A MULTI-COUPLED FINITE ELEMENT ANALYSIS OF RESISTANCE SPOT WELDING PROCESS

A two-dimensional axisymmetric finite element model is developed to analyze the transient thermal and mechanical behaviors of the Resistance Spot Welding （RSW） process using commercial software ANSYS. Firstly a direct-coupled electrical-thermal Finite Element Analysis （FEA） is performed to analyze the transient thermal characteristics of the RSW process. Then based on the thermal results a sequential coupled thermo-elastic-plastic analysis is conducted to determine the mechanical features of the RSW process. The thermal history of the whole process and the temperature distribution of the weldment are obtained through the analysis. The mechanical features, including the distributions of the contact pressure at both the faying surface and the electrode-workpiece interface, the stress and strain distributions in the weldment and their changes during the RSW process, the deformation of the weldment and the electrode displacement are also calculated.

A pseudo-coupled numerical approach for stability analysis of frozen soil slopes based on finite element limit analysis method

To simplify the stability analysis of frozen soil slope, a pseudo-coupled numerical approach is developed. In this approach, the coupled heat transfer and water flow in frozen soils are simulated first, and based on the computed thermal-hydro field, the stability of frozen soil slope is evaluated. Although the shear strength for frozen soil is very complicated and is usually represented by a nonlinear MC failure criterion, a simple linear MC yield criterion is utilized. In this method, the internal friction angle is expressed as a function of volumetric ice content and the cohesion is fitted as a simple bilinear expression of Tand volumetric water content. To assess slope stability, the limit analysis is employed in conjunction with the recently developed a-section search algorithm. A frozen soil slope example is used to examine the proposed pseudo-coupled numerical approach, and numerical studies validate its effectiveness. Based on numerical results, it is seen that slope stability may be remarkably influenced by warming air （or grotmd surface） temperature. With increasing ground surface temperature, slope stability indicated by FOS may reduce to 1.0, implying that wanning air temperature could be a trigger of frozen soil slope failure.

An explicit finite element method for dynamic analysis in three-medium coupling system and its application

In this paper, an explicit finite element method to analyze the dynamic responses of three-medium coupled systems with any terrain is developed on the basis of the numerical simulation of the continuous conditions on the bounda-ries among fluid saturated porous medium, elastic single-phase medium and ideal fluid medium. This method is a very effective one with the characteristic of high calculating speed and small memory needed because the formulae for this explicit finite element method have the characteristic of decoupling, and which does not need to solve sys-tem of linear equations. The method is applied to analyze the dynamic response of a reservoir with considering the dynamic interactions among water, dam, sediment and basement rock. The vertical displacement at the top point of the dam is calculated and some conclusions are given.

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.

Validation and application of three-dimensional discontinuous deformation analysis with tetrahedron finite element meshed block

In the last decade, three dimensional discontin- uous deformation analyses （3D DDA） has attracted more and more attention of researchers and geotechnical engineers worldwide. The original DDA formulation utilizes a linear displacement function to describe the block movement and deformation, which would cause block expansion under rigid body rotation and thus limit its capability to model block de- formation. In this paper, 3D DDA is coupled with tetrahe- dron finite elements to tackle these two problems. Tetrahe- dron is the simplest in the 3D domain and makes it easy to implement automatic discretization, even for complex topol- ogy shape. Furthermore, element faces will remain planar and element edges will remain straight after deformation for tetrahedron finite elements and polyhedral contact detection schemes can be used directly. The matrices of equilibrium equations for this coupled method are given in detail and an effective contact searching algorithm is suggested. Valida- tion is conducted by comparing the results of the proposed coupled method with that of physical model tests using one of the most common failure modes, i.e., wedge failure. Most of the failure modes predicted by the coupled method agree with the physical model results except for 4 cases out of the total 65 cases. Finally, a complex rockslide example demon- strates the robustness and versatility of the coupled method.

Thermal-electrical Coupled Analysis and Experimental Investigation on Spark Plasma Sintering of SiC Ceramics

Finite element simulations were conducted to study the mechanism of spark plasma sintering. The spark plasma sintering of SiC ceramics was simulated by the Marc software based on the load current curve and temperature-time curve deserved by SPS experiment. The concept of equivalent radiation coefficient was presented and applied during the simulation. The temperature distribution regularity of SiC ceramics sintered by SPS technology was got by thermal-electrical coupled finite element simulation. The experimental results show that by thermal-electrical coupled finite element analysis, the temperature rising and distribution regularity of nonconductive material can be preferable forecasted in the sintering process of SPS. In the initial stage of the heat preservation, the temperature of the central part of the sample has achieved sintering temperature, but now, the temperature of the sample is not uniform. The temperature for each part of the die is also quite different and the sample temperature in the center is higher than that in the edge. In the end of heat preservation, the central temperature of the sample is 50 ℃higher than the required sintering temperature, and the temperature gap for each part of the die decreases gradually.

Coupled pile soil interaction analysis in undrained condition

The effective stress method is developed to predict the axial capacity of piles in clay. The effective stress state changes due to the resulting pore pressure change and therefore, the strength and stiffness of the soil will change. In this work, the finite element method is utilized as a tool for the analysis of pile-soil systems in undrained condition. The computer program CRISP was developed to suit the problem requirements. CRISP uses the finite element technique and allows predictions to be made of ground deformation using critical state theories. Eight-node isoparametric element was added to the program in addition to the slip element. A pile loading problem was solved in which the pile-soil system is analyzed in undrained condition. The pile is modelled as elastic-plastic material, while the soil is assumed to follow the modified Cam clay model. During undrained loading condition, the settlement values increase by 22% when slip elements are used. The surface settlement increases by about three times when the load is doubled and the surface settlement at all points increases when using slip elements due to the mode of motion which allows smooth movement of the adjacent soil with respect to the pile. The vertical displacement increases as the distance decreases from the pile and negligible values are obtained beyond 10D (where D is the pile diameter) from the center of the pile and these values are slightly increased when slip elements are used. The vertical effective stress along a section at a distance D from the pile center is approximately the same for all load increments and lower values of effective vertical stress can be obtained when slip elements are used.

Dynamic analysis of spatial parallel manipulator with rigid and flexible couplings

The dynamics of spatial parallel manipulator with rigid and flexible links is explored. Firstly, a spatial beam element model for finite element analysis is established. Then, the differential equation of motion of beam element is derived based on finite element method. The kinematic constraints of parallel manipulator with rigid and flexible links are obtained by analyzing the motive parameters of moving platform and the relationships of movements of kinematic chains, and the overall kinetic equation of the parallel mechanism with rigid and flexible links is derived by assembling the differential equations of motion of components. On the basis of abovementioned analyses, the dynamic mechanical analysis of the spatial parallel manipulator with rigid and flexible links is conducted. After obtaining the method for force analysis and expressions for the calculation of dynamic stress of flexible components, the dynamic analysis and simulation of spatial parallel manipulator with rigid and flexible links is performed. The result shows that because of the elastic deformation of flexible components in the parallel mechanism with rigid and flexible links, the force on each component in the mechanism fluctuates sharply, and the change of normal stress at the root of drive components is also remarkable. This study provides references for further studies on the dynamic characteristics of parallel mechanisms with rigid and flexible links and for the optimization of the design of the mechanism.

Influence of radial forging process on strain inhomogeneity of hollow gear shaft using finite element method and orthogonal design

Due to the current trend towards lightweight design in automotive industry,hollow stepped gear shafts for automobile and its radial forging process are widely investigated.Utilizing coupled finite element thermo-mechanical model,radial forging process of a hollow stepped gear shaft for automobile was simulated.The optimal combination of three process parameters including initial temperature,rotation rate and radial reduction was also selected using orthogonal design method.To examine the strain inhomogeneity of the forging workpiece,the strain inhomogeneity factor was introduced.The results reveal that the maximum effective strain and the minimum effective strain appeared in the outermost and innermost zones of different cross sections for the hollow stepped gear shaft,respectively.Optimal forging parameters are determined as a combination of initial temperature of 780°C,rotation rate of 21°/stroke and radial reduction of 3 mm.

Importance of Three-Dimensional Piezoelectric Coupling Modeling in Quantitative Analysis of Piezoelectric Actuators

This paper demonstrates the importance of three-dimensional(3-D)piezoelectric coupling in the electromechanical behavior of piezoelectric devices using three-dimensional finite element analyses based on weak and strong coupling models for a thin cantilevered piezoelectric bimorph actuator.It is found that there is a significant difference between the strong and weak coupling solutions given by coupling direct and inverse piezoelectric effects(i.e.,piezoelectric coupling effect).In addition,there is significant longitudinal bending caused by the constraint of the inverse piezoelectric effect in the width direction at the fixed end(i.e.,3-D effect).Hence,modeling of these effects or 3-D piezoelectric coupling modeling is an electromechanical basis for the piezoelectric devices,which contributes to the accurate prediction of their behavior.

Two-dimensional simulation on the rolling process of semi-solid 60Si2Mn by finite element method

The effect of various process variables on the law of metal flow for semi-solid rolling 60Si2Mn was studied by finite element method. Semi-solid 60Si2Mn can be described as compressible rigid visco-plastic porous material saturated with liquid. In terms of ther-mo-mechanical coupling condition, the distributions of stress, velocity and temperature were studied using software MARC. The simulation results show that the rigid visco-plastic model can accurately describe the semi-solid 60Si2Mn rolling process. The great deformation can achieve completely in view of low flow stress of semi-solid slurry.

SECTIONAL FINITE ELEMENT ANALYSIS OF COUPLED DEFORMATION BETWEEN ELASTOPLASTIC SHEET METAL AND VISCO-ELASTOPLASTIC BODY

The present paper is devoted to developing a new numerical simulation method for the analysis of viscous pressure forming （VPF）, which is a sheet flexible-die forming （FDF） process. The pressure-carrying medium used in VPF is one kind of semisolid, flowable and viscous material and its deformation behavior can be described by the visco-elastoplastic constitutive model. A sectional finite element model for the coupled deformation analysis between the viscoelastoplastic pressure-carrying medium and the elastoplastic sheet metal is proposed. The resolution of the Updated Lagrangian （UL） formulation is based on a static explicit approach. The frictional contact between sheet metal and visco-elastoplastic pressure-carrying medium is treated by the penalty function method. Coupled deformation between sheet metal and visco-elastoplastic pressure-carrying medium with large slip is analyzed to validate the developed algorithm. Finally, the viscous pressure bulging （VPB） process of DC06 sheet metal is simulated. Good agreement between numerical simulation results and experimental measurements shows the validity of the developed algorithm.

Application of semi-analytical finite element method coupled with infinite element for analysis of asphalt pavement structural response

A specific computational program SAFEM was developed based on semi-analytical finite element （FE） method for analysis of asphalt pavement structural responses under static loads. The reliability and efficiency of this FE program was proved by comparison with the general commercial FE software ABAQUS. In order to further reduce the computational time without decrease of the accuracy, the infinite element was added to this program. The results of the finite-infinite element coupling analysis were compared with those of finite element analysis derived from the verified FE program, The study shows that finite-infinite element coupling analysis has higher reliability and efficiency.

Uncertainty assessment in hydro-mechanical-coupled analysis of saturated porous medium applying fuzzy finite element method

The purpose of the present study was to develop a fuzzy finite element method,for uncertainty quantification of saturated soil properties on dynamic response of porous media,and also to discrete the coupled dynamic equations known as u-p hydro-mechanical equations.Input parameters included fuzzy numbers of Poisson's ratio,Young's modulus,and permeability coefficient as uncertain material of soil properties.Triangular membership functions were applied to obtain the intervals of input parameters in five membership grades,followed up by a minute examination of the effects of input parameters uncertainty on dynamic behavior of porous media.Calculations were for the optimized combinations of upper and lower bounds of input parameters to reveal soil response including displacement and pore water pressure via fuzzy numbers.Fuzzy analysis procedure was verified,and several numerical examples were analyzed by the developed method,including a dynamic analysis of elastic soil column and elastic foundation under ramp loading.Results indicated that the range of calculated displacements and pore pressure were dependent upon the number of fuzzy parameters and uncertainty of parameters within equations.Moreover,it was revealed that for the input variations looser sands were more sensitive than dense ones.

Three-Dimensional Thermo-mechanical Coupled FEM Simulation for Hot Continuous Rolling of Large-Diameter Mandrel Bar

Based on the important boundary conditions of rolling simulation including friction, heat conduction and interactionsof the workpiece and rolls, the hot continuous rolling processes of large-diameter mandrel round bar (200 mm indiameter) in 6VH-stand hot tandem mill are successfully simulated by three-dimensional coupled thermomechanicalelastoplastic finite element method (FEM). The distributions of stress, strain, temperature and the rolling force andtorque for the two-pass and four-pass continuous rolling are calculated respectively. Thus, the two and four-passroll schedules are verified, respectively. The simulation results show that it is safe to produce 200 mm round barby the two-pass (oval pass and round pass) continuous rolling on the existing equipment compared to the four-passcontinuous rolling. There are concave surfaces and increased widths occurring at the end of rolled billet due touneven deformations between the outside and inside of the workpiece as well as the free spreading close to the rollgap of the final pass.

Numerical analysis of ossicular chain lesion of human ear

Abstract Lesion of ossicular chain is a common ear disease impairing the sense of hearing. A comprehensive numerical model of human ear can provide better understanding of sound transmission. In this study, we propose a three-dimensional finite element model of human ear that incorporates the canal, tympanic membrane, ossicular bones, middle ear suspensory ligaments/muscles, middle ear cavity and inner ear fluid. Numerical analysis is conducted and employed to predict the effects of middle ear cavity, malleus handle defect, hypoplasia of the long process of incus, and stapedial crus defect on sound transmission. The present finite element model is shown to be reasonable in predicting the ossicular mechanics of human ear.

Cavity noise sensitivity analysis of tire contour design factors and application of contour optimization methodology

Cavity resonance noise of passenger car tires is generated by interacting excitation between a tire structure and the fill gas (air), and generally lies in a frequency range of 200?250 Hz. As such, this noise is strongly perceived and may be a serious source of driver annoyance. Thus, many studies regarding the cavity noise mechanism and its reduction have already been conducted. In this work, a vibro-acoustic coupled analysis was conducted between a tire structure and air cavity. Using this analysis, we can more accurately simulate the tire noise performance in the region of the cavity resonance frequency. An analysis of the effects of variation of tire contour design factors was conducted, using design-of-experiments methods. Finally, a multi-objective optimization was performed using in-house codes to reduce the cavity noise level while minimizing the loss of other performances, such as diminished ride comfort and handling caused by the variations of contour. As a result of this optimization, an optimized contour shape was derived, which satisfied the multi-objective performances.

Three-Dimensional Isogeometric Analysis of Flexoelectricity with MATLAB Implementation

Flexoelectricity is a general electromechanical phenomenon where the electric polarization exhibits a linear dependency to the gradient of mechanical strain and vice versa.The truncated pyramid compression test is among the most common setups to estimate the flexoelectric effect.We present a three-dimensional isogeometric formulation of flexoelectricity with its MATLAB implementation for a truncated pyramid setup.Besides educational purposes,this paper presents a precise computational model to illustrate how the localization of strain gradients around pyramidal boundary shapes contributes in generation of electrical energy.The MATLAB code is supposed to help learners in the Isogeometric Analysis and Finite Elements Methods community to learn how to solve a fully coupled problem,which requires higher order approximations,numerically.The complete MATLAB code which is available as source code distributed under a BSD-style license,is provided in the part of Supplementary Materials of the paper.

Temperature field analysis and its application in hot continuous rolling of Inconel 718 superalloy

A coupled thermo-mechanical model containing metal flow and temperature field for calculating temperature variation has been developed on fourteen-pass hot continuous rolling of round rod for Inconel 718 alloy using 3D elastic-plastic finite element method （FEM）. The temperature of characteristic analysis points in the intermediate cross-section of the workpiece has been simulated at initial temperature ranging from 960 to 1000 ℃ and initial velocity in range of 0.15-0.55 m·s^-1. Based on finite element analysis and microstructural observation in cylindrical hot compression experiments, the appropriate hot continuous rolling technologies have been designed for rod products with different diameters. For a real rolling practice, the simulated surface temperature was examined and is in good agreement with the measured one.

Analysis of barrel structure optimization for a mortar

Considering the maximum elastic limitation of the used material with newly advanced technology,the study focuses on optimization of a mortar barrel structure by thinning the wall to reduce the weight.Firstly,static analysis of barrel structure parameters is done based on finite element analysis（FEA）method and 3Dsolid model of the barrel is established based on Unigraphics NX（UG）.Secondly,the 3Dsolid model is simplified and transplanted to ANSYS for barrel wall pressure calculation.Thus,the change curves of the stress exerted on the barrel wall at different locations perpendicular to the axial direction with wall thinning are drawn.By analyzing all possible optimization schemes,the optimal design that enables the barrel to have higher bearing capacity is got.The optimized barrel structure is verified by means of fluid-solid coupling dynamic response analysis.The results show that the static analysis results are closer to real stress conditions than dynamic analysis results.Finally,the barrel weight is reduced by 13%after simulation optimization and the light weight design of the barrel is effective and reliable.