Grain refinement of Mg-Al alloys by optimization of process parameters based on three-dimensional finite element modeling of roll casting

To study the influence of roll casting process parameters on temperature and thermal-stress fields for the AZ31 magnesium alloy sheets,three-dimensional geometric and 3D finite element models for roll casting were established based on the symmetry of roll casting by ANSYS software.Meshing method and smart-sizing algorithm were used to divide finite element mesh in ANSYS software.A series of researches on the temperature and stress distributions during solidification process with different process parameters were done by 3D finite element method.The temperatures of both the liquid-solid two-phase zone and liquid phase zone were elevated with increasing pouring temperature.With the heat transfer coefficient increasing,the two-phase region for liquid-solid becomes smaller.With the pouring temperature increasing and the increase of casting speed,the length of two-phase zone rises.The optimized of process parameters（casting speed 2 m/min,pouring temperature 640 ℃ and heat transfer coefficient 15 kW/（m2·℃） with the water pouring at roller exit was used to produce magnesium alloy AZ31 sheet,and equiaxed grains with the average grain size of 50 μm were achieved after roll casting.The simulation results give better understanding of the temperature variation in phase transformation zone and the formation mechanism of hot cracks in plates during roll casting and help to design the optimized process parameters of roll casting for Mg alloy.

Parameter identifications for a rotor system based on its finite element model and with varying speeds

In order to achieve prediction for vibration of rotating machinery, an accurate finite element （FE） model and an efficient parameter identification method of the rotor system are required. In this research, a test rig is used as a prototype of a rotor system to validate a novel parameter identification technique based on an FE model. Rotor shaft vibration at varying operating speeds is measured and correlated with the FE results. Firstly, the theories of the FE modelling and identification technique are introduced. Then disk unbalance parameter, stiffness and damping coefficients of the bearing supports on the test rig are identified. The calculated responses of the FE model with identified parameters are studied in comparison with the experimental results.

A Unified Dimensionless Parameter for Finite Element Mesh for Beams Resting on Elastic Foundation

Discretising a structure into elements is a key step in finite element(FE)analysis.The discretised geometry used to formulate an FE model can greatly affect accuracy and validity.This paper presents a unified dimensionless parameter to generate a mesh of cubic FEs for the analysis of very long beams resting on an elastic foundation.A uniform beam resting on elastic foundation with various values of flexural stiffness and elastic supporting coefficients subject to static load and moving load is used to illustrate the application of the proposed parameter.The numerical results show that(a)Even if the values of the flexural stiffness of the beam and elastic supporting coefficient of the elastic foundation are different,the same proposed parameter“s”can ensure the same accuracy of the FE solution,but the accuracy may differ for use of the same element length;(b)The proposed dimensionless parameter“s”can indeed be used as a unified index to generate the mesh for a beam resting on elastic foundation,whereas the use of the same element length as a criterion may be misleading;(c)The errors between the FE and analytical solutions for the maximum vertical displacement,shear force and bending moment of the beam increase with the dimensionless parameter“s”;and(d)For the given allowable errors for the vertical displacement,shear force and bending moment of the beam under static load and moving load,the corresponding values of the proposed parameter are provided to guide the mesh generation.

Introduction to Mesh Based Generated Lumped Parameter Models for Electromagnetic Problems using Triangular Elements

This paper is an introduction to mesh based generated reluctance network modeling using triangular elements.Many contributions on mesh based generated reluctance networks using rectangular shaped elements have been published,but very few on those generated from a mesh using triangular elements.The use of triangular elements is aimed at extending the application of the approach to any shape of modeled devices.Basic concepts of the approach are presented in the case of electromagnetic devices.The procedure for coding the approach in the case of a flat linear permanent magnet machine is presented.Codes developed under MATLAB environment are also included.

Finite Element Analysis and Experiment Research on Surface Residual Stress of Ceramics Grinding

The theoretical model of residual stress of ceramics grinding has been established applying thermal elastoplastic mechanics theory. While grinding at the course of grinding wheel moved along workpiece surface the distributing regulation of residual stress can be simplified into thermal elastioplastic mechanical issue, under the action of the both moving centralized force and heat source. Calculating and evaluating of surface residual stress using current procedure of finite element analysis which has been reformed is successful. Comparing with X-ray diffraction experiment method, satisfactory precision has been acquired. The results of experiment show the changing regularity of residual stresses after grinding Al 2O 3 using diamond wheel, on condition that alter grinding parameters. The values of residual compress stress are taken place changing at key certain critical point on their figure as follow: When grinding depth a p is lower than 50 μm, the residual compress stresses are increased with grinding depth increasing, on the contrary as a p>50 μm. At V w<8 m/min, the residual compress stresses increased rapidly with feed speed of workpiece increasing, on the contrary at V w>8 m/min.When V s<25 m/s the residual stress increased with wheel speed increasing and keep stable in value at V s>25 m/s.According to grinding mechanism the cause of residual stress transform has been explained.

Experiment and finite element analysis of micromilling force

For predicting the milling force in process of micromilling aluminum alloy, the law for micromilling force changing under different milling parameters was studied. The elastic-plastic finite elelent model of micromilling was found using general commercial software. During modeling, the Johnson-Cook＇ s coupled thermal- mechanical model was used as workpieee material model, the Johnson-Cook＇ s shear failure principle was adopted as workpiece failure principle, and the coupled thermal-mechanical hexahedron strain hybrid modules and serf-adaptive grid technology based on the updated Lagrange formulation were used to mesh the workpiece＇ s elements, while the friction between tool and workpiece obeys the modified Coulomb＇ s law that combines with the sliding friction and the adhesive friction. By means of finite element analysis, the law for micromilling force changing under different milling parameters was obtained, and the results were analyzed and compared. Finally micromilling experiments were carried out to validate the results of simulation.

High voltage DC leakage detection for double-lined hazardous waste landfill based on finite element method

According to the structural characteristics of hazardous waste landfill, a new model based on the finite element method （FEM） is developed. The detection layer is considered as a sealed space and it is assumed that total current flows through the leak for the high resistivity of geomembrane liner. The leak current is regarded as a positive point current ＋I and the other current source is -I. Electrical potential of an arbitrary point in detection layer satisfies Poisson equation. Experiments for detecting leaks in liner were carried out. Excellent agreement between experimental data and simulated model data validates the new model. Parametric curves for a single leak show that with optimum selection of field survey parameters leaks can be detected effectively. For multiple leaks, the simulated results indicate that they are detectable when leak separation is larger than measurement spacing.

Flexural wave bandgap properties of phononic crystal beams with interval parameters

Uncertainties are unavoidable in practical engineering,and phononic crystals are no exception.In this paper,the uncertainties are treated as the interval parameters,and an interval phononic crystal beam model is established.A perturbation-based interval finite element method(P-IFEM)and an affine-based interval finite element method(A-IFEM)are proposed to study the dynamic response of this interval phononic crystal beam,based on which an interval vibration transmission analysis can be easily implemented and the safe bandgap can be defined.Finally,two numerical examples are investigated to demonstrate the effectiveness and accuracy of the P-IFEM and A-IFEM.Results show that the safe bandgap range may even decrease by 10%compared with the deterministic bandgap without considering the uncertainties.

基于APDL的船用电梯井架参数化建模与仿真

基于APDL软件,对船用电梯井架进行参数化建模和有限元分析,实现了电梯井架的快速设计、优化和分析。具体方法是采用多面体拼接法对电梯井架进行几何建模,然后定义参数化变量,通过改变参数化变量的值来实现电梯井架的参数化设计。最后利用有限元分析方法对电梯井架进行仿真分析。结果表明,该方法能够提高设计效率,减少制造成本,同时也能保证产品质量。因此,在电梯井架的设计和制造中具有一定的应用价值。通过调整参数、进行工程设计的优化,可以在设计阶段找到成本效益最佳的设计方案,从而避免了在后期制造和维护过程中出现意外的高成本,帮助预测维护成本和整个产品的生命周期成本。

电路参数对石墨加热元件发热特性的影响规律研究

电路参数是石墨加热元件发热性能的决定性因素,对电路参数的影响规律研究是高性能、高可靠性石墨加热器设计的基础。对石墨加热装置的失效过程进行研究,确定发热元件可靠性量化指标——温度均匀度;在此基础上,确定对加热元件热输出性能进行量化的四个电路参数:加热元件厚度、发热条宽度、发热条缝隙、缝隙处的倒圆半径;对发热电路进行参数化建模,并采用有限元电热耦合仿真对加热元件电路参数对加热能力和可靠性的影响机理进行研究。结果表明:加热元件的厚度决定了其热输出能力,而其余三个电路参数决定了加热元件的可靠性。本文的研究成果对高性能石墨加热装置的研制具有重要的支撑作用。

基于有限元分析的活塞压力计形变系数理论计算

基于有限元分析方法,计算了600 kPa气体活塞压力计和500 MPa油介质活塞压力计的形变系数。根据活塞间隙压力分布与间隙形变的耦合关系,采用迭代计算,确定了在某一测量压力下活塞系统的最终压力分布和间隙。在此基础上,计算了在各压力点下的活塞有效面积,并通过最小二乘拟合获得了压力形变系数。基于Python和ANSYS APDL编写了计算程序,研究了参数微调对计算结果的影响,并评估了形变系数计算结果的不确定度。对于600 kPa气体活塞压力计,形变系数的有限元计算结果与简单理论计算结果相差仅0.8%;对于500 MPa油介质活塞压力计,形变系数的有限元计算结果与实验测量值在不确定度范围内一致。

柱塞泵进油口尺寸对润滑脂流量的影响分析

为使在柱塞泵设计过程中进口段尺寸选取的有理论依据,计算润滑脂在管道不同尺寸条件下的流量和沿程阻力。根据流变学及流体力学理论,对润滑脂在管道内的流动状态进行分析,推导出润滑脂在进口段的流量方程,确定润滑脂管道流动的层流临界条件。研究结果表明:对于研究的柱塞泵,在进口段长度0~15 mm范围内流量呈现出骤降的趋势,长度大于15 mm后流量变化较为平稳;在进口段半径0~30 mm范围内流量呈现出平缓增大的趋势,半径大于30 mm后流量急剧上升。有限元仿真结果与数值分析结果一致,且有相似的变化规律,证明了管道流量方程的准确性。因此,推导的润滑脂管道流动方程适用于润滑泵的工程设计。

柴油机活塞缸套摩擦副润滑和多柔体动力学耦合特性

为研究四冲程车用柴油机活塞-缸套摩擦副的动力学及润滑特性,提出了一种新的活塞-缸套摩擦动力学耦合模型.模型中采用绝对节点坐标公式(ANCF)描述活塞-连杆-曲轴多柔体动力系统,采用平均雷诺方程和微凸体接触理论描述混合润滑模型,基于商用软件结合二次开发程序实现仿真计算.对活塞缸套摩擦副的润滑动力学计算分析表明,由于缸内压力和活塞敲击作用,缸套会产生最大值为23.6μm的瞬时变形.与刚体模型相比,考虑部件的弹性变形不仅会使活塞横向位移增加40%,还会使得活塞润滑域出现油膜压力的局部集中.另外,柔体模型的循环平均功耗更小,与刚体模型相比相差17.7%.

基于参数化建模方法的复合式盾构机刀盘力学性能分析与结构优化

刀盘是盾构机的核心部件之一,合理的刀盘结构设计是安全高效掘进的基础。为了快速高效建立刀盘有限元模型并分析其力学性能,采用基于APDL(ANSYS parametric design language)命令流开发的参数化建模方法,建立某型号复合式盾构机刀盘的数字模型。对刀盘施加极限工况下的推力和扭矩,通过静力学分析得到刀盘的应力分布和变形分布,确定最大应力和最大变形位置,校核刀盘的静强度和静刚度。进一步以刀盘总质量为优化目标,以刀盘强度和刚度为约束条件建立基于参数化建模的刀盘结构优化方法,提出刀盘结构优化流程。通过参数敏感性分析确定刀盘优化参数,探究相关参数对刀盘强度和刚度的影响。对复合式盾构机刀盘的关键参数进行优化。结果表明:优化后刀盘的最大应力降低了12%,最大变形降低了20%,质量减轻了119 kg。因此,基于参数化建模的优化方法可以提供刀盘的强度与刚度,并同时降低刀盘质量。研究成果可为后续多目标刀盘结构优化提供参考。

基于有限元分析的发动机活塞轻量化设计

在有限元分析的基础上,采用材料替换及结构拓补优化的方法对某发动机活塞进行轻量化设计。利用SolidWorks建立活塞三维模型,将活塞原始材料1015铝合金替换为7075铝合金;运用Altair Inspire有限元分析软件分别对两种材料的活塞进行静力学分析及模型质量测量,采用拓扑优化方法进行结构优化。仿真结果表明:优化后活塞质量减轻了64%,活塞的最大应力减小了12%,安全系数提升了3.7。

直升机ACF智能旋翼压电叠堆输出特性仿真分析

压电叠堆是ACF智能旋翼中后缘襟翼的致动元件,其输出性能的好坏直接影响后缘襟翼的偏转效率。基于COMSOL Multiphysics有限元平台,对全电极和叉指电极两种构型的压电叠堆进行了参数化建模,对叠堆自由位移和阻塞力两种典型输出特性进行了仿真分析,并利用理论进行了校验。结果表明,基于参数化建模的压电叠堆有限元模型具有良好的准确性,其计算结果与理论模型计算结果基本保持一致;两种构型压电叠堆的输出特性随激励电压的变化都是趋于线性的;相同激励电压下,同横截面积的叉指电极型压电叠堆的自由位移小于全电极型,减小比例与各陶瓷层活性区面积的缩减比例一致,而两种构型叠堆的阻塞力大小相当,叉指电极的尺寸缩进不会使得阻塞力明显降低。

Numerical modeling techniques for noise emission of free railway wheels

In this article,we consider the numerical prediction of the noise emission from a wheelset in laboratory conditions.We focus on the fluid-structure interaction leading to sound emission in the fluid domain by analyzing three different methods to account for acoustic sources.These are a discretized baffled piston using the discrete calculation method(DCM),a closed cylindrical volume using the boundary element method(BEM)and radiating elastic disks in a cubic enclosure solved with the finite element method(FEM).We provide the validation of the baffled piston and the BEM using measurements of the noise emission of a railway wheel by considering ground reflections in the numerical models.Selected space-resolved waveforms are compared with experimental results as well as with a fluid-structure interaction finite element model.The computational advantage of a discretized disk mounted on a baffle and BEM compared to FEM is highlighted,and the baffled pistons limitations caused by a lack of edge radiation effects are investigated.

Tuning microstructures of TC4 ELI to improve explosion resistance

A reasonable heat treatment process for TC4 ELI titanium alloy is crucial to tune microstructures to improve its explosion resistance.However,there is limited investigation on tuning microstructures of TC4 ELI to improve explosion resistance.Moreover,the current challenge is quantifying microstructural changes'effects on explosion resistance and incorporating microstructural changes into finite element models.This work aims to tune microstructures to improve explosion resistance and elucidate their anti-explosion mechanism,and find a suitable method to incorporate microstructural changes into finite element models.In this work,we systematically study the deformation and failure characteristics of TC4 ELI plates with varying microstructures using an air explosion test and LS-DYNA finite element modeling.The Johnson-Cook(JC)constitutive parameters are used to quantify the effects of microstructural changes on explosion resistance and incorporate microstructural changes into finite element models.Because of the heat treatment,one plate has equiaxed microstructure and the other has bimodal microstructure.The convex of the plate after the explosion has a quadratic relationship with the charge mass,and the simulation results demonstrate high reliability,with the error less than 17.5%.Therefore,it is feasible to obtain corresponding JC constitutive parameters based on the differences in microstructures and mechanical properties and characterize the effects of microstructural changes on explosion resistance.The bimodal target exhibits excellent deformation resistance.The response of bimodal microstructure to the shock wave may be more intense under explosive loading.The well-coordinated structure of the bimodal target enhances its resistance to deformation.

基于BIM技术的异形空间结构参数化设计

设计人员传统的设计思路为根据设计经验对建筑造型和结构进行设计,而场馆建筑造型独特且复杂,设计难度大,传统的设计方法繁琐且需消耗大量的设计资源,不能很好地解决异形场馆建筑结构中的复杂问题。本文以某异形空间结构为研究对象,采用参数化技术对该异形空间结构进行设计,将BIM设计理念融入设计中,解决结构选型分析问题,运用Grasshopper建立该结构的参数化模型,并运用Abaqus对所建立的参数化模型进行计算分析和结构力学特性的优化,最后利用BIM软件进行三维模型应用,为结构工程师解决异形空间结构的设计提供新的思路和方法。

矿用减速器直齿轮强度动态有限元分析

传统的齿轮接触应力和弯曲应力是利用理论计算进行静强度校核。为了提高齿轮传动中接触应力和弯曲应力的计算精度与效率,利用Creo2.0软件快速建立了某矿用减速器直齿圆柱齿轮的参数化模型,并使用ABAQUS软件及其子模型技术对齿轮最大接触应力和齿根最大弯曲应力进行动态分析,从而为齿轮的设计及优化提供一种新的设计方法。