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.

Finite Element Method Simulation of Wellbore Stability under Different Operating and Geomechanical Conditions

The variation of the principal stress of formations with the working and geo-mechanical conditions can trigger wellbore instabilities and adversely affect the well completion.A finite element model,based on the theory of poro-elasticity and the Mohr-Coulomb rock damage criterion,is used here to analyze such a risk.The changes in wellbore stability before and after reservoir acidification are simulated for different pressure differences.The results indicate that the risk of wellbore instability grows with an increase in the production-pressure difference regardless of whether acidification is completed or not;the same is true for the instability area.After acidizing,the changes in the main geomechanical parameters(i.e.,elastic modulus,Poisson’s ratio,and rock strength)cause the maximum wellbore instability coefficient to increase.

Modularized and Parametric Modeling Technology for Finite Element Simulations of Underground Engineering under Complicated Geological Conditions

The surrounding geological conditions and supporting structures of underground engineering are often updated during construction,and these updates require repeated numerical modeling.To improve the numerical modeling efficiency of underground engineering,a modularized and parametric modeling cloud server is developed by using Python codes.The basic framework of the cloud server is as follows:input the modeling parameters into the web platform,implement Rhino software and FLAC3D software to model and run simulations in the cloud server,and return the simulation results to the web platform.The modeling program can automatically generate instructions that can run the modeling process in Rhino based on the input modeling parameters.The main modules of the modeling program include modeling the 3D geological structures,the underground engineering structures,and the supporting structures as well as meshing the geometric models.In particular,various cross-sections of underground caverns are crafted as parametricmodules in themodeling program.Themodularized and parametric modeling program is used for a finite element simulation of the underground powerhouse of the Shuangjiangkou Hydropower Station.This complicatedmodel is rapidly generated for the simulation,and the simulation results are reasonable.Thus,this modularized and parametric modeling program is applicable for three-dimensional finite element simulations and analyses.

Study on hot deformation behavior of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy using a combination of strain-compensated Arrhenius constitutive model and finite element simulation method

Isothermal hot compression experiments were conducted on homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy to investigate hot deformation behavior at the temperature range of 673-773 K and the strain rate range of 0.001-1 s^(-1)by using a Gleeble-1500D thermo mechanical simulator.Metallographic characterization on samples deformed to true strain of 0.70 illustrates the occurrence of flow localization and/or microcrack at deformation conditions of 673 K/0.01 s^(-1),673 K/1 s^(-1)and 698 K/1 s^(-1),indicating that these three deformation conditions should be excluded during hot working of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy.Based on the measured true stress-strain data,the strain-compensated Arrhenius constitutive model was constructed and then incorporated into UHARD subroutine of ABAQUS software to study hot deformation process of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy.By comparison with measured force-displacement curves,the predicted results can describe well the rheological behavior of homogenized Mg-8.5Gd-4.5Y-0.8Zn-0.4Zr alloy,verifying the validity of finite element simulation of hot compression process with this complicated constitutive model.Numerical results demonstrate that the distribution of values of material parameters(α,n,Q and ln A)within deformed sample is inhomogeneous.This issue is directly correlated to the uneven distribution of equivalent plastic strain due to the friction effect.Moreover,at a given temperature the increase of strain rate would result in the decrease of equivalent plastic strain within the central region of deformed sample,which hinders the occurrence of dynamic recrystallization(DRX).

Seismic Wavelet Analysis Based on Finite Element Numerical Simulation

The practice of exploration and production has proved that explosives are excited in different surrounding rocks and the seismic wavelets collected have different characteristics. In this paper, by establishing a numerical model of the explosion in the well, using finite element analysis technology for numerical simulation, the simulation calculated the stress structure in the near-source area of the earthquake excitation, and extracted the seismic wavelet. The results show that the simulation seismic wavelet characteristics of different thin interbedded sand and mudstone structures have changed significantly. Through excitation simulation, the amplitude and spectrum information of seismic wavelets can be compared and analyzed, and the excitation parameters can be optimized. .

Finite Element Simulation of Radial Tire Building and Shaping Processes Using an Elasto-Viscoplastic Model

The comprehensive tire building and shaping processes are investigated through the finite element method(FEM)in this article.The mechanical properties of the uncured rubber from different tire components are investigated through cyclic loading-unloading experiments under different strain rates.Based on the experiments,an elastoviscoplastic constitutive model is adopted to describe themechanical behaviors of the uncured rubber.The distinct mechanical properties,including the stress level,hysteresis and residual strain,of the uncured rubber can all be well characterized.The whole tire building process(including component winding,rubber bladder inflation,component stitching and carcass band folding-back)and the shaping process are simulated using this constitutive model.The simulated green tire profile is in good agreement with the actual profile obtained through 3D scanning.The deformation and stress of the rubber components and the cord reinforcements during production can be obtained fromthe FE simulation,which is helpful for judging the rationality of the tire construction design.Finally,the influence of the parameter“drum width”is investigated,and the simulated result is found to be consistent with the experimental observations,which verifies the effectiveness of the simulation.The established simulation strategy provides some guiding significance for the improvement of tire design parameters and the elimination of tire production defects.

Modeling and Simulation of High Frequency Electromagnetics Wave Propagation on Vivaldi Antenna Using Finite Element Method

The simulation of the electromagnetic wave propagation plays an important role in predicting the performance of wireless transmission and communication systems. This research paper performs a numerical simulation using the finite element method (FEM) to study electromagnetic propagation through both conductive and dielectric media. The simulations are made using the COMSOL Multiphysics software which notably implements the finite element method. The microwave is produced by a Vivaldi antenna at the respective frequencies of 2.6 and 5 GHz and the propagation equation is formulated from Maxwell’s equations. The results obtained show that in the air, strong electric fields are observed in the slot and the micro-strip line for the two frequencies, they are even greater when the wave propagates in the glass and very weak for the copper. The 3D evolutions of the wave in air and glass present comparable values at equal frequencies, the curves being more regular in air (dielectric). The radiation patterns produced for air and glass are directional, with a large main lobe, which is narrower at 5 GHz. For copper, the wave propagation is quite uniform in space, and the radiation patterns show two main lobes with a much larger size at 2.6 GHz than at 5 GHz. The propagation medium would therefore influence the range of values of the gain of the antenna.

Research and Application of a Multi-Field Co-Simulation Data Extraction Method Based on Adaptive Infinitesimal Element

Regarding the spatial profile extraction method of a multi-field co-simulation dataset,different extraction directions,locations,and numbers of profileswill greatly affect the representativeness and integrity of data.In this study,a multi-field co-simulation data extractionmethod based on adaptive infinitesimal elements is proposed.Themultifield co-simulation dataset based on related infinitesimal elements is constructed,and the candidate directions of data profile extraction undergo dimension reduction by principal component analysis to determine the direction of data extraction.Based on the fireworks algorithm,the data profile with optimal representativeness is searched adaptively in different data extraction intervals to realize the adaptive calculation of data extraction micro-step length.The multi-field co-simulation data extraction process based on adaptive microelement is established and applied to the data extraction process of the multi-field co-simulation dataset of the sintering furnace.Compared with traditional data extraction methods for multi-field co-simulation,the approximate model constructed by the data extracted from the proposed method has higher construction efficiency.Meanwhile,the relative maximum absolute error,root mean square error,and coefficient of determination of the approximationmodel are better than those of the approximation model constructed by the data extracted from traditional methods,indicating higher accuracy,it is verified that the proposed method demonstrates sound adaptability and extraction efficiency.

Finite element simulation of welded thin-walled stainless steel container based on SYSWELD

The temperature field and stress fields of 18 - 8 stainless steel container structure were computed during and after tungsten inert gas （TIG） arc welding based on the SYSWELD software. The convection, radiation and conduction were all considered during the simulation process as well as temperature-dependent material properties. The results show that the peak temperature occurs on the heat source location. Steep temperature gradients are observed ahead of the heat source. Axial tensile stress and hoop compressive stress are observed in the weld seam between cylinder and head. Axial compressive stress and hoop tensile stress are observed near the weld seam between cylinder and heads. Axial compressive stress and hoop tensile stress are observed in the axial weld seam of cylinder. Axial tensile stress and hoop compressive stress are observed near the axial weld seam of cylinder. The aim of the above research is to provide a basic theory and some calculation methods for the thin-walled container welding technology so that the failures of these structures in service due to residual stresses may be minimized.

3D finite element numerical simulation of advanced detection in roadway for DC focus method

Within the roadway advanced detection methods, DC resistivity method has an extensive application because of its simple principle and operation. Numerical simulation of the effect of focusing current on advanced detection was carried out using a three-dimensional finite element method （FEM）, meanwhile the electric-field distribution of the point source and nine-point power source were calculated and analyzed with the same electric charges. The results show that the nine-point power source array has a very good ability to focus, and the DC focus method can be used to predict the aquifer abnormality body precisely. By comparing the FEM modelling results with physical simulation results from soil sink, it is shown that the accuracy of forward simulation meets the requirement and the artificial disturbance from roadway has no impact on the DC focus method.

Discrete element and finite element coupling simulation and experiment of hot granule medium pressure forming

The granule medium of discreteness is supposed to be continuous（Drucker-Prager model） in the existing finite element simulation analysis on the hot granule medium pressure forming（HGMF） process, so the granule medium may produce tensile stress in the process of pressure-transferring and flowing, which does not coincide with the reality. The analysis method, discrete element and finite element（DE-FE） coupling simulation, is proposed to solve the problem. The material parameters of simulation model are obtained by the pressure-transfer performance test of granule medium and the hot uniaxial tensile test of sheet metal. The DE-FE coupling simulation platform is established by adopting Visual Basic language. The features in the process that AA7075-T6 conical parts are formed by the HGMF process are analyzed and verified by the process test. The studies show that the results of DE-FE coupling simulation coincide well with the test results, which provides a new analysis method to solve the mechanics problem in the coupling of discrete and continuum.

NUMERICAL SIMULATION OF UNSTEADY-STATE UNDEREXPANDED JET USING DISCONTINUOUS GALERKIN FINITE ELEMENT METHOD

A discontinuous Galerkin finite element method （DG-FEM） is developed for solving the axisymmetric Euler equations based on two-dimensional conservation laws. The method is used to simulate the unsteady-state underexpanded axisymmetric jet. Several flow property distributions along the jet axis, including density, pres- sure and Mach number are obtained and the qualitative flowfield structures of interest are well captured using the proposed method, including shock waves, slipstreams, traveling vortex ring and multiple Mach disks. Two Mach disk locations agree well with computational and experimental measurement results. It indicates that the method is robust and efficient for solving the unsteady-state underexpanded axisymmetric jet.

Finite element simulation of ball spinning of NiTi shape memory alloy tube based on variable temperature field

As a new attempt,ball spinning was used to manufacture the nickel-titanium shape memory alloy（NiTi SMA） tube at elevated temperature.The NiTi bar with a nominal composition of Ni50.9Ti49.1（mole fraction,%） was solution treated and was used as the original tube blank for ball spinning.Based on the variable temperature field and the constitutive equation,rigid-viscoplastic finite element method（FEM） was applied in order to simulate the ball spinning of NiTi SMA tube.The temperature field,the stress field,the strain field and the load prediction were obtained by means of FEM.FEM results reveal that there is a temperature increase of about 160 ℃ in the principal deformation zone of the spun part.It can be found from the stress fields and the strain fields that the outer wall of NiTi SMA tube is easier to meet the plastic yield criterion than the inner wall,and the plastic deformation zone is caused to be in a three-dimensional compressive stress state.The radial strain and the tangential strain are characterized by the compressive strain,while the axial strain belongs to the tensile strain.The variation of spinning loads with the progression of the ball is of great importance in predicting the stable flow of the spun part.

Finite Element Simulation of the Vibratory Characteristics for Quartz Tuning Fork Gyroscope

The micro quartz crystal tuning fork gyroscope is a new type of vibratory gyroscope. The gyroscope should be analyzed and simulated early in the design stage in order to offer reliable basis for design and to shorten the period of development. Thus the vibratory characteristics of the gyroscope is simulated with the finite element method of coupled field. The optimum exciting frequency and the factors which influence the gyroscope sensitivity are determined. The method for adjusting the frequency deviation between driving and detecting modes is also proposed.

Finite element simulation and optimal analysis of surfacing on steel orthotropic bridge deck

To analyze the stress state of steel orthotropic deck pavement and provide reference for the design of the overlay, the inner stress state and strain distribution of surfacing under the load of the deformation of the whole bridge structure and tyre load are analyzed by the finite element method of submodeling. Influence of surfacing modulus on the strain state of the overlay is analyzed for the purpose of the optimal design of the overlay structure. Analysis results show that the deformation of the whole bridge structure has no evident influence on the stress state of the overlay. The key factor of the overlay design is the transverse tensile strain in the overlay above the upper edge of web plate of rib. The stress state of the overlay is influenced evidently by the modulus of rigidity transform overlay. And the stress state of the overlay can be optimized and lowered by increasing the modulus and thickness of rigidity transform overlay, The fatigue test has been done to evaluate the fatigue performance and modulus of different deck pavement materials such as epoxy asphalt, SBS modified asphalt, rosphalt asphalt which can provide reference for deck pavement structure design.

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 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.

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.