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

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

Three-Dimensional Simulations of RESET Operation in Phase-Change Random Access Memory with Blade-Type Like Phase Change Layer by Finite Element Modeling

An optimized device structure for reducing the RESET current of phase-change random access memory （PCRAM） with blade-type like （BTL） phase change layer is proposed. The electrical thermal analysis of the BTL cell and the blade heater contactor structure by three-dimensional finite element modeling are compared with each other during RESET operation. The simulation results show that the programming region of the phase change layer in the BTL cell is much smaller, and thermal electrical distributions of the BTL cell are more concentrated on the TiN/GST interface. The results indicate that the BTL cell has the superiorities of increasing the heating efficiency, decreasing the power consumption and reducing the RESET current from 0.67mA to 0.32mA. Therefore, the BTL cell will be appropriate for high performance PCRAM device with lower power consumption and lower RESET current.

Physics-based seismic analysis of ancient wood structure:fault-to-structure simulation

Based on the domain reduction method,this study employs an SEM-FEM hybrid workflow which integrates the advantages of the spectral element method(SEM)for flexible and highly efficient simulation of seismic wave propagation in a three-dimensional(3D)regional-scale geophysics model and the finite element method(FEM)for fine simulation of structural response including soil-structure interaction,and performs a physics-based simulation from initial fault rupture on an ancient wood structure.After verification of the hybrid workflow,a large-scale model of an ancient wood structure in the Beijing area,The Tower of Buddhist Incense,is established and its responses under the 1665 Tongxian earthquake and the 1730 Yiheyuan earthquake are simulated.The results from the simulated ground motion and seismic response of the wood structure under the two earthquakes demonstrate that this hybrid workflow can be employed to efficiently provide insight into the relationships between geophysical parameters and the structural response,and is of great significance toward accurate input for seismic simulation of structures under specific site and fault conditions.

RESEARCH ON THE SELECTION OF FRICTION MODELS IN THE FINITE ELEMENT SIMULATION OF WARM EXTRUSION

During the process of finite element simulation of precision warm forging, the selection of friction models has a direct effect on the precision accuracy of finite element simulation results. Among all the factors which influence the selection of friction models, the distribution rule of normal stress at the tool-workpiece interface is a key one. To find out the distribution rule of normal stress at the tool-workpiece interface, this paper has made a systematic research on three typical plastic deformation processes: forward extrusion, backward extrusion, and lateral extrusion by a method of finite element simulation. Then on the base of synthesizing and correcting traditional friction models, a new general friction model which is fit for warm extrusion is developed at last.

Simulation-based Estimation of Thermal Behavior of Direct Feed Drive Mechanism with Updated Finite Element Model

Linear motors generate high heat and cause significant deformation in high speed direct feed drive mechanisms.It is relevant to estimate their deformation behavior to improve their application in precision machine tools.This paper describes a method to estimate its thermal deformation based on updated finite element（FE）model methods.Firstly,a FE model is established for a linear motor drive test rig that includes the correlation between temperature rise and its resulting deformation.The relationship between the input and output variables of the FE model is identified with a modified multivariate input/output least square support vector regression machine.Additionally,the temperature rise and displacements at some critical points on the mechanism are obtained experimentally by a system of thermocouples and an interferometer.The FE model is updated through intelligent comparison between the experimentally measured values and the results from the regression machine.The experiments for testing thermal behavior along with the updated FE model simulations is conducted on the test rig in reciprocating cycle drive conditions.The results show that the intelligently updated FE model can be implemented to analyze the temperature variation distribution of the mechanism and to estimate its thermal behavior.The accuracy of the thermal behavior estimation with the optimally updated method can be more than double that of the initial theoretical FE model.This paper provides a simulation method that is effective to estimate the thermal behavior of the direct feed drive mechanism with high accuracy.

Kinematic source model for simulation of near-fault ground motion field using explicit finite element method

This paper briefly reviews the characteristics and major processes of the explicit finite element method in modeling the near-fault ground motion field. The emphasis is on the finite element-related problems in the finite fault source modeling. A modified kinematic source model is presented, in which vibration with some high frequency components is introduced into the traditional slip time function to ensure that the source and ground motion include sufficient high frequency components. The model presented is verified through a simple modeling example. It is shown that the predicted near-fault ground motion field exhibits similar characteristics to those observed in strong motion records, such as the hanging wall effect, vertical effect, fling step effect and velocity pulse effect, etc.

Finite Element Simulation of In-Stent Restenosis with Tissue Growth Model

In this study, a finite element simulation of in-stent restenosis (ISR) is conducted to simulate the deployment and expansion of a stent in an occluded artery with a contact model and a mechanics-based growth model. A tissue growth model based on the multiplicative decomposition of deformation is applied to investigate the growth of the plaque and artery wall upon the stent’s implantation. Due to the high stresses at the contact points between the stent struts and the tissue, further tissue injury or restenosis is observed. The simulation results show that after the stent deployment, the von Mises stress is significantly larger in the plaque compared to the artery wall, especially in the region that is in contact with the stent. However, the growth of the plaque and artery tends to even out the stress concentration over time. The tissue growth is found to be more significant near the inner wall than the outer layer. A 0.77 mm restenosis is predicted, which agrees with published clinical observations. The features of the artery growth are carefully analyzed, and the underlying mechanism is discussed. This study is the first attempt to apply finite element analysis to artery restenosis, which establishes a framework for predicting ISR’s occurrence and severity. The results also provide insights into understanding the underlying mechanism of in-stent restenosis.

Multi-field dynamic modeling and numerical simulation of aluminum alloy resistance spot welding

In order to explore the influence of welding parameters and to investigate the Al alloy (AA) nugget formation process, a comprehensive model involving electrical-thermal-mechanical and metallurgical analysis was established to numerically display the resistance spot welding (RSW) process within multiple fields and understand the AA-RSW physics. A multi-disciplinary finite element method (FEM) framework and a empirical sub-model were built to analyze the affecting factors on weld nugget and the underlying nature of welding physics with dynamic simulation procedure. Specifically, a counter-intuitive phenomenon of the resistance time-variation caused by the transient inverse virtual variation (TIVV) effect was highlighted and analyzed on the basis of welding current and temperature distribution simulation. The empirical model describing the TIVV phenomenon was used for modifying the dynamic resistance simulation during the AA spot welding process. The numerical and experimental results show that the proposed multi-field FEM model agrees with the measured AA welding feature, and the modified dynamic resistance model captures the physics of nugget growth and the electrical-thermal behavior under varying welding current and fluctuating heat input.

Numerical simulation of materials-oriented ultra-precision diamond cutting:review and outlook

Ultra-precision diamond cutting is a promising machining technique for realizing ultra-smooth surface of different kinds of materials.While fundamental understanding of the impact of workpiece material properties on cutting mechanisms is crucial for promoting the capability of the machining technique,numerical simulation methods at different length and time scales act as important supplements to experimental investigations.In this work,we present a compact review on recent advancements in the numerical simulations of material-oriented diamond cutting,in which representative machining phenomena are systematically summarized and discussed by multiscale simulations such as molecular dynamics simulation and finite element simulation:the anisotropy cutting behavior of polycrystalline material,the thermo-mechanical coupling tool-chip friction states,the synergetic cutting responses of individual phase in composite materials,and the impact of various external energetic fields on cutting processes.In particular,the novel physics-based numerical models,which involve the high precision constitutive law associated with heterogeneous deformation behavior,the thermo-mechanical coupling algorithm associated with tool-chip friction,the configurations of individual phases in line with real microstructural characteristics of composite materials,and the integration of external energetic fields into cutting models,are highlighted.Finally,insights into the future development of advanced numerical simulation techniques for diamond cutting of advanced structured materials are also provided.The aspects reported in this review present guidelines for the numerical simulations of ultra-precision mechanical machining responses for a variety of materials.

Numerical simulation of the mechanical behavior of superconducting tape in conductor on round core cable using the cohesive zone model

Cables composed of rare-earth barium copper oxide(REBCO)tapes have been extensively used in various superconducting devices.In recent years,conductor on round core(CORC)cable has drawn the attention of researchers with its outstanding current-carrying capacity and mechanical properties.The REBCO tapes are wound spirally on the surface of CORC cable.Under extreme loadings,the REBCO tapes with layered composite structures are vulnerable,which can lead to degradation of critical current and even quenching of superconducting devices.In this paper,we simulate the deformation of CORC cable under external loads,and analyze the damage inside the tape with the cohesive zone model(CZM).Firstly,the fabrication and cabling of CORC are simulated,and the stresses and strains generated in the tape are extracted as the initial condition of the next step.Then,the tension and bending loads are applied to CORC cable,and the damage distribution inside the tape is presented.In addition,the effects of some parameters on the damage are discussed during the bending simulations.

Three-dimensional finite element analysis on effects of tunnel construction on nearby pile foundation

A three-dimensional finite element simulation was carried out to investigate the effects of tunnel construction on nearby pile foundation.The displacement controlled model (DCM) was used to simulate the tunneling-induced volume loss effects.The numerical model was verified based on the results of a centrifuge test and a set of parametric studies was implemented based on this model.There is good agreement between the trend of the results of the centrifuge test and the present model.The results of parametric studies show that the tunnelling-induced pile internal force and deformation depend mainly on the pile?tunnel distance,the pile length to tunnel depth ratio and the volume loss.Two different zones are separated by a 45° line projected from the tunnel springline.Within the zone of influence,the pile is subjected to tensile force and large settlement;whereas outside the zone of influence,dragload and small settlement are induced.It is also established that the impact of tunnelling on a pile group is substantially smaller as compared with a single pile in the same location with the rear pile in a group,demonstrating a positive pile group effect.

Numerical simulation analysis for deformation deviation and experimental verification for an antenna thin-wall parts considering riveting assembly with finite element method

In the process of thin-wall parts assembly for an antenna,the parts assembly deformation deviation is occurring due to the riveting assembly.In view of the riveting assembly deformation problems,it can be analyzed through transient and static simulation.In this work,the theoretical deformation model for riveting assembly is established with round head rivet.The simulation analysis for riveting deformation is carried out with the riveting assembly piece including four rivets,which comparing with the measuring points experiment results of riveting test piece through dealing with the experimental data using the point coordinate transform method and the space line fitting method.Simultaneously,the deformation deviation of the overall thin-wall parts assembly structure is analyzed through finite element simulation;and its results are verified by the measuring experiment for riveting assembly with the deformation deviation of some key points on the thin-wall parts.Through the comparison analysis,it is shown that the simulation results agree well with the experimental results,which proves the correctness and effectiveness of the theoretical analysis,simulation results and the given experiment data processing method.Through the study on the riveting assembly for thin-wall parts,it will provide a theoretical foundation for improving thin-wall parts assembly quality of large antenna in future.

Multiscale Hybrid-Mixed Finite Element Method for Flow Simulation in Fractured Porous Media

The multiscale hybrid-mixed(MHM)method is applied to the numerical approximation of two-dimensional matrix fluid flow in porous media with fractures.The two-dimensional fluid flow in the reservoir and the one-dimensional flow in the discrete fractures are approximated using mixed finite elements.The coupling of the two-dimensional matrix flow with the one-dimensional fracture flow is enforced using the pressure of the one-dimensional flow as a Lagrange multiplier to express the conservation of fluid transfer between the fracture flow and the divergence of the one-dimensional fracture flux.A zero-dimensional pressure(point element)is used to express conservation of mass where fractures intersect.The issuing simulation is then reduced using the MHM method leading to accurate results with a very reduced number of global equations.A general system was developed where fracture geometries and conductivities are specified in an input file and meshes are generated using the public domain mesh generator GMsh.Several test cases illustrate the effectiveness of the proposed approach by comparing the multiscale results with direct simulations.

Experimental and finite element analysis for fracture of coating layer of galvannealed steel sheet

Mechanical properties of galvannealed (GA) steel sheet used for automotive exposed panel and predicted failure phenomenon of its coating layer were evaluated using finite element method. V-bending test was performed to understand better the fracture of coating layer of GA steel sheet during plastic deformation. Yield strength of the coating layer was calculated by using a relative difference between hardness of coating layer measured from the nano-indentation test and that of substrate. To measure shearing strength at the interface between substrate and coating layer, shearing test with two specimens attached by an adhesive was carried out. Using the mechanical properties measured, a series of finite element analyses coupled with a failure model was performed. Results reveal that the fracture of coating layer occurs in an irregular manner at the region where compressive deformation is dominant. Meanwhile, a series of vertical cracks perpendicular to material surface are observed at the tensile stressed-region. It is found that 0.26-0.28 of local equivalent plastic strain exists at the coating and substrate at the beginning of failure. The fracture of coating layer depends on ductility of the coating layer considerably as well.

Probabilistic stability analyses of undrained slopes by 3D random fields and finite element methods

A long slope consisting of spatially random soils is a common geographical feature. This paper examined the necessity of three-dimensional(3 D) analysis when dealing with slope with full randomness in soil properties. Although 3 D random finite element analysis can well reflect the spatial variability of soil properties, it is often time-consuming for probabilistic stability analysis. For this reason, we also examined the least advantageous(or most pessimistic) cross-section of the studied slope. The concept of"most pessimistic" refers to the minimal cross-sectional average of undrained shear strength. The selection of the most pessimistic section is achievable by simulating the undrained shear strength as a 3 D random field. Random finite element analysis results suggest that two-dimensional(2 D) plane strain analysis based the most pessimistic cross-section generally provides a more conservative result than the corresponding full 3 D analysis. The level of conservativeness is around 15% on average. This result may have engineering implications for slope design where computationally tractable 2 D analyses based on the procedure proposed in this study could ensure conservative results.

Study on Dynamic Mechanical Behavior of Al-Mg-Si Alloy

The dynamic mechanical behavior of Al-Mg-Si alloy was investigated under different strain rates by mechanical property and microstructure characterization,constitutive behavior analysis and numerical simulation in the present study.As the strain rate increases,the yield strength,ultimate tensile strength and elongation increase first,then remain almost constant,and finally increase.The alloy always exhibits a typical ductile fracture mode,not depending on the strain rate.However,as the strain rate increases,the number of dimples gradually increases.Tensile deformation can refine grains,however,the grain structure is slightly affected by the strain rate.An optimized Johnson-Cook constitutive equation was used to describe the mechanical behavior and obtained by fitting the true stress-strain curves.The parameter C was described by a function related to the strain rate.The fitting true stress-strain curves by the JC model agree very well with the experimental true stress-strain curves.The true stress-strain curves calculated by the finite element numerical simulation agree well with the experimental true stress-strain curves.

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.

Constitutive Behavior of the Interface between UHPC and Steel Plate without Shear Connector:From Experimental to Numerical Study

The application of ultra-high performance concrete(UHPC)as a covering layer for steel bridge decks has gained widespread popularity.By employing a connection without a shear connector between the steel plate and UHPC,namely,the sandblasted interface and the epoxy adhesive with sprinkled basalt aggregate interface,the installation cannot only be simplified but also the stress concentration resulting from the welded shear connectors can be eliminated.This study develops constitutive models for these two interfaces without shear connectors,based on the interfacial pull-off and push-out tests.For validation,three-point bending tests on the steel-UHPC composite plates are conducted.The results indicated that the proposed bilinear traction-separation model for the sandblasted interface and the trapezoidal traction-separation model for the epoxy adhesive with sprinkled basalt aggregate interface can generally calibrate the interfacial behavior.However,the utilization of the experimentally determined pure shear strength underestimates the load-carrying capacity of the composite plates in the case of three-point bending tests.By recalling the Mohr-Coulomb criterion,this underestimation is attributed to the enhancement of the interface shear strength by the presence of normal stress.

Direct Pointwise Comparison of FE Predictions to StereoDIC Measurements:Developments and Validation Using Double Edge-Notched Tensile Specimen

To compare finite element analysis(FEA)predictions and stereovision digital image correlation(StereoDIC)strain measurements at the same spatial positions throughout a region of interest,a field comparison procedure is developed.The procedure includes(a)conversion of the finite element data into a triangular mesh,(b)selection of a common coordinate system,(c)determination of the rigid body transformation to place both measurements and FEA data in the same system and(d)interpolation of the FEA nodal information to the same spatial locations as the StereoDIC measurements using barycentric coordinates.For an aluminum Al-6061 double edge notched tensile specimen,FEA results are obtained using both the von Mises isotropic yield criterion and Hill’s quadratic anisotropic yield criterion,with the unknown Hill model parameters determined using full-field specimen strain measurements for the nominally plane stress specimen.Using Hill’s quadratic anisotropic yield criterion,the point-by-point comparison of experimentally based full-field strains and stresses to finite element predictions are shown to be in excellent agreement,confirming the effectiveness of the field comparison process.

Numerical Investigation of Thermal Behavior of CNC Machine Tool and Its Effects on Dimensional Accuracy of Machined Parts

The dimensional accuracy of machined parts is strongly influenced by the thermal behavior of machine tools (MT). Minimizing this influence represents a key objective for any modern manufacturing industry. Thermally induced positioning error compensation remains the most effective and practical method in this context. However, the efficiency of the compensation process depends on the quality of the model used to predict the thermal errors. The model should consistently reflect the relationships between temperature distribution in the MT structure and thermally induced positioning errors. A judicious choice of the number and location of temperature sensitive points to represent heat distribution is a key factor for robust thermal error modeling. Therefore, in this paper, the temperature sensitive points are selected following a structured thermomechanical analysis carried out to evaluate the effects of various temperature gradients on MT structure deformation intensity. The MT thermal behavior is first modeled using finite element method and validated by various experimentally measured temperature fields using temperature sensors and thermal imaging. MT Thermal behavior validation shows a maximum error of less than 10% when comparing the numerical estimations with the experimental results even under changing operation conditions. The numerical model is used through several series of simulations carried out using varied working condition to explore possible relationships between temperature distribution and thermal deformation characteristics to select the most appropriate temperature sensitive points that will be considered for building an empirical prediction model for thermal errors as function of MT thermal state. Validation tests achieved using an artificial neural network based simplified model confirmed the efficiency of the proposed temperature sensitive points allowing the prediction of the thermally induced errors with an accuracy greater than 90%.