Modal and Thermal Analysis of a Modified Connecting Rod of an Internal Combustion Engine Using Finite Element Method

The connecting rod is one of the most important moving components in an internal combustion engine. The present work determined the possibility of using aluminium alloy 7075 material to design and manufacture a connecting rod for weight optimisation without losing the strength of the connecting rod. It considered modal and thermal analyses to investigate the suitability of the material for connecting rod design. The parameters that were considered under the modal analysis were: total deformation, and natural frequency, while the thermal analysis looked at the temperature distribution, total heat flux and directional heat flux of the four connecting rods made with titanium alloy, grey cast iron, structural steel and aluminium 7075 alloy respectively. The connecting rod was modelled using Autodesk inventor2017 software using the calculated parameters. The steady-state thermal analysis was used to determine the induced heat flux and directional heat flux. The study found that Aluminium 7075 alloy deformed more than the remaining three other materials but has superior qualities in terms of vibrational natural frequency, total heat flux and lightweight compared to structural steel, grey cast iron and titanium alloy.

Numerical Simulation of Stress-Strain State for Nonhomogeneous Shell-Type Structures Based on the Finite Element Method

Projective-iterative version of finite element method has developed for numerical simulation of the stress-strain state of nonhomogeneous shell-type structures (shells with openings). Plastic deformation of the material is taken into account when using the method of elastic solutions that reduce the solution of elastoplastic problems to solution of elastic problems. Developed PIV’s significant savings of computer calculation has been compared with the calculation on a fine mesh of traditional FEM. Designed scheme allows analysis of the mutual influence of openings. Analysis of the transformation zone of plastic deformation is developed. For definiteness, the cylindrical shell structures with several rectangular openings are considered.

Prediction of Welding Deformation of Underframe

An inherent strain method was applied to the welding deformation analysis of left girder of GM’s Buick’s chassis underframe assembly. Three models are used in the calculation. Model 1 takes into account the longitudinal and transverse inherent strains; model 2 considers only longitudinal inherent strain; model 3 also takes into account the longitudinal and transverse inherent strains, but inherent strains are taken according to the function instead of the constant, for simulating the variation of the girder’s stiffness during welding process. The result shows the deformation of model 2 is less than that of the model 1, the error is less than 10% of the absolute displacement. So the longitudinal inherent strain is the main factor determining boxes-girder’s welding deformation. The deformation of model 3 is also less than that of the model 1, because the inherent strains of the model 3 are less than that of the model 1. At last, the welding deformation of the whole underframe was analyzed. The analysis results can be taken as references not only for the choices of welding sequence, welding parameters and fixture’s location, but also for welding deformation prediction of other car chassis.

Welding deformation control of medium-thickness structures made by advanced high strength steel

In order to investigate the residual angular deformation in fillet welding of T-joint of HG785 high strength steel with a medium thickness plate, both detailed thermo-mechanical finite element simulation and conventional gas metal arc welding experiment were carried out in the present study. In-process deformation control method using backheating method to reduce the residual deformation was discussed.

PREDICTION OF WELDING DEFORMATIONS BY FEM BASED ON INHERENT STRAINS

Welding deformations can be predicted by inherent strains that are assumed to be distributed in the welds and nearby area. This method is more convenient compared with the thermo elasto plastic finite element method because only elastic analysis is necessary. The problem is how to know the inherent strains in advance during deformation analysis. The relations between inherent strains and welding parameters based on some experimental curves and a 3 D FEM model were introduced. According to this study, the longitudinal and transverse inherent strains that are the most important factors on welding deformations can be determined. The effectiveness of the proposed methods is demonstrated through the deformation analysis of a large welded cylinder with multipass welds as an example.

Prediction and controlling for welding deformation of propeller base structure

Welding deformation often brings about manufacturing problems such as dimensional inaccuracies during assembly and reduces fabrication efficiency.Prediction and controlling welding deformation can help to improve the quality of welded structures.In this paper,the welding deformation of propeller base struc-tures is predicted by means of numerical approaches and mechanical constraints are proposed to control deformations in welding process.Thermal elasto-plastic finite element method(TEP FEM)is employed to simulate welding process of the base structure.Computed accuracy of welding deformation by TEP FEM analysis is verified by comparing with experimental data of tee joint welding.Results show that welding deformations of the base mainly comprise out-of-plane distortion of ring fringe and radial distortion of cylindrical plate.Exerting mechanical constraints of fixed points at fringe and rigid supports inside cylin-der can decrease out-of-plane and radial distortions effectively.The numerical approach adopted in this article can serve as an effective tool to optimize welding process planning in integrated design method.

Assessment of gas tungsten arc welding thermal cycles on Inconel 718 alloy

Heat moving source models along with transient heat analysis by finite element method were used to determine weld thermal cycles and isothermal sections obtained from the application of a gas tungsten arc welding beads on Inconel 718 plates. Analytical (Rosenthal’s thick plate model) and finite element results show an acceptable approximation with the experimental weld thermal cycles. The isothermal sections determined by numerical simulation show a better approximation with the experimental welding profile for double-ellipse model heat distribution than Gauss model. To analyze the microstructural transformation produced by different cooling rates in the fusion and heat affected zones, Vickers microhardness measurements (profile and mapping representation) were conducted. A hardness decrement for the heat affected zone (~200 HV0.2) and fusion zone (~240 HV0.2) in comparison with base material (~350 HV0.2) was observed. This behavior has been attributed to the heterogeneous solubilization process of the γ″ phase (nickel matrix), which, according to the continuous-cooling-transformation curve, produced the Laves phase,δ and MC transition phases, generating a loss in hardness close to the fusion zone.

Computational analysis of linear friction welding process and micromechanical modeling of deformation behavior for medium carbon steel

Finite element simulation of linear friction welding(LFW) medium carbon steel was carried out using the ABAQUS software. A two-dimensional(2D) coupled thermo-mechanical model was established. First, the temperature fields of medium carbon steel during LFW process were investigated. And then, the Mises stress and the 1st, 2nd and 3rd principal stresses fields' evolution of the steel during LFW process were studied. The deformation behavior of LFW carbon steel was analyzed by using micromechanics model based on ABAQUS with Python code. The Lode parameter was expressed using the Mohr stress circle and it was investigated in detail.

基于Lagrange-Galerkin有限元方法的焊接热循环轻量化求解

焊接热循环的干扰因素多、变化速度快、影响范围广,常需要对其进行即时预测与控制,以保证焊接质量。以焊缝中心温度分布与变化为研究对象,将其简化为一维焊接热循环瞬态热传导问题,并基于Lagrange-Galerkin有限元方法,进行算域离散与插值。开发了一种轻量化的焊接热循环求解算法,研究不同时刻下焊缝中心温度分布曲线与变化曲线的即时变化。以镍基Inconel 718合金2 mm薄板对接接头为例,进行数值模拟实例演算,结果表明计算耗时约0.41~0.72 s,满足数据与轻量化计算的要求。

内压薄壁圆柱壳电阻凸焊接头疲劳寿命研究

为提高凸焊接头在使用过程中的安全性能,笔者采用有限元法和等效结构应力法,对内压薄壁圆柱壳电阻凸焊接头疲劳寿命预测方法进行了研究。提出了一种考虑预压载荷对圆柱壳形状影响的建模方法,计算了不同预压载荷下的筒体变形和凸焊接头疲劳寿命。研究结果表明薄壁圆柱壳在凸焊接头处的变形对凸焊接头疲劳寿命有显著影响。建议在制造中采取措施减小焊接过程对圆柱壳在开孔区的变形的影响,从而使凸焊接头获得较高的疲劳寿命。

弹载天线模块热变形仿真预测与试验研究

以典型的弹载天线模块为研究对象,采用ABAQUS软件建立其热变形仿真预测模型。同时,在相同条件下,采用所搭建的基于数字图像相关法(DIC)的热变形测量系统提取并计算变温前、后弹载天线模块的热变形,以验证热变形仿真模型的准确性。结果表明,ABAQUS的仿真结果与DIC方法测量的弹载天线模块热变形结果吻合度较好,验证了所建立的有限元仿真模型能准确且有效地评估弹载天线模块的热变形情况。

柔性件对接点焊装配偏差有限元分析

文章针对柔性件对接点焊产生的装配偏差问题,在完成“N-2-1”柔性定位的基础上,首先采用影响系数法对柔性件装配偏差进行建模,分析焊接时产生的装配偏差;其次,利用Ansys进行有限元仿真计算,研究焊点数量以及焊接热对装配偏差产生的影响;最后,以车身门框焊装为例进行了实例研究,该方法可适用于柔性件在考虑焊接热影响下多焊点装配偏差分析。

基于热弹塑性有限元法的船体板极限强度研究

利用Abaqus软件,分析了热弹塑性有限元法在对接焊船体矩形板极限强度评估中的应用。首先,基于热弹塑性有限元法,直接获取船体板焊接残余应力与变形。进而采用非线性有限元法,评估了2块不同板厚(9.5 mm、11 mm)对接焊船体矩形板在轴向压缩载荷下的极限强度。研究表明,壳单元与实体单元计算所得温度场、残余应力场、变形结果相近,但前者计算效率显著提高。不同矩形板厚度对矩形板纵向残余应力的分布影响较小,但对其垂向挠度峰值影响较大。不同厚度矩形板通过数值模拟得到的极限强度值与Faulkner简化公式计算值误差分别为4.2%和5.1%,因此数值模拟值与公式计算值较吻合。

基于热弹塑性有限元法的双腹加筋板焊接顺序研究

为进一步研究双腹加筋板不同焊接顺序下残余应力和变形的分布规律,基于热弹塑性有限元法,采用有限元软件Abaqus对双腹加筋板进行了焊接数值模拟,分析了双腹加筋板不同焊接顺序下残余应力和变形的分布规律。分别采用壳单元和实体单元对双腹加筋板远离焊缝区及焊缝区建模,以提高计算效率,并建立了壳单元与实体单元自由度之间的线性约束。计算比较了双腹板同步焊接与连续焊接下的加筋板焊接残余应力与变形,共计17种焊接顺序。结果表明:相比于连续焊接,双腹加筋板采用同步焊接产生的残余应力与角变形较小,双腹加筋板同步焊接角变形的幅值比连续焊接角变形幅值减小了47.1%。

Characteristics of Deformation and Strength of Concrete in Plane Strain State

The characteristics of deformation and strength of concrete under the plane strain condition are studied experimentally with the triaxial apparatus designed by the authors and are compared with those under the plane stress condition. A formula of stress transformation between plane stress and plane strain conditions is proposed for the elasto-plastic state, and it provides a theoretical basis for simplifying nonlinear analysis and fully using the strength of concrete.

TRANSIENT TEMPERATURE FIELDS AND RESIDUAL STRESS FIELDS OF METALLIC MATERIALS UNDER WELDING

Based on the situation of welding thermal conduction and thermo-elasto-platicity research, this paper explores some problems in this field. First, the boundary element method for nonlinear problems is improved by linearization of nonlinear problems and used in welding thermal conduction analysis. Second, the thermo-elasto-plastic finite element method is used for the welding stress calculation, in which the phase transformation is considered by the 'equivalent linear expansion coefficient method'. The comparison of the calculated results with experimental data shows that the methods provided in this paper are available.

Thermal Stress Analysis of Welded Joint in 1420 Al-Li Alloy Induced by Thermal Cycling

A model of double grains under plane stress state has been established. According to the double grain model, thermal stress induced by thermal cycling in welding fusion zone is numerically simulated by finite element method, and the microstructures before and after thermal cycling are observed. The effect of thermal stress on weld microstructure is discussed. Experimental and analysis results show that the difference between the coefficients of thermal expansion and elastic modulus for grains along different crystal directio n can produce alternate thermal misfit stress and strain near boundaries under thermal cycling. At the temperature of upper and lower limit, thermal stress nearby grain boundary reaches maxima. Thermal stress induced changes in microstructure, which expressed by the sending dislocations from boundaries to matrix, piling up against the boundaries and the increasing of dislocation density.

基于Workbench的齿轮稳态温度场和传动误差分析

基于Workbench建立了齿轮温度场和传动误差有限元分析模型,对不同转速和转矩齿轮温度场、不同转速和不同温度下齿轮传动误差进行了分析。通过Ansys的Workbench对齿轮温度场进行仿真,得到齿轮温度场和齿轮啮合线温度场分布结果;把温度结果作为载荷,通过间接耦合的方法应用于齿轮传动误差仿真研究中,得到齿轮传动误差仿真结果。结果表明,随着齿轮转速和转矩的增加,齿轮温度整体呈现出上升趋势;齿轮转速、转矩分别与齿轮啮合线温度变化量近似呈现出线性关系。齿轮传动误差仿真分析中,随着齿轮转速和温度增加,齿轮传动误差曲线分别上移和下移,但齿轮传动误差曲线峰谷值变化不大;齿轮转速、温度分别与齿轮传动误差变化量近似呈现出线性关系。

面向天线板热变形的有限元模型修正方法

为满足卫星天线板的在轨热变形测量要求,需要建立精确有限元模型模拟天线板热变形过程。蜂窝夹层板作为天线板主体结构,在有限元建模过程中通常需要对其进行简化处理,导致有限元计算结果与实验测量值之间存在差异。针对上述问题,进行了高温环境下天线板结构的热变形实验,得到温度场分布与热变形位移矩阵。通过对温度场拟合得到有限元模型热载荷。在此基础上,提出了利用天线板有限元模型与实验模型面外位移测量矩阵的均方根误差作为修正目标,基于多岛遗传算法的有限元模型修正方法,对模型材料参数与边界条件进行修正。修正后有限元模型的预测精度得到了明显提高。

高压工况上游泵送机械密封热力变形与密封性能分析

为研究高压工况下上游泵送机械密封的性能,考虑密封环与润滑液膜间的流固热力耦合作用,建立了其热弹流润滑模型,基于有限单元方法求解液膜润滑方程、密封环热传导方程和热力变形方程,采用三重迭代算法实现膜压、膜厚、温度和变形之间的耦合求解,研究了转速、密封压力和介质温度对上游泵送机械密封端面变形的影响规律,分析了热力变形作用下密封的上游泵送能力。研究结果表明,高压工况下密封端面产生了沿上游泵送方向收敛的液膜间隙,高密封压力下的力变形是主要原因,热变形部分抵消了压力变形带来的影响;随转速的增大,液膜沿上游泵送方向的收敛程度减小,上游泵送率增大,摩擦因数增大;随着密封介质压力的增大,液膜收敛程度增大,摩擦因数减小,上游泵送率大幅减小;随密封介质温度的升高,液膜收敛程度减小,摩擦因数减小,上游泵送率有所增加。研究结果可为高压上游泵送机械密封环的结构优化和设计提供理论参考。