Statistical analysis of finite element modeling in sheet metal forming and springback analysis

This work focuses on development of a method to statistically study forming and springback problems of TRansformation Induced Plasticity (TRIP) through an industrial case study. A Design of Experiments (DOE) approach was used to study the sensitivity of predictions to four user input parameters in implicit and explicit sheet metal forming codes. Numerical results were compared to experimental measurements of parts stamped in an industrial production line. The accuracy of forming strain predictions for TRIP steel were comparable with conventional steel, but the springback predictions of TRIP steel were far less accurate. The statistical importance of selected parameters for forming and springback prediction is also discussed. Changes of up to ±10% in Young's modulus and coefficient of friction were found to be insignificant in improving or deteriorating the statistical correlation of springback accuracies.

Finite element modeling of a generic stemless hip implant design in comparison with conventional hip implants

In this study, the finite element modeling and comparison of the stress and strain analyses were carried out for three different structures that are intact bone, stemless implant and stemmed one. Currently proposed stemless design studied here is the generic concept of stemless implant. This generic stemless implant reconstruction was numerically compared to the conventional stemmed implant and also to the intact bone as control solution. Two loading conditions were applied to the most proximal part of the models, while the most distal part was fixed for all degrees of freedom. The models were divided into two regions and studied along two paths of medial and lateral aspect. The results of this study showed that the stemless implant had less deviation from the control solution of the bone in all regions and in both loading conditions, comparing to the large deviation of the stemmed implant from the intact bone. However, it was shown that the fixation of this type of implant and its effect on sub-trochanter region must be carefully considered for designing the final product of any specific design of stemless implant.

Finite element modeling and analysis of thrombosis in middle cerebral artery

Thrombotic stroke, which is caused by blood clot in the cerebral artery, is a major source of increased mortality and morbidity. Considering as efficient and fastest methods, mathematical approaches have gained significant importance for analyzing and understanding the biological events like thrombosis. This paper presents a computational model to analyze the effects of thrombosis using the theory of coupled fluid dynamics-structure interaction. The finite element method is used for the modeling of thrombosis (blood clot) of different stages in the middle cerebral artery with physiological compliance. The developed model is used to investigate the consequences that occur due to the various sizes of clots in the artery in the form of blood flow velocity, blood pressure, and artery wall stress. Such numerical assessment will facilitate better understanding of the biophysical process in case of thrombosis and thus would support medical practitioners to take faster curing steps.

Finite element analysis of residual stresses in metallic coatings through a compound casting

Al and Mg alloys are widely used in industry as main lightweight alloys. They have excellent properties, such as low density, high ductility, and high specific strength, and so on. Generally speaking, Mg alloys are better than Al alloys. However the corrosion of Mg alloys is much more difficult to control compared Al alloys. Therefore to combine these two lightweight alloys, a composite-like structure is an ideal solution since Al alloys can be used as protective coatings for Mg alloys. Compound casting is a realistic technique to get this coating system. In the current study, we numerically study the compound casting using finite element method (FEM) to make these two alloys, a composite-like structure, satisfy requirements to resist corrosion required from industry, in which the aluminum layer is acting as a protective coating for the magnesium substrate. Several finite element models have been developed by using the birth and death element technique and we focus on compound casting-induced residual stresses in the compounded structure. The numerical results obtained from the proposed finite element models show the distribution profiles of thermal residual stresses. We found the major factors influencing the residual stresses are the temperature to pre-heating the Al substrate and the thickness of Mg deposits. © (2014) Trans Tech Publications, Switzerland.

A finite element simulation of micro-mechanical frictional behaviour in metal forming

Friction is a critical factor for sheet metal forming (SMF). The Coulomb friction model is usually used in most finite element (FE) simulation for SMF. However, friction is a function of the local contact deformation conditions, such as local pressure, roughness and relative velocity. Frictional behaviour between contact surfaces can be based on three cases: boundary, hydrodynamic and mixed lubrication. In our microscopic friction model based on the finite element method (FEM), the case of dry contact between sheet and tool has been considered. In the view of microscopic geometry, roughness depends upon amplitude and wavelength of surface asperities of sheet and tool. The mean pressure applied on the surface differs from the pressure over the actual contact area. The effect of roughness (microscopic geometric condition) and relative speed of contact surfaces on friction coefficient was examined in the FE model for the microscopic friction behaviour. The analysis was performed using an explicit FE formulation. In this study, it was found that the roughness of deformable sheet decreases during sliding and the coefficient of friction increases with increasing roughness of contact surfaces. Also, the coefficient of friction increases with the increase of relative velocity and adhesive friction coefficient between contact surfaces.

Finite element modelling of metallic tubular crash structures with an explicit code

Numerous experimental studies have been carried out to investigate the collapse of tubular metallic crash structures under axial compression. Some simple theoretical models have been developed but these often assume one type of progressive collapse, which is not always representative of the real situation. Finite Element (FE) models, when further refined, have the potential to predict the actual collapse mode and how it influences the load-displacement and energy absorption characteristics. This paper describes an FE modelling investigation with the explicit code LS−DYNA. An automatic mesh generation programme written by the authors is used to set up shell and solid element tube models. Mesh specification issues and features relating to the contact and friction models are discussed in detail. The crush modes, load-deflection characteristics and energy absorption values found in the simulations are compared with a reasonable degree of correlation to those observed in a physical testing programme; however, improvements are still required.

The design and development of an integrated system for object-oriented finite element computing

Finite Element Method (FEM) is widely used in Science and Engineering since 1960’s. The vast majority of FEM software is procedure-oriented. However, this conventional style of designing FEM software encounters problems in maintenance, reuse, and expansion of the software. Recently the object-oriented finite element method attracts the attention of lots of researchers, and now there is a growing interest in this method. In this paper, the object-oriented finite element (OOFE) is briefly introduced. Then the design and development of an integrated OOFE system is described. A comparison of the integrated OOFE system and a procedure-oriented system shows that our OOFE system has many advantages.

Three-dimensional Finite Element modelling of laser shock peening process

Laser shock peening (LSP) is an innovative surface treatment technique for metal alloys, with the great improvement of their fatigue, corrosion and wear resistance performance. Finite element method has been widely applied to simulate the LSP to provide the theoretically predictive assessment and optimally parametric design. In the current work, 3-D numerical modelling approaches, combining the explicit dynamic analysis, static equilibrium analysis algorithms and different plasticity models for the high strain rate exceeding 106s-1, are further developed. To verify the proposed methods, 3-D static and dynamic FEA of AA7075-T7351 rods subject to two-sided laser shock peening are performed using the FEA package–ABAQUS. The dynamic and residual stress fields, shock wave propagation and surface deformation of the treated metal from different material modelling approaches have a good agreement.

Analytical solutions and finite element modelling of deep drawing process for cylindrical metal cups

Analytical modelling of deep drawing process is of value in preliminary process design to illustrate the influence of major variables including friction and strain hardening on punch loads, cup dimensions and process limits. In this study, analytical models including theoretical solution and a series of finite element models are developed to account for the influences of process parameters including friction coefficient, tooling geometry and material properties on deep drawing of metal cups. The accuracy of both the theoretical and finite element solutions is satisfactory compared with those from experimental work.

A study of guided wave propagation in timber pole using spectral finite element method

Timber is one of the most widely used structural material all over the world. Round timbers can be seen as a structural component in historical buildings, jetties, short span bridges and also as piles for foundation and poles for electrical and power distribution. To evaluate the current condition of these cylindrical type timber structures, guided wave has a great potential. However, the difficulties associated with the guided wave propagation in timber materials includes orthotropic behaviour of wood, moisture contents, temperature, grain direction, etc. In addition, the effect of fully or partially filled surrounding media, such as soil, water, etc. causes attenuation on the generated stress wave. In order to investigate the effects of these parameters on guided wave propagation, extensive numerical simulation is required to conduct parametric studies. Moreover, due to the presence of multi modes in guided wave propagation, dispersion curves are of great importance. Even though conventional finite element method (FEM) can determine dispersion curves along with wave propagation in time domain, it is highly computationally expensive. Furthermore, incorporating orthotropic behaviour and surrounding media to model a thick cylindrical wave (large diameter cylindrical structures) make conventional FEM inefficient for this purpose. In contrast, spectral finite element method (SFEM) is a semi analytical method to model the guided wave propagation which does not need fine meshes compared to the other methods, such as FEM or finite difference method (FDM). Also, even distribution of mass and stiffness of structures can be obtained with very few elements using SFEM. In this paper, the suitability of SFEM is investigated to model guided wave propagation through an orthotropic cylindrical waveguide with the presence of surrounding soil. Both the frequency domain analysis (dispersion curves) and time domain reconstruction for a multi-mode generated input signal are presented under different loading location. The dispersion curves obtained from SFEM are compared against analytical solution to verify its accuracy. Lastly, different numerical issues to solve for the dispersion curves and time domain results using SFEM are also discussed.

Effects of micro-structural parameters on mechanical properties of carbon nanotube polymer nanocomposites

A comparison between the elastic modulus of carbon nanotube (CNT) polymer nano composites predicted by classical micromechanics theories, based on continuum mechanics and experimental data, was made and the results revealed a great difference. To improve the accuracy of these models, a new two-step semi-analytical method was developed, which allowed consideration of the effect of the interphase, in addition to CNT and matrix, in the modeling of nanocomposites. Based on this developed method, the inuence of microstructural parameters, such as CNT volume fraction, CNT aspect ratio, partial and complete agglomerations of CNTs, and overlap and exfoliation of CNTs, on the overall elastic modulus of nanocomposites was investigated. ©2014 Sharif University of Technology. All rights reserved.

A study on mechanical behavior of functionally-graded carbon nanotube-reinforced nanocomposites

In this study, we are focusing on the investigation of the effects of gradient patterns on mechanical behavior of functionally-graded carbon nanotube-reinforced nanocomposites and considering typical beams made of such nanocomposites. Both analytic and finite element-based numerical models were developed. Analytic model was developed based on the first-order shear deformation and Timoshenko beam theories meanwhile finite element models were developed using Abaqus in conjunction with user-defined subroutines for defining the continuously gradient material properties for different gradient patterns. Position-dependent elastic modulus equations for four continuously graded patterns were studied. A nongraded pattern was used for benchmarking with the same geometry and total carbon nanotube (CNT) contents. For validation and verification, the results on both deflection and stress of these nanocomposite beams were analyzed, which clearly showed high influence from gradient patterns on these mechanical behaviors of such beams.