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.

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.

Set-based parametric modeling, buckling and ultimate strength estimation of stiffened ship structures

There have been a great demand for a suitable and convenient method in the field of buckling analysis of stiffened ship structures, which is essential to structural safety assessment and is significantly time-consuming. Modeling, buckling behaviors and ultimate strength prediction of stiffened panels were investigated. The modeling specification including nonlinear finite element model and imperfections generation, and post-buckling analysis procedure of stiffened plates were demonstrated. And a software tool using set-based finite element method was developed and executed in the MSC. Marc environment. Different types of stiffen panels of marine structures have been employed to investigate the buckling behavior and assess the validity in the estimation of ultimate strength. A comparison between results of the generally accepted methods, experiments and the software tool developed was demonstrated. It is shown that the software tool can predict the ultimate capacity of stiffened panels with imperfections with a good accuracy.

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.

Inverse Load Identification in Stiffened Plate Structure Based on in situ Strain Measurement

For practical engineering structures,it is usually difficult to measure external load distribution in a direct manner,which makes inverse load identification important.Specifically,load identification is a typical inverse problem,for which the models(e.g.,response matrix)are often ill-posed,resulting in degraded accuracy and impaired noise immunity of load identification.This study aims at identifying external loads in a stiffened plate structure,through comparing the effectiveness of different methods for parameter selection in regulation problems,including the Generalized Cross Validation(GCV)method,the Ordinary Cross Validation method and the truncated singular value decomposition method.With demonstrated high accuracy,the GCV method is used to identify concentrated loads in three different directions(e.g.,vertical,lateral and longitudinal)exerted on a stiffened plate.The results show that the GCV method is able to effectively identify multi-source static loads,with relative errors less than 5%.Moreover,under the situation of swept frequency excitation,when the excitation frequency is near the natural frequency of the structure,the GCV method can achieve much higher accuracy compared with direct inversion.At other excitation frequencies,the average recognition error of the GCV method load identification less than 10%.

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.

Explicit Topology Optimization Design of Stiffened Plate Structures Based on the Moving Morphable Component(MMC)Method

This paper proposes an explicit method for topology optimization of stiffened plate structures.The present work is devoted to simultaneously optimizing stiffeners’shape,size and layout by seeking the optimal geometry parameters of a series of moving morphable components(MMC).The stiffeners with straight skeletons and the stiffeners with curved skeletons are considered to enhance the modeling and optimization capability of the current approach.All the stiffeners are represented under the Lagrangian-description framework in a fully explicit way,and the adaptive ground structure method,as well as dynamically updated plate/shell elements,is used to obtain optimized designs with more accurate analysis results.Compared with existing works,the proposed approach provides an explicit description of the structure.Thus,a stiffened plate structure with clear stiffener distribution and smooth geometric boundary can be obtained.Several numerical examples provided,including straight and curved stiffeners,hierarchical stiffeners,and a stiffened plate with a cutout,validate the effectiveness and applicability of the proposed approach.

Three-Dimensional Thermo-Elastic-Plastic Finite Element Method Modeling for Predicting Weld-Induced Residual Stresses and Distortions in Steel Stiffened-Plate Structures

The objective of the present paper is to develop nonlinear finite element method models for predicting the weld-induced initial deflection and residual stress of plating in steel stiffened-plate structures. For this purpose, three-dimensional thermo-elastic-plastic finite element method computations are performed with varying plate thickness and weld bead length (leg length) in welded plate panels, the latter being associated with weld heat input. The finite element models are verified by a comparison with experimental database which was obtained by the authors in separate studies with full scale measurements. It is concluded that the nonlinear finite element method models developed in the present paper are very accurate in terms of predicting the weld-induced initial imperfections of steel stiffened plate structures. Details of the numerical computations together with test database are documented.

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.

THE LAYOUT OPTIMIZATION OF STIFFENERS FOR PLATE-SHELL STRUCTURES

The plate-shell structures with stiffeners are widely used in a broad range of engineering structures. This study presents the layout optimization of stiffeners. The minimum weight of stiffeners is taken as the objective function with the global stiffness constraint. In the layout optimization, the stiffeners should be placed at the locations with high strain energy/or stress. Conversely, elements of stiffeners with a small strain energy/or stress are considered to be used inefficiently and can be removed. Thus, to identify the element efficiency so that most inefficiently used elements of stiffeners can be removed, the element sensitivity of the strain energy of stiffeners is introduced, and a search criterion for locations of stiffeners is presented. The layout optimization approach is given for determining which elements of the stiffeners need to be kept or removed. In each iterative design, a high efficiency reanalysis approach is used to reduce the computational effort. The present approach is implemented for the layout optimization of stiffeners for a bunker loaded by the hydrostatic pressure. The numerical results show that the present approach is effective for dealing with layout optimization of stiffeners for plate-shell structures.

Structural-acoustic optimization of stiffened panels based on a genetic algorithm

For the structural-acoustic radiation optimization problem under external loading,acoustic radiation power was considered to be an objective function in the optimization method. The finite element method(FEM) and boundary element method(BEM) were adopted in numerical calculations,and structural response and the acoustic response were assumed to be de-coupled in the analysis. A genetic algorithm was used as the strategy in optimization. In order to build the relational expression of the pressure objective function and the power objective function,the enveloping surface model was used to evaluate pressure in the acoustic domain. By taking the stiffened panel structural-acoustic optimization problem as an example,the acoustic power and field pressure after optimized was compared. Optimization results prove that this method is reasonable and effective.

Analyzing the Form-Finding of a Large-Span Transversely Stiffened Suspended Cable System: A Method Considering Construction Processes

The precise control of the shape of transversely stiffened suspended cable systems is crucial. However, existing form-finding methods primarily rely on iterative calculations that treat loads as fixed known conditions. These methods are inefficient and fail to accurately control shape results. In this study, we propose a form-finding method that analyzes the load response of models under different sag and stress levels, taking into account the construction process. To analyze the system, a structural finite element model was established in ANSYS, and geometric nonlinear analysis was conducted using the Newton-Raphson method. The form-finding analysis results demonstrate that the proposed method achieves precise control of shape, with a maximum shape error ranging from 0.33% to 0.98%. Furthermore, the relationships between loads and tension forces are influenced by the deformed shape of the structures, exhibiting significant geometric nonlinear characteristics. Meanwhile, the load response analysis reveals that the stress level of the self-equilibrium state in the transversely stiffened suspended cable system is primarily governed by strength criteria, while shape is predominantly controlled by stiffness criteria. Importantly, by simulating the initial tensioning process as an initial condition, this method solves for a counterweight that satisfies the requirements and achieves a self-equilibrium state with the desired shape. The shape of the self-equilibrium state is precisely controlled by simulating the construction process. Overall, this work presents a new method for analyzing the form-finding process of large-span transversely stiffened suspended cable system, considering the construction process which was often overlooked in previous studies.

Effect of Molecular Weight and Molecular Distribution on Skin Structure and Shear Strength Distribution near the Surface of Thin-Wall Injection Molded Polypropylene

In this study, the relationship between skin structure and shear strength distribution of thin-wall injection molded polypropylene (PP) molded at different molecular weight and molecular distribution was investigated. Skin-core structure, cross-sectional morphology, crystallinity, crystal orientation, crystal morphology and molecular orientation were evaluated by using polarized optical microscope, differential scanning calorimeter, X-ray spectroscopic analyzer and laser Raman spectroscopy, respectively, while the shear strength distribution was investigated using a micro cutting method called SAICAS (Surface And Interfacial Cutting Analysis System). The results indicated that the difference of molecular weight and molecular weight distribution showed own skin layer thickness. Especially, high molecular weight sample showed thicker layer of the lamellar orientation and molecular orientation than low molecular weight sample. In addition, wide molecular distribution sample showed large crystal orientation layer.

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.