A simple numerical method for three-dimensional analysis of simple expansion chamber mufflers of rectangular as well as circular cross-section with a stationary medium

Three-dimensional effects are a primary source of discrepancy between the measured values of automotive muffler performance and those predicted by the plane wave theory at higher frequencies. The basically exact method of (truncated) eigenfunction expansions for simple expansion chambers involves very complicated algebra, and the numerical finite element method requires large computation time and core storage. A simple numerical method is presented in this paper. It makes use of compatibility conditions for acoustic pressure and particle velocity at a number of equally spaced points in the planes of the junctions (or area discontinuities) to generate the required number of algebraic equations for evaluation of the relative amplitudes of the various modes (eigenfunctions), the total number of which is proportional to the area ratio. The method is demonstrated for evaluation of the four-pole parameters of rigid-walled, simple expansion chambers of rectangular as well as circular cross-section for the case of a stationary medium. Computed values of transmission loss are compared with those computed by means of the plane wave theory, in order to highlight the onset (cutting-on) of various higher order modes and the effect thereof on transmission loss of the muffler. These are also compared with predictions of the finite element methods (FEM) and the exact methods involving eigenfunction expansions, in order to demonstrate the accuracy of the simple method presented here.

The influence of Zr layer thickness on contact deformation and fracture in a ZrN-Zr multilayer coating

In order to understand the influence of ductile metal interlayer on the overall deformation behavior of metal/nitride multilayer, different configurations of metal and nitride layers were deposited and tested under indentation loading. To provide insight into the trends in deformation with multilayer spacings, an FEM model with elastic-perfect plastic metal layers alternate with an elastic nitride on top of an elastic-plastic substrate. The strong strain mismatch between the metal and nitride layers significantly alters the stress field under contact loading leading to micro-cracking in the nitride, large tensile stresses immediately below the contact, and a transition from columnar sliding in thin metal films to a more uniform bending and microcracking in thicker coatings.

A novel free floating accelerometer force balance system for shock tunnel applications

In order to overcome the interference of the model mounting system with the external aerodynamics of the body during shock tunnel testing, a new free floating internally mountable balance system that ensures unrestrained model motion during testing has been designed, fabricated and tested. Minimal friction ball bearings are used for ensuring the free floating condition of the model during tunnel testing. The drag force acting on a blunt leading edge flat plate at hypersonic Mach number has been measured using the new balance system. Finite element model (FEM) and CFD are exhaustively used in the design as well as for calibrating the new balance system. The experimentally measured drag force on the blunt leading edge flat plate at stagnation enthalpy of 0.7 and 1.2 MJ/kg and nominal Mach number of 5.75 matches well with FEM results. The concept can also be extended for measuring all the three fundamental aerodynamic forces in short duration test facilities like free piston driven shock tunnels.

Appraisal of Bishop's method of slope stability analysis

The stability of slopes is a major problem in geotechnical engineering. Of the methods available for the analysis of soil slopes such as limit equilibrium methods, limit analysis and numerical methods such as FEM and FDM, limit equilibrium methods are popular and generally used, owing to their simplicity in formulation and in evaluating the overall factor of safety of slope. However limit equilibrium methods possess certain disadvantages. They do not consider whether the slope is an embankment or natural slope or an excavation and ignore the effect of incremental construction, initial stress, stress strain behavior etc. In the work reported in this paper, a comparative study of actual state of stress and actual factor of safety and Bishop's factor of safety is performed. The actual factor of safety is obtained by consideration of contours of mobilised shear strains. Using Bishop's method of slices, the critical slip surfaces of a number of soil slopes with different geometries are determined and both the factors of safety are obtained. The actual normal stresses and shear stresses are determined from finite difference formulation using FLAG (Fast Lagrangian Analysis of Continuaa) with Mohr-Coulomb model. The comparative study is performed in terms of parameter lambda(c phi) (= gamma H tan phi/c). I is shown that actual factor of safety is higher than Bishop's factor of safety depending on slope angle and lambda(c phi).

3D finite element modelling of a composite patch repair

Composite-patching on cracked/weak metallic aircraft structures improves structural integrity. A Boron Epoxy patch employed to repair a cracked Aluminum sheet is modeled employing 3D Finite Element Method (FEM). SIFs extracted using ''displacement extrapolation'' are used to measure the repair effectiveness. Two issues viz., patch taper and symmetry have been looked into.

On an Integrated Transfer Matrix method for multiply connected mufflers

The commercial automotive mufflers are generally of a complicated shape with multiply connected parts and complex acoustic elements. The analysis of such complex mufflers has always been a great challenge. In this paper, an Integrated Transfer Matrix method has been developed to analyze complex mufflers. Integrated transfer matrix relates the state variables across the entire cross-section of the muffler shell, as one moves along the axis of the muffler, and can be partitioned appropriately in order to relate the state variables of different tubes constituting the cross-section. The paper presents a generalized one-dimensional (1-D) approach, using the transfer matrices of simple acoustic elements, which are available from the literature. The present approach is robust and flexible owing to its capability to construct an overall matrix of the muffler with the transfer matrices of individual acoustic elements and boundary conditions, which can then be used to evaluate the transmission loss, insertion loss, etc. Results from the present approach have been validated through comparisons with the available experimental and three-dimensional finite element method (FEM) based results. The results show good agreement with both measurements and FEM analysis up to the cut-off frequency. (C) 2011 Elsevier Ltd. All rights reserved.

Non-destructive evaluation of porosity and its effect on mechanical properties of carbon fiber reinforced polymer composite materials

In this work, an attempt is made to induce porosity of varied levels in carbon fiber reinforced epoxy based polymer composite laminates fabricated using prepregs by varying the fabrication parameters such as applied vacuum, autoclave pressure and curing temperature. Different NDE tools have been utilized to evaluate the porosity content and correlate with measurable parameters of different NDE techniques. Primarily, ultrasonic imaging and real time digital X-ray imaging have been tried to obtain a measurable parameter which can represent or reflect the amount of porosity contained in the composite laminate. Also, effect of varied porosity content on mechanical properties of the CFRP composite materials is investigated through a series of experimental investigations. The outcome of the experimental approach has yielded interesting and encouraging trend as a first step towards developing an NDE tool for quantification of effect of varied porosity in the polymer composite materials.

Non-destructive evaluation of porosity and its effect on mechanical properties of carbon fiber reinforced polymer composite materials

Structural adhesive bonding is widely used to execute assemblies in automobile and aerospace structures. The quality and reliability of these bonded joints must be ensured during service. In this context non destructive evaluation of these bonded structures play an important role. Evaluation of adhesively bonded composite single lap shear joints has been attempted through experimental approach. Series of tests, non-destructive as well as destructive were performed on different sets of carbon fiber reinforced polymer (CFRP) composite lap joint specimens with varied bond quality. Details of the experimental investigations carried out and the outcome are presented in this paper.

Three-dimensional acoustic analysis of an elliptical chamber muffler with a side inlet and a side outlet

The acoustical behaviour of an elliptical chamber muffler having a side inlet and side outlet port is analyzed in this paper, wherein a uniform velocity piston source is assumed to model the 3-D acoustic field in the elliptical chamber cavity. Towards this end, we consider the modal expansion of the acoustic pressure field in the elliptical cavity in terms of the angular and radial Mathieu func-tions, subjected to the rigid wall condition. Then, the Green's function due to the point source lo-cated on the side (curved) surface of the elliptical chamber is obtained. On integrating this function over the elliptical piston area on the curved surface of the elliptical chamber and subsequent divi-sion by the area of the elliptic piston, one obtains the acoustic pressure field due to the piston driven source which is equivalent to considering plane wave propagation in the side ports. Thus, one can obtain the acoustic pressure response functions, i.e., the impedance matrix (Z) parameters due to the sources (ports) located on the side surface, from which one may also obtain a progressive wave rep-resentation in terms of the scattering matrix (S). Finally, the acoustic performance of the muffler is evaluated in terms of the Transmission loss (TL) which is computed in terms of the scattering pa-rameters. The effect of the axial length of the muffler and the angular location of the ports on the TL characteristics is studied in detail. The acoustically long chambers show dominant axial plane wave propagation while the TL spectrum of short chambers indicates the dominance of the trans-versal modes. The 3-D analytical results are compared with the 3-D FEM simulations carried on a commercial software and are shown to be in an excellent agreement, thereby validating the analyti-cal procedure suggested in this work.

Friction Welding of Thixocast A356 Aluminium Alloy

In this paper, a numerical model for friction welding of thixo-cast materials is developed, which includes a coupling of thermal effect and plastic deformation using a finite element method (FEM). As the constitutive equations for flow behavior of materials for a thixo-cast material are expected to be different from those of conventionally cast material of the same alloy, the necessary material data are experimentally determined from isothermal hot compression tests of the A356 thixocast alloy. The Johnson-Cook model has been employed to represent the flow behavior of the thixocast A356 alloy. The purpose of this FEM analysis is to provide better understanding of the friction welding process of thixo-cast material, and to obtain optimized process parameters before an actual welding is carried out.

Non-rotating beams isospectral to a given rotating uniform beam

In this paper, we seek to find non-rotating beams with continuous mass and flexural stiffness distributions, that are isospectral to a given uniform rotating beam. The Barcilon-Gottlieb transformation is used to convert the fourth order governing equation of a non-rotating beam, to a canonical fourth order eigenvalue problem. If the coefficients in this canonical equation match with the coefficients of the uniform rotating beam equation, then the non-rotating beam is isospectral to the given rotating beam. The conditions on matching the coefficients leads to a pair of coupled differential equations. We solve these coupled differential equations for a particular case, and thereby obtain a class of non-rotating beams that are isospectral to a uniform rotating beam. However, to obtain isospectral beams, the transformation must leave the boundary conditions invariant. We show that the clamped end boundary condition is always invariant, and for the free end boundary condition to be invariant, we impose certain conditions on the beam characteristics. We also verify numerically that the frequencies of the non-rotating beam obtained using the finite element method (FEM) are the exact frequencies of the uniform rotating beam. Finally, the example of beams having a rectangular cross-section is presented to show the application of our analysis. Since experimental determination of rotating beam frequencies is a difficult task, experiments can be easily conducted on these rectangular non-rotating beams, to calculate the frequencies of the rotating beam. (c) 2012 Elsevier Ltd. All rights reserved.

Detailed investigation of contact deformation in ZrN/Zr multiplayer-understanding the role of volume fraction, bilayer spacing, and morphology of interfaces

A systematic study was done to understand the influence of volume fractions and bilayer spacings for metal/nitride multilayer coating using finite element method (FEM). An axisymmetric model was chosen to model the real situation by incorporating metal and substrate plasticity. Combinations of volume fractions and bilayer spacings were chosen for FEM analysis consistent with experimental results. The model was able to predict trends in cracking with respect to layer spacing and volume fraction. Metal layer plasticity is seen to greatly influence the stress field inside nitride. It is seen that the thicker metal induces higher tensile stresses inside nitride and hence leads to lower cracking loads. Thin metal layers < 10 nm were seen to have curved interfaces, and hence, the deformation mode was interfacial delamination in combination with edge cracking. There is an optimum seen with respect to volume fraction similar to 13% and metal layer thickness similar to 30 nm, which give maximum crack resistance.

Structural health monitoring of aerospace structural components using wave propagation based diagnostics

The paper discusses a wave propagation based method for identifying the damages in an aircraft built up structural component such as delamination and skin-stiffener debonding. First, a spectral finite element mode l (SFEM) is developed for modeling wave propagation in general built-up structures by using the concept of assembling 2D spectral plate elements. The developed numerical model is validated using conventional 2-D FEM. Studies are performed to capture the mode coupling,that is, the flexural-axial coupling present in the wave responses. Lastly, the damages in these built up structures are then identified using the developed SFEM model and the measured responses using the concept Damage Force Indicator (DFI) technique.

Crack stability in edge-notched clamped beam specimens: modeling and experiments

Stability of a fracture toughness testing geometry is important to determine the crack trajectory and R-curve behavior of the specimen. Few configurations provide for inherent geometric stability, especially when the specimen being tested is brittle. We propose a new geometrical construction called the single edge notched clamped bend specimen (SENCB), a modified form of three point bending, yielding stable cracking under load control. It is shown to be particularly suitable for small-scale structures which cannot be made free-standing, (e.g., thin films, coatings). The SENCB is elastically clamped at the two ends to its parent material. A notch is inserted at the bottom center and loaded in bending, to fracture. Numerical simulations are carried out through extended finite element method to derive the geometrical factor f(a/W) and for different beam dimensions. Experimental corroborations of the FEM results are carried out on both micro-scale and macro-scale brittle specimens. A plot of vs a/W, is shown to rise initially and fall off, beyond a critical a/W ratio. The difference between conventional SENB and SENCB is highlighted in terms of and FEM simulated stress contours across the beam cross-section. The `s of bulk NiAl and Si determined experimentally are shown to match closely with literature values. Crack stability and R-curve effect is demonstrated in a PtNiAl bond coat sample and compared with predicted crack trajectories from the simulations. The stability of SENCB is shown for a critical range of a/W ratios, proving that it can be used to get controlled crack growth even in brittle samples under load control.

Role of interface curvature on stress distribution under indentation for ZrN/Zr multilayer coating

Contact damage in curved interface nano-layeredmetal/nitride (150 (ZrN)/10 (Zr) nm) multilayer is investigated in order to understand the role of interface morphology on contact damage under indentation. A finite element method (FEM) model was formulated with different wavelengths of 1000 nm, 500 nm, 250 nm and common height of 50 nm, which gives insight on the effect of different curvature on stress field generated under indentation. Elastic-plastic properties were assigned to the metal layer and substrate while the nitride layer was assigned perfectly elastic properties. Curved interface multilayers show delamination along the metal/nitride interface and vertical cracks emanating from the ends of the delamination. FEM revealed the presence of tensile stress normal to the interface even under the contact, along with tensile radial stresses, both present at the valley part of the curve, which leads to vertical cracks associated with interfacial delamination. Stress enhancement was seen to be relatively insensitive to curvature. (C) 2014 Elsevier B.V. All rights reserved.