Numerical investigation of the effects of drill geometry on drilling induced delamination of carbon fiber reinforced composites

Drilling is a major process in the manufacturing of holes required for the assemblies of composite laminates in aerospace industry. Simulation of drilling process is an effective method in optimizing the drill geometry and process parameters in order to improve hole quality and to reduce the drill wear. In this research we have developed three-dimensional (3D) FE model for drilling CFRP. A 3D progressive intra-laminar failure model based on the Hashin's theory is considered. Also an inter-laminar delamination model which includes the onset and growth of delamination by using cohesive contact zone is developed. The developed model with inclusion of the improved delamination model and real drill geometry is used to make comparison between the step drill of different stage ratio and twist drill. Thrust force, torque and work piece stress distributions are estimated to decrease by the use of step drill with high stage ratio. The model indicates that delamination and other workpiece defects could be controlled by selection of suitable step drill geometry. Hence the 3D model could be used as a design tool for drill geometry for minimization of delamination in CFRP drilling. © 2013 Elsevier Ltd.

Wear analysis and prediction of the life of a riveting die used in the automotive industry

Knowledge on the life span of the riveting dies used in the automotive industry is sparse. It is often the case that only when faulty products are produced are workers aware that their tool needs to be changed. This is of course costly both in terms of time and money. Responding to this challenge, this paper proposes a methodology which integrates wear and stress analysis to quantify the life of a riveting die. Experiments are carried out to measure the applied load required to split a rivet. The obtained results (i.e. force curves) are used to validate the wear mechanisms of the die observed using scanning electron microscopy. Sliding, impact, and adhesive wears are observed on the riveting die after a certain number of riveting cycles. The stress distribution on the die during riveting is simulated using a finite element (FE) approach. In order to confirm the accuracy of the FE model, the experimental force results are compared with the ones produced from FE simulation. The maximum and minimum von Mises' stresses generated from the FE model are input into a Goodman diagram and an S-N curve to compute the life of the riveting die. It is found that the riveting die is predicted to run for 4 980 000 cycles before failure.

K&C局部损伤混凝土材料模型在精细有限元模拟中的应用

This paper presents a study on concrete fracture and the associated mesh sensitivity using the finite element (FE) method with a local concrete model in both tension (Mode I) and compression.To enable the incorporation of dynamic loading, the FE model is developed using a transient dynamic analysis code LS-DYNA Explicit.A series of investigations have been conducted on typical fracture scenarios to evaluate the model performances and calibration of relevant parameters.The K&C damage model was adopted because it is a comprehensive local concrete model which allows the user to change the crack band width, fracture energy and rate dependency of the material.Compressive localisation modelling in numerical modelling is also discussed in detail in relation to localisation.An impact test specimen is modelled.

Assessment of the impact speed and angle conditions for the EN1317 barrier tests

Roadside safety barriers designs are tested with passenger cars in Europe using standard EN1317 in which the impact angle for normal, high and very high containment level tests is 20°. In comparison to EN1317, the US standard MASH has higher impact angles for cars and pickups (25°) and different vehicle masses. Studies in Europe (RISER) and the US have shown values for the 90th percentile impact angle of 30°–34°. Thus, the limited evidence available suggests that the 20° angle applied in EN 1317 may be too low.
The first goal of this paper is to use the US NCHRP database (Project NCHRP 17–22) to assess the distribution of impact angle and collision speed in recent ROR accidents. Second, based on the findings of the statistical analysis and on analysis of impact angles and speeds in the literature, an LS-DYNA finite element analysis was carried out to evaluate the normal containment level of concrete barriers in non-standard collisions. The FE model was validated against a crash test of a portable concrete barrier carried out at the UK Transport Research Laboratory (TRL).
The accident data analysis for run-off road accidents indicates that a substantial proportion of accidents have an impact angle in excess of 20°. The baseline LS-DYNA model showed good comparison with experimental acceleration severity index (ASI) data and the parametric analysis indicates a very significant influence of impact angle on ASI. Accordingly, a review of European run-off road accidents and the configuration of EN 1317 should be performed.

Überwachung der Vorspannkraft Externer Spannglieder mit Hilfe der Modalanalyse

Aufgrund ihrer Vorteile hinsichtlich Dauerhaftigkeit und Bauwerkssicherheit ist in Deutschland seit 1998 die externe Vorspannung in Hohlkastenbrücken zur Regelbauweise geworden. Durch Verwendung der austauschbaren externen Vorspannung verspricht man sich im Brückenbau weitere Verbesserungen der Robustheit und damit eine Verlängerung der Lebensdauer. Trotz des besseren Korrosionsschutzes im Vergleich zur internen Vorspannung mit Verbund sind Schäden nicht völlig auszuschließen. Um die Vorteile der externen Vorspannung zu nutzen, ist daher eine periodische Überwachung der Spanngliedkräfte, z. B. während der Hauptprüfung des Bauwerks, durchzuführen. Für die Überwachung der Spanngliedkräfte bei Schrägseilbrücken haben sich die Schwingungsmessmethoden als wirtschaftlich und leistungsfähig erwiesen. Für die Übertragung der Methode auf den Fall der externen Vorspannung, wo kürzere Schwingungslängen vorliegen, waren zusätzliche Untersuchungen hinsichtlich der effektiven Schwingungslänge, der Randbedingungen sowie der effektiven Biegesteifigkeit erforderlich. Im Rahmen der vorliegenden Arbeit wurde das Modellkorrekturverfahren, basierend auf der iterativen Anpassung eines F.E.-Modells an die identifizierten Eigenfrequenzen und Eigenformen des Spanngliedes, für die Bestimmung der Spanngliedkräfte verwendet. Dieses Verfahren ermöglicht die Berücksichtigung der Parameter (Schwingungslänge, Randbedingungen und effektive Biegesteifigkeit) bei der Identifikation der effektiven Spanngliedkräfte. Weiterhin ist eine Modellierung jeder beliebigen Spanngliedausbildung, z. B. bei unterschiedlichen Querschnitten in den Verankerungs- bzw. Umlenkbereichen, gewährleistet. Zur Anwendung bei der Ermittlung der Spanngliedkräfte wurde eine spezielle Methode, basierend auf den besonderen dynamischen Eigenschaften der Spannglieder, entwickelt, bei der die zuvor genannten Parameter innerhalb jedes Iterationsschrittes unabhängig korrigiert werden, was zur Robustheit des Identifikationsverfahrens beiträgt. Das entwickelte Verfahren ist in einem benutzerfreundlichen Programmsystem implementiert worden. Die erzielten Ergebnisse wurden mit dem allgemeinen Identifikationsprogramm UPDATE_g2 verglichen; dabei ist eine sehr gute Übereinstimmung festgestellt worden. Beim selbst entwickelten Verfahren wird die benötigte Rechenzeit auf ca. 30 % reduziert [100 sec à 30 sec]. Es bietet sich daher für die unmittelbare Auswertung vor Ort an. Die Parameteridentifikationsverfahren wurden an den Spanngliedern von insgesamt sechs Brücken (vier unterschiedliche Spannverfahren) angewendet. Die Anzahl der getesteten Spannglieder beträgt insgesamt 340. Die Abweichung zwischen den durch Schwingungs-messungen identifizierten und gemessenen (bei einer Brücke durch eine Abhebekontrolle) bzw. aufgebrachten Spanngliedkräften war kleiner als 3 %. Ferner wurden die Auswirkungen äußerer Einflüsse infolge Temperaturschwankungen und Verkehr bei den durchgeführten Messungen untersucht. Bei der praktischen Anwendung sind Besonderheiten aufgetreten, die durch die Verwendung des Modellkorrekturverfahrens weitgehend erfasst werden konnten. Zusammenfassend lässt sich sagen, dass die Verwendung dieses Verfahrens die Genauigkeit im Vergleich mit den bisherigen Schwingungsmessmethoden beachtlich erhöht. Ferner wird eine Erweiterung des Anwendungsbereiches auch auf Spezialfälle (z. B. bei einem unplanmäßigen Anliegen) gewährleistet.

Parameter identification of structural dynamic models by inverse statistical analysis

Auf dem Gebiet der Strukturdynamik sind computergestützte Modellvalidierungstechniken inzwischen weit verbreitet. Dabei werden experimentelle Modaldaten, um ein numerisches Modell für weitere Analysen zu korrigieren. Gleichwohl repräsentiert das validierte Modell nur das dynamische Verhalten der getesteten Struktur. In der Realität gibt es wiederum viele Faktoren, die zwangsläufig zu variierenden Ergebnissen von Modaltests führen werden: Sich verändernde Umgebungsbedingungen während eines Tests, leicht unterschiedliche Testaufbauten, ein Test an einer nominell gleichen aber anderen Struktur (z.B. aus der Serienfertigung), etc. Damit eine stochastische Simulation durchgeführt werden kann, muss eine Reihe von Annahmen für die verwendeten Zufallsvariablengetroffen werden. Folglich bedarf es einer inversen Methode, die es ermöglicht ein stochastisches Modell aus experimentellen Modaldaten zu identifizieren. Die Arbeit beschreibt die Entwicklung eines parameter-basierten Ansatzes, um stochastische Simulationsmodelle auf dem Gebiet der Strukturdynamik zu identifizieren. Die entwickelte Methode beruht auf Sensitivitäten erster Ordnung, mit denen Parametermittelwerte und Kovarianzen des numerischen Modells aus stochastischen experimentellen Modaldaten bestimmt werden können.

Improving flood models using LiDAR: progress and problems

Airborne scanning laser altimetry (LiDAR) is an important new data source for river flood modelling. LiDAR can give dense and accurate DTMs of floodplains for use as model bathymetry. Spatial resolutions of 0.5m or less are possible, with a height accuracy of 0.15m. LiDAR gives a Digital Surface Model (DSM), so vegetation removal software (e.g. TERRASCAN) must be used to obtain a DTM. An example used to illustrate the current state of the art will be the LiDAR data provided by the EA, which has been processed by their in-house software to convert the raw data to a ground DTM and separate vegetation height map. Their method distinguishes trees from buildings on the basis of object size. EA data products include the DTM with or without buildings removed, a vegetation height map, a DTM with bridges removed, etc. Most vegetation removal software ignores short vegetation less than say 1m high. We have attempted to extend vegetation height measurement to short vegetation using local height texture. Typically most of a floodplain may be covered in such vegetation. The idea is to assign friction coefficients depending on local vegetation height, so that friction is spatially varying. This obviates the need to calibrate a global floodplain friction coefficient. It’s not clear at present if the method is useful, but it’s worth testing further. The LiDAR DTM is usually determined by looking for local minima in the raw data, then interpolating between these to form a space-filling height surface. This is a low pass filtering operation, in which objects of high spatial frequency such as buildings, river embankments and walls may be incorrectly classed as vegetation. The problem is particularly acute in urban areas. A solution may be to apply pattern recognition techniques to LiDAR height data fused with other data types such as LiDAR intensity or multispectral CASI data. We are attempting to use digital map data (Mastermap structured topography data) to help to distinguish buildings from trees, and roads from areas of short vegetation. The problems involved in doing this will be discussed. A related problem of how best to merge historic river cross-section data with a LiDAR DTM will also be considered. LiDAR data may also be used to help generate a finite element mesh. In rural area we have decomposed a floodplain mesh according to taller vegetation features such as hedges and trees, so that e.g. hedge elements can be assigned higher friction coefficients than those in adjacent fields. We are attempting to extend this approach to urban area, so that the mesh is decomposed in the vicinity of buildings, roads, etc as well as trees and hedges. A dominant points algorithm is used to identify points of high curvature on a building or road, which act as initial nodes in the meshing process. A difficulty is that the resulting mesh may contain a very large number of nodes. However, the mesh generated may be useful to allow a high resolution FE model to act as a benchmark for a more practical lower resolution model. A further problem discussed will be how best to exploit data redundancy due to the high resolution of the LiDAR compared to that of a typical flood model. Problems occur if features have dimensions smaller than the model cell size e.g. for a 5m-wide embankment within a raster grid model with 15m cell size, the maximum height of the embankment locally could be assigned to each cell covering the embankment. But how could a 5m-wide ditch be represented? Again, this redundancy has been exploited to improve wetting/drying algorithms using the sub-grid-scale LiDAR heights within finite elements at the waterline.

Analysis of the effects of damping in the models validation

The search for better performance in the structural systems has been taken to more refined models, involving the analysis of a growing number of details, which should be correctly formulated aiming at defining a representative model of the real system. Representative models demand a great detailing of the project and search for new techniques of evaluation and analysis. Model updating is one of this technologies, it can be used to improve the predictive capabilities of computer-based models. This paper presents a FRF-based finite element model updating procedure whose the updating variables are physical parameters of the model. It includes the damping effects in the updating procedure assuming proportional and non proportional damping mechanism. The updating parameters are defined at an element level or macro regions of the model. So, the parameters are adjusted locally, facilitating the physical interpretation of the adjusting of the model. Different tests for simulated and experimental data are discussed aiming at evaluating the characteristics and potentialities of the methodology.

Rotor support stiffness estimation by sensitivity analysis

In the present work, a method for rotor support stiffness estimation via a model updating process using the sensitivity analysis is presented. This method consists in using the eigenvalues sensitivity analysis, relating to the rotor support stiffnesses variation to perform the adjustment of the model based on the minimization of the difference between eigenvalues of reference and eigenvalues obtained via mathematical model from previously adopted support bearing stiffness values. The mathematical model is developed by the finite element method and the method of adjustment should converge employing an iterative process. The performance and robustness of the method have been analyzed through a numerical example.

Experimental damage detection using system norms

Nowadays there is great interest in structural damage detection in systems using nondestructive tests. Once the failure is detected, as for instance a crack, it is possible to take providences. There are several different approaches that can be used to obtain information about the existence, location and extension of the fault in the system by non-destructive tests. Among these methodologies, one can mention different optimization techniques, as for instance classical methods, genetic algorithms, neural networks, etc. Most of these techniques, which are based on element-byelement adjustments of a finite element (FE) model, take advantage of the dynamic behavior of the model. However, in practical situations, usually, is almost impossible to obtain an accuracy model. In this paper, it is proposed an experimental technique for damage location. This technique is based on H: norm to obtain the damage location. The dynamic properties of the structure were identified using experimental data by eigensystem realization algorithm (ERA). The experimental test was carried out in a beam structure through varying the mass of an element. For the output signal was used a piezoelectric sensor. The signal of input of sine form was generated through SignalCalc® software.

Ajuste de modelos estruturais aplicado em problema de contato

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Estimação de rigidezes de mancais de rotores por análise de sensibilidade

Pós-graduação em Engenharia Mecânica - FEIS

Application of Volterra series in nonlinear mechanical system identification and in structural health monitoring problems

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

Reduced-order modelling, circuit-level design and SOI fabrication of microelectromechanical resonators

This thesis deals with two important research aspects concerning radio frequency (RF) microresonators and switches. First, a new approach for compact modeling and simulation of these devices is presented. Then, a combined process flow for their simultaneous fabrication on a SOI substrate is proposed. Compact models for microresonators and switches are extracted by applying mathematical model order reduction (MOR) to the devices finite element (FE) description in ANSYS c° . The behaviour of these devices includes forms of nonlinearities. However, an approximation in the creation of the FE model is introduced, which enables the use of linear model order reduction. Microresonators are modeled with the introduction of transducer elements, which allow for direct coupling of the electrical and mechanical domain. The coupled system element matrices are linearized around an operating point and reduced. The resulting macromodel is valid for small signal analysis around the bias point, such as harmonic pre-stressed analysis. This is extremely useful for characterizing the frequency response of resonators. Compact modelling of switches preserves the nonlinearity of the device behaviour. Nonlinear reduced order models are obtained by reducing the number of nonlinearities in the system and handling them as input to the system. In this way, the system can be reduced using linear MOR techniques and nonlinearities are introduced directly in the reduced order model. The reduction of the number of system nonlinearities implies the approximation of all distributed forces in the model with lumped forces. Both for microresonators and switches, a procedure for matrices extraction has been developed so that reduced order models include the effects of electrical and mechanical pre-stress. The extraction process is fast and can be done automatically from ANSYS binary files. The method has been applied for the simulation of several devices both at devices and circuit level. Simulation results have been compared with full model simulations, and, when available, experimental data. Reduced order models have proven to conserve the accuracy of finite element method and to give a good description of the overall device behaviour, despite the introduced approximations. In addition, simulation is very fast, both at device and circuit level. A combined process-flow for the integrated fabrication of microresonators and switches has been defined. For this purpose, two processes that are optimized for the independent fabrication of these devices are merged. The major advantage of this process is the possibility to create on-chip circuit blocks that include both microresonators and switches. An application is, for example, aswitched filter bank for wireless transceiver. The process for microresonators fabrication is characterized by the use of silicon on insulator (SOI) wafers and on a deep reactive ion etching (DRIE) step for the creation of the vibrating structures in single-crystal silicon and the use of a sacrificial oxide layer for the definition of resonator to electrode distance. The fabrication of switches is characterized by the use of two different conductive layers for the definition of the actuation electrodes and by the use of a photoresist as a sacrificial layer for the creation of the suspended structure. Both processes have a gold electroplating step, for the creation of the resonators electrodes, transmission lines and suspended structures. The combined process flow is designed such that it conserves the basic properties of the original processes. Neither the performance of the resonators nor the performance of the switches results affected by the simultaneous fabrication. Moreover, common fabrication steps are shared, which allows for cheaper and faster fabrication.

Creep and damage models for the service behaviour of structural members

Deformability is often a crucial to the conception of many civil-engineering structural elements. Also, design is all the more burdensome if both long- and short-term deformability has to be considered. In this thesis, long- and short-term deformability has been studied from the material and the structural modelling point of view. Moreover, two materials have been handled: pultruded composites and concrete. A new finite element model for thin-walled beams has been introduced. As a main assumption, cross-sections rigid are considered rigid in their plane; this hypothesis replaces that of the classical beam theory of plane cross-sections in the deformed state. That also allows reducing the total number of degrees of freedom, and therefore making analysis faster compared with twodimensional finite elements. Longitudinal direction warping is left free, allowing describing phenomena such as the shear lag. The new finite-element model has been first applied to concrete thin-walled beams (such as roof high span girders or bridge girders) subject to instantaneous service loadings. Concrete in his cracked state has been considered through a smeared crack model for beams under bending. At a second stage, the FE-model has been extended to the viscoelastic field and applied to pultruded composite beams under sustained loadings. The generalized Maxwell model has been adopted. As far as materials are concerned, long-term creep tests have been carried out on pultruded specimens. Both tension and shear tests have been executed. Some specimen has been strengthened with carbon fibre plies to reduce short- and long- term deformability. Tests have been done in a climate room and specimens kept 2 years under constant load in time. As for concrete, a model for tertiary creep has been proposed. The basic idea is to couple the UMLV linear creep model with a damage model in order to describe nonlinearity. An effective strain tensor, weighting the total and the elasto-damaged strain tensors, controls damage evolution through the damage loading function. Creep strains are related to the effective stresses (defined by damage models) and so associated to the intact material.