Characterizing the class of local metal sheet thickening processes

The need to create high-value products for specialist applications, and the search for efficient forming routes that obviate the need for some machining steps, is driving Interest In a novel class of forming processes aiming to create locally thickened features within sheet work- pieces. A number of novel forming processes have been proposed to meet this need, but it is as yet unclear which processes will be most effective in creating local thickening of various geometries, and many process configurations have yet to be tried. This paper aims to provide some basic principles for designing and characterising process behaviour. A simplified generic description of sheet thickening processes is provided, with two tools of variable operating on a sheet workpiece in plane strain, with different tool separations and motions parameterised. A comprehensive numerical study of the behaviour of this class of processes is conducted in Abaqus to predict the main characteristics of the material flow in each configuration. The results are used to classify the different basic behaviours that can be achieved by the sheet-bulk thickening processes and to give guidance on future process development, capability and applicability. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.

The forming of variable cross-section I-beams by hot rolling

A process is presented for the forming of variable cross-section I-beams by hot rolling. Optimized I-beams with variable cross-section offer a significant weight advantage over prismatic beams. By tailoring the cross-section to the bending moment experienced within the beam, around 30% of the material can be saved compared to a standard section. Production of such beams by hot rolling would be advantageous, as It combines high volume capacity with high material yields. Through controlled variation of the roll gap during multiple passes, beams with a variable cross-section have been created using shaped rolls similar to those used for conventional I-beam rolling. The process was tested experimentally on a small scale rolling mill, using plasticine as the modelling material. These results were then compared to finite element simulations of individual stages of the process conducted using Abaqus/Standard. Results here show that the process can successfully form a beam with a variable depth web. The main failure modes of the process, and the limitations on the achievable variations In geometry are also presented. Finally, the question of whether or not optimal beam geometries can be created by this process Is discussed. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.

Thermo-hydro-geomechanical simulations of methane gas production from deep sea methane hydrate formations

A new constitutive model called Methane Hydrate Critical State (MHCS) model was conducted to investigate the geomechanical response of the gas-hydrate-bearing sediments at the Nankai Trough during the wellbore construction process. The strength and dilatancy of gas-hydrate-bearing soil would gradually disappear when the bonds are destroyed because of excessively shearing, which are often observed in dense soils and also in bonded soils such as cemented soil and unsaturated soil. In this study, the MHCS model, which presents such softening features, would be incorporated into a staged-finite-element model in ABAQUS, which mainly considered the loading history of soils and the interaction between cement-casing-formation. This model shows the influence of gas-hydrate-bearing soil to the deformation and stability of a wellbore and the surrounding sediments during wellbore construction. At the same time, the conventional Mohr-Coulomb model was used in the model to show the advantages of MHCS model by comparing the results of the two models.

Experimental and numerical investigation of the seismic behavior of rectangular tunnels in soft soils

Underground structures constitute crucial components of the transportation networks. Considering their significance for modern societies, their proper seismic design is of great importance. However, this design may become very tricky, accounting of the lack of knowledge regarding their seismic behavior. Several issues that are significantly affecting this behavior (i.e. earth pressures on the structure, seismic shear stresses around the structure, complex deformation modes for rectangular structures during shaking etc.) are still open. The problem is wider for the non-circular (i.e. rectangular) structures, were the soilstructure interaction effects are expected to be maximized. The paper presents representative experimental results from a test case of a series of dynamic centrifuge tests that were performed on rectangular tunnels embedded in dry sand. The tests were carried out at the centrifuge facility of the University of Cambridge, within the Transnational Task of the SERIES EU research program. The presented test case is also numerically simulated and studied. Preliminary full dynamic time history analyses of the coupled soil-tunnel system are performed, using ABAQUS. Soil non-linearity and soil-structure interaction are modeled, following relevant specifications for underground structures and tunnels. Numerical predictions are compared to experimental results and discussed. Based on this comprehensive experimental and numerical study, the seismic behavior of rectangular embedded structures is better understood and modeled, consisting an important step in the development of appropriate specifications for the seismic design of rectangular shallow tunnels.

CCS工程中盖层渗透率对CO_2逃逸的影响

针对CO_2埋存后可能存在的逃逸问题进行了分析, 在对ABAQUS商用软件进行二次开发的基础上, 针对各个因素进行了计算; 并对简单情况进行了理论推导, 验证了数值模型的正确性.考虑到CO_2逃逸过程中可能发生相态变化, 数值模拟时分别采用理想气体状态方程和范德华方程以对结果进行比较, 结果表明, 在盖层均匀和通常的气藏条件下, CO_2完全渗漏需要l5xl0~4年以上; 盖层含井或有裂缝时会导致CO_2快速逃逸, 完全逃逸在lxl0~4年左右, 在选址时应该尽量避免

弹塑性海床上的海底管道沉降特性分析

海底管线的在位稳定性问题是海底管线设计中的关键问题之一,为对海底管线的设计提供理论依据,采用有限元软件ABAQUS对管土系统进行分析。海床土体采用Ramberg-Osgood模型进行模拟,管土接触面采用"接触对"的算法进行处理,解决了管道嵌入海床的动边界接触问题。通过改变管道的水下重、环境载荷、管径、屈服应力等参数进行计算。数值计算结果表明这些参数对管道的沉降量都有一定程度的影响。

桩靴压入对固定平台基础扰动的数值模拟

运用商业有限元软件ABAQUS对桩靴压入过程对固定式平台基础的扰动进行了数值模拟。首先将计算结果与离心机实验结果进行了对照,以验证本文所采用本构模型和数值模拟方法的可行性;然后对桩靴压入不同深度时由于扰动引起的固定式平台的桩基础的应力和变形,以及桩周围土体的变形进行了模拟和分析。结果表明,桩基础周围一倍桩靴直径范围内的土体受到明显影响。

南海天然气水合物加热开采过程中海底稳定性研究

利用Abaqus有限元软件，结合我国南海水合物的矿藏情况，对水合物的加热开采过程进行传热分析。首先利用热流值计算输入的总热量，再根据已分解的水合物计算水合物分解消耗的热量以及产出的天然气燃烧后产生的热量，估算在加热开采过程中的热效率(用于水合物分解的热量与输入热量之比)、能量效率(开采所得甲烷气体燃烧后放出的热量与输入热量之比)与水合物分解范围之间的关系。结果表明，当水合物分解到一定范围后，产出热量会小于输入热量，所以在实际开采过程中应控制水合物的分解范围，以保证较高的热效率。以此为依据对水合物在实际开采过程中的分解范围控制及布井情况进行分析，在确定水合物最大分解范围之后，假设在水合物区打竖直开采井，对水合物加热开采过程进行热力耦合计算。这里计算的温度场为一个瞬态温度场，随着加热的进行，水合物的分解范围从井筒附近向外围不断扩大。水合物分解后，沉积物弹性模量和强度会明显降低，在模拟过程中，把沉积物的参数设成温度的函数，通过温度场来控制沉积物参数的变化，从而解决水合物分解过程中的移动边界问题。按上述方法计算出水合物加热开采过程中不同分解范围时海床表面岩体的位移情况及矿区岩体的塑性区情况，最后总结出水合物开采过程中海床表面的位移变化规律及矿区岩体的塑性区发展规律，给出合理的开采建议。

Coupled Temperature-Displacement Modelling of Injection Stretch Blow Moulding of PET bottles using Buckley Model

This study presents a fully coupled temperature–displacement finite element modelling of the injection stretch-blow moulding (ISBM) process of polyethylene terephthalate (PET) bottles using ABAQUS with a view to optimising the process conditions. A physically-based material model (Buckley model) was used to predict the mechanical behaviour of PET at temperatures slightly above its glass transition temperature. A model incorporating heat transfer between the stretch rod, the preform and the mould was built using axisymmetric solid elements. Extensive finite element analyses were carried out to predict the deformation, the distribution and history of strain and temperature during ISBM of a 20 g–330 ml bottle, which was made in an in situ test on a Sidel SB06 machine. Comparisons of numerical results with the measurements demonstrate that the model can satisfactorily model the sidewall thickness and material distributions. It is also shown that significant non-linear differentials exist in temperature and strain in both bottle thickness and length directions during the process. This justifies the employment of a volume approach to accurately predict the final mechanical properties of the bottles governed by the orientation and crystallinity which are highly temperature and strain dependent.

Finite element investigation of the structural behaviour of deck slabs in composite bridges

This research studies the structural behaviour of bridge deck slabs under static patch loads in steel–concrete composite bridges and investigates compressive membrane action (CMA) in concrete bridge decks slabs, which governs the structural behaviour. A non-linear 3D finite element analysis models was developed using ABAQUS 6.5 software packages. Experimental data from one-span composite bridge structures are used to validate and calibrate the proposed FEM models. A series of parametric studies is conducted. The analysis results are discussed and conclusions on the behaviour of the bridge decks are presented.

Validating Injection Stretch-Blow Molding Simulation Through Free Blow Trials

A 2D isothermal finite element simulation of the injection stretch-blow molding (ISBM) process for polyethylene terephthalate (PET) containers has been developed through the commercial finite element package ABAQUS/standard. In this work, the blowing air to inflate the PET preform was modeled through two different approaches: a direct pressure input (as measured in the blowing machine) and a constant mass flow rate input (based on a pressure-volume-time relationship). The results from these two approaches were validated against free blow and free stretch-blow experiments, which were instrumented and monitored through high-speed video. Results show that simulation using a constant mass flow rate approach gave a better prediction of volume vs. time curve and preform shape evolution when compared with the direct pressure approach and hence is more appropriate in modeling the preblowing stage in the injection stretch-blow molding process

Viscoelastic Material Models of Polypropylene for Thermoforming Applications

Polypropylene (PP), a semi-crystalline material, is typically solid phase thermoformed at temperatures associated with crystalline melting, generally in the 150° to 160°Celsius range. In this very narrow thermoforming window the mechanical properties of the material rapidly decline with increasing temperature and these large changes in properties make Polypropylene one of the more difficult materials to process by thermoforming. Measurement of the deformation behaviour of a material under processing conditions is particularly important for accurate numerical modelling of thermoforming processes. This paper presents the findings of a study into the physical behaviour of industrial thermoforming grades of Polypropylene. Practical tests were performed using custom built materials testing machines and thermoforming equipment at Queen′s University Belfast. Numerical simulations of these processes were constructed to replicate thermoforming conditions using industry standard Finite Element Analysis software, namely ABAQUS and custom built user material model subroutines. Several variant constitutive models were used to represent the behaviour of the Polypropylene materials during processing. This included a range of phenomenological, rheological and blended constitutive models. The paper discusses approaches to modelling industrial plug-assisted thermoforming operations using Finite Element Analysis techniques and the range of material models constructed and investigated. It directly compares practical results to numerical predictions. The paper culminates discussing the learning points from using Finite Element Methods to simulate the plug-assisted thermoforming of Polypropylene, which presents complex contact, thermal, friction and material modelling challenges. The paper makes recommendations as to the relative importance of these inputs in general terms with regard to correlating to experimentally gathered data. The paper also presents recommendations as to the approaches to be taken to secure simulation predictions of improved accuracy.

Non-linear finite-element analysis of punching capacities of steel-concrete bridge deck slabs

Punching failure is the common failure mode in concrete bridge deck slabs when these structural components are subjected to local patch loads, such as tyre loads. Past research has shown that reinforced concrete slabs in girder–slab type bridges have a load-carrying capacity far greater than the ultimate static loads predicted by traditional design methods, because of the presence of compressive membrane action. However, due to the instability problems from punching failure, it is difficult to predict ultimate capacities accurately in numerical analyses. In order to overcome the instability problems, this paper establishes an efficient non-linear finite-element analysis using the commercial finite-element package Abaqus. In the non-linear finite-element analysis, stabilisation methods were adopted and failure criteria were established to predict the ultimate punching behaviour of deck slabs in composite steel–concrete bridges. The proposed non-linear finite-element analysis predictions showed a good correlation on punching capacities with experimental tests.

Modelling and Instrumentation of Stretch Blow Moulding

The injection stretch blow moulding process is used to manufacture PET containers used in the soft drinks and carbonated soft drinks industry. The process consists of a test tube like specimen known as a preform which is heated, stretch and blown into a mould to form the container. This research is focused on developing a validated simulation of the process thus enabling manufacturers to design their products in a virtual environment without the need to waste time, material and energy. The simulation has been developed using the commercial FEA package Abaqus and has been validated using state of the art data acquisition system consisting of measurements for preform temperature (inner and outer wall) using a device known as THERMOscan (Figure 1), stretch rod force and velocity, internal pressure and air temperature inside the preform using an instrumented stretch rod and the?exact?timing of when the preform touches the mould wall using contact sensors.? In addition, validation studies have also been performed by blowing a perform without a mould and using high sped imaging technology in cooperation with an advanced digital image correlation system (VIC 3D) to provided new quantitative information on the behaviour of PET during blowing.? The approach has resulted in a realistic simulation in terms of accurate input parameters, preform shape evolution and prediction of final properties.

Automatic Insertion of Cohesive Elements for Delamination

Composite damage modelling with cohesive elements has initially been limited to the analysis of interface damage or delamination. However, their use is also being extended to the analysis of inplane tensile failure arising from matrix or fibre fracture. These interface elements are typically placed at locations where failure is likely to occur, which infers a certain a priori knowledge of the crack propagation path(s). In the case of a crack jump for example, the location of the jump is usually not obvious, and the simulation would require the placement of cohesive elements at all element faces. A better option, presented here, is to determine the potential location of cohesive elements and insert them during the analysis. The aim of this work is to enable the determination of the crack path, as part of the solution process. A subroutine has been developed and implemented in the commercial finite element package ABAQUS/Standard[1] in order to automatically insert cohesive elements within a pristine model, on the basis of the analysis of the current stress field. Results for the prediction of delamination are presented in this paper.