Contribution to the Full 3D Finite Element Modelling of a Hybrid Stepping Motor with and without Current in the Coils

The paper presents our contribution to the full 3D finite element modelling of a hybrid stepping motor using COMSOL Multiphysics software. This type of four-phase motor has a permanent magnet interposed between the two identical and coaxial half stators. The calculation of the field with or without current in the windings (respectively with or without permanent magnet) is done using a mixed formulation with strong coupling. In addition, the local high saturation of the ferromagnetic material and the radial and axial components of the magnetic flux are taken into account. The results obtained make it possible to clearly observe, as a function of the intensity of the bus current or the remanent induction, the saturation zones, the lines, the orientations and the magnetic flux densities. 3D finite element modelling provide more accurate numerical data on the magnetic field through multiphysics analysis. This analysis considers the actual operating conditions and leads to the design of an optimized machine structure, with or without current in the windings and/or permanent magnet.

3D finite element analysis on pile-soil interaction of passive pile group

The interaction between pile and soft soil of the passive pile group subjected to soil movement was analyzed with three-dimensional finite element model by using ANSYS software. The soil was assumed to be elastic-plastic complying with the Drucker-Prager yield criterion in the analysis. The large displacement of soil was considered and contact elements were used to evaluate the interaction between pile and soil. The influences of soil depth of layer and number of piles on the lateral pressure of the pile were investigated, and the lateral pressure distributions on the (2×1) pile group and on the (2×2) pile group were compared. The results show that the adjacent surcharge may result in significant lateral movement of the soft soil and considerable pressure on the pile. The pressure acting on the row near the surcharge is higher than that on the other row, due to the "barrier" and arching effects in pile groups. The passive load and its distribution should be taken into account in the design of the passive piles.

3D Finite Element Simulation of Tunnel Boring Machine Construction Processes in Deep Water Conveyance Tunnel

Applying stiffness migration method,a 3D finite element mechanical model is established to simulate the excavation and advance processes.By using 3D nonlinear finite element method,the tunnel boring machine(TBM) excavation process is dynamically simulated to analyze the stress and strain field status of surrounding rock and segment.The maximum tensile stress of segment ring caused by tunnel construction mainly lies in arch bottom and presents zonal distribution.The stress increases slightly and limitedly in the course of excavation.The maximum and minimum displacements of segment,manifesting as zonal distribution,distribute in arch bottom and vault respectively.The displacements slightly increase with the advance of TBM and gradually tend to stability.

A multiscale 3D finite element analysis of fluid/solute transport in mechanically loaded bone

The transport of fluid, nutrients, and signaling molecules in the bone lacunar-canalicular system （LCS） is critical for osteocyte survival and function. We have applied the fluorescence recovery after photobleaching （FRAP） approach to quantify load-induced fluid and solute transport in the LCS in situ, but the measurements were limited to cortical regions 30-50 μm underneath the periosteum due to the constrains of laser penetration. With this work, we aimed to expand our understanding of load-induced fluid and solute transport in both trabecular and cortical bone using a multiscaled image-based finite element analysis （FEA） approach. An intact murine tibia was first re-constructed from microCT images into a three-dimensional （3D） linear elastic FEA model, and the matrix deformations at various locations were calculated under axial loading. A segment of the above 3D model was then imported to the biphasic poroelasticity analysis platform （FEBio） to predict load-induced fluid pressure fields, and interstitial solute/fluid flows through LCS in both cortical and trabecular regions. Further, secondary flow effects such as the shear stress and/or drag force acting on osteocytes, the presumed mechano-sensors in bone, were derived using the previously developed ultrastructural model of Brinkman flow in the canaliculi. The material properties assumed in the FEA models were validated against previously obtained strain and FRAP transport data measured on the cortical cortex. Our results demonstrated the feasibility of this computational approach in estimating the fluid flux in the LCS and the cellular stimulation forces （shear and drag forces） for osteocytes in any cortical and trabecular bone locations, allowing further studies of how the activation of osteocytes correlates with in vivo functional bone formation. The study provides a promising platform to reveal potential cellular mechanisms underlying the anabolic power of exercises and physical activities in treating patients with skeletal deficiencies.

3D Finite Element Analysis of a Man Hip Joint Femur under Impact Loads

Objective： The biomechanical characters of the bone fracture of the man femoral hip joint under impact loads are explored. Methods ：A biosystem model of the man femoral hip joint by using the GE （ General Electric） lightspeed multi-lay spiral CT is conducted. A 3D finite element model is established by employing the finite element software ANSYS. The FE analysis mainly concentrates on the effects of the impact directions arising from intense movements and the parenchyma on the femoral hip joint on the stress distributions of the proximal femur. Results：The parenchyma on the hip joint has relatively large relaxation effect on the impact loads. Conclusion：Effects of the angle δ of the impact load to the anterior direction and the angle γ of the impact load to the femur shaft on the bone fracture are given;δ has larger effect on the stress and strain distributions than the angle γ,which mainly represents the fracture of the upper femur including the femoral neck fracture when the posterolateral femur is impacted, consistent with the clinical resuits.

Grain refinement of Mg-Al alloys by optimization of process parameters based on three-dimensional finite element modeling of roll casting

To study the influence of roll casting process parameters on temperature and thermal-stress fields for the AZ31 magnesium alloy sheets,three-dimensional geometric and 3D finite element models for roll casting were established based on the symmetry of roll casting by ANSYS software.Meshing method and smart-sizing algorithm were used to divide finite element mesh in ANSYS software.A series of researches on the temperature and stress distributions during solidification process with different process parameters were done by 3D finite element method.The temperatures of both the liquid-solid two-phase zone and liquid phase zone were elevated with increasing pouring temperature.With the heat transfer coefficient increasing,the two-phase region for liquid-solid becomes smaller.With the pouring temperature increasing and the increase of casting speed,the length of two-phase zone rises.The optimized of process parameters（casting speed 2 m/min,pouring temperature 640 ℃ and heat transfer coefficient 15 kW/（m2·℃） with the water pouring at roller exit was used to produce magnesium alloy AZ31 sheet,and equiaxed grains with the average grain size of 50 μm were achieved after roll casting.The simulation results give better understanding of the temperature variation in phase transformation zone and the formation mechanism of hot cracks in plates during roll casting and help to design the optimized process parameters of roll casting for Mg alloy.

Propagations of Rayleigh and Love waves in ZnO films/glass substrates analyzed by three-dimensional finite element method

Propagation characteristics of surface acoustic waves（SAWs） in ZnO films/glass substrates are theoretically investigated by the three-dimensional（3D） finite element method. At first, for（11ˉ20） ZnO films/glass substrates, the simulation results confirm that the Rayleigh waves along the [0001] direction and Love waves along the [1ˉ100] direction are successfully excited in the multilayered structures. Next, the crystal orientations of the ZnO films are rotated, and the influences of ZnO films with different crystal orientations on SAW characterizations, including the phase velocity, electromechanical coupling coefficient, and temperature coefficient of frequency, are investigated. The results show that at appropriate h/λ, Rayleigh wave has a maximum k^2 of 2.4% in（90°, 56.5°, 0°） ZnO film/glass substrate structure; Love wave has a maximum k^2 of 3.81% in（56°, 90°, 0°） ZnO film/glass substrate structure. Meantime, for Rayleigh wave and Love wave devices, zero temperature coefficient of frequency（TCF） can be achieved at appropriate ratio of film thickness to SAW wavelength. These results show that SAW devices with higher k^2 or lower TCF can be fabricated by flexibly selecting the crystal orientations of ZnO films on glass substrates.

STUDY ON THREE-DIMENSIONAL FINITE BODIES CONTAINING CRACKS USING THE FINITE ELEMENT METHOD OF LINES

The three-dimensional finite element method of lines is presented, and the basic processing description of 3D FEMOL in cracking questions is given in detail. Applications to 3D bodies with cracks indicate that good accuracy can be obtained with relatively coarse girds. In particular, application to the tension specimen shows very good agreement with the evaluation of stress intensity factors, which is better than the results of other methods. This implies a considerable potential for using this method in the 3D analysis of finite geometry solids and suggests a possible extension of this technique to nonlinear material behavior.

Finite Element Simulation of Flexible Roll Forming with Supplemented Material Data and the Experimental Verification

Flexible roll forming is a promising manufacturing method for the production of variable cross section products. Considering the large plastic strain in this forming process which is much larger than that of uniform deformation phase of uniaxial tensile test, the widely adopted method of simulating the forming processes with non-supplemented material data from uniaxial tensile test will certainly lead to large error. To reduce this error, the material data is supplemented based on three constitutive models. Then a finite element model of a six passes flexible roll forming process is established based on the supplemented material data and the original material data from the uniaxial tensile test. The flexible roll forming experiment of a B pillar reinforcing plate is carried out to verify the proposed method. Final cross section shapes of the experimental and the simulated results are compared. It is shown that the simulation calculated with supplemented material data based on Swift model agrees well with the experimental results, while the simulation based on original material data could not predict the actual deformation accurately. The results indicate that this material supplement method is reliable and indispensible, and the simulation model can well reflect the real metal forming process. Detailed analysis of the distribution and history of plastic strain at different positions are performed. A new material data supplement method is proposed to tackle the problem which is ignored in other roll forming simulations, and thus the forming process simulation accuracy can be greatly improved.

3D topographic correction of the BSR heat flow and detection of focused fluid flow

The bottom-simulating reflector（BSR） is a seismic indicator of the bottom of a gas hydrate stability zone. Its depth can be used to calculate the seafloor surface heat flow. The calculated BSR heat flow variations include disturbances from two important factors：（1） seafloor topography, which focuses the heat flow over regions of concave topography and defocuses it over regions of convex topography, and（2） the focused warm fluid flow within the accretionary prism coming from depths deeper than BSR. The focused fluid flow can be detected if the contribution of the topography to the BSR heat flow is removed. However, the analytical equation cannot solve the topographic effect at complex seafloor regions. We prove that 3D finite element method can model the topographic effect on the regional background heat flow with high accuracy, which can then be used to correct the topographic effect and obtain the BSR heat flow under the condition of perfectly flat topography. By comparing the corrected BSR heat flow with the regional background heat flow, focused fluid flow regions can be detected that are originally too small and cannot be detected using present-day equipment. This method was successfully applied to the midslope region of northern Cascadia subducting margin. The results suggest that the Cucumber Ridge and its neighboring area are positive heat flow anomalies, about 10%–20% higher than the background heat flow after 3D topographic correction. Moreover, the seismic imaging associated the positive heat flow anomaly areas with seabed fracture–cavity systems. This suggests flow of warm gas-carrying fluids along these high-permeability pathways, which could result in higher gas hydrate concentrations.

3D Eddy Current and Temperature Field Analysis of Large Hydro-generators in Leading Phase Operations

As a common practice,a large hydro-generator will operate in leading phase conditions to absorb the reactive power of the power grid.However,the accurate and precise prediction of the leading phase operation capacity of a large hydro-generator has always been a formidable challenge to engineers and academicians because it is extremely hard to compute the eddy currents and losses as well as the local overheating in the pressure plate and finger.To address this problem,a full three dimensional(3D)finite element model and method of the coupled eddy current and temperature fields in the end region of a large hydro-generator are developed.The equivalent medium parameters used in the computations are comprehensively discussed.Moreover,some numerically based solution methodologies for accurate computation of the field and armature currents under different leading phase conditions are proposed.Numerical results on the coupled eddy current and temperature fields in the end regions of a 250 MW hydro-generator confirm positively the feasibility of the present work.

Evolution of 3D tectonic stress field and fault movement in North China

Based on data of fault movement surveying, we simulate the evolution process of three dimensional stress field in North China by three dimensional finite element method. Evolutional patterns in one-year time scale from 1986 to 1997 have been illustrated and the evolution characteristics of stress field have been analyzed. In comparison with the seismic activity among that time interval in North China, we have primarily discussed the relationship between the evolution of stress field and seismic activity.

3D Nonlinear Analysis of the Preloading Filling Spiral Case of the Jinping-I Hydropower Station

In consideration of the contact between the steel spiral casing and the peripheral reinforced concrete, a nonlinear analysis for the combined bearing structure of the JinPing-I preloading filling spiral case has been made with ANSYS. Contrasts of the stress of the reinforcing bars, the biggest width of the crack and the outspread section of the crack has been made with the different parameters of preloading pressure and reinforcement scheme, resulting in a reasonable preloading pressure and reinforcement scheme. This conclusion has been applied to the spiral casing of JinPing-I hydropower station.

3D finite element analysis of a two-surface wear model in fretting tests

This article aims at developing a computationally efficient framework to simulate the erosion of two contact surfaces in three-dimensional(3D),depending on the body resistance.The framework involves finite element(FE)resolution of a fretting problem,wear computation via a non-local criterion including a wear distribution parameter(WDP),as well as updating of the geometry and automatic remeshing.Its originality is based on the capability to capture the damage on each surface and obtain local and global results for a quantitative and qualitative analysis.Numerical simulations are carried out for two 3D contact specimens with different values of WDP.The results highlight the importance of correctly modelling wear:One-surface wear model is sufficient from a global point of view(wear volume),or whenever the wear resistance for a body is much higher than that of another one,whereas a 3D two-surface wear model is essential to capturing local effects(contact pressure,wear footprint,etc.)related to the difference in wear resistance of the bodies.

Lateral bearing characteristics of subsea wellhead assembly in the hydrate trial production engineering

Conductor and suction anchor are the key equipment providing bearing capacity in the field of deep-water drilling or offshore engineering,which have the advantages of high operation efficiency and short construction period.In order to drill a horizontal well in the shallow hydrate reservoir in the deep water,the suction anchor wellhead assembly is employed to undertake the main vertical bearing capacity in the second round of hydrate trial production project,so as to reduce the conductor running depth and heighten the kick-off point position.However,the deformation law of the deep-water suction anchor wellhead assembly under the moving load of the riser is not clear,and it is necessary to understand the lateral bearing characteristics to guide the design of its structural scheme.Based on 3D solid finite element method,the solid finite element model of the suction anchor wellhead assembly is established.In the model,the seabed soil is divided into seven layers,the contact between the wellhead assembly and the soil is simulated,and the vertical load and bending moment are applied to the wellhead node to simulate the riser movement when working in the deep water.The lateral bearing stability of conventional wellhead assembly and suction anchor wellhead assembly under the influence of wellhead load is discussed.The analysis results show that the bending moment is the main factor affecting the lateral deformation of the wellhead string;the anti-bending performance from increasing the outer conductor diameter is better than that from increasing the conductor wall thickness;for the subsea wellhead,the suction anchor obviously improves the lateral bearing capacity and reduces the lateral deformation.The conduct of the suction anchor wellhead assembly still needs to be lowered to a certain depth that below the maximum disturbed depth to ensure the lateral bearing stability,Thus,a method for the minimum conductor running depth for the suction anchor wellhead assembly is developed.The field implementations show that compared with the first round of hydrate trial production project,the conductor running depth is increased by 9.42 m,and there is no risk of wellhead overturning during the trial production.The method for determining the minimum conductor running depth in this paper is feasible and will still play an important role in the subsequent hydrate exploration and development.

Three-dimensional simulation of pore scale fluid flow in granular ore media with realistic geometry

The images of granular ore media were captured by X-ray CT scanner. Combined with digital image processing and finite element techniques, the three-dimensional geometrical model, which represents the realistic pore structure of the media, was constructed. With this model, three dimensional pore scale fluid flow among particles was simulated. Then the distributions of fluid flow velocity and pressure were analyzed and the hydraulic conductivity was calculated. The simulation results indicate the fluid flow behaviors are mainly dominated by the volume and topological structure of pore space. There exist obvious preferential flow and leaching blind zones simultaneously in the medium. The highest velocities generally occur in those narrow pores with high pressure drops. The hydraulic conductivity obtained by simulation is the same order of magnitude as the laboratory test result, which denotes the validity of the model. The pore-scale and macro-scale are combined and the established geometrical model can be used for the simulations of other phenomena during heap leaching process.

Study on effect of segments erection tolerance and wedge-shaped segment on segment ring in shield tunnel

Deformation and dislocations of segments of shield tunnel in construction stage have apparent effect on tunnel structure stress and even cause local cracks and breakage in tunnel. 3D finite element method was used to analyze two segment ring models under uniform injected pressure: (1) segment ring without wedge-shaped segment, which has 16 types of preinstall erection tolerance; (2) segment ring with wedge-shaped segment, which has no preinstall erection tolerance. The analysis results indicate that different erection tolerances can cause irregular deformation in segment ring under uniform injected pressure, and that the tolerance values are enlarged further. Wedge-shaped segment apparently affects the overall deformation of segment ring without erection tolerances. The uniform injected pressure can cause deformation of ring with wedge-shaped segment irregular, and dislocations also appear in this situation. The stress of segment with erection tolerances is much larger than that of segment without erection tolerances. Enlarging the central angle of wedge-shaped segment can make the irregular deformation and dis- locations of segments smaller. The analysis results also provide basis for erection tolerance control and improvement of segment constitution.

A case study on behaviors of composite soil nailed wall with bored piles in a deep excavation

A complete case of a deep excavation was explored. According to the practical working conditions, a 3D non-linear finite element procedure is used to simulate a deep excavation supported by the composite soil nailed wall with bored piles in soft soil. The modified cam clay model is employed as the constitutive relationship of the soil in the numerical simulation. Results from the numerical analysis are fitted well with the field data, which indicate that the research approach used is reliable. Based on the field data and numerical results of the deep excavation supported by four different patterns of the composite soil nailed wall, the significant corner effect is founded in the 3D deep excavation. If bored piles or soil anchors are considered in the composite soil nailed wall, they are beneficial to decreasing deformations and internal forces of bored piles, cement mixing piles, soil anchors, soil nailings and soil around the deep excavation. Besides, the effects due to bored piles are more significant than those deduced from soil anchors. All mentioned above prove that the composite soil nailed wall with bored piles is feasible in the deep excavation.

3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of aluminum 6061-T6

Abstract Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling （3D FEM） approach for the micro end-milling orAl6061-T6. Finite element （FE） simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects ofmiU helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.

3D finite element method （FEM） simulation of groundwater flow during backward erosion piping

Backward erosion piping is an important failure mechanism for cohesive water retaining structures which are founded on a sandy aquifer. At present, the prediction models for safety assessment are often based on 2D assumptions. In this work, a 3D numerical approach of the groundwater flow leading to the erosion mechanism of backward erosion piping is presented and discussed. Comparison of the 2D and 3D numerical results explicitly demonstrates the inherent 3D nature of the piping phenomenon. In addition, the influence of the seepage length is investigated and discussed for both piping initiation and piping progression. The results clearly indicate the superiority of the presented 3D numerical model compared to the established 2D approach. Moreover, the 3D numerical results enable a better understanding of the complex physical mechanism involved in backward erosion piping and thus can lead to a significant improvement in the safety assessment of water retaining structures.