Development of the multi-scale analysis model to simulate strain localization occurring during material processing

Abstract A detailed description of possibilities given by the developed Cellular Automata—Finite Element (CAFE) multi scale model for prediction of the initiation and propagation of micro shear bands and shear bands in metallic materials subjected to plastic deformation is presented in the work. Particular emphasis in defining the criterion for initiation of micro shear and shear bands, as well as in defining the transition rules for the cellular automata, is put on accounting for the physical aspects of these phenomena occurring in two different scales in the material. The proposed approach led to the creation of the real multi scale model of strain localization phenomena. This model predicts material behavior in various thermo-mechanical processes. Selected examples of applications of the developed model to simulations of metal forming processes, which involve strain localization, are presented in the work. An approach based on the Smoothed Particle Hydrodynamic, which allows to overcome difficulties with remeshing in the traditional CAFE method, is a subject of this work as well. In the developed model remeshing becomes possible and difficulties limiting application of the CAFE method to simple deformation processes are solved. Obtained results of numerical simulaA detailed description of possibilities given by the developed Cellular Automata—Finite Element (CAFE) multi scale model for prediction of the initiation and propagation of micro shear bands and shear bands in metallic materials subjected to plastic deformation is presented in the work. Particular emphasis in defining the criterion for initiation of micro shear and shear bands, as well as in defining the transition rules for the cellular automata, is put on accounting for the physical aspects of these phenomena occurring in two different scales in the material. The proposed approach led to the creation of the real multi scale model of strain localization phenomena. This model predicts material behavior in various thermo-mechanical processes. Selected examples of applications of the developed model to simulations of metal forming processes, which involve strain localization, are presented in the work. An approach based on the Smoothed Particle Hydrodynamic, which allows to overcome difficulties with remeshing in the traditional CAFE method, is a subject of this work as well. In the developed model remeshing becomes possible and difficulties limiting application of the CAFE method to simple deformation processes are solved. Obtained results of numerical simulations are compared with the experimental results of cold rolling process to show good predicative capabilities of the developed model.tions are compared with the experimental results of cold rolling process to show good predicative capabilities of the developed model.

Experimental and numerical analysis of the deformed process of cracks/cavities

In this paper, the three-point bending tests of beams with a small single-edge crack are conducted to demonstrate the reliability and accuracy of the laser diffraction technique in detecting its deformation and evolution. As a comparison, the quasi-static analysis of the beam subjected to 3-point bending is further proceeded using the finite element method and the related results have been in good agreement with those from the tests.

Computational thermal analysis of a continuous flow micro Polymerase Chain Reaction (PCR) chip

The first continuous flow micro PCR introduced in 1998 has attracted considerable attention for the past several years because of its ability to amplify DNA at much faster rate than the conventional PCR and micro chamber PCR method. The amplification is obtained by moving the sample through 3 different fixed temperature zones. In this paper, the thermal behavior of a continuous flow PCR chip is studied using commercially available finite element software. We study the temperature uniformity and temperature gradient on the chip’s top surface, the cover plate and the interface of the two layers. The material for the chip body and cover plate is glass. The duration for the PCR chip to achieve equilibrium temperature is also studied.

Analysis of springback variation in sheet metal forming

This thesis investigated how the variation in inputs, such as material and processing conditions affected the shape defect phenomenon (springback) for sheet metal forming processes. Using a stochastic Finite Element modelling tool, it was found that the material type and fluctuations in material properties significantly influenced the variation in springback.

Improving stamping tryout using variational analysis, FE simulations and robustness

The tryout process at an automotive sheet metal production plant is outlined and analysed with the aim of augmenting the process to improve robustness through an understanding of variation using Finite Element (FE) analysis and other tools. The result is tryout can produce a more robust stamping process.

Three dimensional stability charts for slopes based on limit analysis methods

This paper uses finite element upper and lower bound limit analysis to produce chart solutions for three-dimensional (3D) natural slopes for both short- and long-term stability. The presented chart solutions are convenient tools that can be used for preliminary design purposes. The rigorous limit analysis results in this paper were found to bracket the true factor of safety within ±10% or better, which can be used as a benchmark for the solutions from other methods. The depth of the slip surfaces is observed to be generally shallow for most analyzed cases, particularly for the long-term slope stability problem. In addition, it was found that using a two-dimensional (2D) analysis may lead to significant differences in estimating safety factors, which can differ by 2%–60% depending on the slope geometry and soil properties. Therefore, great care and judgement are required when applying 2D analyses to 3D slope problems.

Analysis of dynamic strains in tibia during human locomotion based on flexible multibody approach integrated with magnetic resonance imaging technique

Bone is known to adapt to the prevalent strain environment while the variation in strains, e.g., due to mechanical loading, modulates bone remodeling, and modeling. Dynamic strains rather than static strains provide the primary stimulus of bone functional adaptation. The finite element method can be generally used for estimating bone strains, but it may be limited to the static analysis of bone strains since the dynamic analysis requires expensive computation. Direct in vivo strain measurement, in turn, is an invasive procedure, limited to certain superficial bone sites, and requires surgical implementation of strain gauges and thus involves risks (e.g., infection). Therefore, to overcome difficulties associated with the finite element method and the in vivo strain measurements, the flexible multibody simulation approach has been recently introduced as a feasible method to estimate dynamic bone strains during physical activity. The purpose of the present study is to further strengthen the idea of using the flexible multibody approach for the analysis of dynamic bone strains. Besides discussing the background theory, magnetic resonance imaging is integrated into the flexible multibody approach framework so that the actual bone geometry could be better accounted for and the accuracy of prediction improved.

Limit analysis solutions for very gentle undrained slopes

In view of the demand for energy resources, offshore engineering has drawn the attention of many investigators over the past decade. Recent studies have revealed that seabed landslides can have a sig-nificant influence on the performance of offshore infrastructure, such as pipelines. The vulnerability triggered by seabed landslides can even lead to loss of life. In this context, the importance of offshore slope stability evaluation is obvious. Slope stability is generally assessed by the limit equilibrium method (LEM). However, the accuracy of the method is often questioned due to the underlying assumptions that it makes. This study utilises numerical finite element upper and lower bound limit analysis to produce solutions for very gentle undrained slopes. Using these techniques, the stability can be bracketed from above and below. In this paper, a range of slope geometries and the inhomogeneity of the natural soil have been taken into account. The solu-tions presented are useful tools for preliminary design.

Analysis of the current distribution in an aluminum electrolysis cell with copper collector-bar cathode assembly

Understanding the magneto-hydrodynamic forces generated due to the external magnetic field and current density distribution within the cell (current in cell linings) is important in the optimization of cell dynamics. It is well documented that these factors play a crucial role in establishing the metal-pad stability of the cell. Conventional cells use the cathode-collector-bar assembly to carry the current through molten aluminium, the cathode and the steel collector-bar to nearest external bus. The electrical conductivity of the steel is so poor relative to the molten aluminium that the outer third of the collector bar carries the maximum load, which in turn increases the horizontal components of the current within the cell. Previous studies have modelled improvement in the cell instability through external magnetic compensation by redistributing current in the cathode busbar. Very little to date has been published on work to improve the current distribution within the cell. In this work, the current distribution in an aluminium electrolysis cell with copper collector-bar was predicted using finite element modelling. A 2D cross-section of a commercial cell was used under steady conditions of electrical fields in anode, electrolyte, molten aluminium and copper cathode-assembly. Different shapes and sizes of the cathode assembly are also considered to optimise the distribution of current throughout the cathode lining. The findings indicated that the copper-bar of similar size to steel could save voltage up to 150 mV. There is a reduction of more than 70% in peak current density value due to the copper inserts. The predicted trends of current distribution show a good agreement with previously published data.

Electric field analysis of spinneret design for needleless electrospinning of nanofibers

Concentrated electric field is crucial in generation of needleless electrospinning; the electric field profile together with electric field intensity of the spinneret directly affect the needleless electrospinning performance. Understanding the electric field of different spinnerets would definitely benefit the design and optimization of needleless electrospinning. Three-dimensional (3D) finite element analysis has been used to analyze the electric field profile and electric field intensity of different spinnerets for needleless electrospinning by using the simulation software COMSOL Multiphysics 3.5a. It has been found that evolution of the spinneret of needleless electrospinning from cylinder to multiple disks and then to multiple rings results in stronger and more concentrated electric field. The analysis based on 3D simulation of the electric field could benefit further development of needleless electrospinning in which the production rate and quality of as-spun nanofibers are of great importance.

Design and analysis of an antenna for wireless energy harvesting in head-mountable DBS device

This paper presents design and simulation of a circular meander dipole antenna at the industrial, scientific, and medical band of 915 MHz for energy scavenging in a passive head-mountable deep brain stimulation device. The interaction of the proposed antenna with a rat body is modeled and discussed. In the antenna, the radiating layer is meandered, and a FR-4 substrate is used to limit the radius and height of the antenna to 14 mm and 1.60 mm, respectively. The resonance frequency of the designed antenna is 915 MHz and the bandwidth of 15 MHz at a return loss of -10 dB in free space. To model the interaction of the antenna with a rat body, two aspects including functional and biological are considered. The functional aspect includes input impedance, resonance frequency, gain pattern, radiation efficiency of the antenna, and the biological aspect involves electric field distribution, and SAR value. A complete rat model is used in the finite difference time domain based EM simulation software XFdtd. The simulated results demonstrate that the specific absorption rate distributions occur within the skull in the rat model, and their values are higher than the standard regulated values for the antenna receiving power of 1W.

Design and analysis of a low actuation voltage electrowetting-on-dielectric device

This paper presents an Electrowetting-on-Dielectric (EWOD) device with optimized insulating layers operated by low actuation voltage. The device consists of an electrode array on a silicon substrate, covered by a dielectric layer and a hydrophobic layer. To characterize the performance of the device, simulations are performed for the dielectric layer of Sio₂ and the hydrophobic layer of Sio₂, Su-8 and Parylene C at different voltages. The volume finite difference approach of the Coventorware software was used to carry out the simulations. Two different molar of di-ionized water droplet were considered in the simulations. It was observed that the device having the Sio₂ dielectric layer and the Parylene C hydrophobic layer moved the 1M KCL (potassium chloride) droplet at the actuation voltage of 25V.