Topology optimization for designing strain-gauge load cells

Load cells are used extensively in engineering fields. This paper describes a novel structural optimization method for single- and multi-axis load cell structures. First, we briefly explain the topology optimization method that uses the solid isotropic material with penalization (SIMP) method. Next, we clarify the mechanical requirements and design specifications of the single- and multi-axis load cell structures, which are formulated as an objective function. In the case of multi-axis load cell structures, a methodology based on singular value decomposition is used. The sensitivities of the objective function with respect to the design variables are then formulated. On the basis of these formulations, an optimization algorithm is constructed using finite element methods and the method of moving asymptotes (MMA). Finally, we examine the characteristics of the optimization formulations and the resultant optimal configurations. We confirm the usefulness of our proposed methodology for the optimization of single- and multi-axis load cell structures.

Colloidal interactions in two-dimensional nematics

The interaction between two disks immersed in a 2D nernatic is investigated i) analytically using the tenser order parameter formalism for the nematic configuration around isolated disks and ii) numerically using finite-element methods with adaptive meshing to minimize the corresponding Landau-de Gennes free energy. For strong homeotropic anchoring, each disk generates a pair of defects with one-half topological charge responsible for the 2D quadrupolar interaction between the disks at large distances. At short distance, the position of the defects may change, leading to unexpected complex interactions with the quadrupolar repulsive interactions becoming attractive. This short-range attraction in all directions is still anisotropic. As the distance between the disks decreases, their preferred relative orientation with respect to the far-field nernatic director changes from oblique to perpendicular.

Determinação da tenacidade à fratura em corte (GIIc) de adesivos estruturais pelo ensaio End-Notched Flexure (ENF)

Os adesivos têm sido alvo de estudo ao longo dos últimos anos para ligação de componentes a nível industrial. Devido à crescente utilização das juntas adesivas, torna-se necessária a existência de modelos de previsão de resistência que sejam fiáveis e robustos. Neste âmbito, a determinação das propriedades dos adesivos é fundamental para o projeto de ligações coladas. Uma abordagem recente consiste no uso de modelos de dano coesivo (MDC), que permitem simular o comportamento à fratura das juntas de forma bastante fiável. Esta técnica requer a definição das leis coesivas em tração e corte. Estas leis coesivas dependem essencialmente de 2 parâmetros: a tensão limite e a tenacidade no modo de solicitação respetivo. O ensaio End-Notched Flexure (ENF) é o mais utilizado para determinar a tenacidade em corte, porque é conhecido por ser o mais expedito e fiável para caraterizar este parâmetro. Neste ensaio, os provetes são sujeitos a flexão em 3 pontos, sendo apoiados nas extremidades e solicitados no ponto médio para promover a flexão entre substratos, o que se reflete numa solicitação de corte no adesivo. A partir deste ensaio, e após de definida a tenacidade em corte (GIIc), existem alguns métodos para estimativa da lei coesiva respetiva. Nesta dissertação são definidas as leis coesivas em corte de três adesivos estruturais através do ensaio ENF e um método inverso de ajuste dos dados experimentais. Para o efeito, foram realizados ensaios experimentais considerado um adesivo frágil, o Araldite® AV138, um adesivo moderadamente dúctil, o Araldite® 2015 e outro dúctil, o SikaForce® 7752. O trabalho experimental consistiu na realização dos ensaios ENF e respetivo tratamento dos dados para obtenção das curvas de resistência (curvas-R) através dos seguintes métodos: Compliance Calibration Method (CCM), Direct Beam Theory (DBT), Corrected Beam Theory (CBT) e Compliance-Based Beam Method (CBBM). Os ensaios foram simulados numericamente pelo código comercial ABAQUS®, recorrendo ao Métodos de Elementos Finitos (MEF) e um MDC triangular, com o intuito de estimar a lei coesiva de cada um dos adesivos em solicitação de corte. Após este estudo, foi feita uma análise de sensibilidade ao valor de GIIc e resistência coesiva ao corte (tS 0), para uma melhor compreensão do efeito destes parâmetros na curva P- do ensaio ENF. Com o objetivo de testar adequação dos 4 métodos de obtenção de GIIc usados neste trabalho, estes foram aplicados a curvas P- numéricas de cada um dos 3 adesivos, e os valores de GIIc previstos por estes métodos comparados com os respetivos valores introduzidos nos modelos numéricos. Como resultado do trabalho realizado, conseguiu-se obter uma lei coesiva única em corte para cada um dos 3 adesivos testados, que é capaz de reproduzir com precisão os resultados experimentais.

Adaptive numerical simulation of reaction - diffusion systems

Fluidized beds, granulation, heat and mass transfer, calcium dynamics, stochastic process, finite element methods, Rosenbrock methods, multigrid methods, parallelization

Dynamic compact thermal models with multiple power sources: application to an ultrathin chip stacking technology

Whereas numerical modeling using finite-element methods (FEM) can provide transient temperature distribution in the component with enough accuracy, it is of the most importance the development of compact dynamic thermal models that can be used for electrothermal simulation. While in most cases single power sources are considered, here we focus on the simultaneous presence of multiple sources. The thermal model will be in the form of a thermal impedance matrix containing the thermal impedance transfer functions between two arbitrary ports. Eachindividual transfer function element ( ) is obtained from the analysis of the thermal temperature transient at node ¿ ¿ after a power step at node ¿ .¿ Different options for multiexponential transient analysis are detailed and compared. Among the options explored, small thermal models can be obtained by constrained nonlinear least squares (NLSQ) methods if the order is selected properly using validation signals. The methods are applied to the extraction of dynamic compact thermal models for a new ultrathin chip stack technology (UTCS).

Siltanosturin teräsrakenteen suunnittelun avuksi luodun ohjelman jatkokehitys

Diplomityössä tehdään jatkokehitystä KCI Konecranes yrityksen siltanosturin laskentaohjelmaan. Ohjelman tärkeimmät jatkokehityskohteet kartoitettiin käyttäjäkyselyn avulla ja niistä valittiin toivotuimmat, sekä diplomityön lujuusopilliseen aihepiiriin parhaiten soveltuvat. Työhön valitut kaksi aihetta ovat koteloprofiilin kaksiosaisen uuman lujuuslaskennan selvittäminen ja siltanosturin kahdeksanpyöräisenpäätykannattajan elementtimallin suunnittelu. Diplomityössä selvitetään jatkokehityskohteisiin liittyvä teoria, mutta varsinainen ohjelmointi jätetään työn ulkopuolelle. Kaksiosaisella uumalla varustetussa koteloprofiilissa nostovaunun kulkukiskon alla olevan uuman yläosa tehdään paksummaksi, jotta uuma kestäisi nostovaunun pyöräkuormasta aiheutuvan paikallisen jännityksen, eliniin sanotun rusennusjännityksen. Rusennusjännityksen määrittäminen uumalevyissä on kaksiosaisen uuman lujuuslaskennan tärkein tehtävä. Rusennuksen aiheuttamankalvojännityksen ja jännityskeskittymien määrittämiseen erilaisissa konstruktioissa etsittiin sopivimmat menetelmät kirjallisuudesta ja standardeista. Kalvojännitys voidaan määrittää luotettavasti käyttäen joko 45 asteen sääntöä tai standardin mukaista menetelmää ja jännityskonsentraatioiden suuruus saadaan kertomallakalvojännitys jännityskonsentraatiokertoimilla. Menetelmien toimivuus verifioitiin tekemällä kymmeniä uuman elementtimalleja erilaisin dimensioin ja reunaehdoin ja vertaamalla elementtimallien tuloksia käsin laskettuihin. Käsin lasketut jännitykset saatiin vastaamaan tarkasti elementtimallien tuloksia. Kaksiosaisen uuman lommahdus- ja väsymislaskentaa tutkittiin alustavasti. Kahdeksanpyöräisiä päätykannattajia käytetään suurissa siltanostureissa pienentämään pyöräkuormia ja radan rusennusjännityksiä. Kahdeksanpyöräiselle siltanosturin päätykannattajalle suunniteltiin elementtimallit molempiin rakenteesta käytettyihin konstruktioihin: nivelöityyn ja jäykkäkehäiseen malliin. Elementtimallien rakentamisessa hyödynnettiin jo olemassa olevia malleja, jolloin niiden lisääminen ohjelmakoodiin nopeutuu ja ne ovat varmasti yhteensopivia muiden laskentamoduuleiden kanssa. Elementtimallien värähtelyanalyysin reunaehtoja tarkasteltiin. Värähtelyanalyysin reunaehtoihin ei tutkimuksen perusteella tarvitse tehdä muutoksia, mutta staattisen analyysin reunaehdot kaipaavat vielä lisätutkimusta.

Insulation System in an Integrated Motor Compressor

A high-speed and high-voltage solid-rotor induction machine provides beneficial features for natural gas compressor technology. The mechanical robustness of the machine enables its use in an integrated motor-compressor. The technology uses a centrifugal compressor, which is mounted on the same shaft with the high-speed electrical machine driving it. No gearbox is needed as the speed is determined by the frequency converter. The cooling is provided by the process gas, which flows through the motor and is capable of transferring the heat away from the motor. The technology has been used in the compressors in the natural gas supply chain in the central Europe. New areas of application include natural gas compressors working at the wellheads of the subsea gas reservoir. A key challenge for the design of such a motor is the resistance of the stator insulation to the raw natural gas from the well. The gas contains water and heavy hydrocarbon compounds and it is far harsher than the sales gas in the natural gas supply network. The objective of this doctoral thesis is to discuss the resistance of the insulation to the raw natural gas and the phenomena degrading the insulation. The presence of partial discharges is analyzed in this doctoral dissertation. The breakdown voltage of the gas is measured as a function of pressure and gap distance. The partial discharge activity is measured on small samples representing the windings of the machine. The electrical field behavior is also modeled by finite element methods. Based on the measurements it has been concluded that the discharges are expected to disappear at gas pressures above 4 – 5 bar. The disappearance of discharges is caused by the breakdown strength of the gas, which increases as the pressure increases. Based on the finite element analysis, the physical length of a discharge seen in the PD measurements at atmospheric pressure was approximated to be 40 – 120 m. The chemical aging of the insulation when exposed to raw natural gas is discussed based on a vast set of experimental tests with the gas mixture representing the real gas mixture at the wellhead. The mixture was created by mixing dry hydrocarbon gas, heavy hydrocarbon compounds, monoethylene glycol, and water. The mixture was chosen to be more aggressive by increasing the amount of liquid substances. Furthermore, the temperature and pressure were increased, which resulted in accelerated test conditions. The time required to detect severe degradation was thus decreased. The test program included a comparison of materials, an analysis of the e ects of di erent compounds in the gas mixture, namely water and heavy hydrocarbons, on the aging, an analysis of the e ects of temperature and exposure duration, and also an analysis on the e ect of sudden pressure changes on the degradation of the insulating materials. It was found in the tests that an insulation consisting of mica, glass, and epoxy resin can tolerate the raw natural gas, but it experiences some degradation. The key material in the composite insulation is the resin, which largely defines the performance of the insulation system. The degradation of the insulation is mostly determined by the amount of gas mixture di used into it. The di usion was seen to follow Fick’s second law, but the coe cients were not accurately defined. The di usion was not sensitive to temperature, but it was dependent upon the thermodynamic state of the gas mixture, in other words, the amounts of liquid components in the gas. The weight increase observed was mostly related to heavy hydrocarbon compounds, which act as plasticizers in the epoxy resin. The di usion of these compounds is determined by the crosslink density of the resin. Water causes slight changes in the chemical structure, but these changes do not significantly contribute to the aging phenomena. Sudden changes in pressure can lead to severe damages in the insulation, because the motion of the di used gas is able to create internal cracks in the insulation. Therefore, the di usion only reduces the mechanical strength of the insulation, but the ultimate breakdown can potentially be caused by a sudden drop in the pressure of the process gas.

Mechanical design and analysis of modular active magnetic bearing test rig

Tässä työssä on tutkittu modulaarisen aktiivimagneettilaakeroidun koelaitteen mekaanista suunnittelua ja analysointia. Suurnopeusroottorin suunnittelun teoria on esitelty. Lisäksi monia analyyttisiä mallinnusmenetelmiä mekaanisten kuormitusten mallintamiseksi on esitelty. Koska kyseessä on suurnopeussähkökone, roottoridynamiikka ja sen soveltuvuus suunnittelussa on esitelty. Magneettilaakerien rakenteeseen ja toimintaan on tutustuttu osana tätä työtä. Kirjallisuuskatsaus nykyisistä koelaitteista esimerkiksi komponenttien ominaisuuksien tunnistamiseen ja roottoridynamiikan tutkimuksiin on esitelty. Työn rajauksena on konseptisuunnittelu muunneltavalle magneettilaakeroidulle (AMB) koelaitteelle ja suunnitteluprosessin dokumentointi. Muunneltavuuteen päädyttiin, koska se mahdollistaa erilaisten komponenttiasetteluiden testaamisen erilaisille magneettilaakerikokoonpanoille ja roottoreille. Pääpaino tässä työssä on suurnopeus induktiokoneen roottorin suunnittelussa ja mallintamisessa. Modulaaristen toimilaitteiden kuten magneettilaakerien ja induktiosähkömoottorin rakenne on esitelty ja modulaarisen rakenteen käytettävyyden hyödyistä koelaitekäytössä on dokumentoitu. Analyyttisiä ja elementtimenetelmään perustuvia tutkimusmenetelmiä on käytetty tutkittaessa suunniteltua suurnopeusroottoria. Suunnittelun ja analysoinnin tulokset on esitelty ja verrattu keskenään eri mallinnusmenetelmien välillä. Lisäksi johtopäätökset sähkömagneettisten osien liittämisen monimutkaisuudesta ja vaatimuksista roottoriin ja toimilaitteisiin sekä mekaanisten että sähkömagneettisten ominaisuuksien optimoimiseksi on dokumentoitu.

Künstliche Randbedingungen und Algebraische Äquivalenzen in der Elastizitätstheorie

In dieser Arbeit werden zwei Aspekte bei Randwertproblemen der linearen Elastizitätstheorie untersucht: die Approximation von Lösungen auf unbeschränkten Gebieten und die Änderung von Symmetrieklassen unter speziellen Transformationen. Ausgangspunkt der Dissertation ist das von Specovius-Neugebauer und Nazarov in "Artificial boundary conditions for Petrovsky systems of second order in exterior domains and in other domains of conical type"(Math. Meth. Appl. Sci, 2004; 27) eingeführte Verfahren zur Untersuchung von Petrovsky-Systemen zweiter Ordnung in Außenraumgebieten und Gebieten mit konischen Ausgängen mit Hilfe der Methode der künstlichen Randbedingungen. Dabei werden für die Ermittlung von Lösungen der Randwertprobleme die unbeschränkten Gebiete durch das Abschneiden mit einer Kugel beschränkt, und es wird eine künstliche Randbedingung konstruiert, um die Lösung des Problems möglichst gut zu approximieren. Das Verfahren wird dahingehend verändert, dass das abschneidende Gebiet ein Polyeder ist, da es für die Lösung des Approximationsproblems mit üblichen Finite-Element-Diskretisierungen von Vorteil sei, wenn das zu triangulierende Gebiet einen polygonalen Rand besitzt. Zu Beginn der Arbeit werden die wichtigsten funktionalanalytischen Begriffe und Ergebnisse der Theorie elliptischer Differentialoperatoren vorgestellt. Danach folgt der Hauptteil der Arbeit, der sich in drei Bereiche untergliedert. Als erstes wird für abschneidende Polyedergebiete eine formale Konstruktion der künstlichen Randbedingungen angegeben. Danach folgt der Nachweis der Existenz und Eindeutigkeit der Lösung des approximativen Randwertproblems auf dem abgeschnittenen Gebiet und im Anschluss wird eine Abschätzung für den resultierenden Abschneidefehler geliefert. An die theoretischen Ausführungen schließt sich die Betrachtung von Anwendungsbereiche an. Hier werden ebene Rissprobleme und Polarisationsmatrizen dreidimensionaler Außenraumprobleme der Elastizitätstheorie erläutert. Der letzte Abschnitt behandelt den zweiten Aspekt der Arbeit, den Bereich der Algebraischen Äquivalenzen. Hier geht es um die Transformation von Symmetrieklassen, um die Kenntnis der Fundamentallösung der Elastizitätsprobleme für transversalisotrope Medien auch für Medien zu nutzen, die nicht von transversalisotroper Struktur sind. Eine allgemeine Darstellung aller Klassen konnte hier nicht geliefert werden. Als Beispiel für das Vorgehen wird eine Klasse von orthotropen Medien im dreidimensionalen Fall angegeben, die sich auf den Fall der Transversalisotropie reduzieren lässt.

Compact Representations for Fast Nonrigid Registration of Medical Images

We develop efficient techniques for the non-rigid registration of medical images by using representations that adapt to the anatomy found in such images. Images of anatomical structures typically have uniform intensity interiors and smooth boundaries. We create methods to represent such regions compactly using tetrahedra. Unlike voxel-based representations, tetrahedra can accurately describe the expected smooth surfaces of medical objects. Furthermore, the interior of such objects can be represented using a small number of tetrahedra. Rather than describing a medical object using tens of thousands of voxels, our representations generally contain only a few thousand elements. Tetrahedra facilitate the creation of efficient non-rigid registration algorithms based on finite element methods (FEM). We create a fast, FEM-based method to non-rigidly register segmented anatomical structures from two subjects. Using our compact tetrahedral representations, this method generally requires less than one minute of processing time on a desktop PC. We also create a novel method for the non-rigid registration of gray scale images. To facilitate a fast method, we create a tetrahedral representation of a displacement field that automatically adapts to both the anatomy in an image and to the displacement field. The resulting algorithm has a computational cost that is dominated by the number of nodes in the mesh (about 10,000), rather than the number of voxels in an image (nearly 10,000,000). For many non-rigid registration problems, we can find a transformation from one image to another in five minutes. This speed is important as it allows use of the algorithm during surgery. We apply our algorithms to find correlations between the shape of anatomical structures and the presence of schizophrenia. We show that a study based on our representations outperforms studies based on other representations. We also use the results of our non-rigid registration algorithm as the basis of a segmentation algorithm. That algorithm also outperforms other methods in our tests, producing smoother segmentations and more accurately reproducing manual segmentations.

A collocation method for high frequency scattering by convex polygons

We consider the problem of scattering of a time-harmonic acoustic incident plane wave by a sound soft convex polygon. For standard boundary or finite element methods, with a piecewise polynomial approximation space, the computational cost required to achieve a prescribed level of accuracy grows linearly with respect to the frequency of the incident wave. Recently Chandler–Wilde and Langdon proposed a novel Galerkin boundary element method for this problem for which, by incorporating the products of plane wave basis functions with piecewise polynomials supported on a graded mesh into the approximation space, they were able to demonstrate that the number of degrees of freedom required to achieve a prescribed level of accuracy grows only logarithmically with respect to the frequency. Here we propose a related collocation method, using the same approximation space, for which we demonstrate via numerical experiments a convergence rate identical to that achieved with the Galerkin scheme, but with a substantially reduced computational cost.

Numerical study of 2D heat transfer in a scraped surface heat exchanger

A numerical study of fluid mechanics and heat transfer in a scraped surface heat exchanger with non-Newtonian power law fluids is undertaken. Numerical results are generated for 2D steady-state conditions using finite element methods. The effect of blade design and material properties, and especially the independent effects of shear thinning and heat thinning on the flow and heat transfer, are studied. The results show that the gaps at the root of the blades, where the blades are connected to the inner cylinder, remove the stagnation points, reduce the net force on the blades and shift the location of the central stagnation point. The shear thinning property of the fluid reduces the local viscous dissipation close to the singularity corners, i.e. near the tip of the blades, and as a result the local fluid temperature is regulated. The heat thinning effect is greatest for Newtonian fluids where the viscous dissipation and the local temperature are highest at the tip of the blades. Where comparison is possible, very good agreement is found between the numerical results and the available data. Aspects of scraped surface heat exchanger design are assessed in the light of the results. (C) 2003 Elsevier Ltd. All rights reserved.

High frequency scattering by convex curvilinear polygons

We consider the scattering of a time-harmonic acoustic incident plane wave by a sound soft convex curvilinear polygon with Lipschitz boundary. For standard boundary or finite element methods, with a piecewise polynomial approximation space, the number of degrees of freedom required to achieve a prescribed level of accuracy grows at least linearly with respect to the frequency of the incident wave. Here we propose a novel Galerkin boundary element method with a hybrid approximation space, consisting of the products of plane wave basis functions with piecewise polynomials supported on several overlapping meshes; a uniform mesh on illuminated sides, and graded meshes refined towards the corners of the polygon on illuminated and shadow sides. Numerical experiments suggest that the number of degrees of freedom required to achieve a prescribed level of accuracy need only grow logarithmically as the frequency of the incident wave increases.

Optimal convergence estimates for the trace of the polynomial L2-projection operator on a simplex

In this paper we study convergence of the L2-projection onto the space of polynomials up to degree p on a simplex in Rd, d >= 2. Optimal error estimates are established in the case of Sobolev regularity and illustrated on several numerical examples. The proof is based on the collapsed coordinate transform and the expansion into various polynomial bases involving Jacobi polynomials and their antiderivatives. The results of the present paper generalize corresponding estimates for cubes in Rd from [P. Houston, C. Schwab, E. Süli, Discontinuous hp-finite element methods for advection-diffusion-reaction problems. SIAM J. Numer. Anal. 39 (2002), no. 6, 2133-2163].

Is the Helmholtz equation really sign-indefinite?

The usual variational (or weak) formulations of the Helmholtz equation are sign-indefinite in the sense that the bilinear forms cannot be bounded below by a positive multiple of the appropriate norm squared. This is often for a good reason, since in bounded domains under certain boundary conditions the solution of the Helmholtz equation is not unique at wavenumbers that correspond to eigenvalues of the Laplacian, and thus the variational problem cannot be sign-definite. However, even in cases where the solution is unique for all wavenumbers, the standard variational formulations of the Helmholtz equation are still indefinite when the wavenumber is large. This indefiniteness has implications for both the analysis and the practical implementation of finite element methods. In this paper we introduce new sign-definite (also called coercive or elliptic) formulations of the Helmholtz equation posed in either the interior of a star-shaped domain with impedance boundary conditions, or the exterior of a star-shaped domain with Dirichlet boundary conditions. Like the standard variational formulations, these new formulations arise just by multiplying the Helmholtz equation by particular test functions and integrating by parts.