Examination of stress and strain in glass structures during pressure treatment using FEM simulation and experimental tests

Otto-von-Guericke-Universität Magdeburg, Fakultät für Maschinenbau, Dissertation, 2016

Integrating open source codes for solid modeling and automatic mesh generation in FEM applications

The applications of the Finite Element Method (FEM) for three-dimensional domains are already well documented in the framework of Computational Electromagnetics. However, despite the power and reliability of this technique for solving partial differential equations, there are only a few examples of open source codes available and dedicated to the solid modeling and automatic constrained tetrahedralization, which are the most time consuming steps in a typical three-dimensional FEM simulation. Besides, these open source codes are usually developed separately by distinct software teams, and even under conflicting specifications. In this paper, we describe an experiment of open source code integration for solid modeling and automatic mesh generation. The integration strategy and techniques are discussed, and examples and performance results are given, specially for complicated and irregular volumes which are not simply connected. © 2011 IEEE.

Energy harvesting through arterial wall deformation: A FEM approach to fluid–structure interactions and magneto-hydrodynamics

Engineers are confronted with the energy demand of active medical implants in patients with increasing life expectancy. Scavenging energy from the patient’s body is envisioned as an alternative to conventional power sources. Joining in this effort towards human-powered implants, we propose an innovative concept that combines the deformation of an artery resulting from the arterial pressure pulse with a transduction mechanism based on magneto-hydrodynamics. To overcome certain limitations of a preliminary analytical study on this topic, we demonstrate here a more accurate model of our generator by implementing a three-dimensional multiphysics finite element method (FEM) simulation combining solid mechanics, fluid mechanics, electric and magnetic fields as well as the corresponding couplings. This simulation is used to optimize the generator with respect to several design parameters. A first validation is obtained by comparing the results of the FEM simulation with those of the analytical approach adopted in our previous study. With an expected overall conversion efficiency of 20% and an average output power of 30 μW, our generator outperforms previous devices based on arterial wall deformation by more than two orders of magnitude. Most importantly, our generator provides sufficient power to supply a cardiac pacemaker.

Characterisation and investigation of local variations in mechanical behaviour in cast aluminium using gradient solidification, Digital Image Correlation and finite element simulation

Due to design and process-related factors, there are local variations in the microstructure and mechanical behaviour of cast components. This work establishes a Digital Image Correlation (DIC) based method for characterisation and investigation of the effects of such local variations on the behaviour of a high pressure, die cast (HPDC) aluminium alloy. Plastic behaviour is studied using gradient solidified samples and characterisation models for the parameters of the Hollomon equation are developed, based on microstructural refinement. Samples with controlled microstructural variations are produced and the observed DIC strain field is compared with Finite Element Method (FEM) simulation results. The results show that the DIC based method can be applied to characterise local mechanical behaviour with high accuracy. The microstructural variations are observed to cause a redistribution of strain during tensile loading. This redistribution of strain can be predicted in the FEM simulation by incorporating local mechanical behaviour using the developed characterization model. A homogeneous FEM simulation is unable to predict the observed behaviour. The results motivate the application of a previously proposed simulation strategy, which is able to predict and incorporate local variations in mechanical behaviour into FEM simulations already in the design process for cast components.

Non-linear modal analysis for beams subjected to axial loads: Analytical and finite-element solutions

A rigorous derivation of non-linear equations governing the dynamics of an axially loaded beam is given with a clear focus to develop robust low-dimensional models. Two important loading scenarios were considered, where a structure is subjected to a uniformly distributed axial and a thrust force. These loads are to mimic the main forces acting on an offshore riser, for which an analytical methodology has been developed and applied. In particular, non-linear normal modes (NNMs) and non-linear multi-modes (NMMs) have been constructed by using the method of multiple scales. This is to effectively analyse the transversal vibration responses by monitoring the modal responses and mode interactions. The developed analytical models have been crosschecked against the results from FEM simulation. The FEM model having 26 elements and 77 degrees-of-freedom gave similar results as the low-dimensional (one degree-of-freedom) non-linear oscillator, which was developed by constructing a so-called invariant manifold. The comparisons of the dynamical responses were made in terms of time histories, phase portraits and mode shapes. (C) 2008 Elsevier Ltd. All rights reserved.

Inductance Calculation of Tooth-Coil Permanent-Magnet Synchronous Machines

Analytical calculation methods for all the major components of the synchronous inductance of tooth-coil permanentmagnet synchronous machines are reevaluated in this paper. The inductance estimation is different in the tooth-coil machine compared with the one in the traditional rotating field winding machine. The accuracy of the analytical torque calculation highly depends on the estimated synchronous inductance. Despite powerful finite element method (FEM) tools, an accurate and fast analytical method is required at an early design stage to find an initialmachine design structure with the desired performance. The results of the analytical inductance calculation are verified and assessed in terms of accuracy with the FEM simulation results and with the prototype measurement results.

Sähkökoneessa esiintyvien voimien yksityiskohtainen mittausjärjestelmä

Hissiteollisuudessa nostokoneistoina käytettyjen sähkömoottoreiden laatuvaatimukset ovat tiuken-tuneet viime vuosina. Erityisesti koneistojen tuottama ääni ja mekaaninen värähtely ovat olleet jat-kuvasti tiukentuneen tarkastelun alaisena. Hissikoriin ja hissiä ympäröiviin rakenteisiin välittyvästä värähtelystä johtuva ääni on yksi hissin laatuvaikutelmaan merkittävimmin vaikuttavia tekijöitä. Nostokoneisto on yksi tärkeimmistä äänen ja värähtelyn lähteistä hissijärjestelmässä. Koneiston suunnittelulla edellä mainittuja tekijöitä voidaan minimoida. Sähkökoneiden suunnittelussa finiit-tielementtimenetelmien (FEM) käyttö on vakiintunut haastavimmissa sovelluksissa. Kone Oyj:llä nostokoneistoina käytetään aksiaalivuokestomagneettitahtikoneita (AFPMSM), joiden FEM simu-lointiin käytetään yleisesti kolmea eri tapaa. Kukin näistä vaihtoehdoista pitää sisällään omat hyö-tynsä, että haittansa. Suunnittelun kannalta tärkeää on oikean menetelmän valinta ai-ka/informatiivisuus suhteen maksimoimiseksi. Erittäin tärkeää on myös saatujen tulosten oikeelli-suus. Tämän diplomityön tavoite on kehittää järjestelmä, jonka avulla AFPMS-koneen voimia voidaan mitata yksityiskohtaisella tasolla. Järjestelmän avulla voidaan tarkastella käytössä olevien FE-menetelmien tulosten oikeellisuutta sekä äänen että värähtelyn syntymekanismeja. Järjestelmän tarkoitus on myös syventää Kone Oyj tietotaitoa AFPMS-koneiden toiminnasta. Tässä työssä esitellään AFPMS-koneen epäideaalisuuksia, jotka voivat vaikuttaa mittajärjestelmän suunnitteluun. Myös koneen epäideaalisuuksiin lukeutuvaa ääntä on tarkasteltu tässä työssä. Jotta työn tavoitteiden mukaista FE-menetelmien vertailua ja tulosten oikeellisuuden tarkastelua voitai-siin tehdä, myös yleisimpiä AFPMS-koneen FE-menetelmiä tarkastellaan. Työn tuloksena on mittajärjestelmän suunnitelma, jonka avulla voidaan toteuttaa kuuden vapausas-teen voimamittaus jokaiselle koneistomagneetille alle 1N resoluutiolla. Suunnitellun järjestelmän toimivuutta on tarkasteltu FE-menetelmiä käyttäen ja järjestelmässä käytettävän voima-anturin ky-vykkyyttä on todennettu referenssimittauksin. Suunniteltu mittajärjestelmä mahdollistaa sähkömoottorin useiden eri epäideaalisuuksien tarkaste-lun yksityiskohtaisella tasolla. Mittausajatuksen soveltaminen myös muiden koneiden tutkimiseen tarjoaa mahdollisuuksia jatkotutkimuksille.

Experimental and theoretical study of workpiece temperature when end milling hardened steels using (TiAl)N-coated and PcBN-tipped tools

The present work shows an experimental and theoretical study on heat flow when end milling, at high-speed, hardened steels applied to moulds and dies. AISI H13 and AISI D2 steels were machined with two types of ball nose end mills: coated with (TiAl)N and tipped with PcBN. The workpiece geometry was designed to simulate tool-workpiece interaction in real situations found in mould industries, in which complex surfaces and thin walls are commonly machined. The compressed and cold air cooling systems were compared to dry machining Results indicated a relatively small temperature variation, with higher range when machining AISI D2 with PcBN-tipped end mill. All cooling systems used demonstrated good capacity to remove heat from the machined surface, especially the cold air. Compressed air was the most indicated to keep workpiece at relatively stable temperature. A theoretical model was also proposed to estimate the energy transferred to the workpiece (Q) and the average convection coefficient ((h) over bar) for the cooling systems used. The model used a FEM simulation and a steepest decent method to find the best values for both variables. (c) 2007 Elsevier B.V. All rights reserved.

The behaviour of osteocyte dendritic processes in bone under cyclic load (il comportamento dei processi dendritici degli osteociti nel tessuto osseo sottoposti a carico ciclico)

Bone is continually being removed and replaced through the actions of basic multicellular units (BMU). This constant upkeep is necessary to remove microdamage formed naturally due to fatigue and thus maintain the integrity of the bone. The repair process in bone is targeted, meaning that a BMU travels directly to the site of damage and repairs it. It is still unclear how targeted remodelling is stimulated and directed but it is highly likely that osteocytes play a role. A number of theories have been advanced to explain the microcrack osteocyte interaction but no complete mechanism has been demonstrated. Osteocytes are connected to each other by dendritic processes. The “scissors model" proposed that the rupture of these processes where they cross microcracks signals the degree of damage and the urgency of the necessary repair. In its original form it was proposed that under applied compressive loading, microcrack faces will be pressed together and undergo relative shear movement. If this movement is greater than the width of an osteocyte process, then the process will be cut in a “scissors like" motion, releasing RANKL, a cytokine known to be essential in the formation of osteoclasts from pre-osteoclasts. The main aim of this thesis was to investigate this theoretical model with a specific focus on microscopy and finite element modelling. Previous studies had proved that cyclic stress was necessary for osteocyte process rupture to occur. This was a divergence from the original “scissors model" which had proposed that the cutting of cell material occurred in one single action. The present thesis is the first study to show fatigue failure in cellular processes spanning naturally occurring cracks and it's the first study to estimate the cyclic strain range and relate it to the number of cycles to failure, for any type of cell. Rupture due to shear movement was ruled out as microcrack closing never occurred, as a result of plastic deformation of the bone. Fatigue failure was found to occur due to cyclic tensile stress in the locality of the damage. The strain range necessary for osteocyte process rupture was quantified. It was found that the lower the process strain range the greater the number of cycles to cell process failure. FEM modelling allowed to predict stress in the vicinity of an osteocyte process and to analyse its interaction with the bone surrounding it: simulations revealed evident creep effects in bone during cyclic loading. This thesis confirms and dismisses aspects of the “scissors model". The observations support the model as a viable mechanism of microcrack detection by the osteocyte network, albeit in a slightly modified form where cyclic loading is necessary and the method of rupture is fatigue failure due to cyclic tensile motion. An in depth study was performed focusing on microscopy analysis of naturally occurring cracks in bone and FEM simulation analysis of an osteocyte process spanning a microcrack in bone under cyclic load.

Desenvolvimento de célula Pockels na topologia reflexiva aplicada a TP óptico de alta tensão.

O trabalho aborda o estudo e o desenvolvimento de um interferômetro sensor de alta tensão, baseado em célula Pockels (modulador eletro-óptico) na topologia reflexiva (\"double pass\") e que é parte integrante de um Transformador de Potencial Óptico (TPO), que utiliza sistema interferométrico de luz branca (WLI-White Light Interferometry), que está sendo desenvolvido pelo grupo do Laboratório de Sensores Ópticos (LSO) do PEA-EPUSP, e é capaz de medir diretamente tensões presentes em sistema elétrico de potência (SEP) classe 69kVRMS. Para desenvolver o tema proposto foi feita uma revisão da literatura baseada em livros, artigos e teses para identificar topologias em moduladores eletro-ópticos transmissiva (\"single pass\") e reflexiva (\"double pass\") para definir o tipo de modulador mais adequado para a aplicação em questão. A partir dos estudos e implementações realizadas, verificou-se um enorme potencial para o desenvolvimento e aplicação da topologia \"double pass\" no sensor interferométrico da célula de alta tensão do TPO. A topologia mostrou-se vantajosa em relação aos protótipos dos TPOs desenvolvidos anteriormente, a partir de características tais como: a facilidade de recurso de alinhamento do feixe de luz, construção e reprodução relacionados ao cristal eletro-óptico, diminuição do número de componentes ópticos volumétricos e aumento da rigidez dielétrica da célula sensora. Simulações computacionais foram realizadas mediante a aplicação do método dos elementos finitos (MEF) que contribuíram para o auxílio do projeto da célula sensora, particularmente, para estimativa do valor da voltagem de meia onda, V?, parâmetro importante para o projeto do TPO. Um protótipo do TPO com célula sensora de alta tensão reflexiva foi implementado e testado no laboratório de alta tensão do IEEUSP a partir de ensaios com tensões nominais de 69kVrms a 60Hz e máxima de 140kVrms a 60 Hz. Como resultado deste trabalho, amplia-se o conhecimento e domínio das técnicas de construção de interferômetros sensores de alta tensão na topologia reflexiva aplicadas a TPOs.

Análise da fluência em vigas de concreto armado simplesmente apoiadas usando o método dos elementos finitos

Reinforced concrete creep is a phenomenon of great importance. Despite being appointed as the main cause of several pathologies, its effects are yet considered in a simplified way by the structural designers. In addition to studying the phenomenon in reinforced concrete structures and its current account used in the structural analysis, this paper compares creep strains at simply supported reinforced concrete beams in analytical and in experimental forms with the finite element method (FEM) simulation results. The strains and deflections obtained through the analytical form were calculated with the Brazilian code NBR 6118 (2014) recommendations and the simplified method from CEB-FIP 90 and the experimental results were extracted from tests available in the literature. Finite element simulations are performed using ANSYS Workbench software, using its 3D SOLID 186 elements and the structure symmetry. Analyzes of convergence using 2D PLANE 183 elements are held as well. At the end, it is concluded that FEM analyses are quantitative and qualitative efficient for the estimation of this non-linearity and that the method utilized to obtain the creep coefficients values is sufficiently accurate.

Modelling and simulations of ductile iron solidification-induced variations in mechanical behaviour on component and microstructural level

The mechanical behaviour and performance of a ductile iron component is highly dependent on the local variations in solidification conditions during the casting process. Here we show a framework which combine a previously developed closed chain of simulations for cast components with a micro-scale Finite Element Method (FEM) simulation of the behaviour and performance of the microstructure. A casting process simulation, including modelling of solidification and mechanical material characterization, provides the basis for a macro-scale FEM analysis of the component. A critical region is identified to which the micro-scale FEM simulation of a representative microstructure, generated using X-ray tomography, is applied. The mechanical behaviour of the different microstructural phases are determined using a surrogate model based optimisation routine and experimental data. It is discussed that the approach enables a link between solidification- and microstructure-models and simulations of as well component as microstructural behaviour, and can contribute with new understanding regarding the behaviour and performance of different microstructural phases and morphologies in industrial ductile iron components in service.

Progettazione di una pinza demolitrice idraulica

Questo elaborato ha come obiettivo quello di progettare una pinza demolitrice idraulica per macchine operatrici che sia effettivamente producibile, industrializzabile, performante, affidabile ed economicamente competitiva per il mercato internazionale odierno. Dopo una prima parte di introduzione all’oggetto di studio e di comparazione con la concorrenza, vengono mostrati i primi studi sulla cinematica e sugli ingombri dell’attrezzatura eseguiti con l’ausilio del software 2D “DraftSight”. A questo punto si passa alla modellazione in 3D eseguita mediante il software “Solidworks” di tutti i componenti analizzando e giustificando le scelte progettuali che sono state fatte. Vengono quindi riportati tutti i calcoli analitici eseguiti, nonché le verifiche strutturali e l’ottimizzazione topologica realizzate mediante l’ausilio del pacchetto FEM “Simulation” di Solidworks. Infine si valutano i risultati ottenuti dalla progettazione e possibili sviluppi futuri.

Improving FEM crash simulation accuracy through local thickness estimation based on CAD data

In this paper, we present a method for estimating local thickness distribution in nite element models, applied to injection molded and cast engineering parts. This method features considerable improved performance compared to two previously proposed approaches, and has been validated against thickness measured by di erent human operators. We also demonstrate that the use of this method for assigning a distribution of local thickness in FEM crash simulations results in a much more accurate prediction of the real part performance, thus increasing the bene ts of computer simulations in engineering design by enabling zero-prototyping and thus reducing product development costs. The simulation results have been compared to experimental tests, evidencing the advantage of the proposed method. Thus, the proposed approach to consider local thickness distribution in FEM crash simulations has high potential on the product development process of complex and highly demanding injection molded and casted parts and is currently being used by Ford Motor Company.