Early design verification of complex assembly variability using a hybrid - model based and physical testing - methodology

Design verification in the digital domain, using model-based principles, is a key research objective to address the industrial requirement for reduced physical testing and prototyping. For complex assemblies, the verification of design and the associated production methods is currently fragmented, prolonged and sub-optimal, as it uses digital and physical verification stages that are deployed in a sequential manner using multiple systems. This paper describes a novel, hybrid design verification methodology that integrates model-based variability analysis with measurement data of assemblies, in order to reduce simulation uncertainty and allow early design verification from the perspective of satisfying key assembly criteria.

Development of dynamic structural testing to current state-of-the-art hybrid testing

Even though computational power used for structural analysis is ever increasing, there is still a fundamental need for testing in structural engineering, either for validation of complex numerical models or to assess material behaviour. In addition to analysis of structures using scale models, many structural engineers are aware to some extent of cyclic and shake-table test methods, but less so of ‘hybrid testing’. The latter is a combination of physical testing (e.g. hydraulic
actuators) and computational modelling (e.g. finite element modelling). Over the past 40 years, hybrid testing of engineering structures has developed from concept through to maturity to become a reliable and accurate dynamic testing technique. The hybrid test method provides users with some additional benefits that standard dynamic testing methods do not, and the method is more cost-effective in comparison to shake-table testing. This article aims to provide the reader with a basic understanding of the hybrid test method, including its contextual development and potential as a dynamic testing technique.

Effects of cement thickness and bonding on the failure loads of CAD/CAM ceramic crowns: Multi-physics FEA modeling and monotonic testing

Objective. To determine the influence of cement thickness and ceramic/cement bonding on stresses and failure of CAD/CAM crowns, using both multi-physics finite element analysis and monotonic testing.Methods. Axially symmetric FEA models were created for stress analysis of a stylized monolithic crown having resin cement thicknesses from 50 to 500 mu m under occlusal loading. Ceramic-cement interface was modeled as bonded or not-bonded (cement-dentin as bonded). Cement polymerization shrinkage was simulated as a thermal contraction. Loads necessary to reach stresses for radial cracking from the intaglio surface were calculated by FEA. Experimentally, feldspathic CAD/CAM crowns based on the FEA model were machined having different occlusal cementation spaces, etched and cemented to dentin analogs. Non-bonding of etched ceramic was achieved using a thin layer of poly(dimethylsiloxane). Crowns were loaded to failure at 5 N/s, with radial cracks detected acoustically.Results. Failure loads depended on the bonding condition and the cement thickness for both FEA and physical testing. Average fracture loads for bonded crowns were: 673.5 N at 50 mu m cement and 300.6 N at 500 mu m. FEA stresses due to polymerization shrinkage increased with the cement thickness overwhelming the protective effect of bonding, as was also seen experimentally. At 50 mu m cement thickness, bonded crowns withstood at least twice the load before failure than non-bonded crowns.Significance. Occlusal "fit" can have structural implications for CAD/CAM crowns; pre-cementation spaces around 50-100 mu m being recommended from this study. Bonding benefits were lost at thickness approaching 450-500 mu m due to polymerization shrinkage stresses. (C) 2012 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Análise técnica do uso de resíduos de poli (tereftalato de etileno) (PET) na indústria têxtil

O aumento no volume de rejeitos industriais e a contínua produção de resíduos de naturezas diversas causam muitas preocupações no âmbito ambiental. Neste contexto, o descarte de embalagens e garrafas de poli(tereftalato de etileno) (PET) tem se tornado um grande problema por conta da pequena atenção que se dá à sua destinação final. Assim sendo, essa pesquisa propõe a análise técnica da utilização de resíduos de PET, oriundos de reciclagem primária, como matéria-prima para a indústria têxtil. Fios de PET reciclado foram comparados aos fios comerciais de poliéster através de diversos ensaios como, por exemplo, resistência à tração e ensaios para solidificação da cor. Ao mesmo tempo, a microscopia eletrônica de varredura (MEV) foi usada para a investigação da morfologia dos fios e melhor interpretação dos resultados. Pôde ser verificado que os fios de PET reciclado apresentam satisfatório desempenho, embora a resistência mecânica e a solidez a cor à luz sejam inferiores àquelas dos fios convencionais de poliéster.

Estimativa de espessura do concreto utilizando o método do eco - impacto

Nesta pesquisa utilizou-se um equipamento experimental que utiliza o método do eco-impacto produzido no Laboratório de Ensaios Físicos do Instituto Politécnico do Rio de Janeiro (UERJ/IPRJ), para estimar a espessuras de placas de concreto através da propagação de ondas de tensão geradas por um impacto. Para determinação dessa espessura, foram investigados vários mecanismos de estruturação do protótipo do equipamento com objetivo de se obter a melhor leitura possível, por meio das literaturas existentes. Entre parâmetros avaliados no estudo, estava o modelo de sensor a ser utilizado, o tipo de impactor, a precisão relacionada à aquisição de dados e o tratamento do mesmo, a distância entre o ponto de impacto e o transdutor (sensor), e o local de teste. Os resultados experimentais concordam com as previsões teóricas e revelam que este método é eficiente para análise de estrutura de concreto. A análise da espessura e resposta em frequência de um novo protótipo desenvolvido e os testes realizados possibilitou um erro médio de espessura real para amostras sem agregados de 0,39% e para as amostras com agregados com de 0,64%. Esses resultados apontam que o equipamento produzido tem potencial e que o mesmo pode ser utilizado para avaliação de estrutura de concreto.

Do we know the strength of the chorioamnion? A critical review and analysis

The chorioamnion is the membrane that surrounds the fetus during gestation. Normally, it must remain intact for the duration of pregnancy, 37-42 weeks, and only rupture during or just before labour and delivery of the fetus. In a significant number (3%) of all births, this does not happen, and membranes rupture before term, resulting in preterm birth and significant perinatal morbidity. It is known that the material properties of chorioamnion may play a major role in mechanical rupture; a number of studies have been undertaken to characterise the physical nature of chorioamnion and examine factors that may predispose to rupture. However, the existing literature is inconsistent in its choice of both physical testing methods and data analysis techniques, motivating the current review. Experimental data from a large number of chorioamnion mechanical studies were collated, and data were converted to standard engineering quantities. The failure strength of the chorioamnion membrane was found consistently to value approximately 0.9 MPa. It is hoped that past and future studies of membrane mechanics can provide insight into the role of chorioamnion in labour and delivery. In addition, biomechanical approaches can help elucidate the potential causes of early rupture, and suggest future protocols or treatments that could both diagnose and prevent its occurrence. © 2009 Elsevier Ireland Ltd.

Use of automatic sand pourers for loose sand models

The consistency of laboratory sand model preparation for physical testing is a fundamental criterion in representing identical geotechnical issues at prototype scale. This objective led to the development of robotic apparatus to eliminate the non-uniformity in manual pouring. Previous studies have shown consistent sand models with high relative density between 50 to 90% produced by the automatic moving-hopper sand pourer at the University of Cambridge, based primarily on a linear correlation to flow rate. However, in the case of loose samples, the influence of other parameters, particularly the drop height, becomes more apparent. In this paper, findings on the effect of flow rate and drop height are discussed in relation to the layer thickness and relative density of loose sand samples. Design charts are presented to illustrate their relationships. The effect of these factors on different sand types is also covered to extend the use of the equipment. © 2010 Taylor & Francis Group, London.

The effect of 3D weaving and consolidation on carbon fiber tows, fabrics, and composites

This article investigates the damage imparted on load-bearing carbon fibers during the 3D weaving process and the subsequent compaction behavior of 3D woven textile preforms. The 3D multi-layer reinforcements were manufactured on a textile loom with few mechanical modifications to produce preforms with fibers orientated in the warp, weft, and through-the-thickness directions. Tensile tests were conducted on three types of commercially available carbon fibers, 12k HTA, 6k HTS, and 3k HTS in an attempt to quantify the effect of fiber damage induced during the 3D weaving process on the mechanical and physical performance of the fiber tows in the woven composite. The tests were conducted on fiber tows sampled from different locations in the manufacturing process from the bobbin, through the creel and loom mechanism, to the final woven fabric. Mechanical and physical testing were then conducted to quantify the tow geometry, orientation and the effect of compaction during manufacture of two styles of 3D woven composite by vacuumassisted resin transfer molding (VaRTM).

Evaluation of a substructured soft Real-time Hybrid Test for performing Seismic analysis of complex structural systems

The hybrid test method is a relatively recently developed dynamic testing technique that uses numerical modelling combined with simultaneous physical testing. The concept of substructuring allows the critical or highly nonlinear part of the structure that is difficult to numerically model with accuracy to be physically tested whilst the remainder of the structure, that has a more predictable response, is numerically modelled. In this paper, a substructured soft-real time hybrid test is evaluated as an accurate means of performing seismic tests of complex structures. The structure analysed is a three-storey, two-by-one bay concentrically braced frame (CBF) steel structure subjected to seismic excitation. A ground storey braced frame substructure whose response is critical to the overall response of the structure is tested, whilst the remainder of the structure is numerically modelled. OpenSees is used for numerical modelling and OpenFresco is used for the communication between the test equipment and numerical model. A novel approach using OpenFresco to define the complex numerical substructure of an X-braced frame within a hybrid test is also presented. The results of the hybrid tests are compared to purely numerical models using OpenSees and a simulated test using a combination of OpenSees and OpenFresco. The comparative results indicate that the test method provides an accurate and cost effective procedure for performing
full scale seismic tests of complex structural systems.

Experimental Investigation of Transient Saltwater Intrusion in Heterogeneous Porous Media

A 2D sandbox style experiment was developed to compare the results of numerical modelling to physical testing for saltwater intrusion in homogeneous and heterogeneous aquifers. The sandbox consisted of a thin central viewing chamber filled with glass beads of varying diameters (780μm, 1090μm and 1325μm) under fully saturated conditions. Dyed saltwater (SW) was introduced at the side boundary and a head difference imposed across the porous media. Images of the SW wedge were recorded at intervals in order to assess the suitability of the numerical models predictions of transient SW intrusion. Numerical modelling of the experimental cases were simulated using SUTRA. Two main parameters were chosen to express the condition of the intruding SW wedge at each recorded time step; the toe penetration length (TL) and the width of the mixing zone (WMZ). The WMZ was larger under transient conditions in the heterogeneous case, while the TL was longer for the homogeneous case. The increased variability in the flow field fo the heterogeneous case resulted in increased dispersion, and thus, increased WMZ.

Modelling Damage in Thin-Walled Structures [Keynote speaker]

A high-fidelity composite damage model is presented and applied to predict low-velocity impact damage, compression after impact (CAI) strength and crushing of thin-walled composite structures. The simulated results correlated well with experimental testing in terms of overall force-displacement response, damage morphologies and energy dissipation. The predictive power of this model makes it suitable for use as part of a virtual testing methodology, reducing the reliance on physical testing.  

Extreme Loads on an Oscillating Wave Surge Converter

A major difficulty in the design of full scale Wave Energy Converters is the need to design for two conflicting design criteria. In one instance devices must be designed to couple heavily to the incident wave force resulting in the efficient extraction of energy in small sea states, however devices must also be capable of withstanding the harsh conditions encountered during extreme seas. This paper presents an initial investigation of the extreme wave loading of a generic, surface-piercing, pitching flap-type device deployed in near shore wave conditions. Slamming of the flap is selected as the extreme load event for further investigation and the experimental methodologies employed are described. Preliminary results showing both local and global loading under such events are presented for the case of a flap tested in a 3-dimensional environment. Results are presented which show flap slamming effects on the pressures experienced on the front face of the flap.

Validation of a 3D damage model for predicting the response of composite structures under crushing loads

A 3D intralaminar continuum damage mechanics based material model, combining damage mode interaction and material nonlinearity, was developed to predict the damage response of composite structures undergoing crush loading. This model captures the structural response without the need for calibration of experimentally determined material parameters. When used in the design of energy absorbing composite structures, it can reduce the dependence on physical testing. This paper validates this model against experimental data obtained from the literature and in-house testing. Results show that the model can predict the force response of the crushed composite structures with good accuracy. The simulated energy absorption in each test case was within 12% of the experimental value. Post-crush deformation and the damage morphologies, such as ply splitting, splaying and breakage, were also accurately reproduced. This study establishes the capability of this damage model for predicting the responses of composite structures under crushing loads.