Meter-Scale Thin-Walled Structure with Lattice Infill for Fuel Tank Supporting Component of Satellite:Multiscale Design and Experimental Verification

Lightweight thin-walled structures with lattice infill are widely desired in satellite for their high stiffness-to-weight ratio and superior buckling strength resulting fromthe sandwich effect.Such structures can be fabricated bymetallic additive manufacturing technique,such as selective laser melting(SLM).However,the maximum dimensions of actual structures are usually in a sub-meter scale,which results in restrictions on their appliance in aerospace and other fields.In this work,a meter-scale thin-walled structure with lattice infill is designed for the fuel tank supporting component of the satellite by integrating a self-supporting lattice into the thickness optimization of the thin-wall.The designed structure is fabricated by SLM of AlSi10Mg and cold metal transfer welding technique.Quasi-static mechanical tests and vibration tests are both conducted to verify the mechanical strength of the designed large-scale lattice thin-walled structure.The experimental results indicate that themeter-scale thin-walled structure with lattice infill could meet the dimension and lightweight requirements of most spacecrafts.

Monitoring of Real-Time Complex Deformed Shapes of Thin-Walled Channel Beam Structures Subject to the Coupling Between Bi-Axial Bending and Warping Torsion

Structural health monitoring(SHM)is a research focus involving a large category of techniques performing in-situ identification of structural damage,stress,external loads,vibration signatures,etc.Among various SHM techniques,those able to monitoring structural deformed shapes are considered as an important category.A novel method of deformed shape reconstruction for thinwalled beam structures was recently proposed by Xu et al.[1],which is capable of decoupling complex beam deformations subject to the combination of different loading cases,including tension/compression,bending and warping torsion,and also able to reconstruct the full-field displacement distributions.However,this method was demonstrated only under a relatively simple loading coupling cases,involving uni-axial bending and warping torsion.The effectiveness of the method under more complex loading cases needs to be thoroughly investigated.In this study,more complex deformations under the coupling between bi-axial bending and warping torsion was decoupled using the method.The set of equations for deformation decoupling was established,and the reconstruction algorithm for bending and torsion deformation were utilized.The effectiveness and accuracy of the method was examined using a thin-walled channel beam,relying on analysis results of finite element analysis(FEA).In the analysis,the influence of the positions of the measurement of surface strain distributions on the reconstruction accuracy was discussed.Moreover,different levels of measurement noise were added to the axial strain values based on numerical method,and the noise resistance ability of the deformation reconstruction method was investigated systematically.According to the FEA results,the effectiveness and precision of the method in complex deformation decoupling and reconstruction were demonstrated.Moreover,the immunity of the method to measurement noise was proven to be considerably strong.

Generation of structured light beams with polarization variation along arbitrary spatial trajectories using tri-layer metasurfaces

Conventionally,the spatially structured light beams produced by metasurfaces primarily highlight the polarization modulation of the beams propagating along the optical axis or the beams'spatial transmission trajectory.In particular,along the optical axis,the polarization state is either constant or varies continuously in each output plane.Here,we develop innovative spatially structured light beams with continually changing polarization along any arbitrary spatial transmission trajectories.With tri-layer metallic metasurfaces,the geometric characteristics of each layer structure can be adjusted to modulate the phase and polarization state of the incident terahertz(THz)wave.The beam will converge to the predefined trajectory along several paths to generate a Bessel-like beam with longitudinal polarization changes.We demonstrate the versatility of the approach by designing two THz-band structured light beams with varying polarization states along the spatial helical transmission trajectory.Continuous linear polarization changes and linear polarization to right circular polarization(RCP)and back to linear polarization changes are realized respectively.The experimental results are basically consistent with the simulated results.Our proposal for arbitrary trajectory structured light beams with longitudinally varying polarization offers a practical method for continuously regulating the characteristics of spatial structured light beams with non-axial transmission.This technique has potential uses in optical encryption,particle manipulation,and biomedical imaging.

Generation of subwavelength inverted pin beam via fiber end integrated plasma structure

A pin-like beam is a kind of structured light with a special intensity distribution that can be against diffraction,which can be seen as a kind of quasi-nondiffracting beam(Q-NDB).Due to its wide applications,recently,numerous researchers have used optical lenses or on-chip integrated optical diffractive elements to generate this kind of beam.We theoretically verify and experimentally demonstrate an all-fiber solution to generate a subwavelength inverted pin beam by integrating a simple plasma structure on the fiber end surface.The output beams generated by two kinds of plasma structures,i.e.,nanoring slot and nanopetal structure,are investigated and measured experimentally.The results show that both the structures are capable of generating subwavelength beams,and the beam generated using the nanopetal structure has the sidelobe suppression ability along the x-axis direction.Our all-fiber device can be flexibly inserted into liquid environments such as cell cultures,blood,and biological tissue fluids to illuminate or stimulate biological cells and molecules in them.It provides a promising fiber-integrated solution for exploring light–matter interaction with subwavelength resolution in the field of biological research.

Simultaneous sorting of arbitrary vector structured beams with spin-multiplexed diffractive metasurfaces

Vector structured beams(VSBs)offer infinite eigenstates and open up new possibilities for highcapacity optical and quantum communications by the multiplexing of the states.Therefore,the sorting and measuring of VSBs are extremely important.However,the efficient manipulations of a large number of VSBs have simultaneously remained challenging up to now,especially in integrated optical systems.Here,we propose a compact spin-multiplexed diffractive metasurface capable of continuously sorting and detecting arbitrary VSBs through spatial intensity separation.By introducing a diffractive optical neural network with cascaded metasurface systems,we demonstrate arbitrary VSBs sorters that can simultaneously identify Laguerre–Gaussian modes(l=−4 to 4,p=1 to 4),Hermitian–Gaussian modes(m=1 to 4,n=1 to 3),and Bessel–Gaussian modes(l=1 to 12).Such a sorter for arbitrary VSBs could revolutionize applications in integrated and high-dimensional optical communication systems.

Energy-absorption forecast of thin-walled structure by GA-BP hybrid algorithm

In order to analyze the influence rule of experimental parameters on the energy-absorption characteristics and effectively forecast energy-absorption characteristic of thin-walled structure, the forecast model of GA-BP hybrid algorithm was presented by uniting respective applicability of back-propagation artificial neural network （BP-ANN） and genetic algorithm （GA）. The detailed process was as follows. Firstly, the GA trained the best weights and thresholds as the initial values of BP-ANN to initialize the neural network. Then, the BP-ANN after initialization was trained until the errors converged to the required precision. Finally, the network model, which met the requirements after being examined by the test samples, was applied to energy-absorption forecast of thin-walled cylindrical structure impacting. After example analysis, the GA-BP network model was trained until getting the desired network error only by 46 steps, while the single BP-ANN model achieved the same network error by 992 steps, which obviously shows that the GA-BP hybrid algorithm has faster convergence rate. The average relative forecast error （ARE） of the SEA predictive results obtained by GA-BP hybrid algorithm is 1.543%, while the ARE of the SEA predictive results obtained by BP-ANN is 2.950%, which clearly indicates that the forecast precision of the GA-BP hybrid algorithm is higher than that of the BP-ANN.

Solidified structure of thin-walled titanium parts by vertical centrifugal casting

The solidified structure of the thin-walled and complicated Ti-6AI-4V castings produced by the vertical centrifugal casting process was studied in the present work. The results show that the wall thickness of the section is featured with homogeneously distributed fine equiaxial grains, compared with the microstructure of the thick-walled section. The grain size of the castings has a tendency to decrease gradually with the increasing of the centrifugal radius. The inter-lamellar space in thick-walled casting parts is bigger than that of the thin-walled parts, and the profile of inter-lamellar space is not susceptible to the centrifugal radius.

Boundary Element Analysis forModeⅢCrack Problems of Thin-Walled Structures from Micro-to Nano-Scales

This paper develops a new numerical framework for modeⅢcrack problems of thin-walled structures by integrating multiple advanced techniques in the boundary element literature.The details of special crack-tip elements for displacement and stress are derived.An exponential transformation technique is introduced to accurately calculate the nearly singular integral,which is the key task of the boundary element simulation of thin-walled structures.Three numerical experiments with different types of cracks are provided to verify the performance of the present numerical framework.Numerical results demonstrate that the present scheme is valid for modeⅢcrack problems of thin-walled structures with the thickness-to-length ratio in the microscale,even nanoscale,regime.

Elastoplastic analysis of thin-walled structures in reservoir area

In the structural design of the high pier,in order to analyze the strength and structure stability,the pier was often considered a thin-walled structure.Elastoplastic incremental theory was used to establish the model of elastoplastic stability of high pier.By considering the combined action of pile,soil and pier together,the destabilization bearing capacity was calculated by using 3-D finite element method(3-D FEM) for piers with different pile and section height.Meanwhile,the equivalent stress in different sections of pier was computed and the processor of destabilization was discussed.When the pier is lower,the bearing capacity under mutual effect of pile,soil and pier is less than the situation when mutual effect is not considered;when the pier is higher,their differences are not conspicuous.Along with the increase of the cross-sectional height,the direction of destabilization bearing capacity is varied and the ultimate capacity is buildup.The results of a stability analysis example are almost identical with the practice.

Dynamic stiffness for thin-walled structures by power series

The dynamic stiffness method is introduced to analyze thin-walled structures including thin-walled straight beams and spatial twisted helix beam. A dynamic stiffness matrix is formed by using frequency dependent shape functions which are exact solutions of the governing differential equations. With the obtained thin-walled beam dynamic stiffness matrices, the thin-walled frame dynamic stiffness matrix can also be formulated by satisfying the required displacements compatibility and forces equilib-rium, a method which is similar to the finite element method (FEM). Then the thin-walled structure natural frequencies can be found by equating the determinant of the system dynamic stiffness matrix to zero. By this way, just one element and several elements can exactly predict many modes of a thin-walled beam and a spatial thin-walled frame, respectively. Several cases are studied and the results are compared with the existing solutions of other methods. The natural frequencies and buckling loads of these thin-walled structures are computed.

Geometric Accuracy and Energy Absorption Characteristics of 3D Printed Continuous Ramie Fiber Reinforced Thin-Walled Composite Structures

The application of continuous natural fibers as reinforcement in composite thin-walled structures offers a feasible approach to achieve light weight and high strength while remaining environmentally friendly.In addition,additive manufacturing technology provides a favorable process foundation for its realization.In this study,the printability and energy absorption properties of 3D printed continuous fiber reinforced thin-walled structures with different configurations were investigated.The results suggested that a low printing speed and a proper layer thickness would mitigate the printing defects within the structures.The printing geometry accuracy of the structures could be further improved by rounding the sharp corners with appropriate radii.This study successfully fabricated structures with vari-ous configurations characterized by high geometric accuracy through printing parameters optimization and path smoothing.Moreover,the compressive property and energy absorption characteristics of the structures under quasi-static axial compression were evaluated and compared.It was found that all studied thin-walled structures exhibited progressive folding deformation patterns during compression.In particular,energy absorption process was achieved through the combined damage modes of plastic deformation,fiber pullout and delamination.Furthermore,the com-parison results showed that the hexagonal structure exhibited the best energy absorption performance.The study revealed the structure-mechanical property relationship of 3D printed continuous fiber reinforced composite thin-walled structures through the analysis of multiscale failure characteristics and load response,which is valuable for broadening their applications.

Emerging Challenges for Numerical Simulations of Quasi-Static Collision Experiments on Laser-Welded Thin-Walled Steel Structures

This paper re-evaluates recently published quasi-static tests on laser-welded thin-walled steel structures in order to discuss the fundamental challenges in collision simulations based on finite element analysis.Clamped square panels were considered,with spherical indenter positioned at the mid-span of the stiffeners and moved along this centerline in order to change the load-carrying mechanism of the panels.Furthermore,the use of panels with single-sided flat bar stiffening and web-core sandwich panels enabled the investigation of the effect of structural topology on structural behavior and strength.The changes in loading position and panel topology resulted in different loading,structural and material gradients.In web-core panels,these three gradients occur at the same locations making the panel global responses sensitive for statistical variations and the failure process time-dependent.In stiffened panel with reduced structural gradient,this sensitivity and time-dependency in failure process is not observed.These observations set challenges to numerical simulations due to spatial and temporal discretization as well as the observed microrotation,which is beyond the currently used assumptions of classical continuum mechanics.Therefore,finally,we discuss the potential of non-classical continuum mechanics as remedy to deal with these phenomena and provide a base for necessary development for future.

LOCALIZED ANALYSIS OF THIN-WALLED STRUCTURE’S BUCKLING/INITIAL POST-BUCKLING AND ITS ACCURACY

A method of localization is proposed to lower the high order of equations in FEM calcula- tion for the stability of a complex thin-walled structure.The localized analysis enables us to obtain both the upper and lower limits for the bifurcating point in a whole linear elastic structural system,as well as an ap- proximate solution to asymptotic post-buckling problem.Some numerical examples are included.

Optimization Design of an Embedded Multi-Cell Thin-Walled Energy Absorption Structures with Local Surface Nanocrystallization

Bymeans of the local surface nanocrystallization that enables to change the material on local positions,an innovative embedded multi-cell(EMC)thin-walled energy absorption structures with local surface nanocrystallization is proposed in this paper.The local surface nanacrystallization stripes are regarded as the moving morphable components in the domain for optimal design.Results reveal that after optimizing the local surface nanocrystallization layout,the specific energy absorption(SEA)is increased by 50.78%compared with the untreated counterpart.Besides,in contrast with the optimized 4-cell structure,the SEA of the nanocrystallized embedded 9-cell structure is further enhanced by 27.68%,in contrast with the 9-cell structure,the SEA of the nanocrystallized embedded clapboard type 9-cell structure is enhanced by 3.61%.Thismethod provides a guidance for the design of newenergy absorption devices.

Transformation Matrix for Combined Loads Applied to Thin-Walled Structures

This paper transforms combined loads, applied at an arbitrary point of a thin-walled open section beam, to the shear centre of the cross-section of the beam. Therein, a generalized transformation matrix for loads with respect to the shear centre is derived, this accounting for the bimoments that develop due to the way the combined loads are applied. This and the authors’ earlier paper (World Journal of Mechanics 2021, 11, 205-236) provide a full solution to the theory of thin-walled, open-section structures bearing combined loading. The earlier work identified arbitrary loading with the section’s area properties that are necessary to axial and shear stress calculations within the structure’s thin walls. In the previous paper attention is paid to the relevant axes of loading and to the transformations of loading required between axes for stress calculations arising from tension/compression, bending, torsion and shear. The derivation of the general transformation matrix applies to all types of loadings including, axial tensile and compression forces, transverse shear, longitudinal bending. One application, representing all these load cases, is given of a simple channel cantilever with an eccentrically located end load.

GEOMETRICALLY NONLINEAR FINITE ELEMENT MODEL OF SPATIAL THIN-WALLED BEAMS WITH GENERAL OPEN CROSS SECTION

Based on the theory of Timoshenko and thin-walled beams, a new finite element model of spatial thin-walled beams with general open cross sections is presented in the paper, in which several factors are included such as lateral shear deformation, warp generated by nonuni- form torsion and second-order shear stress, coupling of flexure and torsion, and large displacement with small strain. With an additional internal node in the element, the element stiffness matrix is deduced by incremental virtual work in updated Lagrangian （UL） formulation. Numerical examples demonstrate that the presented model well describes the geometrically nonlinear property of spatial thin-walled beams.

Modeling and Free Vibration Behavior of Rotating Composite Thin-walled Closed-section Beams with SMA Fibers

Smart structure with active materials embedded in a rotating composite thin-walled beam is a class of typical structure which is using in study of vibration control of helicopter blades and wind turbine blades. The dynamic behavior investigation of these structures has significance in theory and practice. However, so far dynamic study on the above-mentioned structures is limited only the rotating composite beams with piezoelectric actuation. The free vibration of the rotating composite thin-walled beams with shape memory alloy（SMA） fiber actuation is studied. SMA fiber actuators are embedded into the walls of the composite beam. The equations of motion are derived based on Hamilton＇s principle and the asymptotically correct constitutive relation of single-cell cross-section accounting for SMA fiber actuation. The partial differential equations of motion are reduced to the ordinary differential equations of motion by using the Galerkin＇s method. The formulation for free vibration analysis includes anisotropy, pitch and precone angle, centrifugal force and SMA actuation effect. Numerical results of natural frequency are obtained for two configuration composite beams. It is shown that natural frequencies of the composite thin-walled beam decrease as SMA fiber volume and initial strain increase and the decrease in natural frequency becomes more significant as SMA fiber volume increases. The actuation performance of SMA fibers is found to be closely related to the rotational speeds and ply-angle. In addition, the effect of the pitch angle appears to be more significant for the lower-bending mode ones. Finally, in all cases, the precone angle appears to have marginal effect on free vibration frequencies. The developed model can be capable of describing natural vibration behaviors of rotating composite thin-walled beam with active SMA fiber actuation. The present work extends the previous analysis done for modeling passive rotating composite thin-walled beam.

Novel Even Beam Splitters Based on Subwavelength Binary Simple Periodic Rectangular Structure

In this paper, a novel method of a subwavelength binary simple periodic rectangular structure is presented to realize even beam splitting by combining the rigorous couple-wave analysis with the genetic algorithm. Several even splitters in the terahertz region were designed and one of the silicon-based beam splitters designed to separate one incident beam into four emergent beams has total efficiency up to 92.23 %. Zero-order diffraction efficiency was reduced to less than 0.192 % and the error of uniformity decreased to 6.51 9 10-6. These results break the limitation of even beam splitting based on the traditional scalar theory. In addition, the effects of the incident angle, wavelength, as well as the polarizing angle on the diffraction efficiency and uniformity were also investigated.

Stability influence factors analysis and construction of a deep beam anchorage structure in roadway roof

Deep beam anchorage structures based on spatial distribution analysis of the cable prestressed field have been proposed for roadway roof support, Stability and other factors that influence deep beam structures are studied in this paper using mechanical calculations, numerical analysis and field measurements, A mechanical model of deep beam structure subjected to multiple loading is established, including analysis of roof support in the return airway of S1203 working face in the Yuwu coal mine, China, The expression of maximum shear stress in the deep beam structure is deduced according to the stress superposition criterion, It is found that the primary factors affecting deep beam structure stability are deep beam thickness, cable pre-tension and cable spacing, The variation of maximum shear stress distribution and prestressed field diffusion effects according to various factors are analyzed using Matlah and FLAC3DTM software, and practical support parameters of the S1203 return airway roof are determined, According to the observations of rock pressure, there is no evidence of roof separation, and the maximum values of roof subsidence and convergence of wall rock are 72 and 48 mm, respectively, The results show that the proposed roof support design with a deep beam structure is feasible and achieves effective control of the roadway roof,

STRUCTURE DESIGN OF THE BEIJING SPECTROMETERⅢBEAM PIPE

The Beijing spectrometer Ⅲ （BESⅢ） beam pipe is in the center of the BESⅢ, which is the detector of the upgrade project of Beijing electron and positron collider （BEPC Ⅱ）. Electrons and positrons collide in the BESⅢ beam pipe. According to the demands of the BEPC Ⅱ, a key program of Chinese Academy of Sciences, the BESⅢ beam pipe is designed based on the finite elements analysis. The BESIII beam pipe is installed in the inner cylinder of the BESⅢ drift chamber. As a vacuum tube, the BESIII beam pipe is designed as 1 000 mm in length, 63 mm in inner diameter and 114 mm in outer diameter, respectively. The BESIII beam pipe consists of a central beryllium pipe cooled by EDM-1, the oil No.1 for electric discharge machining, and two extended copper pipes cooled by deionized water （DW）. The three parts are jointed by vacuum welding. Factors taken into account in the design are as follows. ① The wall thickness of the central beryllium pipe should be designed as small as possible to reduce the multi-scattering and improve the particle momentum resolution. And the wall thickness of the extended copper pipe should be designed as large as possible to protect the detectors from the backgrounds. ②The BESⅢ beam pipe must be sufficiently cooled to avoid the damage and prevents its influence to the BESⅢ drift chamber （DC） operation. The inner surface temperature of the DC inner cylinder must be maintained at 293±2 K. ③ The magnetic permeability of the materials used in the BESⅢ beam pipe must be less than 1.05 H/m to avoid large magnetic field distortions. ④ The static pressure of the vacuum chamber of the BESⅢ beam pipe must be less than 800 μPa. The simulating results show that the designed structure of the BESⅢ beam pipe satisfies the requirements mentioned above. The structure design scheme is evaluated and adonted hv the headouarters of BEPCⅡ.