Finite element aided design evolution of composite leaf spring

This paper shows the process of the virtual production development of the mechanical connection between the top leaf of a dual composite leaf spring system to a shackle using finite element methods. The commercial FEA package MSC/MARC has been used for the analysis. In the original design the joint was based on a closed eye-end. Full scale testing results showed that this configuration achieved the vertical proof load of 150 kN and 1 million cycles of fatigue load. However, a problem with delamination occurred at the interface between the fibres going around the eye and the main leaf body. To overcome this problem, a second design was tried using transverse bandages of woven glass fibre reinforced tape to wrap the section that is prone to delaminate. In this case, the maximum interlaminar shear stress was reduced by a certain amount but it was still higher than the material’s shear strength. Based on the fact that, even with delamination, the top leaf spring still sustained the maximum static and fatigue loads required, the third design was proposed with an open eye-end, eliminating altogether the interface where the maximum shear stress occurs. The maximum shear stress predicted by FEA is reduced significantly and a safety factor of around 2 has been obtained. Thus, a successful and safe design has been achieved.

Design and validation of a sheet metal shearing experimental procedure

Throughout the industrial processes of sheet metal manufacturing and refining, shear cutting is widely used for its speed and cost advantages over competing cutting methods. Industrial shears may include some force measurement possibilities, but the force is most likely influenced by friction losses between shear tool and the point of measurement, and are in general not showing the actual force applied to the sheet. Well defined shears and accurate measurements of force and shear tool position are important for understanding the influence of shear parameters. Accurate experimental data are also necessary for calibration of numerical shear models. Here, a dedicated laboratory set-up with well defined geometry and movement in the shear, and high measurability in terms of force and geometry is designed, built and verified. Parameters important to the shear process are studied with perturbation analysis techniques and requirements on input parameter accuracy are formulated to meet experimental output demands. Input parameters in shearing are mostly geometric parameters, but also material properties and contact conditions. Based on the accuracy requirements, a symmetric experiment with internal balancing of forces is constructed to avoid guides and corresponding friction losses. Finally, the experimental procedure is validated through shearing of a medium grade steel. With the obtained experimental set-up performance, force changes as result of changes in studied input parameters are distinguishable down to a level of 1%.

Analysis of Semi-solid Processing for Metal Matrix Composite Synthesis Using Factorial Design

The main goal in this work is to conduct a quantitative analysis of the mechanical stir casting process for obtaining particulate metal matrix composites. A combined route of stirring at semi-solid state followed by stirring at liquid state is proposed. A fractional factorial design was developed to investigate the influence and interactions of factors as: time, rotation, initial fraction and particle size, on the incorporated fraction. The best incorporations were obtained with all factors at high levels, as well as that very long stirring periods have no strong influence being particle size and rotation the most important factors on the incorporated fraction. Particle wetting occurs during stirring at semisolid state, highlighting the importance of the interactions between particles and the alloy globularized phase. The role of the alloying element Mg as a wettability-promoting agent is discussed. The shear forces resulting from the stirring system is emphasized and understood as the effect of rotation itself added to the propeller blade geometry.

Design of concrete platforms offshore using the three-layer shell theory

The concrete offshore platforms, which are subjected a several loading combinations and, thus, requires an analysis more generic possible, can be designed using the concepts adopted to shell elements, but the resistance must be verify in particular cross-sections to shear forces. This work about design of shell elements will be make using the three-layer shell theory. The elements are subject to combined loading of membrane and plate, totalizing eight components of internal forces, which are three membrane forces, three moments (two out-of-plane bending moments and one in-plane, or torsion, moment) and two shear forces. The design method adopted, utilizing the iterative process proposed by Lourenco & Figueiras (1993) obtained from equations of equilibrium developed by Gupta (1896) , will be compared to results of experimentally tested shell elements found in the literature using the program DIANA.

Design of dental implants, influence on the osteogenesis and fixation

The fixation and the bone ingrowth at the interface of porous cylindrical implants (total porosity of 37% and average pores diameter of 480 mu m) were compared in vivo to rough cylindrical implants (R-a = 5.3 mu m), both of commercially pure titanium, made by powder metallurgy. The implants were inserted into the tibias of 20 rabbits and the animals were sacrificed 4 and 8 weeks after surgery. The percentage of bone-implant contact observed in porous implant was significantly larger than in the rough ones for all of sacrifice periods, respectively, 57% vs. 46% after 4 weeks, and 59% vs. 50% after 8 weeks. The mechanical tests showed a significant increase in the shear strength of the porous implants for the two analyzed periods, 4 and 8 weeks (14 and 20 MPa), when compared with rough ones (4 and 13 MPa). These results suggest that porous implants improve the contact at the implant-bone interface and increase the fixation to the bone, improving the osseointegration. Thus, the porous implant might be an alternative to dental implant in less favorable conditions, and appear to be better fixed to bone, offering promising alternatives.

Stepping-motor-driven constant-shear-rate rotating viscometer

Despite the frequent use of stepping motors in robotics, automation, and a variety of precision instruments, they can hardly be found in rotational viscometers. This paper proposes the use of a stepping motor to drive a conventional constant-shear-rate laboratory rotational viscometer to avoid the use of velocity sensor and gearbox and, thus, simplify the instrument design. To investigate this driving technique, a commercial rotating viscometer has been adapted to be driven by a bipolar stepping motor, which is controlled via a personal computer. Special circuitry has been added to microstep the stepping motor at selectable step sizes and to condition the torque signal. Tests have been carried out using the prototype to produce flow curves for two standard Newtonian fluids (920 and 12 560 mPa (.) s, both at 25 degrees C). The flow curves have been obtained by employing several distinct microstep sizes within the shear rate range of 50-500 s(-1). The results indicate the feasibility of the proposed driving technique.

Effect of fiber orientation on the shear behavior of glass fiber/epoxy composites

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Hygrotermal effects evaluation using the losipescu shear test for glare laminates

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Unconfined shear strength of compacted unsaturated plastic soils

A central goal in unsaturated soil mechanics research is to create a smooth transition between traditional soil mechanics approaches and an approach that is applicable to unsaturated soils. Undrained shear strength and the liquidity index of reconstituted or remoulded saturated soils are consistently correlated, which has been demonstrated by many studies. In the liquidity index range from 1 (at w(l)) to 0 (at w(p)), the shear strength ranges from approximately 2 kPa to 200 kPa. Similarly, for compacted soil, the shear strength at the plastic limit ranges from 150 kPa to 250 kPa. When compacted at their optimum water content, most soils have a suction that ranges from 20 kPa to 500 kPa; however, in the field, compacted materials are subjected to drying and wetting, which affect their initial suction and as a consequence their shear strength. Unconfined shear tests were performed on five compacted tropical soils and kaolin. Specimens were tested in the as-compacted condition, and also after undergoing drying or wetting. The test results and data from prior literature were examined, taking into account the roles of void ratio, suction, and relative water content. An interpretation of the phenomena that are involved in the development of the undrained shear strength of unsaturated soils in the contexts of soil water retention and Atterberg limits is presented, providing a practical view of the behaviour of compacted soil based on the concept of unsaturated soil. Finally, an empirical correlation is presented that relates the unsaturated state of compacted soils to the unconfined shear strength.

Design of laminated piezocomposite shell transducers with arbitrary fiber orientation using topology optimization approach

Sensor and actuator based on laminated piezocomposite shells have shown increasing demand in the field of smart structures. The distribution of piezoelectric material within material layers affects the performance of these structures; therefore, its amount, shape, size, placement, and polarization should be simultaneously considered in an optimization problem. In addition, previous works suggest the concept of laminated piezocomposite structure that includes fiber-reinforced composite layer can increase the performance of these piezoelectric transducers; however, the design optimization of these devices has not been fully explored yet. Thus, this work aims the development of a methodology using topology optimization techniques for static design of laminated piezocomposite shell structures by considering the optimization of piezoelectric material and polarization distributions together with the optimization of the fiber angle of the composite orthotropic layers, which is free to assume different values along the same composite layer. The finite element model is based on the laminated piezoelectric shell theory, using the degenerate three-dimensional solid approach and first-order shell theory kinematics that accounts for the transverse shear deformation and rotary inertia effects. The topology optimization formulation is implemented by combining the piezoelectric material with penalization and polarization model and the discrete material optimization, where the design variables describe the amount of piezoelectric material and polarization sign at each finite element, with the fiber angles, respectively. Three different objective functions are formulated for the design of actuators, sensors, and energy harvesters. Results of laminated piezocomposite shell transducers are presented to illustrate the method. Copyright (C) 2012 John Wiley & Sons, Ltd.

Shear force and torsion in reinforced concrete beam elements: theoretical analysis based on Brazilian Standard Code ABNT NBR 6118:2007

Reinforced concrete beam elements are submitted to applicable loads along their life cycle that cause shear and torsion. These elements may be subject to only shear, pure torsion or both, torsion and shear combined. The Brazilian Standard Code ABNT NBR 6118:2007 [1] fixes conditions to calculate the transverse reinforcement area in beam reinforced concrete elements, using two design models, based on the strut and tie analogy model, first studied by Mörsch [2]. The strut angle θ (theta) can be considered constant and equal to 45º (Model I), or varying between 30º and 45º (Model II). In the case of transversal ties (stirrups), the variation of angle α (alpha) is between 45º and 90º. When the equilibrium torsion is required, a resistant model based on space truss with hollow section is considered. The space truss admits an inclination angle θ between 30º and 45º, in accordance with beam elements subjected to shear. This paper presents a theoretical study of models I and II for combined shear and torsion, in which ranges the geometry and intensity of action in reinforced concrete beams, aimed to verify the consumption of transverse reinforcement in accordance with the calculation model adopted As the strut angle on model II ranges from 30º to 45º, transverse reinforcement area (Asw) decreases, and total reinforcement area, which includes longitudinal torsion reinforcement (Asℓ), increases. It appears that, when considering model II with strut angle above 40º, under shear only, transverse reinforcement area increases 22% compared to values obtained using model I.

Performance evaluation of asphalt pavements using the Incremental-Recursive procedure of the Mechanistic-Empirical design software CalME

Il concetto di “sostenibilità” si riferisce allo sviluppo dei sistemi umani attraverso il più piccolo impatto possibile sul sistema ambientale. Le opere che si inseriscono bene nel contesto ambientale circostante e le pratiche che rispettano le risorse in maniera tale da permettere una crescita e uno sviluppo a lungo termine senza impattare sull’ambiente sono indispensabili in una società moderna. I progressi passati, presenti e futuri che hanno reso i conglomerati bituminosi materiali sostenibili dal punto di vista ambientale sono particolarmente importanti data la grande quantità di conglomerato usato annualmente in Europa e negli Stati Uniti. I produttori di bitume e di conglomerato bituminoso stanno sviluppando tecniche innovative per ridurre l’impatto ambientale senza compromettere le prestazioni meccaniche finali. Un conglomerato bituminoso ad “alta lavorabilità” (WMA), pur sviluppando le stesse caratteristiche meccaniche, richiede un temperatura di produzione minore rispetto a quella di un tradizionale conglomerato bituminoso a caldo (HMA). L’abbassamento della temperature di produzione riduce le emissioni nocive. Questo migliora le condizioni dei lavoratori ed è orientato verso uno sviluppo sostenibile. L’obbiettivo principale di questa tesi di laurea è quello di dimostrare il duplice valore sia dal punto di vista dell’eco-compatibilità sia dal punto di vista meccanico di questi conglomerati bituminosi ad “alta lavorabilità”. In particolare in questa tesi di laurea è stato studiato uno SMA ad “alta lavorabilità” (PGGWMA). L’uso di materiali a basso impatto ambientale è la prima fase verso un progetto ecocompatibile ma non può che essere il punto di partenza. L’approccio ecocompatibile deve essere esteso anche ai metodi di progetto e alla caratterizzazione di laboratorio dei materiali perché solo in questo modo è possibile ricavare le massime potenzialità dai materiali usati. Un’appropriata caratterizzazione del conglomerato bituminoso è fondamentale e necessaria per una realistica previsione delle performance di una pavimentazione stradale. La caratterizzazione volumetrica (Mix Design) e meccanica (Deformazioni Permanenti e Comportamento a fatica) di un conglomerato bituminoso è una fase importante. Inoltre, al fine di utilizzare correttamente i materiali, un metodo di progetto avanzato ed efficiente, come quello rappresentato da un approccio Empirico-Meccanicistico (ME), deve essere utilizzato. Una procedura di progetto Empirico-Meccanicistica consiste di un modello strutturale capace di prevedere gli stati di tensione e deformazione all’interno della pavimentazione sotto l’azione del traffico e in funzione delle condizioni atmosferiche e di modelli empirici, calibrati sul comportamento dei materiali, che collegano la risposta strutturale alle performance della pavimentazione. Nel 1996 in California, per poter effettivamente sfruttare i benefici dei continui progressi nel campo delle pavimentazioni stradali, fu iniziato un estensivo progetto di ricerca mirato allo sviluppo dei metodi di progetto Empirico - Meccanicistici per le pavimentazioni stradali. Il risultato finale fu la prima versione del software CalME che fornisce all’utente tre approcci diversi di l’analisi e progetto: un approccio Empirico, uno Empirico - Meccanicistico classico e un approccio Empirico - Meccanicistico Incrementale - Ricorsivo. Questo tesi di laurea si concentra sulla procedura Incrementale - Ricorsiva del software CalME, basata su modelli di danno per quanto riguarda la fatica e l’accumulo di deformazioni di taglio dai quali dipendono rispettivamente la fessurazione superficiale e le deformazioni permanenti nella pavimentazione. Tale procedura funziona per incrementi temporali successivi e, usando i risultati di ogni incremento temporale, ricorsivamente, come input dell’incremento temporale successivo, prevede le condizioni di una pavimentazione stradale per quanto riguarda il modulo complesso dei diversi strati, le fessurazioni superficiali dovute alla fatica, le deformazioni permanenti e la rugosità superficiale. Al fine di verificare le propreità meccaniche del PGGWMA e le reciproche relazioni in termini di danno a fatica e deformazioni permanenti tra strato superficiale e struttura della pavimentazione per fissate condizioni ambientali e di traffico, è stata usata la procedura Incrementale – Ricorsiva del software CalME. Il conglomerato bituminoso studiato (PGGWMA) è stato usato in una pavimentazione stradale come strato superficiale di 60 mm di spessore. Le performance della pavimentazione sono state confrontate a quelle della stessa pavimentazione in cui altri tipi di conglomerato bituminoso sono stati usati come strato superficiale. I tre tipi di conglomerato bituminoso usati come termini di paragone sono stati: un conglomerato bituminoso ad “alta lavorabilità” con granulometria “chiusa” non modificato (DGWMA), un conglomerato bituminoso modificato con polverino di gomma con granulometria “aperta” (GGRAC) e un conglomerato bituminoso non modificato con granulometria “chiusa” (DGAC). Nel Capitolo I è stato introdotto il problema del progetto ecocompatibile delle pavimentazioni stradali. I materiali a basso impatto ambientale come i conglomerati bituminosi ad “alta lavorabilità” e i conglomerati bituminosi modificati con polverino di gomma sono stati descritti in dettaglio. Inoltre è stata discussa l’importanza della caratterizzazione di laboratorio dei materiali e il valore di un metodo razionale di progetto delle pavimentazioni stradali. Nel Capitolo II sono stati descritti i diversi approcci progettuali utilizzabili con il CalME e in particolare è stata spiegata la procedura Incrementale – Ricorsiva. Nel Capitolo III sono state studiate le proprietà volumetriche e meccaniche del PGGWMA. Test di Fatica e di Deformazioni Permanenti, eseguiti rispettivamente con la macchina a fatica per flessione su quattro punti e il Simple Shear Test device (macchina di taglio semplice), sono stati effettuati su provini di conglomerato bituminoso e i risultati dei test sono stati riassunti. Attraverso questi dati di laboratorio, i parametri dei modelli della Master Curve, del danno a fatica e dell’accumulo di deformazioni di taglio usati nella procedura Incrementale – Ricorsiva del CalME sono stati valutati. Infine, nel Capitolo IV, sono stati presentati i risultati delle simulazioni di pavimentazioni stradali con diversi strati superficiali. Per ogni pavimentazione sono stati analizzati la fessurazione superficiale complessiva, le deformazioni permanenti complessive, il danno a fatica e la profondità delle deformazioni in ognuno degli stati legati.

Performance evaluation of low environmental impact asphalt concretes using the mechanistic empirical design method based on laboratory fatigue and permanent deformation models

The "sustainability" concept relates to the prolonging of human economic systems with as little detrimental impact on ecological systems as possible. Construction that exhibits good environmental stewardship and practices that conserve resources in a manner that allow growth and development to be sustained for the long-term without degrading the environment are indispensable in a developed society. Past, current and future advancements in asphalt as an environmentally sustainable paving material are especially important because the quantities of asphalt used annually in Europe as well as in the U.S. are large. The asphalt industry is still developing technological improvements that will reduce the environmental impact without affecting the final mechanical performance. Warm mix asphalt (WMA) is a type of asphalt mix requiring lower production temperatures compared to hot mix asphalt (HMA), while aiming to maintain the desired post construction properties of traditional HMA. Lowering the production temperature reduce the fuel usage and the production of emissions therefore and that improve conditions for workers and supports the sustainable development. Even the crumb-rubber modifier (CRM), with shredded automobile tires and used in the United States since the mid 1980s, has proven to be an environmentally friendly alternative to conventional asphalt pavement. Furthermore, the use of waste tires is not only relevant in an environmental aspect but also for the engineering properties of asphalt [Pennisi E., 1992]. This research project is aimed to demonstrate the dual value of these Asphalt Mixes in regards to the environmental and mechanical performance and to suggest a low environmental impact design procedure. In fact, the use of eco-friendly materials is the first phase towards an eco-compatible design but it cannot be the only step. The eco-compatible approach should be extended also to the design method and material characterization because only with these phases is it possible to exploit the maximum potential properties of the used materials. Appropriate asphalt concrete characterization is essential and vital for realistic performance prediction of asphalt concrete pavements. Volumetric (Mix design) and mechanical (Permanent deformation and Fatigue performance) properties are important factors to consider. Moreover, an advanced and efficient design method is necessary in order to correctly use the material. A design method such as a Mechanistic-Empirical approach, consisting of a structural model capable of predicting the state of stresses and strains within the pavement structure under the different traffic and environmental conditions, was the application of choice. In particular this study focus on the CalME and its Incremental-Recursive (I-R) procedure, based on damage models for fatigue and permanent shear strain related to the surface cracking and to the rutting respectively. It works in increments of time and, using the output from one increment, recursively, as input to the next increment, predicts the pavement conditions in terms of layer moduli, fatigue cracking, rutting and roughness. This software procedure was adopted in order to verify the mechanical properties of the study mixes and the reciprocal relationship between surface layer and pavement structure in terms of fatigue and permanent deformation with defined traffic and environmental conditions. The asphalt mixes studied were used in a pavement structure as surface layer of 60 mm thickness. The performance of the pavement was compared to the performance of the same pavement structure where different kinds of asphalt concrete were used as surface layer. In comparison to a conventional asphalt concrete, three eco-friendly materials, two warm mix asphalt and a rubberized asphalt concrete, were analyzed. The First Two Chapters summarize the necessary steps aimed to satisfy the sustainable pavement design procedure. In Chapter I the problem of asphalt pavement eco-compatible design was introduced. The low environmental impact materials such as the Warm Mix Asphalt and the Rubberized Asphalt Concrete were described in detail. In addition the value of a rational asphalt pavement design method was discussed. Chapter II underlines the importance of a deep laboratory characterization based on appropriate materials selection and performance evaluation. In Chapter III, CalME is introduced trough a specific explanation of the different equipped design approaches and specifically explaining the I-R procedure. In Chapter IV, the experimental program is presented with a explanation of test laboratory devices adopted. The Fatigue and Rutting performances of the study mixes are shown respectively in Chapter V and VI. Through these laboratory test data the CalME I-R models parameters for Master Curve, fatigue damage and permanent shear strain were evaluated. Lastly, in Chapter VII, the results of the asphalt pavement structures simulations with different surface layers were reported. For each pavement structure, the total surface cracking, the total rutting, the fatigue damage and the rutting depth in each bound layer were analyzed.

A Design Method for Flexure-Based Compliant Mechanisms on the Basis of Stiffness and Stress Characteristics

Geometric nonlinearities of flexure hinges introduced by large deflections often complicate the analysis of compliant mechanisms containing such members, and therefore, Pseudo-Rigid-Body Models (PRBMs) have been well proposed and developed by Howell [1994] to analyze the characteristics of slender beams under large deflection. These models, however, fail to approximate the characteristics for the deep beams (short beams) or the other flexure hinges. Lobontiu's work [2001] contributed to the diverse flexure hinge analysis building on the assumptions of small deflection, which also limits the application range of these flexure hinges and cannot analyze the stiffness and stress characteristics of these flexure hinges for large deflection. Therefore, the objective of this thesis is to analyze flexure hinges considering both the effects of large-deflection and shear force, which guides the design of flexure-based compliant mechanisms. The main work conducted in the thesis is outlined as follows. 1. Three popular types of flexure hinges: (circular flexure hinges, elliptical flexure hinges and corner-filleted flexure hinges) are chosen for analysis at first. 2. Commercial software (Comsol) based Finite Element Analysis (FEA) method is then used for correcting the errors produced by the equations proposed by Lobontiu when the chosen flexure hinges suffer from large deformation. 3. Three sets of generic design equations for the three types of flexure hinges are further proposed on the basis of stiffness and stress characteristics from the FEA results. 4. A flexure-based four-bar compliant mechanism is finally studied and modeled using the proposed generic design equations. The load-displacement relationships are verified by a numerical example. The results show that a maximum error about the relationship between moment and rotation deformation is less than 3.4% for a flexure hinge, and it is lower than 5% for the four-bar compliant mechanism compared with the FEA results.

Processing-structure-property relationships in solid-state shear pulverization: Parametric study of specific energy

Solid-state shear pulverization (SSSP) is a unique processing technique for mechanochemical modification of polymers, compatibilization of polymer blends, and exfoliation and dispersion of fillers in polymer nanocomposites. A systematic parametric study of the SSSP technique is conducted to elucidate the detailed mechanism of the process and establish the basis for a range of current and future operation scenarios. Using neat, single component polypropylene (PP) as the model material, we varied machine type, screw design, and feed rate to achieve a range of shear and compression applied to the material, which can be quantified through specific energy input (Ep). As a universal processing variable, Ep reflects the level of chain scission occurring in the material, which correlates well to the extent of the physical property changes of the processed PP. Additionally, we compared the operating cost estimates of SSSP and conventional twin screw extrusion to determine the practical viability of SSSP.