revolving part.The electrodes motion and material removal method of co-rotating electrochemical machining are different from traditional electrochemical machining.An equivalent kinematic model is established to analyze the novel electrodes motion,since the anode and cathode rotate in the same direction while the cathode simultaneously feeds along the line of centres.According to the kinematic equations of the electrodes and Faraday’s law,a material removal model is established to simulate the evolution of the anode profile in co-rotating electrochemical machining.The simulation results indicate that the machining accuracy of the convex structure is strongly affected by the angular velocity ratio and the radius of the cathode tool.An increase of the angular velocity ratio can improve the machining accuracy of a convex structure.A small difference in the radius of the cathode tool will cause changes in the shape of the sidewalls of the convex structure.The width of the cathode window affects only the width of the convex structure and the inclination a of the sidewall.A relation between the width of the cathode window and the width of the convex structure was obtained.The formation process for a convex structure under electrochemical dissolution was revealed.Based on the simulation results,the optimal angular velocity ratio and cathode radius were selected for an experimental verification,and 12 convex structures were simultaneously fabricated on the inner surface of a thin-walled revolving part.The experimental results are in good agreement with the simulation results,which verifies the correctness of the theoretical analysis.Therefore,inner surface co-rotating electrochemical machining is an effective method for fabricating convex structures on the inner surface of a revolving part.

CONSTITUTIVE EQUATION OF CO-ROTATIONAL DERIVATIVE TYPE FOR ANISOTROPIC-VISCOELASTIC FLUID

A constitutive equation theory of Oldroyd fluid B type,i.e.the co-rotational derivative type,is developed for the anisotropic-viscoelastic fluid of liquid crystalline(LC)polymer.Analyzing the influence of the orientational motion on the material behavior and neglecting the influence,the constitutive equation is applied to a simple case for the hydrodynamic motion when the orientational contribution is neglected in it and the anisotropic relaxation,retardation times and anisotropic viscosi- ties are introduced to describe the macroscopic behavior of the anisotropic LC polymer fluid.Using the equation for the shear flow of LC polymer fluid,the analytical expressions of the apparent viscosity and the normal stress differences are given which are in a good agreement with the experimental results of Baek et al.For the fiber spinning flow of the fluid,the analytical expression of the extensional viscosity is given.

A 3-Node Co-Rotational Triangular Finite Element for Non-Smooth,Folded and Multi-Shell Laminated Composite Structures

Based on the first-order shear deformation theory,a 3-node co-rotational triangular finite element formulation is developed for large deformation modeling of non-smooth,folded and multi-shell laminated composite structures.The two smaller components of the mid-surface normal vector of shell at a node are defined as nodal rotational variables in the co-rotational local coordinate system.In the global coordinate system,two smaller components of one vector,together with the smallest or second smallest component of another vector,of an orthogonal triad at a node on a non-smooth intersection of plates and/or shells are defined as rotational variables,whereas the two smaller components of the mid-surface normal vector at a node on the smooth part of the plate or shell(away from non-smooth intersections)are defined as rotational variables.All these vectorial rotational variables can be updated in an additive manner during an incremental solution procedure,and thus improve the computational efficiency in the nonlinear solution of these composite shell structures.Due to the commutativity of all nodal variables in calculating of the second derivatives of the local nodal variables with respect to global nodal variables,and the second derivatives of the strain energy functional with respect to local nodal variables,symmetric tangent stiffness matrices in local and global coordinate systems are obtained.To overcome shear locking,the assumed transverse shear strains obtained from the line-integration approach are employed.The reliability and computational accuracy of the present 3-node triangular shell finite element are verified through modeling two patch tests,several smooth and non-smooth laminated composite shells undergoing large displacements and large rotations.

Co-rotational Oldroyd Fluid B Model for Spinning Flow of Liquid Crystalline Polymer

The relationship between the extensional viscosity and material parameters was studied through the analytical formulas of stress and extensional viscosity. The differential equations were solved to obtain the relationship between extensional viscosity and strain rates. The results obtained qualitatively agree with the experimental results. The study makes it practicable to simulate the rheologic behaviors of spinning flow of liquid crystalline polymer using co-rotational Oldroyd fluid B model.

An unsymmetric constitutive equation for anisotropic viscoelastic fluid

A continuum constitutive theory of corotational derivative type is developed for the anisotropic viscoelastic fluid-liquid crystalline （LC） polymers. A concept of anisotropic viscoelastic simple fluid is introduced. The stress tensor instead of the velocity gradient tensor D in the classic Leslie-Ericksen theory is described by the first Rivlin-Ericksen tensor A and a spin tensor W measured with respect to a co-rotational coordinate system. A model LCP-H on this theory is proposed and the characteristic unsymmetric behaviour of the shear stress is predicted for LC polymer liquids. Two shear stresses thereby in shear flow of LC polymer liquids lead to internal vortex flow and rotational flow. The conclusion could be of theoretical meaning for the modern liquid crystalline display technology. By using the equation, extrusion-extensional flows of the fluid are studied for fiber spinning of LC polymer melts, the elongational viscosity vs. extension rate with variation of shear rate is given in figures. A considerable increase of elongational viscosity and bifurcation behaviour are observed when the orientational motion of the director vector is considered. The contraction of extru- date of LC polymer melts is caused by the high elongational viscosity. For anisotropic viscoelastic fluids, an important advance has been made in the investigation on the constitutive equation on the basis of which a seriesof new anisotropic non-Newtonian fluid problems can be addressed.

连接翼布局的非线性屈曲分析

以连接翼结构为研究对象,通过非线性有限元方法对其进行非线性屈曲分析,研究连接翼几何参数和载荷分布对结构非线性屈曲特性的影响规律。连接翼采用基于Co-Rotational格式的三角形平板壳单元进行建模,采用弧长法计算非线性屈曲的位移突跳现象以及后临界变形模式。研究结果表明连接翼典型的载荷-位移曲线模式包括刚度软化、位移突跳不稳定和刚度刚化三部分。连接翼夹角增大后非线性屈曲载荷因子逐步降低,但存在一个临界夹角,当角度超过临界角后载荷-位移曲线模式中的位移突跳不稳定阶段就不会出现。增加连接翼高度可提高结构的非线性屈曲载荷。在连接翼夹角不变条件下,减小下翼展长可有效提高非线性屈曲载荷,同时其载荷-位移曲线模式中的位移突跳不稳定阶段也将不存在。调整连接翼的载荷分布,将载荷更多地施加于上翼的同时减少下翼的载荷可提高结构的非线性屈曲载荷。

New conception in continuum theory of constitutive equation for anisotropic crystalline polymer liquids

A new continuum theory of the constitutive equation of co-rotational derivative type is developed for anisotropic viscoelastic fluid—liquid crystalline (LC) polymers. A new concept of simple anisotropic fluid is introduced. On the basis of principles of anisotropic simple fluid, stress behaviour is described by velocity gradient tensor and spin tensor instead of the velocity gradient tensor in the classic Leslie—Ericksen continuum theory. Analyzing rheological nature of the fluid and using tensor analysis a general form of the constitutive equ- ation of co-rotational type is established for the fluid. A special term of high order in the equation is introduced by author to describe the sp- ecial change of the normal stress differences which is considered as a result of director tumbling by Larson et al. Analyzing the experimental results by Larson et al., a principle of Non- oscillatory normal stress is introduced which leads to simplification of the problem with relaxation times. The special behaviour of non- symmetry of the shear stress is predicted by using the present model for LC polymer liquids. Two shear stresses in shear flow of LC polymer liquids may lead to vortex and rotation flow, i.e. director tumbling in the flow. The first and second normal stress differences are calculated by the model special behaviour of which is in agree- ment with experiments. In the research, the com- putational symbolic manipulation such as computer software Maple is used. For the anisotropic viscoelastic fluid the constitutive equation theory is of important fundamental significance.

Modeling Study of Planar Flexible Manipulator Undergoing Large Deformation

The planar flexible manipulator undergoing large deformation is investigated by using finite element method (FEM). Three kinds of reference frames are employed to describe the deformation of arbitrary point in the flexible manipulator, which are global frame, body-fixed frame and co-rotational frame. The rigid-flexible coupling dynamic equation of the planar flexible manipulator is derived using the Hamilton’s principle. Numerical simulations are carried out in the end of this paper to demonstrate the effectiveness of the proposed model. The simulation results indicate that the proposed model is efficient not only for small deformation but also for large deformation.

液晶高分子各向异性粘弹流体拉伸流动中拉伸粘度的解析计算研究

将聚合物熔体的挤出过程看作是剪切流动主导的剪切单元,采用用液晶聚合物熔体或溶液LCP-B本构方程;采用共转Oldroyd B流体模型计算出取向运动拉伸粘度的影响.无量纲拉伸粘度随松弛时间和剪切速率的变化曲线.得到了无量纲拉伸粘度随剪切速率之间变化关系.

A new constitutive theory for extrusion-extensional flow of anisotropic liquid crystalline polymer fluid

A new continuum theory of the constitutive equation of co-rotational derivative type was developed by the author for anisotropic viscoelastic fluid-liquid crystalline (LC) polymers (S.F. Han, 2008, 2010) . This paper is a continuation of the recent publication [1] to study extrusion-extensional flow of the fluid. A new concept of simple anisotropic fluid is introduced. On the basis of anisotropic simple fluid, stress behavior is described by velocity gradient tensor F and spin tensor W instead of the velocity gradient tensor D in the classic Leslie?Ericksen continuum theory. A special form of the constitutive equation of the co-rotational type is established for the fluid. Using the special form of the constitutive equation in components a computational analytical theory of the extrusion-extensional flow is developed for the LC polymer liquids - anisotropic viscoelastic fluid. Application of the constitutive theory to the flow is successful in predicting bifurcation of elongational viscosity and contraction of extrudate for LC polymer liquids–anisotropic viscoelastic fluid. The contraction of extrudate of LC polymer liquids may be associated with the stored elastic energy conversion into that necessary for bifurcation of elongational viscosity in extrusion extensional flow of the fluid.

A 3D hard-magnetic rod model based on co-rotational formulations

Hard-magnetic soft materials have attracted broad interests because of their flexible programmability,non-contact activation and rapid response in various applications such as soft robotics,biomedical devices and flexible electronics.Such multifunctional materials consist of a soft matrix embedded with hard-magnetic particles,and can exhibit large deformations under external magnetic stimuli.Here,we develop a three-dimensional(3D)rod model to predict spatial deformations(extension,bending and twist)of slender hard-magnetic elastica.The model follows Kirchhoff hypothesis and thus reduces the 3D magneto-elastic energy function to a one-dimensional(1D)form.Besides,the co-rotational formulation is applied to describe rigid body motion,and explicit time integration is adopted for the nonlinear resolution.Moreover,we explore finite bending,post-buckling and twisting of hard-magnetic elastica under external magnetic fields with different directions and amplitudes.Representative examples with various configurations show superior efficiency and accuracy of the model(the difference less than 1%with only a small number of elements)compared to conventional solid element.Our model could be used to guide rational designs on programmable shape morphing of ferromagnetic slender structures.

Modified unified co-rotational framework with beam,shell and brick elements for geometrically nonlinear analysis

The co-rotational finite element formulation is an attractive technique extending the capabilities of an existing high performing linear element to geometrically nonlinear analysis.This paper presents a modified co-rotational framework,unified for beam,shell,and brick elements.A unified zero-spin criterion is proposed to specify the local element frame,whose origin is always located at the centroid.Utilizing this criterion,a spin matrix is introduced,and the local frame is invariant to the element nodal ordering.Additionally,the projector matrix is redefined in a more intuitive way,which is the derivative of local co-rotational element frame with respect to the global one.Furthermore,the nodal rotation is obtained with pseudo vector and instantaneous rotation,under a high-order accurate transformation.The resulting formulations are achieved in unified expression and thus a series of linear elements can be embedded into the framework.Several examples are presented to demonstrate the efficiency and accuracy of the proposed framework for large displacement analysis.

Flow Structure and Heat Transfer Between Two Disks Rotating Independently

In the present paper, fluid flow and convective heat transfer between two co-axial disks rotating independently are dealt with mainly based on the author's recent research on that topic. Three rotational modes, i.e. co-rotation, rotor-stator, and counter-rotation, are considered. Theory of rotating non-isothermal fluids with the presence of disk rotation and thermal effects is addressed. Rotational buoyancy effects on the flow structure development are highlighted. Results of flow visualization and heat transfer measurements are discussed to explore the thermal flow mechanisms involved in the two-disk flows at various rotational and geometric conditions. Potential issues open to the future investigation are also proposed.

Rotation-based finite elements:reference-configuration geometry and motion description

Infinitesimal-rotation finite elements allow creating a linear problem that can be exploited to systematically reduce the number of coordinates and obtain efficient solutions for a wide range of applications,including those governed by nonlinear equations.This paper discusses the limitations of conventional infinitesimal-rotation finite elements(FE)in capturing correctly the initial stress-free reference-configuration geometry,and explains the effect of these limitations on the definition of the inertia used in the motion description.An alternative to conventional infinitesimal-rotation finite elements is a new class of elements that allow developing inertia expressions written explicitly in terms of constant coefficients that define accurately the reference-configuration geometry.It is shown that using a geometrically inconsistent(GI)approach that introduces the infinitesimal-rotation coordinates from the outset to replace the interpolation-polynomial coefficients is the main source of the failure to capture correctly the reference-configuration geometry.On the other hand,by using a geometrically consistent(GC)approach that employs the position gradients of the absolute nodal coordinate formulation(ANCF)to define the infinitesimal-rotation coordinates,the reference-configuration geometry can be preserved.Two simple examples of straight and tapered beams are used to demonstrate the basic differences between the two fundamentally different approaches used to introduce the infinitesimal-rotation coordinates.The analysis presented in this study sheds light on the differences between the incremental co-rotational solution procedure,widely used in computational structural mechanics,and the non-incremental floating frame of reference formulation(FFR),widely used in multibody system(MBS)dynamics.

Implementation of total Lagrangian formulation for the elasto-plastic analysis of plane steel frames exposed to fire

In this paper,the co-rotational total Lagrangian forms of finite element formulations are derived to perform elasto-plastic analysis for plane steel frames that either experience increasing external loading at ambient temperature or constant external loading at elevated temperatures.Geometric nonlinearities and thermal-expansion effects are considered.A series of programs were developed based on these formulations.To verify the accuracy and efficiency of the nonlinear finite element programs,numerical benchmark tests were performed,and the results from these tests are in a good agreement with the literature.The effects of the nonlinear terms of the stiffness matrices on the computational results were investigated in detail.It was also demonstrated that the influence of geometric nonlinearities on the incremental steps of the finite element analysis for plane steel frames in the presence of fire is limited.