Densification simulation of compacted Al powders using multi-particle finite element method

The powder compaction simulations were performed to demonstrate deformation behavior of particles and estimate the effect of different punch speeds and particle diameters on the relative density of powder by a multi-particle finite element model(MPFEM). Individual particle discretized with a finite element mesh allows for a full description of the contact mechanics. In order to verify the reliability of compaction simulation by MPFEM, the compaction tests of porous aluminum with average particle size of 20 μm and 3 μm were performed at different ram speeds of 5, 15, 30 and 60 mm/min by MTS servo-hydraulic tester. The results show that the slow ram speed is of great advantage for powder densification in low compaction force due to sufficient particle rearrangement and compaction force increases with decrease in average particle size of aluminum.

A Characteristics-Mix Stabilized Finite Element Method for Variable Density Incompressible Navier-Stokes Equations

This paper describes a characteristics-mix finite element method for the computation of incompressible Navi-er-Stokes equations with variable density. We have introduced a mixed scheme which combines a characteristics finite element scheme for treating the mass conservation equation and a finite element method to deal with the momentum equation and the divergence free constraint. The proposed method has a lot of attractive computational properties: parameter-free, very flexible, and averting the difficulties caused by the original equations. The stability of the method is proved. Finally, several numerical experiments are given to show that this method is efficient for variable density incompressible flows problem.

Simulation of die wall friction's effect on density distribution in metallic powder compaction

A computer simulation procedure for metal powder die compaction was described. Friction behavior of metal powder during cold compaction was simulated by the finite element method. The movement of powder relative to the die wall was taken into consideration by utilizing the shear friction model. Friction between the powder and the rigid die wall leads to inhomogeneous density distribution during the compaction process. The floating die technique and double punch pressing can attain more homogenous compacts than the fixed die technique can do. The results obtained from numerical analysis agree well with the experimental results. Simulation model was built in MSC.Mentat, and MSC.Marc software was used to calculate the powder compaction process.

Numerical simulation of hydraulic fracturing and associated microseismicity using finite-discrete element method

Hydraulic fracturing （HF） technique has been extensively used for the exploitation of unconventional oiland gas reservoirs. HF enhances the connectivity of less permeable oil and gas-bearing rock formationsby fluid injection, which creates an interconnected fracture network and increases the hydrocarbonproduction. Meanwhile, microseismic （MS） monitoring is one of the most effective approaches to evaluatesuch stimulation process. In this paper, the combined finite-discrete element method （FDEM） isadopted to numerically simulate HF and associated MS. Several post-processing tools, includingfrequency-magnitude distribution （b-value）, fractal dimension （D-value）, and seismic events clustering,are utilized to interpret numerical results. A non-parametric clustering algorithm designed specificallyfor FDEM is used to reduce the mesh dependency and extract more realistic seismic information.Simulation results indicated that at the local scale, the HF process tends to propagate following the rockmass discontinuities; while at the reservoir scale, it tends to develop in the direction parallel to themaximum in-situ stress. 2014 Institute of Rock and Soil Mechanics, Chinese Academy of Sciences. Production and hosting byElsevier B.V. All rights reserved.

Finite-Element Simulation and Experimental Research of the Hot-Press Sintering of Nano-Sized Ceramic Powders

Numerical simulation of hot-press sintering of nano-sized ceramic powders was introduced by the commercial finite element code MSC.MARC. The powder plastic model and the thermo-mechanical coupled quadrilateral element were developed and adopted in the simulation. The mechanical and thermal properties of the nano-sized alumina based powders were determined.In addition, the experimental research and numerical simulation of the sintering process of different initial densities were carried out. The stress state in sintering of green compacts with different initial densities was analyzed by the densification theory.The reason for the density fluctuations of as-sintered ceramic bulks was found out.

Finite element method simulation for tensile process of sintered iron-base material

Different material properties leads to different metal fracture behaviors. Even if the powder material is composed of plastic metal, the fracture still does not show macroscopic plastic deformation characteristics if the material contains a large number of voids. Eight node isoparametric elastic plastic finite element method was used to simulate the tensile process of sintered powder material. By setting a number of voids in the analyzed metal cuboid, the initial density was taken into consideration. The material properties of the three dimensional solid for the tensile simulation were defined with reference to the known pure iron material parameters. The load displacement curves during elongation were obtained with a universal testing machine, and then the simulated curves were compared with the experimental results. The factors that cause the stress concentration and strength decrease were analyzed according to the simulated equivalent von Mises stress distribution.

Numerical simulation of tire/soil interaction using a verified 3D finite element model

The compaction and stress generation on terrain were always investigated based on empirical approaches or testing methods for tire/soil interaction.However,the analysis should be performed for various tires and at different soil strengths.With the increasing capacity of numerical computers and simulation software,finite element modeling of tire/terrain interaction seems a good approach for predicting the effect of change on the parameters.In this work,an elaborated 3D model fully complianning with the geometry of radial tire 115/60R13 was established,using commercial code Solidwork Simulation.The hyper-elastic and incompressible rubber as tire main material was analyzed by Moony-Rivlin model.The Drucker-Prager yield criterion was used to model the soil compaction.Results show that the model realistically predicts the laboratory tests outputs of the modeled tire on the soft soil.

Correlation mechanism between force chains and friction mechanism during powder compaction

The relation between friction mechanism and force chains characteristics has not yet been fully studied in the powder metallurgy research area.In this work,a uniaxial compression discrete element model is established based on the compaction process of ferrous powder.Furthermore,the correlation mechanism between force chains and the friction mechanism during powder compaction is investigated.The simulation results reveal a strong correlation between the variation of the friction coefficient and the evolution of force chains.During the powder compaction,the friction coefficient would eventually tend to be stable,a feature which is also closely related to the slip ratio between particles.The side wall friction and the friction between particles would have an important effect on the direction of force chain growth in about one-third of the area near the side wall.The research results provide theoretical guidance for improving the densification process of the powder according to the force chain and friction.

Real-time determination of sandy soil stiffness during vibratory compaction incorporating machine learning method for intelligent compaction

An emerging real-time ground compaction and quality control, known as intelligent compaction(IC), has been applied for efficiently optimising the full-area compaction. Although IC technology can provide real-time assessment of uniformity of the compacted area, accurate determination of the soil stiffness required for quality control and design remains challenging. In this paper, a novel and advanced numerical model simulating the interaction of vibratory drum and soil beneath is developed. The model is capable of evaluating the nonlinear behaviour of underlying soil subjected to dynamic loading by capturing the variations of damping with the cyclic shear strains and degradation of soil modulus. The interaction of the drum and the soil is simulated via the finite element method to develop a comprehensive dataset capturing the dynamic responses of the drum and the soil. Indeed, more than a thousand three-dimensional(3D) numerical models covering various soil characteristics, roller weights, vibration amplitudes and frequencies were adopted. The developed dataset is then used to train the inverse solver using an innovative machine learning approach, i.e. the extended support vector regression, to simulate the stiffness of the compacted soil by adopting drum acceleration records. Furthermore, the impacts of the amplitude and frequency of the vibration on the level of underlying soil compaction are discussed.The proposed machine learning approach is promising for real-time extraction of actual soil stiffness during compaction. Results of the study can be employed by practising engineers to interpret roller drum acceleration data to estimate the level of compaction and ground stiffness during compaction.

Numerical modeling and simulation of metal powder compaction of balancer

The constitutive relation of powder material was derived based on the assumption that metal powder is a kind of elasto-plastic material, complying with an elliptical yield criterion. The constitutive integration algorithm was discussed. A way to solve the elastic strain increment in each iteration step during elasto-plastic transition stage was formulated. Different integration method was used for elastic and plastic strain. The relationship between model parameters and relative density was determined through experiments. The model was implemented into user-subroutines of Marc. With the code, computer simulations for compaction process of a balancer were performed. The part is not axisymmetric and requires two lower punches and one upper punch to form. The relative density distributions of two design cases, in which different initial positions of the punches were set, were obtained and compared. The simulation results indicate the influence of punch position and movement on the density distribution of the green compacts.

Phase-field simulation of lack-of-fusion defect and grain growth during laser powder bed fusion of Inconel 718

The anisotropy of the structure and properties caused by the strong epitaxial growth of grains during laser powder bed fusion(L-PBF)significantly affects the mechanical performance of Inconel 718 alloy components such as turbine disks.The defects(lack-of-fusion Lo F)in components processed via L-PBF are detrimental to the strength of the alloy.The purpose of this study is to investigate the effect of laser scanning parameters on the epitaxial grain growth and LoF formation in order to obtain the parameter space in which the microstructure is refined and LoF defect is suppressed.The temperature field of the molten pool and the epitaxial grain growth are simulated using a multiscale model combining the finite element method with the phase-field method.The LoF model is proposed to predict the formation of LoF defects resulting from insufficient melting during L-PBF.Defect mitigation and grain-structure control during L-PBF can be realized simultaneously in the model.The simulation shows the input laser energy density for the as-deposited structure with fine grains and without LoF defects varied from 55.0–62.5 J·mm^(-3)when the interlayer rotation angle was 0°–90°.The optimized process parameters(laser power of 280 W,scanning speed of 1160 mm·s^(-1),and rotation angle of 67°)were computationally screened.In these conditions,the average grain size was 7.0μm,and the ultimate tensile strength and yield strength at room temperature were(1111±3)MPa and(820±7)MPa,respectively,which is 8.8%and10.5%higher than those of reported.The results indicating the proposed multiscale computational approach for predicting grain growth and Lo F defects could allow simultaneous grain-structure control and defect mitigation during L-PBF.

Probability Density Analysis of Nonlinear Random Ship Rolling

Ship rolling in random waves is a complicated nonlinear motion that contributes substantially to ship instability and capsizing.The finite element method(FEM)is employed in this paper to solve the Fokker Planck(FP)equations numerically for homoclinic and heteroclinic ship rolling under random waves described as periodic and Gaussian white noise excitations.The transient joint probability density functions(PDFs)and marginal PDFs of the rolling responses are also obtained.The effects of stimulation strength on ship rolling are further investigated from a probabilistic standpoint.The homoclinic ship rolling has two rolling states,the connection between the two peaks of the PDF is observed when the periodic excitation amplitude or the noise intensity is large,and the PDF is remarkably distributed in phase space.These phenomena increase the possibility of a random jump in ship motion states and the uncertainty of ship rolling,and the ship may lose stability due to unforeseeable facts or conditions.Meanwhile,only one rolling state is observed when the ship is in heteroclinic rolling.As the periodic excitation amplitude grows,the PDF concentration increases and drifts away from the beginning location,suggesting that the ship rolling substantially changes in a cycle and its stability is low.The PDF becomes increasingly uniform and covers a large region as the noise intensity increases,reducing the certainty of ship rolling and navigation safety.The current numerical solutions and analyses may be applied to evaluate the stability of a rolling ship in irregular waves and capsize mechanisms.

Topology optimization design of the main structure of 6-DOF manipulator based on the variable density method

In order to solve the problems of too large mass,too complex structure and poor flexibility of the 6 DOF manipulator,the topological optimization theory based on variable density method is applied to the 6-DOF manipulator,the topology optimization of the main structural components of the manipulator is carried out with the help of the finite element software ANSYS,and the optimized structure is simplified according to the density distribution of the units and the requirements of manufacturability.the results are compared and analysed by static mechanics.It shows that the whole mass of the 6-DOF manipulator is reduced by 47.23%without changing the original mechanical properties after topological optimization,and the optimized model can meet the requirements of manufacturability,the optimization effect is signifcant,which can be used as a reference for the structure optimization of the 6-DOF manipulator.

川滇主要断裂带应力应变积累速率的三维有限元模拟:初步结果

川滇地区构造活动强烈,活动断裂众多,强震活动频繁.了解主要活动断裂的应力应变积累速率对于评估该区的长期地震危险性具有重要参考作用.本文新建立川滇地区及其主要活动断裂的三维黏弹性有限元模型,其中考虑了该区的岩石圈结构分层以及介质在水平和深度方向的不均匀性;采用1996—2018年的平均GPS水平速度场约束模型的侧边界,同时考虑川滇地块深部介质的拖曳力过程,模拟计算了构造加载作用下模型的动力学响应——区域变形特征和断裂的应力积累速率.模拟的位移场能很好拟合GPS观测的速度场,模拟的水平主应力方向在川滇块体和华南块体西缘与地震震源主应力方向相符,反映所建模型与模拟结果有较好的可信度.尝试将模拟的应力积累速率与基于GPS/GNSS观测的应变速率相结合,计算能反映区域地壳应变积累程度的弹性应变能密度分布;讨论了主要断裂带的背景应力、弹性应变能密度和库仑应力积累速率与M≥6.0地震发生的关系.结果显示除了模型边界附近的应力奇异地带外,川滇其余地区1996年以来M≥6.0地震大多数发生在模拟应力积累速率高或次高的断裂带(段),以及弹性应变能密度积累速率中偏高的断裂带(段).在模拟的背景应力速率高而且库仑应力增长快的龙门山断裂带南段和鲜水河断裂带最南段,分别在本文写作和定稿阶段发生2022年6月1日四川芦山M6.1地震和2022年9月5日四川泸定M6.8地震.认为研究区具有类似高或者次高的模拟应力和弹性应变能密度积累速率、但至今无强震发生和记录的断裂带(段),潜在的地震危险性需要关注.

外包钢壳混凝土拱形桥塔节段拼装几何姿态预测研究

赣州市集结大桥主桥为外包钢壳混凝土拱形桥塔斜拉桥,为确保钢混组合拱形桥塔节段拼装精准合龙,采用MIDAS Civil软件建立拱形桥塔空间几何模型,分析外包钢壳和混凝土湿重对桥塔变形的影响,采用切线初始位移法对桥塔施工阶段位移进行预测,通过求解制造线形对桥塔待拼装节段进行预偏修正,并与实测数据进行对比。结果表明:外包钢壳能显著减小桥塔变形;施工阶段桥塔变形主要由混凝土湿重引起,临时支撑能有效减小混凝土浇筑产生的横向变形。基于切线初始位移法的几何姿态预测方法能有效预测桥塔拼装全过程几何姿态,实测成桥阶段桥塔各节段最大偏位为6 mm,小于施工控制要求,具有较高的实施精度,可保证成桥状态下桥塔几何姿态的准确性。

电磁冲击处理对M50轴承钢显微组织与强韧性的影响

建立了电-磁-热多场耦合的电磁冲击仿真模型,利用该模型预测了电磁冲击过程中试样表面的温度变化过程,分析了电磁冲击处理对材料强韧性的影响,并利用扫描电子显微镜(SEM)和电子背散射衍射(EBSD)对材料内部微观结构和断口形貌进行了表征和分析。结果表明:该模型成功预测了电磁冲击过程中试样表面的温度变化过程,且预测值与测量值吻合良好;合适的电磁冲击处理工艺(EST2)可以使材料具有较好的综合力学性能且有效提高材料性能的一致性,在保持平均抗拉强度基本不变的前提下,试样的断后伸长率提高了17.2%,冲击韧性提高了5.5%,屈服强度和抗拉强度一致性分别提高了52.8%和59.9%,冲击韧性一致性提高了42.6%。

随机振动下管径壁厚对航空液压管路的疲劳寿命的影响

根据目前存在由流量设计的不同管径液压管路的疲劳寿命达不到要求的情况,不同管径和壁厚的航空液压导管在随机振动工况下进行疲劳寿命的影响分析。将管路模型简化处理并进行模态分析和随机振动响应分析,最后结合疲劳损伤累积理论和材料的S-N曲线数据得出不同管径壁厚下的疲劳寿命时间。结果表明:当管径和壁厚越大时,对疲劳寿命时间的影响越大。

翁结水库碾压混凝土重力坝动力特性及其抗滑稳定分析

重力坝是水利工程中最常用的主要水工建筑物之一,混凝土重力坝在地震作用下的动力稳定是坝工设计中的重要问题.本文以翁结碾压混凝土重力坝为对象,取位于河谷中的7、8号溢流坝段和9号非溢流坝段,建立三维有限元模型,通过计算分析了碾压混凝土重力坝在不同工况下的应力变形规律及抗滑稳定性.结果表明:静力荷载作用下,坝体位移符合重力坝一般规律,坝踵主拉应力范围较小;动力荷载作用下,位移等响应在坝顶达到最大,符合鞭鞘效应特征,同时坝体残余位移较小,坝体在一些部位出现瞬时拉应力超标现象,坝基塑性区未发生贯通;对7、8号坝段和9号坝段在建基面及碾压层面进行抗滑稳定验算,坝体坝基均满足稳定要求.

基于PFEM法的黄土地基振杆密实过程大变形分析

采用粒子有限元方法(PFEM)及结构性土的本构模型,对振杆密实法加固砂质黄土地基的大变形过程进行了数值模拟研究,分析了振杆贯入过程中周围土体的位移场、应力场、速度场以及塑性体应变等分布规律,揭示了砂质黄土地基深层振动密实机理.结果表明:现场实测和数值模拟获得的地面垂直振动速度峰值变化趋势较为一致,验证了粒子有限元方法的可靠性;垂直激振的振杆能够同时引起土体垂直方向和水平方向上位移场、应力场和速度场的变化;在距振源水平距离5R(R为振杆半径)范围内,土颗粒以半梭形向外扩展并趋于密实,同时水平应力大幅增加并产生预压效果;以塑性体应变作为加固范围的评价标准,结果表明土体径向加固范围随振杆贯入深度增加而略有增大,最大径向加固范围约为3.2R,且振杆底端以下1R~2R范围亦有密实效果.

Cu-20%Fe粉末异步轧制有限元模拟及工艺参数影响规律

为研究高铁含量铜铁粉末异步轧制的成形规律及合理选取工艺参数,应用Shima-Oyane屈服准则,在MSC.Marc有限元软件中建立粉末轧制有限元模型,通过实验验证了该模型的有效性。利用仿真结合轧制实验方法分析了异速比、压下率、轧制速度、轧辊直径及辊面摩擦系数等工艺参数对生坯相对密度和轧制力的影响规律。结果表明:相较于粉末对称轧制,采用异步的方式能显著减小轧制力,提高生坯密度分布均匀性;过大的压下率和轧辊直径分别会对生坯造成边裂和缠辊等不良影响,过低的压下率和摩擦系数导致生坯不能顺利轧制成形。实验结果与有限元模拟结果相符,相对密度模拟结果最大误差为3.89%,轧制力模拟结果最大误差为9.49%,研究结果对铜铁粉末异步轧制成形工艺优化有较好的借鉴价值。