3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V

As an emerging hole-machining methodology, helical milling process has become increasingly popular in aeromaterials manufacturing research, especially in areas of aircraft structural parts, dies, and molds manufacturing. Helical milling process is highly demanding due to its complex tool geometry and the progressive material failure on the workpiece. This paper outlines the development of a 3D finite element model for helical milling hole of titanium alloy Ti-6Al-4V using commercial FE code ABAQUS/Explicit. The proposed model simulates the helical milling hole process by taking into account the damage initiation and evolution in the workpiece material. A contact model at the interface between end-mill bit and workpiece has been established and the process parameters specified. Furthermore, a simulation procedure is proposed to simulate different cutting processes with the same failure parameters. With this finite element model, a series of FEAs for machined titanium alloy have been carried out and results compared with laboratory experimental data. The effects of machining parameters on helical milling have been elucidated, and the capability and advantage of FE simulation on helical milling process have been well presented.

FEM Analysis to Optimally Design End Mill cutters for Milling of Ti-6Al-4V

This paper presents an FEM analysis conducted for optimally designing end mill cutters through verifying the cutting tool forces and stresses for milling Titanium alloy Ti-6Al-4 V. Initially, the theoretical tool forces are calculated by considering the cutting edge on a cutting tool as the curve of an intersection over a spherical/flat surface based on the model developed by Lee & Altinas [1]. Considering the lowest tool forces the cutting tool parameters are taken and optimal design of end mill is decided for different sizes. Then the 3D CAD models of the end mills are developed and used for Finite Element Method to verify the cutting forces for milling Ti-6Al-4 V. The cutting tool forces, stress, strain concentration (s), tool wear, and temperature of the cutting tool with the different geometric shapes are simulated considering Ti-6Al-4 V as work piece material. Finally, the simulated and theoretical values are compared and the optimal design of cutting tool for different sizes are validated. The present approach considers to improve the quality of machining surface and tool life with effects of the various parameters concerning the oblique cutting process namely axial, radial and tangential forces. Various simulated test cases are presented to highlight the approach on optimally designing end mill cutters.

Novel periodically loaded multilayer resonators

In this paper novel 3D periodic multilayer structures are investigated in MIC technology, and a periodically loaded multilayer waveguide resonant structure is proposed. This is a very compact structure and still maintains simple fabrication process. The resonator is designed at 10 and 28 GHz. The simulated results of this resonator, which is obtained from commercial FEM software package HFSS, are confirmed by experimental results. The experiments are based oil the same resonator structure, only at 10 GHz. By modifying the conventional waveguide resonator, with the proposed structure, a minimum 30% shorter resonator can be achieved, which is very important at filter applications. (C) 2002 Wiley Periodicals, Inc.

Upper and lower bounds of 180 degrees unit element of a ridge waveguide: Calculations and measurements

The upper and lower bounds on the actual solution of any microwave structure is of general interest. The purpose of this letter is to compare some calculations using the mode-matching and finite-element methods, with some measurements on a 180 degrees ridge waveguide insert between standard WR62 rectangular waveguides. The work suggests that the MMM produces an upper bound, while the FEM places a lower bound on the measurement. (C) 2001 John Wiley & Sons, Inc.

Finite element investigation of the structural behaviour of deck slabs in composite bridges

This research studies the structural behaviour of bridge deck slabs under static patch loads in steel–concrete composite bridges and investigates compressive membrane action (CMA) in concrete bridge decks slabs, which governs the structural behaviour. A non-linear 3D finite element analysis models was developed using ABAQUS 6.5 software packages. Experimental data from one-span composite bridge structures are used to validate and calibrate the proposed FEM models. A series of parametric studies is conducted. The analysis results are discussed and conclusions on the behaviour of the bridge decks are presented.

Computational Investigation of Inlet Distortion at High Angles of Attack

Lip separation is one of the primary sources of inlet distortion, which can result in a loss in fan stability. High angles of incidence are one of several critical causes of lip separation. There have been many studies into inlet performance at high incidence, including the resulting distortion levels when lip separation occurs. However, the vast majority of these investigations have been carried out experimentally, with little in the way of computational results for inlet performance at high incidence. The flow topology within an inlet when lip separation has occurred is also not well understood. This work aims to demonstrate a suitable model for the prediction of inlet flows at high incidence using ANSYS CFX, looking at both the performance of the inlet and the separated flow topology within the inlet. The attenuating effect of the fan is also investigated, with particular emphasis on the flow redistribution ahead of the fan. The results show that the model used is suitable for predicting inlet performance in adverse operating conditions, showing good agreement with experimental results. In addition, the attenuation of the distortion by the fan is also captured by the numerical model.

Thermal fatigue analysis of solar panel structure for micro-satellite applications

Thermal fatigue analysis based on 2D finite difference and 3D finite element methods is carried out to study the performance of solar panel structure during micro-satellite life time. Solar panel primary structure consists of honeycomb structure and composite laminates. The 2D finite difference (I-DEAS) model yields predictions of the temperature profile during one orbit. Then, 3D finite element analysis (ANSYS) is applied to predict thermal fatigue damage of solar panel structure. Meshing the whole structure with 2D multi-layer shell elements with sandwich option is not efficient, as it misses thermal response of the honeycomb structure. So we applied a mixed approach between 3D solid and 2D shell elements to model the solar panel structure without the sandwich option.

Transient Heat Conduction of Variable Stiffness Composite Laminate

Recent research on Variable Stiffness (VS) laminates, which are constructed by steering the fiber orientation as a spatial function of location, have shown to improve laminate performance under mechanical loads. Two distinct cases of stiffness variation can be achieved either by variation of the fiber orientation in the direction of the global x-axis, or perpendicular to it. In the present paper, thermal analysis of a VS laminate is performed to study the effect of steering fibers on transient heat conduction under uniform heat flux using finite element method. The goal of the present paper is a parametric study of the effect of variable stiffness properties on transient response including time to reach steady state and temperature profile. Also, stress resultants and maximum stress location are investigated under different boundary conditions. A FEM algorithm is applied to exactly incorporate the boundary conditions for stress resultant analysis.

Thermal fatigue analysis of small-satellite structure

The small-satellite thermal subsystem main function is to control temperature ranges on equipments, and payload for the orbit specified. Structure subsystem has to ensure the satellite structure integrity. Structure integrity should meet two constraints; first constraint is accepted fatigue damage due to cyclic temperature, and second one is tolerable mounting accuracy at payload and Attitude Determination and Control Subsystem (ADCS) equipments’ seats. First, thermal analysis is executed by applying finitedifference method (IDEAS) and temperature profile for satellite components case is evaluated. Then, thermal fatigue analysis is performed applying finite-element analysis (ANSYS) to calculate the resultant damage due to on-orbit cyclic stresses, and structure deformations at the payload and ADCS equipments seats.

Transient Heat Conduction of Variable Stiffness Composite Laminate

Recent research on Variable Stiffness (VS) laminates, which are constructed by steering the fiber orientation as a spatial function of location, have shown to improve laminate performance under mechanical loads. Two distinct cases of stiffness variation can be achieved either by variation of the fiber orientation in the direction of the global x-axis, or perpendicular to it. In the present paper, thermal analysis of VS laminate is performed to study the effect of steering fibers on transient heat conduction under uniform heat flux using finite element method. The goal of the present paper is a parametric study of the
effect of variable stiffness properties on transient response including time to reach steady state and temperature profile. Also, stress resultants and maximum stress location are investigated under different boundary conditions. A FEM algorithm is applied to exactly incorporate the boundary conditions.

The development of a surface defect machining method for hard turning processes

Hard turning (HT) is a material removal process employing a combination of a single point cutting tool and high speeds to machine hard ferrous alloys which exhibit hardness values over 45 HRC. In this paper, a surface defect machining (SDM) method for HT is proposed which harnesses the combined advantages of porosity machining and pulsed laser pre-treatment processing. From previous experimental work, this was shown to provide better controllability of the process and improved quality of the machined surface. While the experiments showed promising results, a comprehensive understanding of this new technique could only be achieved through a rigorous, in depth theoretical analysis. Therefore, an assessment of the SDM technique was carried out using both finite element method (FEM) and molecular dynamics (MD) simulations.
FEM modelling was used to compare the conventional HT of AISI 4340 steel (52 HRC) using an Al2O3 insert with the proposed SDM method. The simulations showed very good agreement with the previously published experimental results. Compared to conventional HT, SDM provided favourable machining outcomes, such as reduced shear plane angle, reduced average cutting forces, improved surface roughness, lower residual stresses on the machined surface, reduced tool–chip interface contact length and increased chip flow velocity. Furthermore, a scientific explanation of the improved surface finish was revealed using a state-of-the-art MD simulation model which suggested that during SDM, a combination of both the cutting action and rough polishing action help improve the machined surface finish.

Prediction of failure and fracture mechanisms of polymeric composites using finite element analysis. Part 1:Particulate filled composites

Micro-mechanical analysis of polymeric composites provides a powerful means for the quantitative assessment of their bulk behavior. In this paper we describe a robust finite element model (FEM) for the micro-structural modeling of the behavior of particulate filled polymer composites under external loads. The developed model is applied to simulate stress distribution in polymer composites containing particulate fillers. Quantitative information about the magnitude and location of maximum stress concentrations obtained from these simulations is used to predict the dominant failure and crack growth mechanisms in these composites. The model predictions are compared with the available experimental data and also with the values found using other methods reported in the literature. These comparisons show the range of the validity of the developed model and its predictive potential.

Microstructure evolution of AA6061 under ultrasonic welding

Ultrasonic metal welding can be used to join two metal foils. There are two different effects under ultrasonic welding. They are surface effect and volume effect. These two effects were validated under macro experiments. Then how to validate in micro test is seldom researched. EBSD method was used to research the microstructure evolution of AA6061 under ultrasonic welding. The image maps indicating all Euler angle and the correlated misorientation angle distribution of both original foil and welding sample were got by EBSD in order to understand how ultrasonic welding affect the grain orientation and microstructure. The test shows that after ultrasonic vibration, the grain size has little change. And ultrasonic vibration results in a very weak texture. FEM results also validate these conclusions.

Wave Interaction with an Oscillating Wave Surge Converter, Part 1: Viscous Effects

Bottom hinged oscillating wave surge converters are known to be an efficient method of extracting power from ocean waves. The present work deals with experimental and numerical studies of wave interactions with an oscillating wave surge converter. It focuses on two aspects: (1) viscous effects on device performance under normal operating conditions; and (2) effects of slamming on device survivability under extreme conditions. Part I deals with the viscous effects while the extreme sea conditions will be presented in Part II. The numerical simulations are performed using the commercial CFD package ANSYS FLUENT. The comparison between numerical results and experimental measurements shows excellent agreement in terms of capturing local features of the flow as well as the dynamics of the device. A series of simulations is conducted with various wave conditions, flap configurations and model scales to investigate the viscous and scaling effects on the device. It is found that the diffraction/radiation effects dominate the device motion and that the viscous effects are negligible for wide flaps.