Development and applications of an experimental database for structural engineering education

A great number of research organisations in Japan have been conducting structural steel experiments for many years, particularly seismic tests of steel structures like cyclic-loading and pseudo-dynamic tests, in order to determine their seismic performances. However, the original test data gained by most research organisations are not well stored in an appropriate manner for distribution and possible usage by others. With the rapid development of information networks, structural engineers and researchers are able to exchange various types of test data through the Internet. In this paper, the authors present the development of a distributed collaborative database system for structural steel experiments. The database is made available on the Internet, and the use of Java language enables efficient interactive retrieval. The potential applications of the developed database system for structural engineering education are validated for the retrieval of experimental data and seismic numerical analysis.

Database for structural steel experiments under a distributed collaboration environment

Due to the high requirements of civil infrastructures against the earthquake in Japan, a great number of research organizations have been conducting the structural steel experiments, in particular the seismic tests such as the cyclic loading test and the pseudo-dynamic test, for many years to determine the seismic performances of steel structures. However, the original test data gained by most research organizations are not well stored in an appropriate manner for distribution and possible usage of others. Although a Numerical Database of Steel Structures (NDSS) was developed some years ago to preserve and share experimental data of the ultimate strength tests acquired at Nagoya University, it was not easy to access this database from other computer platform due to the lack of the support of proper communication media. With the rapid development of information networks and their browsers, structural engineers and researchers are able to exchange various types of test data through Internet. This paper presents the development of a distributed collaborative database system for structural steel experiments. The database is made available on the World-Wide Web, and the Java language enables the interactive retrieval efficiently. The applications of the developed database system for the retrieval of experimental data and seismic numerical analysis are validated in the form of examples.

Contact pressure evolution and its relation to wear in sheet metal forming

For a given sheet metal forming process, an accurate determination of the contact pressure distribution is an essential step towards the estimation of tool life. This investigation utilizes finite element (FE) analysis to model and explain the evolution and distribution of contact pressure over the die radius, throughout the duration of a channel forming process. It was found that a typical two-peak steady-state contact pressure response exists for the majority of the process. However, this was preceded by an initial transient response, characterized by extremely large and localized contact pressures, which were more than double the magnitude of the steady-state peak pressure. The validity of the predicted contact pressure behavior was assessed via detailed numerical analysis and by examining the wear response of an experimental stamping operation. The experimental results revealed that the high contact pressure zones of the transient response corresponded to a severe galling wear mechanism. Therefore, the transient response may be of primary significance to the tool wear response; thus questioning the applicability of traditional bending-under-tension wear tests for sheet metal stamping processes. Finally, a parametric study was conducted, examining the influence of the major process parameters on the steady-state and peak transient contact pressures, using the developed FE model. It was found that the bend ratio and the blank material ultimate tensile strength had the most influence on the peak contact pressures. The main process-related parameters, friction coefficient and blank holder force, were found to have only a minor influence.

A microfluidic electroosmotic mixer and the effect of potential and frequency on its mixing efficiency

This paper presents the design and numerical simulation of a T-shape microfluidic electroosmotic micromixer. It is equipped with six microelectrodes that are embedded in the side surfaces of the microchannel. The electrode array consists of two sets of three 20 ¿m and 60 ¿m microelectrodes arranged in the form of two opposing triangles. Numerical analysis of electric potential and frequency effects on mixing efficiency of the micromixer is carried out by means of two sets of simulations. First, the electric potential is kept at 2 V while the frequency is varied within 10-50 Hz. The highest achieved mixing efficiency is 96% at 22 Hz. Next, the frequency is kept at 30 Hz whilst the electric potential is varied within 1-5 V. The best achieved mixing efficiency is 97% at 3 V.

Using the solid-shell element to model the roll forming of large radii profiles

Roll forming is an incremental bending process for forming metal sheet, strip or coiled stock. Although Finite Element Analysis (FEA) is a standard tool for metal forming simulation, it is only now being increasingly used for the analysis of the roll forming process. This is because of the excessive computational time due to the long strip length and the multiple numbers of stands that have to be modelled. Typically a single solid element is used through the thickness of the sheet for roll forming simulations. Recent investigations have shown that residual stresses introduced during steel processing may affect the roll forming process and therefore need to be included in roll forming simulations. These residual stresses vary in intensity through the thickness and this cannot be accounted for by using only one solid element through the material thickness, in this work a solid-shell element with an arbitrary number of integration points has been used to simulate the roll forming process. The system modelled is that of roll forming a V-channel with dual phase DP780 sheet steel. In addition, the influence of other modelling parameters, such as friction, on CPU time is further investigated. The numerical results are compared to experimental data and a good correlation has been observed. Additionally the numerical results show that the CPU time is reduced in the model without friction and that considering friction does not have a significant effect on springback prediction in the numerical analysis of the roll forming process.

Use of artificial neural networks as explicit finite difference operators

Results of a numerical exercise, substituting a numerical operator by an artificial neural network (ANN) are presented in this paper. The numerical operator used is the explicit form of the finite difference (FD) scheme. The FD scheme was used to discretize the one-dimensional transport equation, which included both the advection and dispersion terms. Inputs to the ANN are the FD representation of the transport equation, and the concentration was designated as the output. Concentration values used for training the ANN were obtained from analytical solutions. The numerical operator was reconstructed from a back calculation of the weights of the ANN. Linear transfer functions were used for this purpose. The ANN was able to accurately recover the velocity used in the training data, but not the dispersion coefficient. This capability was improved when numerical dispersion was taken into account; however, it is limited to the condition: C/P<0.5 , where C is the Courant number and P , the Peclet number (i.e., the restriction imposed by the Neumann stability condition).

An analytical approach to predict web-warping and longitudinal strain in flexible roll formed sections of variable width

To reduce weight and improve passenger safety there is an increased need in the automotive industry to use Ultra High Strength Steel (UHSS) for structural and crash components. However, the application of UHSS is restricted by their limited formability and the difficulty of forming them in conventional stamping. An alternative method of manufacturing structural auto body parts from UHSS is the flexible roll forming process, which allows the manufacture of metal sheet with high strength and limited ductility into complex and weight-optimized components. One major problem in the flexible roll forming of UHSS is the web-warping defect, which is the deviation in height of the web area over the length of the profile. It has been shown that web-warping is strongly dependant to the permanent longitudinal strain formed in the flange of the part. Flexible roll forming is a continuous process with many roll stands, which makes numerical analysis extremely time intensive and computationally expensive. An analytical model of web-warping is therefore critical to improve design efficiency during the early process design stage before FEA is applied. This paper establishes for the first time an analytical model for the prediction of web-warping for the flexible roll forming of a section with variable width. The model is based on evaluating longitudinal edge strain in the flange of the part. This information is then used in combination with a simple geometrical model to investigate the relationship between web-warping and longitudinal strain with respect to process parameters.

A first step towards a simple in-line shape compensation routine for the roll forming of high strength steel

The roll forming process is increasingly used in the automotive industry for the manufacture of structural and crash components from Ultra High Strength Steel (UHSS). Due to the high strength of UHSS (<1GPa) even small and commonly observed material property variations from coil to coil can result in significant changes in material yield and through that affect the final shape of the roll formed component. This requires the re-adjustment of tooling to compensate for shape defects and maintain part geometry resulting in costly downtimes of equipment. This paper presents a first step towards an in-line shape compensation method that based on the monitoring of roll load and torque allows for the estimation of shape defects and the subsequent re-adjustment of tooling for compensation. For this the effect of material property variation on common shape defects observed in the roll forming process as well as measurable process parameters such as roll load and torque needs to be understood. The effect of yield strength and material hardening on roll load and torque as well as longitudinal bow is investigated via experimental trials and numerical analysis. A regression analysis combined with Analysis of Variance (ANOVA) techniques is employed to establish the relationships between the process and material parameters and to determine their percentage influence on longitudinal bow, roll load and torque. The study will show that the level of longitudinal bow, one of the major shape defects observed in roll forming, can be estimated by variations in roll load and torque.

Adaptive fuzzy multi-surface sliding control of multiple-input and multiple-output autonomous flight systems

In this study, we proposed an adaptive fuzzy multi-surface sliding control (AFMSSC) for trajectory tracking of 6 degrees of freedom inertia coupled aerial vehicles with multiple inputs and multiple outputs (MIMO). It is shown that an adaptive fuzzy logic-based function approximator can be used to estimate the system uncertainties and an iterative multi-surface sliding control design can be carried out to control flight. Using AFMSSC on MIMO autonomous flight systems creates confluent control that can account for both matched and mismatched uncertainties, system disturbances and excitation in internal dynamics. It is proved that the AFMSSC system guarantees asymptotic output tracking and ultimate uniform boundedness of the tracking error. Simulation results are presented to validate the analysis.

An extension of the flower pattern diagram for roll forming

The initial process design of a roll forming system is often based on the traditional ‘flower pattern diagram’. In this diagram, the cross sections of the strip at each roll stand are superimposed on a single plane; the diagram is a 2D representation of the 3D process. In the present work, the flower pattern is extended into three dimensions. To demonstrate the method, the forming path or trajectory of a point at the edge of the strip during forming a V-section is considered. The forming path is a surface curve that lies on a cylindrical surface having its axis along the machine axis. This surface is unwrapped to give its plane development and important features of the forming process can be determined and are readily interpreted from this plane curve. It is shown that at any stage in the process, the axial strain and the curvature of the sheet adjacent to the point are dependent on the slope of the trajectory in this plane projection. This new diagram, which apparently has not been used previously, provides a useful initial method of examining the roll forming process and optimising the flower pattern. The model is purely geometric, as is the original flower pattern approach, and does not include the effect of material behaviour. The concept is applied to several cases available in the literature. It shows that the lowest level of shape defect in the part is achieved when the trajectory of the strip edge follows the shortest line length between the start and finish of forming, leading to the least longitudinal strain introduced in the flange. This trend is in agreement with previous experimental observations, suggesting that the analytical model proposed may be applied for early process design and optimisation before time-consuming numerical analysis is performed.

Generalized characteristics of photo-elastic birefringence in polymer strip waveguides

This work investigates the material birefringence in a polymer strip waveguide which originates from thermal stress during the fabrication process. The stress is estimated through a comprehensive numerical study based on a realistic finite element model. The characteristics of birefringence are obtained in a generalized form and expressed by an empirical formula, which is applicable to various polymer materials. The developed formula can be employed to specify the photo-elastic birefringence of a polymer strip channel only by knowing the birefringence in its planar film. This will eliminate the necessity of extensive numerical analysis of thermal stress in such polymer waveguides, and accordingly help the management of stress-induced effects efficiently.

An analytical model for web-warping in variable width flexible roll forming

The development of ultra/advanced high strength steels (U/AHSS) has challenged traditional forming methods due to their higher strength and reduced formability. An alternative method is flexible roll forming, which allows the manufacture of sheet metal of high strength and limited ductility into complex and weight-optimized components. However, one major problem in flexible roll forming is the web-warping defect, which is the deviation in height of the web over the length of the profile. The authors’ previous work developed an analytical model to predict the magnitude of web-warping. That model was purely geometric and neglected the effect of material properties. This work develops an analytical solution for the prediction of web-warping that considers both geometric and material parameters. The model results were validated by comparison with numerical and experimental results. The impact of this new model will be the ability to provide a rapid initial design assessment before an intensive numerical analysis of flexible roll forming is conducted.

Separation of longitudinal and flexural wave in a cylindrical structure based on sensor arrangement for non-destructive evaluation

Low strain integrity testing is commonly used to assess the in situ condition of the poles or piles. For poles, it is important to calculate the embedment length and location of damage which is highly influenced by the accurate determination of the wave velocity. In general, depending on impact location and orientation, both longitudinal and bending waves may generate inside the pole, and these two waves have very distinct characteristics and wave velocity. These differences are even more prominent in the low frequency which is usually induced in the low strain non-destructive testing. Consequently, it will be useful if these two waves can be separated for the condition assessment of the poles. In this paper, a numerical analysis is performed on a pole considering that both waves are generated, and a method is proposed to differentiate these two waves based on an appropriate sensor arrangement that includes the location and the orientation of the sensors. Continuous wavelet transform is applied on the numerical signal to calculate the phase velocity of the waves and compared with analytical phase velocity curves. From the results, it can be seen that appropriate location and orientation of the sensors can separate the longitudinal and flexural waves as they match significantly well with the corresponding analytical phase velocity curves of these two waves.

Directional moisture transfer through a wild silkworm cocoon wall

A silkworm cocoon is a porous biological structure with multiple protective functions. In the current work, the authors have used both experimental and numerical methods to reveal the unique moisture transfer characteristics through a wild Antheraea pernyi silkworm cocoon wall, in comparison with the long-domesticated Bombyx mori silkworm cocoon walls. The water vapor transmission and water vapor permeability (WVP) properties show that the A. pernyi cocoons exhibit directional moisture transfer behavior, with easier moisture transfer from inside out than outside in [e.g., the average WVP is 0.057 g/(h m bar) from inside out and is 0.034 g/(h m bar) from outside in]. Numerical analysis shows that the cubic mineral crystals in the outer section of the A. pernyi cocoon wall create a rough surface that facilitates air turbulence and promotes disturbance amplitude of the flow field, leading to lengthened water vapor transfer path and increased tortuosity of the moist air. It also indicates the vortex of water vapor can be generated in the outer section of cocoon wall, which increases the diffusion distance of water vapor and enhances the turbulence kinetic energy and turbulence eddy dissipation, signifying higher moisture resistance in the outer section. The difference in moisture resistance of the multiple A. pernyi cocoon layers is largely responsible for the unique directional moisture transfer behavior of this wild silkworm cocoon. These findings may inspire a biomimicry approach to develop novel lightweight moisture management materials and structures.

Constitutive modelling of high strength titanium alloy Ti-6Al-4 V for sheet forming applications at room temperature

To enable the design and optimisation of forming processes at room temperature the material behaviour of Ti-6Al-4 V needs to be accurately represented in numerical analysis and this requires an advanced material model. In particular, an accurate representation of the shape and size of the yield locus as well as its evolution during forming is important. In this study a rigorous set of experiments on the quasi-static deformation behaviour of a Ti-6Al-4 V alloy sheet sample at room temperature was conducted for various loading conditions and a constitutive material model developed. To quantify the anisotropy and asymmetry properties, tensile and compression tests were carried out for different specimen orientations. To examine the Bauschinger effect and the transient hardening behaviour in - plane tensile - compression and compression - tensile tests were performed. Balanced biaxial and plane strain tension tests were conducted to construct and validate the yield surface of the Ti-6Al-4 V alloy sheet sample at room temperature. A recently proposed anisotropic elastic-plastic constitutive material model, so-called HAH, was employed to describe the behaviour, in particular for load reversals. The HAH yield surface is composed of a stable component, which includes plastic anisotropy and is distorted by a fluctuating component. The key of the formulation is the use of a suitable yield function that reproduces the experimental observations well for the stable component. Meanwhile, the rapid evolution of the material structure must be captured at the macro - scale level by the fluctuating component embedded in the HAH model. Compared to conventional hardening equations, the proposed model leads to higher accuracy in predicting the Bauschinger effect and the transient hardening behaviour for the Ti-6Al-4 V sheet sample tested at room temperature.