Effect of Types and Orders of Electromagnetic Field Finite Element Meshes on Power Communication Harmonic Parameters Calculation Results of Tubular Hydrogenerators

In generator design field,waveform total harmonic distortion(THD)and telephone harmonic factor(THF)are parameters commonly used to measure the impact of generator no-load voltage harmonics on the power communication quality.Tubular hydrogenerators are considered the optimal generator for exploiting low-head,high-flow hydro resources,and they have seen increasingly widespread application in China's power systems recent years.However,owing to the compact and constrained internal space of such generators,their internal magnetic-field harmonics are pronounced.Therefore,accurate calculation of their THD and THF is crucial during the analysis and design stages to ensure the quality of power communication.Especially in the electromagnetic field finite element modeling analysis of such generators,the type and order of the finite element meshes may have a significant impact on the THD and THF calculation results,which warrants in-depth research.To address this,this study takes a real 34 MW large tubular hydrogenerator as an example,and establishes its electromagnetic field finite element model under no-load conditions.Two types of meshes,five mesh densities,and two mesh orders are analyzed to reveal the effect of electromagnetic field finite element mesh types and orders on the calculation results of THD and THF for such generators.

Reliability Prediction of Wrought Carbon Steel Castings under Fatigue Loading Using Coupled Mold Optimization and Finite Element Simulation

The fatigue life and reliability of wrought carbon steel castings produced with an optimized mold design are predicted using a finite element method integrated with reliability calculations.The optimization of the mold is carried out using MAGMASoft mainly based on porosity reduction as a response.After validating the initial mold design with experimental data,a spring flap,a common component of an automotive suspension system is designed and optimized followed by fatigue life prediction based on simulation using Fe-safe.By taking into consideration the variation in both stress and strength,the stress-strength model is used to predict the reliability of the component under fatigue loading.Under typical loading conditions of 70 kN,the analysis showed that 95%of the steel spring flaps achieve infinite life.However,under maximum loading conditions of 90 kN,reliability declined significantly,with only 65%of the spring flaps expected to withstand the stress without failure.The study also identified a safe load-induced stress of 95 MPa on the spring flap.The findings suggest that transitioning from forged to cast spring flaps is a promising option,particularly if further improvements in casting design reduce porosity to negligible levels,potentially achieving 100%reliability under typical loading conditions.This integrated approach of mold optimization coupled with reliability estimation under realistic service loading conditions offers significant potential for the casting industry to produce robust,cost-effective products.

Optimizing design of lattice materials based on finite element simulation

The optimized design of simple cross-truss and column lattice structures was carried out by the SolidWorks simulation module.The effective density of the structure was calculated according to the weight reduction requirements proposed by the project.Then,the vari-ation curve between the maximum bearing stress of the unit structure and the structural variables was obtained by simulation.Meanwhile,the mathematical equation between the maximum bearing stress and the structural variables could be obtained through MATLAB fitting.The results indicated that with the decrease in the number of cells,the compressive strength of the prepared column lattice increased(400 to 4 cells,compressive strength 29 MPa to 160 MPa).However,the yield strength increased with the number of cells.The compression strength of the simple cross-truss lattice samples indicated an increase trend with the decrease of the pillar size(an increase of the number of units),reaching 91 MPa(pillar diameter 0.52 mm,number of units 25).While the yield strength increased with the increasing of the number of units.In addition,the additive manufacturing processes of simple cubic lattice and simple cross-pillar lattice were investigated using selective laser melting.The compression performance obtained from the experiment is compared with the simulation results,which are in good agreement.The results of this paper can provide an important reference for optimizing design of lattice materials.

Hermite Finite Element Method for Vibration Problem of Euler-Bernoulli Beam on Viscoelastic Pasternak Foundation

Viscoelastic foundation plays a very important role in civil engineering. It can effectively disperse the structural load into the foundation soil and avoid the damage caused by the concentrated load. The model of Euler-Bernoulli beam on viscoelastic Pasternak foundation can be used to analyze the deformation and response of buildings under complex geological conditions. In this paper, we use Hermite finite element method to get the numerical approximation scheme for the vibration equation of viscoelastic Pasternak foundation beam. Convergence and error estimation are rigourously established. We prove that the fully discrete scheme has convergence order O(τ2+h4), where τis time step size and his space step size. Finally, we give four numerical examples to verify the validity of theoretical analysis.

Two-dimensional finite element mesh generation algorithm for electromagnetic field calculation

Two-dimensional finite element mesh generation algorithm for electromagnetic field calculation is proposed in this paper to improve the efficiency and accuracy of electromagnetic calculation. An image boundary extraction algorithm is developed to map the image on the geometric domain. Identification algorithm for the location of nodes in polygon area is proposed to determine the state of the node. To promote the average quality of the mesh and the efficiency of mesh generation, a novel force-based mesh smoothing algorithm is proposed. One test case and a typical electromagnetic calculation are used to testify the effectiveness and efficiency of the proposed algorithm. The results demonstrate that the proposed algorithm can produce a high-quality mesh with less iteration.

Research on Pantograph and Overhead Contact System′s Simulation of High Speed Railway and Comparison of Three Calculation Methods by Finite Element Method

This study relies on the project about Jining to Tongliao railway electrification reconstruction project.The dynamic simulation model of the pantograph-OCS(overhead contact system)suitable for Jitong project is designed,according to the corresponding numerical calculation method and workflow.Firstly,We establish the pantograph and catenary′s BIM models,and the parameters related to the dynamic simulation of the pantograph system are attached to the BIM model.Then,the BIM model is transformed into a mechanical analysis model,which is input into the dynamic simulation software of pantograph-OCS.The rationality of the design scheme of the pantograph system is verified through simulation.

Analysis of the Elastic-Plastic Dynamic Finite Element on a Jointed Rock Mass

Aim To study the elastic plastic dynamical constitutive relations about a jointed rock mass under explosion load and its computer simulation. Methods\ Stress history is taken into account and stresses will follow changes in time during a period of explosion load. According to the principle of static force balance, the corresponding nodal concentrated force is calculated and the nodal displacement is counted. The elastic plastic dynamic finite element equations are thus obtained. Results\ A finite element method is given for a jointed rock mass under explosion load. Conclusion\ The problem of large plastic deformation for jointed rock mass on blasting was efficiently resolved through dynamic finite element analysis and the range of damages by blasting simulated, and this pushes forward the problem to engineering practice.

ALE FINITE ELEMENT ANALYSIS OF NONLINEAR SLOSHING PROBLEMS BASED ON F LUID VELOCITY POTENTIAL

Base d on fluid velocity potential, an ALE finite element formulation for the analysi s of nonlinear sloshing problems has been developed. The ALE kinemat ical description is introduced to move the computational mesh independently of f luid motion, and the container fixed noninertial coordinate system is employed to establish the governing equations so that the mesh is needed to be updated in this coordinate system only. This leads to a very simple mesh moving algorithm which makes it easy to trace the motion of the moving boundaries and the free su rface without producing undesirable distortion of the computational mesh. The fi nite element method and finite difference method are used spacewise and timewise , respectively. A numerical example involving either forced horizontal oscillati on or forced pitching oscillation of the fluid filled container is presented to illustrate the effectiveness and the robustness of the method. In additi on, this work can be extended for the fluid structure interaction problems.

COUPLED SIMULATION OF 3D ELECTRO-MAGNETO-FLOW FIELD IN HALL-HEROULT CELLS USING FINITE ELEMENT METHOD

Two full 3D steady mathematical models are developed by finite element method （FEM） to calcalate coupled physics fields. the electro-magnetic model is built and solved first and so is the fluid motion model with the acquired electromagnetic force as source body forces in Navier-Stokes equations. Effects caused by the ferromagnetic shell, busbar system around, and open boundary problem as well as inside induced current were considered in terms of the magnetic field. Furthermore, a new modeling method is found to set up solid models and then mesh them entirely with so-called structuralized grids, namely hex-mesh. Examples of 75kA prebaked cell with two kinds of busbar arrangements are presented. Results agree with those disclosed in the literature and confirm that the coupled simulation is valid. It is also concluded that the usage of these models facilitates the consistent analysis of the electric field to magnetic field and then flow motion to the greater extent, local distributions of current density and magnetic flux density are very much dependent on the cell structure, the steel shell is a shield to reduce the magnetic field and flow pattern is two dimensional in the main body of the metal pad.

Finite Element Analysis of 3-D Electromagnetic Field in Bloom Continuous Casting Mold

Three-dimensional finite element model of electromagnetic stirrer was built to predict magnetic field in a bloom continuous casting mold for steel during operation. The effects of current intensity, current frequency, and mold copper plate thickness on the magnetic field distribution in the mold were investigated. The results show that the magnetic induction intensity increases linearly with the increase in current intensity and decreases with the increase in current frequency. Increasing current intensity and frequency is available in increasing the electromagnetic force. The Joule heat decreases gradually from surface to center of bloom, and a maximum Joule heat can be found on corner of bloom. The prediction of magnetic induction intensity is in good agreement with the measured values.

Applications of finite element simulation in orthopedic and trauma surgery

Research in different areas of orthopedic and trauma surgery requires a methodology that allows both a more economic approach and the ability to reproduce different situations in an easy way. Simulation models have been introduced recently in bioengineering and could become an essential tool in the study of any physiological unity, regardless of its complexity. The main problem in modeling with finite elements simulation is to achieve an accurate reproduction of the anatomy and a perfect correlation of the different structures, in any region of the human body. Authors have developed a mixed technique, joining the use of a three-dimensional laser scanner Roland Picza captured together with computed tomography(CT) and 3D CT images, to achieve a perfect reproduction of the anatomy. Finite element(FE) simulation lets us know the biomechanical changes that take place after hipprostheses or osteosynthesis implantation and biological responses of bone to biomechanical changes. The simulation models are able to predict changes in bone stress distribution around the implant, so allowing preventing future pathologies. The development of a FE model of lumbar spine is another interesting application of the simulation. The model allows research on the lumbar spine, not only in physiological conditions but also simulating different load conditions, to assess the impact on biomechanics. Different degrees of disc degeneration can also be simulated to determine the impact on adjacent anatomical elements. Finally, FE models may be useful to test different fixation systems, i.e., pedicular screws, interbody devices or rigid fixations compared with the dynamic ones. We have also developed models of lumbar spine and hip joint to predict the occurrence of osteoporotic fractures, based on densitometric determinations and specific biomechanical models, including approaches from damage and fracture mechanics. FE simulations also allow us to predict the behavior of orthopedic splints applied to the correction of deformities, providing the recovering force-displacement and angle-moment curves that characterize the mechanical behavior of the splint in the overall range of movement.

Finite element analysis and simulation for cold precision forging of a helical gear

To investigate the effects of billet geometry on the cold precision forging process of a helical gear, six different billet geometries were designed utilizing the relief-hole principle. And the influences of the billet geometry on the forming load and the deformation uniformity were analyzed by three-dimensional （3D） finite element method （FEM） under the commercial software DEFORM 3D. The billet geometry was optimized to meet lower forming load and better deformation uniformity requirement. Deformation mechanism was studied through the distribution of flow velocity field and effective strain field. The forging experiments of the helical gear were successfully performed using lead material as a model material under the same process conditions used in the FE simulations. The results show that the forming load decreases as the diameter of relief-hole do increases, but the effect of do on the deformation uniformity is very complicated. The forming load is lower and the deformation is more uniform when do is 10 mm.

Three-dimensional finite element analysis on effects of tunnel construction on nearby pile foundation

A three-dimensional finite element simulation was carried out to investigate the effects of tunnel construction on nearby pile foundation.The displacement controlled model (DCM) was used to simulate the tunneling-induced volume loss effects.The numerical model was verified based on the results of a centrifuge test and a set of parametric studies was implemented based on this model.There is good agreement between the trend of the results of the centrifuge test and the present model.The results of parametric studies show that the tunnelling-induced pile internal force and deformation depend mainly on the pile?tunnel distance,the pile length to tunnel depth ratio and the volume loss.Two different zones are separated by a 45° line projected from the tunnel springline.Within the zone of influence,the pile is subjected to tensile force and large settlement;whereas outside the zone of influence,dragload and small settlement are induced.It is also established that the impact of tunnelling on a pile group is substantially smaller as compared with a single pile in the same location with the rear pile in a group,demonstrating a positive pile group effect.

Finite Element Numerical Simulation of Ground Subsidence in Liangjia Colliery

Being aimed at the ground subsidence due to underground coal mining,a numerical model of rock was established and an appropriate method of numerical simulation was put forward.Using the measured subsidence data on the ground,the equivalent mechanical parameters of the rock stratums can be back-calculated by the properly treatment of coal excavation area,then the ground subsidence of other coal mining area can be predicted by FFM.It provided reference for the treatment of the buildings on the ground of this colliery.

Plastic characterization of metals by combining nanoindentation test and finite element simulation

Materials with the same elastic modulus E and representative stress and strain （σr,εr） present similar indentation-loading curves, whatever the value of strain hardening exponent n. Based on this definition, a good approach was proposed to extract the plastic properties or constitutive equations of metals from nanoindentation test combining finite element simulation. Firstly, without consideration of strain hardening, the representative stress was determined by varying assumed representative stress over a wide range until a good agreement was reached between the computed and experimental loading curves. Similarly, the corresponding representative strain was determined with different hypothetical values of strain hardening exponent in the range of 0-0.6. Through modulating assumed strain hardening exponent values to make the computed unloading curve coincide with that of the experiment, the real strain hardening exponent was acquired. Once the strain hardening exponent was determined, the initial yield stress ay of metals could be obtained by the power law constitution. The validity of the proposed methodology was verified by three real metals： AISI 304 steel, Fe andA1 alloy.

DEFORMATION ANALYSIS OF SHEET METAL SINGLE-POINT INCREMENTAL FORMING BY FINITE ELEMENT METHOD SIMULATION

Single-point incremental forming （SPIF） is an innovational sheet metal forming method without dedicated dies, which belongs to rapid prototyping technology. In generalizing the SPIF of sheet metal, the deformation analysis on forming process becomes an important and useful method for the planning of shell products, the choice of material, the design of the forming process and the planning of the forming tool. Using solid brick elements, the finite element method（FEM） model of truncated pyramid was established. Based on the theory of anisotropy and assumed strain formulation, the SPIF processes with different parameters were simulated. The resulted comparison between the simulations and the experiments shows that the FEM model is feasible and effective. Then, according to the simulated forming process, the deformation pattern of SPIF can be summarized as the combination of plane-stretching deformation and bending deformation. And the study about the process parameters＇ impact on deformation shows that the process parameter of interlayer spacing is a dominant factor on the deformation. Decreasing interlayer spacing, the strain of one step decreases and the formability of blank will be improved. With bigger interlayer spacing, the plastic deformation zone increases and the forming force will be bigger.

RESEARCH ON THE SELECTION OF FRICTION MODELS IN THE FINITE ELEMENT SIMULATION OF WARM EXTRUSION

During the process of finite element simulation of precision warm forging, the selection of friction models has a direct effect on the precision accuracy of finite element simulation results. Among all the factors which influence the selection of friction models, the distribution rule of normal stress at the tool-workpiece interface is a key one. To find out the distribution rule of normal stress at the tool-workpiece interface, this paper has made a systematic research on three typical plastic deformation processes: forward extrusion, backward extrusion, and lateral extrusion by a method of finite element simulation. Then on the base of synthesizing and correcting traditional friction models, a new general friction model which is fit for warm extrusion is developed at last.

Finite element simulation of inertia friction welding of superalloy bars

A thermo-mechanical coupling.finite element model was built to investigate the inertia friction welding of GH4169 bars. The remeshing and map solution techniques were adopted. Ttle whole welding process was investigated by adopting an innovative heat generation model and the flywheel rotational speed measured via the experiment. The simulated evolution of axial shortening shows a good agreement with the experiment. In addition, extensive .strain concentration presents in the interface and flash, and the largest ,strain exists near the flash root. Moreover, an intere.sting thermal reflux phenomenon during the cooling stage was found.

Numerical simulation analysis for deformation deviation and experimental verification for an antenna thin-wall parts considering riveting assembly with finite element method

In the process of thin-wall parts assembly for an antenna,the parts assembly deformation deviation is occurring due to the riveting assembly.In view of the riveting assembly deformation problems,it can be analyzed through transient and static simulation.In this work,the theoretical deformation model for riveting assembly is established with round head rivet.The simulation analysis for riveting deformation is carried out with the riveting assembly piece including four rivets,which comparing with the measuring points experiment results of riveting test piece through dealing with the experimental data using the point coordinate transform method and the space line fitting method.Simultaneously,the deformation deviation of the overall thin-wall parts assembly structure is analyzed through finite element simulation;and its results are verified by the measuring experiment for riveting assembly with the deformation deviation of some key points on the thin-wall parts.Through the comparison analysis,it is shown that the simulation results agree well with the experimental results,which proves the correctness and effectiveness of the theoretical analysis,simulation results and the given experiment data processing method.Through the study on the riveting assembly for thin-wall parts,it will provide a theoretical foundation for improving thin-wall parts assembly quality of large antenna in future.

Modeling shale with consideration of bedding planes by cohesive finite element method

Shale contains distributed directional bedding planes,which make the shale transverse isotropic.To model shale with consideration of the bedding planes,a cohesive finite element method(CFEM)is developed based on the randomized triangular mesh.The interface orientation generated from such mesh tends to be uniformly distributed with the element number increasing.To represent the bedding plane,the interfaces aligned with the bedding plane are assigned the cohesive law that characterizes the bedding plane while the other interfaces are assigned the cohesive law that characterizes the matrix.By this means,the anisotropy characteristics of the stiffness and the strength of shale are well represented.The simulation examples demonstrate that the bedding plane has a significant influence on the fracture trajectory,which is consistent with the observation in the experiment.It is suggested that this modeling method of shale is feasible.It provides an alternative approach to fracture simulation in shale.