Prediction of residual stresses in roller burnished components : a finite element approach

Surface finish is an important factor in creating the durable metal components, and fatigue strength can be improved if compressive residual stresses are produced in the surface. Burnishing is a finishing process and compressive residual stresses are induced during the process. The present study of minimizing the surface roughness based on the experimental work, and finite element model was developed to evaluate the analytical results. Commercial purity Mild Steel and Aluminium were selected as work specimens and a high carbon high chromium roller was used as a tool for the burnishing process.

Recent advances of finite elements for laminated composite plates

A large amount of finite elements have been developed for finite element analysis of laminated composite plates. The laminated plate theories are reviewed and summarized in this paper. The focus of this review is on the recently developed laminated finite elements since 1990. The 2-D triangular and quadrilateral displacement-based and mixed/hybrid-based finite element models, which were developed based on the first-order shear deformation theories, the higher-order shear deformation theories, the zig-zag theories and the global-local higher-order deformation theories, and the layer-wise laminated plate theories are reviewed in this paper and also their related patents. Finally, some points on the development of the laminated finite elements are summarized.

Finite element modeling of a generic stemless hip implant design in comparison with conventional hip implants

In this study, the finite element modeling and comparison of the stress and strain analyses were carried out for three different structures that are intact bone, stemless implant and stemmed one. Currently proposed stemless design studied here is the generic concept of stemless implant. This generic stemless implant reconstruction was numerically compared to the conventional stemmed implant and also to the intact bone as control solution. Two loading conditions were applied to the most proximal part of the models, while the most distal part was fixed for all degrees of freedom. The models were divided into two regions and studied along two paths of medial and lateral aspect. The results of this study showed that the stemless implant had less deviation from the control solution of the bone in all regions and in both loading conditions, comparing to the large deviation of the stemmed implant from the intact bone. However, it was shown that the fixation of this type of implant and its effect on sub-trochanter region must be carefully considered for designing the final product of any specific design of stemless implant.

Analytical solutions and finite element modelling of deep drawing process for cylindrical metal cups

Analytical modelling of deep drawing process is of value in preliminary process design to illustrate the influence of major variables including friction and strain hardening on punch loads, cup dimensions and process limits. In this study, analytical models including theoretical solution and a series of finite element models are developed to account for the influences of process parameters including friction coefficient, tooling geometry and material properties on deep drawing of metal cups. The accuracy of both the theoretical and finite element solutions is satisfactory compared with those from experimental work.

Finite element simulations of the cyclic elastoplastic behaviour of copper thin films

A large-scale computational and statistical strategy is presented to investigate the development of plastic strain heterogeneities and plasticity induced roughness at the free surface in multicrystalline films subjected to cyclic loading conditions, based on continuum crystal plasticity theory. The distribution of plastic strain in the grains and its evolution during cyclic straining are computed using the finite element method in films with different ratios of in-plane grain size and thickness, and as a function of grain orientation (grains with a {1 1 1} or a {0 0 1} plane parallel to the free surface and random orientations). Computations are made for 10 different realizations of aggregates containing 50 grains and one large aggregate with 225 grains. It is shown that overall cyclic hardening is accompanied by a significant increase in strain dispersion. The case of free-standing films is also addressed for comparison. The overall surface roughness is shown to saturate within 10 to 15 cycles. Plasticity induced roughness is due to the higher deformation of {0 0 1} and random grains and due to the sinking or rising at some grain boundaries.

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.