A Multiphysics Finite Element Model of a 35A Automotive Connector Including Multiscale Rough Surface Contact

2012 ◽  
Vol 134 (1) ◽  
Author(s):  
Santosh V. Angadi ◽  
Robert L. Jackson ◽  
Song-yul Choe ◽  
George T. Flowers ◽  
Bong-Yi Lee ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Rough Surface ◽  
Temperature Rise ◽  
Thermal Contact ◽  
Element Model ◽  
Electrical Contacts ◽  
Contact Method ◽  
Surface Contact ◽  
Rough Surface Contact

Electrical contacts influence the reliability and performance of relays, electrical connectors, high power connectors, and similar systems, and are therefore a key region which needs to be considered. In the current study, a new inclusive multiphysics (involving mechanical, electrical, and thermal fields) finite element model (FEM) of a 35A automotive connector has been developed. The contact resistance is predicted using a multiscale rough surface contact method and is embedded in the multiphysics FEM. The coupled connector model is solved to obtain stresses, displacements, contact pressures, electrical and thermal contact resistances, voltage, current density, and temperature distributions. It appears that the current flows mostly through very small regions that are usually near the contacting surfaces in the connector, thereby suggesting that the available conducting material can be more efficiently used by developing optimized connector designs. Through analytical calculations and experimental measurements of temperature rise (ΔT or change in temperature) for the cable and the connector, it is believed that a large portion of the temperature rise in actual 35A connectors is due to the Joule heating in the supply cables. The model is a powerful tool that can be used for the basic connector characterization, prototype evaluation, and design through various material properties, and surface finishes.

scholarly journals Two-dimensional finite element analysis investigation of the heat partition ratio of a friction brake

2018 ◽  
Vol 232 (12) ◽  
pp. 1489-1501 ◽  
Author(s):  
Le Qiu ◽  
Hong-Sheng Qi ◽  
Alastair Wood
Keyword(s):  
Heat Flux ◽  
Finite Element ◽  
Finite Element Model ◽  
Thermal Contact ◽  
Element Model ◽  
Partition Ratio ◽  
Thermal Contact Conductance ◽  
Interface Temperature ◽  
Two Dimensional ◽  
Heat Partition

A two-dimensional coupled temperature–displacement finite element model is developed for a pad-disc brake system based on a restricted rotational pad boundary condition. The evolution of pressure, heat flux, and temperature along the contact interface during braking applications is analysed with the finite element model. Results indicate that different rotational pad boundary conditions significantly impact the interface pressure distribution, which in turn affects interface temperature and heat flux distributions, and suggest that a particular pad rotation condition is most appropriate for accurately modelling friction braking processes. The importance of the thermal contact conductance in the analysis of heat transfer in friction braking is established, and it is confirmed that the heat partition ratio is not uniformly distributed along the interface under normal and high interface thermal conductance conditions.

A Finite Element Model of a Rotating Platform Total Knee Employing a Nonlinear, Dual-Surface-Contact Formulation

2000 ◽  
Author(s):  
Jason K. Otto ◽  
Thomas D. Brown ◽  
John J. Callaghan
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Mobile Bearing ◽  
Element Model ◽  
Polyethylene Insert ◽  
Rotating Platform ◽  
Mobile Interface ◽  
Surface Contact ◽  
Total Knee

Abstract Mobile bearing total knees avoid the conformity/constraint tradeoff of fixed bearing total knees. However, a recent in vivo fluoroscopic study of the most popular mobile bearing total knee in the U.S. showed that bearing motion failed to occur in half of the patients observed. A nonlinear, multiple-surface contact finite element model of a rotating platform total knee was therefore developed to investigate the interaction at the “mobile” interface (contact between the tibial tray and the polyethylene insert) under physiologically relevant loads (1–4 BW) and rotations (10° endorotation). The data showed that there was a linear relationship between axial load and the torque resisting endorotation. Peak contact stresses were located on the medial and lateral peripheral edges of the polyethylene insert. All relative rotation occurred at the “mobile” interface. The same trends were seen in a complementary experimental study of the same components, suggesting that the finite element model is valid under these loading conditions.

An Efficient Multi-Scale Modeling Method that Reveals Coupled Effects Between Surface Roughness and Roll-Stack Deformation in Cold Sheet Rolling

2021 ◽  
pp. 1-53
Author(s):  
Feng Zhang ◽  
Arif S Malik
Keyword(s):  
Surface Roughness ◽  
Finite Element ◽  
Rough Surface ◽  
Material Behavior ◽  
Sheet Rolling ◽  
Elastic Plastic ◽  
Multi Scale ◽  
Macro Scale ◽  
Surface Contact ◽  
Rough Surface Contact

Abstract In thin-gauge cold rolling of metal sheet, the surface roughness of work-rolls is known to affect the rolled sheet surface morphology, the required rolling load, and the roll wear. While modeling of rough surfaces using statistical asperity theory has been widely applied to problems involving semi-infinite solids, the application of asperity distributions and their elastic-plastic behavior has not been considered in roll-stack models for cold sheet rolling. In this work, a simplified-mixed finite element method (SM-FEM) is combined with statistical elastic-plastic asperity theory to study contact interference and coupling effects between a rough work-roll surface and the roll-stack mechanics in cold sheet rolling. By mixing equivalent rough-surface contact foundations, Hertz foundations, and Timoshenko beam stiffness, an approach is created to efficiently model interactions between the micro-scale asperities and the macro-scale roll-stack deformation. Nonlinearities from elastic-plastic material behavior of the asperities and the sheet, as well as changing contact conditions along the roll length, are also accommodated. Performance of the multi-scale SM-FEM approach is made by comparison to a continuum finite element virtual material model. 3D studies for a 4-high mill reveal new multi-scale coupling behaviors, including non-uniform roughness transfer, and perturbations to the sheet thickness ‘crown’ and contact force profiles. The described multi-scale SM-FEM approach is general and applies to rough surface contact problems involving plates and shear-deformable beams having multiple contact interfaces and arbitrary surface profiles.

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