Potential Application in Energy Harvesting of Intermodal Energy Exchange in a Frame: FEM Analysis

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

Safety factors in sheet pile wall design: considerations by using traditional methods and FEM analysis

The purpose of the work is: define and calculate a factor of collapse related to traditional method to design sheet pile walls. Furthermore, we tried to find the parameters that most influence a finite element model representative of this problem. The text is structured in this way: from chapter 1 to 5, we analyzed a series of arguments which are usefull to understanding the problem, while the considerations mainly related to the purpose of the text are reported in the chapters from 6 to 10. In the first part of the document the following arguments are shown: what is a sheet pile wall, what are the codes to be followed for the design of these structures and what they say, how can be formulated a mathematical model of the soil, some fundamentals of finite element analysis, and finally, what are the traditional methods that support the design of sheet pile walls. In the chapter 6 we performed a parametric analysis, giving an answer to the second part of the purpose of the work. Comparing the results from a laboratory test for a cantilever sheet pile wall in a sandy soil, with those provided by a finite element model of the same problem, we concluded that:in modelling a sandy soil we should pay attention to the value of cohesion that we insert in the model (some programs, like Abaqus, don’t accept a null value for this parameter), friction angle and elastic modulus of the soil, they influence significantly the behavior of the system (structure-soil), others parameters, like the dilatancy angle or the Poisson’s ratio, they don’t seem influence it. The logical path that we followed in the second part of the text is reported here. We analyzed two different structures, the first is able to support an excavation of 4 m, while the second an excavation of 7 m. Both structures are first designed by using the traditional method, then these structures are implemented in a finite element program (Abaqus), and they are pushed to collapse by decreasing the friction angle of the soil. The factor of collapse is the ratio between tangents of the initial friction angle and of the friction angle at collapse. At the end, we performed a more detailed analysis of the first structure, observing that, the value of the factor of collapse is influenced by a wide range of parameters including: the value of the coefficients assumed in the traditional method and by the relative stiffness of the structure-soil system. In the majority of cases, we found that the value of the factor of collapse is between and 1.25 and 2. With some considerations, reported in the text, we can compare the values so far found, with the value of the safety factor proposed by the code (linked to the friction angle of the soil).

FEM Analysis to Optimally Design End Mill cutters for Milling of Ti-6Al-4V

This paper presents an FEM analysis conducted for optimally designing end mill cutters through verifying the cutting tool forces and stresses for milling Titanium alloy Ti-6Al-4 V. Initially, the theoretical tool forces are calculated by considering the cutting edge on a cutting tool as the curve of an intersection over a spherical/flat surface based on the model developed by Lee & Altinas [1]. Considering the lowest tool forces the cutting tool parameters are taken and optimal design of end mill is decided for different sizes. Then the 3D CAD models of the end mills are developed and used for Finite Element Method to verify the cutting forces for milling Ti-6Al-4 V. The cutting tool forces, stress, strain concentration (s), tool wear, and temperature of the cutting tool with the different geometric shapes are simulated considering Ti-6Al-4 V as work piece material. Finally, the simulated and theoretical values are compared and the optimal design of cutting tool for different sizes are validated. The present approach considers to improve the quality of machining surface and tool life with effects of the various parameters concerning the oblique cutting process namely axial, radial and tangential forces. Various simulated test cases are presented to highlight the approach on optimally designing end mill cutters.

FEM and experimental analysis of a wind turbine blade

This paperwork compares the a numerical validation of the finite element model (FEM) with respect the experimental tests of a new generation wind turbine blade designed by TPI Composites Inc. called BSDS (Blade System Design Study). The research is focused on the analysis by finite element (FE) of the BSDS blade and its comparison with respect the experimental data from static and dynamic investigations. The goal of the research is to create a general procedure which is based on a finite element model and will be used to create an accurate digital copy for any kind of blade. The blade prototype was created in SolidWorks and the blade of Sandia National Laboratories Blade System Design Study was accurately reproduced. At a later stage the SolidWorks model was imported in Ansys Mechanical APDL where the shell geometry was created and modal, static and fatigue analysis were carried out. The outcomes of the FEM analysis were compared with the real test on the BSDS blade at Clarkson University laboratory carried out by a new procedures called Blade Test Facility that includes different methods for both the static and dynamic test of the wind turbine blade. The outcomes from the FEM analysis reproduce the real behavior of the blade subjected to static loads in a very satisfying way. A most detailed study about the material properties could improve the accuracy of the analysis.

A comparative analysis between FEM and Boundary Methods in bending of Plates

Two different methods of analysis of plate bending, FEM and BM are discussed in this paper. The plate behaviour is assumed to be represented by using the linear thin plate theory where the Poisson-Kirchoff assumption holds. The BM based in a weighted mean square error technique produced good results for the problem of plate bending. The computational effort demanded in the BM is smaller than the one needed in a FEM analysis for the same level of accuracy. The general application of the FEM cannot be matched by the BM. Particularly, different types of geometry (plates of arbitrary geometry) need a similar but not identical treatment in the BM. However, this loss of generality is counterbalanced by the computational efficiency gained in the BM in the solution achievement

Maastoajoneuvon korin teräsrakenteiden värähtelyominaisuuksien FEM-analysointimenetelmien kehittäminen

Tämä diplomityö on tehty Patria Vehicles Oy:n toimeksiannosta. Patria Vehicles Oy:n tuotantoon kuuluvat vaativiin maasto-olosuhteisiin soveltuvat sotilasajoneuvot. Tutkimuksen tarkoituksena oli kehittää menetelmäohjeet, kuinka FEM-analyysillä voidaan tutkia tuotekehitysvaiheessa ajoneuvon korin teräsrakenteiden värähtelyominaisuuksia ja dynaamista käyttäytymistä. Tutkimuksessa on käytetty Ideas-FEM-ohjelmistoa. Dynaamisten ongelmien ratkaisemiseksi on ymmärrettävä rakenteiden dynaamista käyttäytymistä. Rakenteiden käyttäytymistä ja muodonmuutoksia on tutkittava kriittisillä ominaistaajuuksilla. Tutkimuksessa on selvitetty, kuinka ajoneuvon elementtimallilla voidaan tehdä ominaisvärähtely- ja vastelaskentaa. Ominaisvärähtelylaskennalla selvitetään rakenteen ominaismuodot ja -taajuudet. Vastelaskennalla tutkitaan erilaisten herätteiden vaikutuksia ajoneuvon dynaamiseen käyttäytymiseen ja määritetään herätteistä rakenteeseen aiheutuvat vasteet ja herätteiden siirtyvyys rakenteessa. Lisäksi tutkitaan herätteiden aiheuttamia todellisia jännityksiä ja siirtymiä, jotta saadaan selville rakenteen todelliset rasitukset. Analyyseillä voidaan tutkia, kuinka ajoneuvon korirakennetta on jäykistettävä ja vaimennettava, jotta siinä ei esiinny haitallista melua ja värähtelyä.

FEM based Virtual Prototyping and Design of Third Harmonic Excitation System for Low Voltage Brushless Alternators

Salient pole brushless alternators coupled to IC engines are extensively used as stand-by power supply units for meeting in- dustrial power demands. Design of such generators demands high power to weight ratio, high e ciency and low cost per KVA out- put. Moreover, the performance characteristics of such machines like voltage regulation and short circuit ratio (SCR) are critical when these machines are put into parallel operation and alterna- tors for critical applications like defence and aerospace demand very low harmonic content in the output voltage. While designing such alternators, accurate prediction of machine characteristics, including total harmonic distortion (THD) is essential to mini- mize development cost and time. Total harmonic distortion in the output voltage of alternators should be as low as possible especially when powering very sophis- ticated and critical applications. The output voltage waveform of a practical AC generator is replica of the space distribution of the ux density in the air gap and several factors such as shape of the rotor pole face, core saturation, slotting and style of coil disposition make the realization of a sinusoidal air gap ux wave impossible. These ux harmonics introduce undesirable e ects on the alternator performance like high neutral current due to triplen harmonics, voltage distortion, noise, vibration, excessive heating and also extra losses resulting in poor e ciency, which in turn necessitate de-rating of the machine especially when connected to non-linear loads. As an important control unit of brushless alternator, the excitation system and its dynamic performance has a direct impact on alternator's stability and reliability. The thesis explores design and implementation of an excitation i system utilizing third harmonic ux in the air gap of brushless al- ternators, using an additional auxiliary winding, wound for 1=3rd pole pitch, embedded into the stator slots and electrically iso- lated from the main winding. In the third harmonic excitation system, the combined e ect of two auxiliary windings, one with 2=3rd pitch and another third harmonic winding with 1=3rd pitch, are used to ensure good voltage regulation without an electronic automatic voltage regulator (AVR) and also reduces the total harmonic content in the output voltage, cost e ectively. The design of the third harmonic winding by analytic methods demands accurate calculation of third harmonic ux density in the air gap of the machine. However, precise estimation of the amplitude of third harmonic ux in the air gap of a machine by conventional design procedures is di cult due to complex geome- try of the machine and non-linear characteristics of the magnetic materials. As such, prediction of the eld parameters by conven- tional design methods is unreliable and hence virtual prototyping of the machine is done to enable accurate design of the third har- monic excitation system. In the design and development cycle of electrical machines, it is recognized that the use of analytical and experimental methods followed by expensive and in exible prototyping is time consum- ing and no longer cost e ective. Due to advancements in com- putational capabilities over recent years, nite element method (FEM) based virtual prototyping has become an attractive al- ternative to well established semi-analytical and empirical design methods as well as to the still popular trial and error approach followed by the costly and time consuming prototyping. Hence, by virtually prototyping the alternator using FEM, the important performance characteristics of the machine are predicted. Design of third harmonic excitation system is done with the help of results obtained from virtual prototype of the machine. Third harmonic excitation (THE) system is implemented in a 45 KVA ii experimental machine and experiments are conducted to validate the simulation results. Simulation and experimental results show that by utilizing third harmonic ux in the air gap of the ma- chine for excitation purposes during loaded conditions, triplen harmonic content in the output phase voltage is signi cantly re- duced. The prototype machine with third harmonic excitation system designed and developed based on FEM analysis proved to be economical due to its simplicity and has the added advan- tage of reduced harmonics in the output phase voltage.

Structural verification of the ESEO spacecraft: from launch loads analysis to composite panels verification

The present thesis work was performed in the frame of ESEO (European Student Earth Orbiter) project. The activities that are described in this document were carried out in the Microsatellites and Space Micro systems Lab led by Professor Paolo Tortora and in ALMASpace company facilities. The thesis deals with ESEO structural analysis, at system and unit level, and verification: after determining the design limit loads to be applied to the spacecraft as an envelope of different launchers load profiles, a finite element structural analysis was performed on the model of the satellite in order to ensure the capability to withstand the loads encountered during the launch; all the analyses were performed according to ESA standards and using the software MSC NASTRAN SIMXPERT. Amplification factors were derived and used to determine loads to be considered at unit level. In particular structural analyses were carried out on the GPS unit, the payload developed for ESEO by students of University of Bologna and results were used in the preparation of GPS payload design definition file. As for the verification phase a study on the panels and inserts to be used in the spacecraft was performed: different designs were created exploiting methods to optimize weight and mechanical behavior. The configurations have been analyzed and results compared to select the final design.

Analysis and improvements of an existing industrial hot stamping machine

The importance of product presentation in the marketing industry is well known. Labels are crucial for providing information to the buyer, but at a modest additional expense, a beautiful label with exquisite embellishments may also give the goods a sensation of high quality and elegance. Enhancing the capabilities of stamping machines is required to keep up with the increasing velocity of the production lines in the modern manufacturing industry and to offer new opportunities for customization. It’s in this context of improvements and refinements that this work takes place. The thesis was developed during an internship at Studio D, the firm that designs the mechanics of the machines produced by Cartes. The The aim of this work is to study possible upgrades for the existing hot stamping machines. The main focus of this work is centred on two objectives: first, evaluating the pressing forces generated by this machine and characterising how the mat used in the stamping process reacts to such forces. Second, propose a new conformation for the press mechanism in order to improve the rigidity and performance of the machines. The first objective is reached through a combined approach: the mat is crudely characterized with experimental data, while the frame of the machine is studied through FEM analysis. The results obtained are combined and used to upgrade a worksheet that allows to estimate the forces exerted by the machines. The second objective is reached with the proposal of new, improved designs for the main components of the machines.

Buckling strength of adhesively-bonded single and double-strap repairs on carbon-epoxy structures

This work reports on an experimental and finite element method (FEM) parametric study of adhesively-bonded single and double-strap repairs on carbon-epoxy structures under buckling unrestrained compression. The influence of the overlap length and patch thickness was evaluated. This loading gains a particular significance from the additional characteristic mechanisms of structures under compression, such as fibres microbuckling, for buckling restrained structures, or global buckling of the assembly, if no transverse restriction exists. The FEM analysis is based on the use of cohesive elements including mixed-mode criteria to simulate a cohesive fracture of the adhesive layer. Trapezoidal laws in pure modes I and II were used to account for the ductility of most structural adhesives. These laws were estimated for the adhesive used from double cantilever beam (DCB) and end-notched flexure (ENF) tests, respectively, using an inverse technique. The pure mode III cohesive law was equalled to the pure mode II one. Compression failure in the laminates was predicted using a stress-based criterion. The accurate FEM predictions open a good prospect for the reduction of the extensive experimentation in the design of carbon-epoxy repairs. Design principles were also established for these repairs under buckling.

Toroid inductor development for a SIC DC-DC converter up to 150kW, based on finite element method

Dissertação para a obtenção do grau de Mestre em Engenharia Electrotécnica Ramo de Energia

Numerical simulation of the punching shear behaviour of self-compacting fibre reinforced flat slabs

This paper presents the numerical simulations of the punching behaviour of centrally loaded steel fibre reinforced self-compacting concrete (SFRSCC) flat slabs. Eight half scaled slabs reinforced with different content of hooked-end steel fibres (0, 60, 75 and 90 kg/m3) and concrete strengths of 50 and 70 MPa were tested and numerically modelled. Moreover, a total of 54 three-point bending tests were carried out to assess the post-cracking flexural tensile strength. All the slabs had a relatively high conventional flexural reinforcement in order to promote the occurrence of punching failure mode. Neither of the slabs had any type of specific shear reinforcement rather than the contribution of the steel fibres. The numerical simulations were performed according to the Reissner-Mindlin theory under the finite element method framework. Regarding the classic formulation of the Reissner-Mindlin theory, in order to simulate the progressive damage induced by cracking, the shell element is discretized into layers, being assumed a plane stress state in each layer. The numerical results are, then, compared with the experimental ones and it is possible to notice that they accurately predict the experimental force-deflection relationship. The type of failure observed experimentally was also predicted in the numerical simulations.

Plastic-damage smeared crack model to simulate the behaviour of structures made by cement based materials

This work proposes a constitutive model to simulate nonlinear behaviour of cement based materials subjected to different loading paths. The model incorporates a multidirectional fixed smeared crack approach to simulate crack initiation and propagation, whereas the inelastic behaviour of material between cracks is treated by a numerical strategy that combines plasticity and damage theories. For capturing more realistically the shear stress transfer between the crack surfaces, a softening diagram is assumed for modelling the crack shear stress versus crack shear strain. The plastic damage model is based on the yield function, flow rule and evolution law for hardening variable, and includes an explicit isotropic damage law to simulate the stiffness degradation and the softening behaviour of cement based materials in compression. This model was implemented into the FEMIX computer program, and experimental tests at material scale were simulated to appraise the predictive performance of this constitutive model. The applicability of the model for simulating the behaviour of reinforced concrete shear wall panels submitted to biaxial loading conditions, and RC beams failing in shear is investigated.

Paperikoneen viira- ja puristinosan mitoituslaskennan ohjeistaminen

Työssä laadittiin viira- ja puristinosan rungoston mitoituslaskentaa varten ohjeet FE-analysointiin. Työ suoritettiin keräämällä aluksi eri yksiköissä Valmetilla käytössä olevat mitoituslaskentaohjeet, aihetta käsittelevät muistiot ja diplomityöt sekä sekä keskustelemalla muiden viira- ja puristinosastolla laskentaa suorittavien suunnittelijoiden kanssa. Tämän jälkeen ohjeista koottiin ja täydennettiin yksi yhteinen ohjeisto, joka on jatkossa kaikkien laskijoiden käytössä. Valmiit ohjeet koottiin Valmetin Rautpohjan osastoiden yhteiseen Notes- järjestelmään. Ohjekannasta tehtiin sellainen, että siihen on helppo myöhemmin lisätä muiden rakenneryhmien ohjeita. Ohjeet jaettiin viiteen ryhmään ohjeiden lukemisen ja päivityksen helpottamiseksi. Mitoituslaskentaohjeiden käyttöä testattiin laskemalla yhden todellisen projektin puristinosan runkolaskelmat ohjeiden avulla. Yhteisen ohjeistuksen avulla yhtenäistettiin mallinnus- ja laskentatapoja niin Valmetin sisällä kuin mitoituslaskentaa tekevien alihankkijoiden keskuudessa.

Mechanical Design of Hydraulic Vise

The general task of clamping devise is to connect the parts to the machining centers so that the work piece could be fixed on its position during the whole machining process. Additionally, the work piece should be clamped easily and rapidly by the machine users. The purpose of this Master’s thesis project was to develop a product design and find out the dimensioning of a hydraulic vise system for Astex Engineering OY, which was taking care of the general principles of product design and development during the design process. Throughout the process, the needs of manufacturing and assembling were taken into consideration for the machinability and minimization of the cost of manufacturing. The most critical component of the clamping devise was modeled by FEM for the issue of strength requirements. This 3D model was created with Solidworks and FEM-analysis was done with Cosmos software. As the result of this design work, a prototype of the hydraulic vise was manufactured for Astex Engineering OY and the practical test.