Finite element analysis of temperature field during multi-layer multi-pass weld-based rapid prototyping

During weld-bused rapid prototyping, the component experiences complex thermal process. In this paper, the temperature field evolution, thermal cycle characteristics, and temperature gradients of multi-layer multi-puss weld-based rapid prototyping are investigated using three-dimensional finite element models presented. The single-puss weld-bused rapid prototyping experiment is carried out. Thermal cycles calculated agree with experimental measurements. Furthermore, simulated results indicate that there exist the pre-heating effect of the fore layer and the post-heating effect of the rear layer in the multi-layer multi-pass weld-based rapid prototyping. In the first layer, the heat accumulates obviously. After the first layer, the dimension increase of the high temperature region behind the molten pool is not obvious. The heat diffusion condition in the first layer is the best, the heat diffusion condition in the second layer is the worst, and the heat diffusion conditions in the higher layers improve gradually.

Finite Element Analysis and Structural Optimization of a Vibration Feeder Based on ANSYS

Based on ANSYS software, a finite element model is built for the fatigue break of a vibration feeder influenced by an exciting force alternate load. We first study the harmonic response of the feeder and discovers the weak links which is an angle steel junction of side plate, feed inlet and the junction panel between the no-feed side plate and the bottom plate. Then, we carry out structural optimization. A streamlined method for optimum design of a vibration feeder is presented.

Finite element analysis of γ'-phase raft mechanism in Ni-based single crystal superalloy

The finite element method was applied to study the mechanics of rafting ofγ' precipitates in a single crystal Ni-based superalloy with the [001] orientation. The results show that the creep and rafting are closely related with the stress and strain energy density distributions in the matrix channels. The application of an external stress leads to differential levels of von Mises stress and strain energy density, and the largest value of the stress appears at the corners of the matrix near the interface. Creep dislocations penetrate preferentially into the most highly stressed matrix channels where theγ'-phase rafting is also enlarged. Meanwhile, the von Mises stress ofγmatrix andγ' precipitate increases with the increase of temperature, thus the rafting becomes easier at a higher temperature. Moreover, according to the analysis of slip systems for the Ni-based superalloy, the critical external load for bowing a dislocation through a matrix channel at 950℃is about 180 MPa, which is consistent with the related experimental results.

Enriched goal-oriented error estimation for fracture problems solved by continuum-based shell extended finite element method

An enriched goal-oriented error estimation method with extended degrees of freedom is developed to estimate the error in the continuum-based shell extended finite element method. It leads to high quality local error bounds in three-dimensional fracture mechanics simulation which involves enrichments to solve the singularity in crack tip. This enriched goal-oriented error estimation gives a chance to evaluate this continuum- based shell extended finite element method simulation. With comparisons of reliability to the stress intensity factor calculation in stretching and bending, the accuracy of the continuum-based shell extended finite element method simulation is evaluated, and the reason of error is discussed.

Structure reliability analysis based on supercavity vehicle steady motion

Taking the steady motion status as a starting point,according to the modeling of actual state of theoretical analysis,a predigested model of supercavity vehicle was established,and relationship expressions of these angles were obtained when the movement of supercavity vehicle was stable.A theoretical analysis on the stability of underwater high-speed movement in the movement simulation program was conducted and the simulation results were given.Then the force status of the supercavity vehicle was elicited from the results.The finite element analysis was carried out based on the stability at all angles obtained from simulation results.Taking a pilot model as example,the Monte Carlo method was adopting to analyze the reliability with the given state of force and displacement.The result indicates that this method is feasible.

Numerical Analysis of Seismic Elastomeric Isolation Bearing in the Base-Isolated Buildings

Base isolation concept is currently accepted as a new strategy for earthquake resistance structures. According to different types of base isolation devices, laminated rubber bearing which is made by thin layers of steel shims bonded by rubber is one of the most popular devices to reduce the effects of earthquake in the buildings. Laminated rubber bearings should be protected against failure or instability because failure of isolation devices may cause serious damage on the structures. Hence, the prediction of the behaviour of the laminated rubber bearing with different properties is essential in the design of a seismic bearing. In this paper, a finite element modeling of the laminated rubber bearing is presented. The procedures of modeling the rubber bearing with finite element are described. By the comparison of the numerical and the experimental, the validities of modelling and results have been determined. The results of this study perform that there is a good agreement between finite element analysis and experimental results.

SENSITIVITY ANALYSIS BASED ON LANCZOS ALGORITHM IN STRUCTURAL DYNAMICS

The sensitivity calculating formulas in structural dynamics was developed by utilizing the mathematical theorem and new definitions of sensitivities. So the singularity problem of sensitivity with repeated eigenvalues is solved completely. To improve the computational efficiency, the reduction system is obtained based on Lanczos vectors. After incorporating the mathematical theory with the Lanczos algorithm, the approximate sensitivity solution can be obtained. A numerical example is presented to illustrate the performance of the method.

Physics-based and data-driven modeling for stability evaluation of buried structures in natural clays

This study presents a hybrid framework to predict stability solutions of buried structures under active trapdoor conditions in natural clays with anisotropy and heterogeneity by combining physics-based and data-driven modeling.Finite-element limit analysis(FELA)with a newly developed anisotropic undrained shear(AUS)failure criterion is used to identify the underlying active failure mechanisms as well as to develop a numerical(physics-based)database of stability numbers for both planar and circular trapdoors.Practical considerations are given for natural clays to three linearly increasing shear strengths in compression,extension,and direct simple shear in the AUS material model.The obtained numerical solutions are compared and validated with published solutions in the literature.A multivariate adaptive regression splines(MARS)algorithm is further utilized to learn the numerical solutions to act as fast FELA data-driven surrogates for stability evaluation.The current MARS-based modeling provides both relative importance index and accurate design equations that can be used with confidence by practitioners.

Modeling of an Internal Stress and Strain Distribution of an Inverted Staggered Thin-Film Transistor Based on Two-Dimensional Mass-Spring-Damper Structure

Equipped with a two-dimensional topological structure,a group of masses,springs and dampers can be demonstrated to model the internal dynamics of a thin-film transistor(TFT).In this paper,the two-dimensional Mass-Spring-Damper(MSD)representation of an inverted staggered TFT is proposed to explore the TFT’s internal stress/strain distributions,and the stress-induced effects on TFT’s electrical characteristics.The 2DMSD model is composed of a finite but massive number of interconnected cellular units.The parameters,such as mass,stiffness,and damping ratios,of each cellular unit are approximated from constitutive equations of the compositematerials,while the electrical properties of the inverted staggered TFT are characterized by utilizing an electro-mechanical coupling relation derived from the quantum mechanics.TFTs are often used in biomedical sensors/transducers attached to human skins,and,for the purpose of simulation and validation,the boundary conditions on the interface between the TFT and the human skin were modeled as a spatially distributed sinusoidal excitation with a frequency of 50 Hz,assuming the TFT thickness is more than tens of microns.The fidelity of the 2D MSD structure in the modeling of an inverted staggered TFT is verified by comparing its simulated total displacement fieldwith that of a finite element analysis(FEA)model.The advantages of the MSD model include a dramatic reduction in memory use by up to 60%and faster computation times that are up to 80%lower.More importantly,the MSD model is better suited than FEA to many problems in accurate tissue modeling for medical applications,for which FEA is becoming a bottleneck.This work develops a novel modeling approach,which can be extended to other types of flexible thin film transistors.

Dynamical Model Updating Based on Modal Tests with Changed Structure

A new approach to modifying the stiffness and mass matrices of finite element models is presented to improve the calculation precision.By measuring the mode frequencies and shapes of both of the original and the new structures with changed stiffness and mass,the stiffness and mass matrices of the finite element model can be updated through matrices calculation and solving algebra equations.Taking a multi-freedom model as an example,the relation between the number of the modes and the correction precision of stiffness and mass matrix elements is researched.The facility and precision of the method are totally confirmed especially when the modeling error is known limited to a definite local range.The feasibility of the approach is proven by an effective engineering application to the model updating of a wing piece used in flutter test.

Microstructure Transformation and Refinement Mechanism of Undercooled Cu-Ni-Co Alloy Based on Simulation of Critical Cutting Speed in Ultrasonic Machining

Both Cu60Ni38Co2 and Cu60Ni40 alloy were naturally cooled after rapid solidification from the liquid phase.The transformation law of the microstructure characteristics of the rapidly solidified alloy with the change of undercooling(ΔT)was systematically studied.It is found that the two alloys experience the same transformation process.The refinement structures under different undercoolings were characterized by electron backscatter diffraction(EBSD).The results show that the characteristics of the refinement structure of the two alloys with low undercooling are the same,but the characteristics of the refinement structure with high undercooling are opposite.The transmission electron microscopy(TEM)results of Cu60Ni38Co2 alloy show that the dislocation network density of low undercooled microstructure is lower than that of high undercooled microstructure.By combining EBSD and TEM,it could be confirmed that the dendrite remelting fracture is the reason for the refinement of the low undercooled structure,while the high undercooled structure is refined due to recrystallization.On this basis,in the processing of copper base alloys,there will be serious work hardening phenomenon and machining hard problem of consciousness problems caused by excessive cutting force.A twodimensional orthogonal turning finite element model was established using ABAQUS software to analyze the changes in cutting speed and tool trajectory in copper based alloy ultrasonic elliptical vibration turning.The results show that in copper based alloy ultrasonic elliptical vibration turning,cutting process parameters have a significant impact on cutting force.Choosing reasonable process parameters can effectively reduce cutting force and improve machining quality.

One-piece coal mine mobile refuge chamber with safety structure and less sealing risk based on FEA

In order to reduce the risk of sealing and improve the structural strength for a coal mine mobile refuge chamber,a new type of one-piece model was designed.Mechanical and mathematical calculation performed an important role.Calculated according to statics and relevant contents,the structure had the same total volume as the traditional segmented structure,but had shorter length,wider width and greater height.Those prevented the structure from stress or deformation failure.Some reinforcing ribs with enough moments of inertia were welded in the external shell.Because of the one-piece structure,this refuge chamber reduced the risk of sealing which was a serious problem of segmented structure.Impact load with 300 ms duration and0.6 MPa over-pressure was settled.Explicit nonlinear dynamic analysis program was used to simulate the response of the refuge chamber.The maximum stress and the maximum displacement were obtained.The refuge chamber including blast airtight doors could meet the rigidity requirement.Weak parts of the chamber were the front and back end shell where bigger displacement values occurred than others.Thus,the calculation indicated that the refuge chamber could meet structural safety requirements.Based on the numerical analysis,suggestions were put forward for further resistance ability improvement.Only large inclined shaft with larger wellhead was suitable for this one-piece coal mine mobile refuge chamber.

The mechanical response of multi-tower continuous-span suspension bridge deck pavement based on whole bridge analysis

The effect of multiple span suspension structure on the mechanical response of bridge deck pavement was studied, and finite element analysis (FEM) of stress and strain of pavement according to the bridge floor system features of super-long and high flexibility was made. Meanwhile, the FEM results were compared with those of the single span suspension structure. Three-stage analytic hierarchy process (AHP) is developed to analyze the mechanical response including whole bridge analysis, partial beams section analysis and orthotropic plate analysis. The most unfavorable load position was determined by the numerical solutions acquired from each stage to study the main mechanical index of multiple span suspension structure. The FEM results showed that the mechanical response numerical solutions by using the three-stage AHP are greater than those by simplified boundary condition, and the force condition of multiple span suspension structure is worse than that of the single span suspension structure.

Influence of Various Earth-Retaining Walls on the Dynamic Response Comparison Based on 3D Modeling

The present work aims to assess earthquake-induced earth-retaining(ER)wall displacement.This study is on the dynamics analysis of various earth-retaining wall designs in hollow precast concrete panels,reinforcement concrete facing panels,and gravity-type earth-retaining walls.The finite element(FE)simulations utilized a 3D plane strain condition to model full-scale ER walls and numerous nonlinear dynamics analyses.The seismic performance of differentmodels,which includes reinforcement concrete panels and gravity-type and hollowprecast concrete ER walls,was simulated and examined using the FE approach.It also displays comparative studies such as stress distribution,deflection of the wall,acceleration across the wall height,lateral wall displacement,lateral wall pressure,and backfill plastic strain.Three components of the created ER walls were found throughout this research procedure.One is a granular reinforcement backfill,while the other is a wall-facing panel and base foundation.The dynamic response effects of varied earth-retaining walls have also been studied.It was discovered that the facing panel of the model significantly impacts the earthquake-induced displacement of ER walls.The proposed analytical model’s validity has been evaluated and compared with the reinforcement concrete facing panels,gravity-type ER wall,scientifically available data,and American Association of State Highway and Transportation Officials(AASHTO)guidelines results based on FE simulation.The results of the observations indicate that the hollow prefabricated concrete ER wall is the most feasible option due to its lower displacement and high-stress distribution compared to the two types.The methodology and results of this study establish standards for future analogous investigations and professionals,particularly in light of the increasing computational capabilities of desktop computers.

基于MSC.PATRAN/NASTRAN的汽车焊装生产线BASE板有限元建模与分析

BASE板是汽车焊装生产线上支撑车身和棍床的关键部件。采用Pro/E软件参数化几何建模技术,根据加筋槽钢型号、加筋数量和加筋间隔的不同,建立了多种几何实体模型;考虑车身截荷和棍床载荷的加载方式,用MSC.PATRAN软件建立了有限元实体模型和面模型共384个;用MSC.NASTRAN求解器计算,经对比分析计算结果,在满足挠度小于0.2mm要求的前提下给出加筋优化设计方案。为BASE板的设计提供有参考价值的依据。

Finite element analysis of stress at implant-bone interface of dental implants with different structures

The effect of structure,elastic modulus and thickness of lower modulus layer in porous titanium implants on the stress distribution at the implant-bone interface was investigated.Three-dimensional finite element models of different titanium implants were constructed.The structures of the implants included the whole lower modulus style （No.1）,bio-mimetic style （No.2）,the whole lower modulus style in cancellous bone （No.3） and the whole dense style No.4.The stress distributions at bone-implant interface under static loading were analyzed using Ansys Workbench 10.0 software.The results indicated that the distribution of interface stress is strongly depended on the structure of the implants.The maximum stresses in cancellous bone and root region of implant No.2 are lower than those in the other three implants.A decrease in the modulus of the low modulus layer facilitates the interface stress transferring.Increasing the thickness of the low modulus layer can reduce the stress and induce a more uniform stress distribution at the interface.Among the four implants,biomimetic style implant No.2 is superior in transferring implant-bone interface stress to surrounding bones.

Friction Shear Stress on the Surface of Iron-Based Coating/HSS during Sliding Wear of Pin Disk

With the increasing demand for lightweight and lower fuel consumption and safety of automobile industry, lightweight materials of high strength steel (HSS) are more and more widely used. The hot stamping technology, which is determined by the inherent mechanical properties of high strength steel, makes molds prone to wear failure in the harsh service environments. In this paper, a finite element model is proposed for analyzing the value and distributions law of friction shear stress of contact surface of the pin disk. Through the simulation process of sliding wear, two kinds of different cladding materials of the pin specimens including H13 and Fe65, were experimented under three different loads by using the software ABAQUS. And then the pin-on- disk wear test at elevated temperature was conducted to verify the effectiveness of the simula-tion results. The results showed that the friction shear stress of pin with iron-based cladding and H13 steel was different under different loads, but the distribution was basically the same;the normal friction shear stress increased gradually along the direction of the pin movement, and the tangential shear stress increased gradually from the center of the pin to the outside of the circle;the value of the friction shear stress of the normal joints on the contact surface was periodically fluctuating in the whole dynamic analysis step, while it was basically stable in the tangential direction.

A SINGULAR VALUE DECOMPOSITION BASED TRUNCATION ALGORITHM IN SOLVING THE STRUCTURAL DAMAGE EQUATIONS

The structural damage identification through modal data often leads to solving a set of linear equations. Special numerical treatment is sometimes required for an accurate and stable solution owing to the ill conditioning of the equations. Based on the singular value decomposition (SVD) of the coefficient matrix, an error based truncation algorithm is proposed in this paper. By rejection of selected small singular values, the influence of noise can be reduced. A simply-supported beam is used as a simulation example to compare the results to other methods. Illustrative numerical examples demonstrate the good efficiency and stability of the algorithm in the nondestructive identification of structural damage through modal data.

Finite element analysis on nut post structure of Three Gorges Project ship lift

A nonlinear finite element model of the nut post reinforced concrete （RC） structure of the safety mechanism in the Three Gorges Project （TGP） ship lift was built by ANSYS software. Some irregular structures such as the nut post and the rotary rod were divided by curved surface into a series of regular parts, and the structures were all meshed to hexahedron. Constraint equations were defined between two interfaces with different element sizes and mesh patterns. PRETS179 elements were used to simulate the preload in the tendons and the pre-stressed screws, and the loss of prestressing force was calculated. Five extreme load cases were analyzed. The stress of each part in the structure was obtained. The results indicate that the maximum compressive stress of concrete C35 is 24.13 MPa, so the concrete may be partially crushed; the maximum tensile stress of the grouting motar is 6.73 MPa, so the grouting motar may partially fracture; the maximum yon Mises stress of the rotary rod is 648.70 MPa, therefore the rotary rod may partially yield.

Deformation warning index for reinforced concrete dam based on structural health monitoring data and numerical simulation

The material mechanical parameters of the dam body and foundation will change when a dam is reinforced during the aging process.This causes significant changes in the structural state of the project and makes it difficult to ensure its structural safety.In this study,a new deformation warning index for reinforced concrete dams was developed according to the prototype monitoring data,statistical models,three-dimensional finite element model(FEM)numerical simulation,and the critical conditions of the dam structure.A statistical model was established to separate the water pressure component.Then,a three-dimensional FEM of the reinforced concrete dam was constructed to simulate the water pressure component.Furthermore,the deformation components that affected the mechanical parameters of the dam under the same amount of reservoir water level change were separated and quantified accurately.In addition,the method for inversion of comprehensive mechanical parameters after dam reinforcement was used.The influence mechanisms of the deformation behavior of concrete dams under the reservoir water level and temperature changes were investigated.A new deformation warning index was developed by combining the forward-simulated critical water pressure component and temperature component in the period of extreme temperature decrease with the aging component separated by the statistical model.The new deformation warning index considers the structural state of the dam before and after reinforcement and links the structural strength criterion and the deformation evolution mechanisms.It provides a theoretical foundation and decision support for long-term service and operation management of reinforced dams.