A DIGITAL TWIN FOR AUTOMATED LAYUP OF PREPREG COMPOSITE SHEETS

2021 ◽  
pp. 1-15
Author(s):  
Yi-Wei Chen ◽  
Rex Jomy Joseph ◽  
Alec Kanyuck ◽  
Shahwaz Khan ◽  
Rishi K. Malhan ◽  
...  
Keyword(s):  
High Speed ◽  
Sheet Material ◽  
Simulation System ◽  
Cotton Cloth ◽  
Average Error ◽  
Composite Sheet ◽  
Element Analysis ◽  
Viscoelastic Composite ◽  
Material Parameters ◽  
Digital Twin

Abstract The composite sheet layup process involves stacking several layers of a viscoelastic prepreg sheet and curing the laminate to manufacture the component. Demands for automating functional tasks in the composite manufacturing processes have dramatically increased in the past decade. A simulation system representing a digital twin of the composite sheet can aid in the development of such an autonomous system for prepreg sheet layup. While Finite Element Analysis (FEA) is a popular approach for simulating flexible materials, material properties need to be encoded to produce high-fidelity mechanical simulations. We present a methodology to predict material parameters of a thin-shell FEA model based on real-world observations of the deformations of the object. We utilize the model to develop a digital twin of a composite sheet. The method is tested on viscoelastic composite prepreg sheets and fabric materials such as cotton cloth, felt and canvas. We discuss the implementation and development of a high-speed FEA simulator based on the VegaFEM library. By using our method to identify sheet material parameters, the sheet simulation system is able to predict sheet behavior within 5 cm of average error and have proven its capability for 10 fps real-time sheet simulation.

A Digital Twin for Automated Layup of Prepreg Composite Sheets

2021 ◽  
Author(s):  
Yi-Wei Chen ◽  
Rex Jomy Joseph ◽  
Alec Kanyuck ◽  
Shahwaz Khan ◽  
Rishi K. Malhan ◽  
...  
Keyword(s):  
High Speed ◽  
Sheet Material ◽  
Simulation System ◽  
Cotton Cloth ◽  
Average Error ◽  
Composite Sheet ◽  
Element Analysis ◽  
Viscoelastic Composite ◽  
Material Parameters ◽  
Digital Twin

Abstract The composite sheet layup process involves stacking several layers of a viscoelastic prepreg sheet and curing the laminate to manufacture the component. Demands for automating functional tasks in the composite manufacturing processes have dramatically increased in the past decade. A simulation system representing a digital twin of the composite sheet can aid in the development of such an autonomous system for prepreg sheet layup. While Finite Element Analysis (FEA) is a popular approach for simulating flexible materials, material properties need to be encoded to produce high-fidelity mechanical simulations. We present a methodology to predict material parameters of a thin-shell FEA model based on real-world observations of the deformations of the object. We utilize the model to develop a digital twin of a composite sheet. The method is tested on viscoelastic composite prepreg sheets and fabric materials such as cotton cloth, felt and canvas. We discuss the implementation and development of a high-speed FEA simulator based on the VegaFEM library [29]. By using our method to identify sheet material parameters, the sheet simulation system is able to predict sheet behavior within 5 cm of average error and have proven its capability for 10 fps real-time sheet simulation.

Homogenized FEA of Composite Sheet Materials for Improved Thermoforming Process

2012 ◽  
Author(s):  
Sathya Narasimhan ◽  
Jorge Rodriguez
Keyword(s):  
Sheet Material ◽  
Layered Composite ◽  
Composite Sheet ◽  
Element Analysis ◽  
Prototype Development ◽  
Development Tool ◽  
Homogenization Approach ◽  
Thermoforming Process ◽  
Analytical Tools ◽  
Single Material

Absence of reliable analytical tools to model thermoforming of automobile headliners leads to lack of understanding of critical relationships between design, material and process, resulting in large proportions of scraps and in some cases, over engineering. Thus, a Finite Element Analysis (FEA) of thermoforming of a composite sheet material has been formulated and implemented. An homogenization approach is suggested, in which the layered composite is treated to behave as a single material. By mapping key process variables into analysis, a simulation has been successfully carried out on a headliner prototype development tool. Results obtained with such development tool show good correlation to key headliner defects such as wrinkles and failures.

Performance analysis of magnetic gear with Halbach array for high power and high speed

2020 ◽  
Vol 64 (1-4) ◽  
pp. 959-967
Author(s):  
Se-Yeong Kim ◽  
Tae-Woo Lee ◽  
Yon-Do Chun ◽  
Do-Kwan Hong
Keyword(s):  
Permanent Magnet ◽  
Eddy Current ◽  
High Power ◽  
High Speed ◽  
Torque Ripple ◽  
Eddy Current Loss ◽  
Element Analysis ◽  
Current Loss ◽  
Halbach Array ◽  
Magnetic Gear

In this study, we propose a non-contact 80 kW, 60,000 rpm coaxial magnetic gear (CMG) model for high speed and high power applications. Two models with the same power but different radial and axial sizes were optimized using response surface methodology. Both models employed a Halbach array to increase torque. Also, an edge fillet was applied to the radial magnetized permanent magnet to reduce torque ripple, and an axial gap was applied to the permanent magnet with a radial gap to reduce eddy current loss. The models were analyzed using 2-D and 3-D finite element analysis. The torque, torque ripple and eddy current loss were compared in both models according to the materials used, including Sm2Co17, NdFeBs (N42SH, N48SH). Also, the structural stability of the pole piece structure was investigated by forced vibration analysis. Critical speed results from rotordynamics analysis are also presented.

Lifetime Prediction of Tires with Regard to Oxidative Aging5

2008 ◽  
Vol 36 (1) ◽  
pp. 63-79 ◽  
Author(s):  
L. Nasdala ◽  
Y. Wei ◽  
H. Rothert ◽  
M. Kaliske
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Temperature Distribution ◽  
Superposition Principle ◽  
Accelerated Aging ◽  
Material Model ◽  
Aging Behavior ◽  
Element Analysis ◽  
Material Parameters ◽  
Reaction Processes

Abstract It is a challenging task in the design of automobile tires to predict lifetime and performance on the basis of numerical simulations. Several factors have to be taken into account to correctly estimate the aging behavior. This paper focuses on oxygen reaction processes which, apart from mechanical and thermal aspects, effect the tire durability. The material parameters needed to describe the temperature-dependent oxygen diffusion and reaction processes are derived by means of the time–temperature–superposition principle from modulus profiling tests. These experiments are designed to examine the diffusion-limited oxidation (DLO) effect which occurs when accelerated aging tests are performed. For the cord-reinforced rubber composites, homogenization techniques are adopted to obtain effective material parameters (diffusivities and reaction constants). The selection and arrangement of rubber components influence the temperature distribution and the oxygen penetration depth which impact tire durability. The goal of this paper is to establish a finite element analysis based criterion to predict lifetime with respect to oxidative aging. The finite element analysis is carried out in three stages. First the heat generation rate distribution is calculated using a viscoelastic material model. Then the temperature distribution can be determined. In the third step we evaluate the oxygen distribution or rather the oxygen consumption rate, which is a measure for the tire lifetime. Thus, the aging behavior of different kinds of tires can be compared. Numerical examples show how diffusivities, reaction coefficients, and temperature influence the durability of different tire parts. It is found that due to the DLO effect, some interior parts may age slower even if the temperature is increased.

Tribological and dynamical analysis of a brake pad with multiple blocks for a high-speed train

2019 ◽  
Vol 234 (11) ◽  
pp. 1771-1788
Author(s):  
YK Wu ◽  
JL Mo ◽  
B Tang ◽  
JW Xu ◽  
B Huang ◽  
...  
Keyword(s):  
High Speed ◽  
Wear Behavior ◽  
Dynamical Analysis ◽  
Brake Disc ◽  
Brake Pad ◽  
High Speed Train ◽  
Brake Squeal ◽  
Element Analysis ◽  
Single Block ◽  
Middle Ring

In this research, the tribological and dynamical characteristics of a brake pad with multiple blocks are investigated using experimental and numerical methods. A dynamometer with a multiblock brake pad configuration on a brake disc is developed and a series of drag-type tests are conducted to study the brake squeal and wear behavior of a high-speed train brake system. Finite element analysis is performed to derive physical explanations for the observed experimental phenomena. The experimental and numerical results show that the rotational speed and braking force have important influences on the brake squeal; the trends of the multiblock and single-block systems are different. In the multiblock brake pad, the different blocks exhibit significantly different magnitudes of contact stresses and vibration accelerations. The blocks located in the inner and outer rings have higher vibration acceleration amplitudes and stronger vibration energies than the blocks located in the middle ring.

Dynamic Analysis of DVG 850 High-Speed Machining Center

2012 ◽  
Vol 487 ◽  
pp. 203-207
Author(s):  
Gong Xue Zhang ◽  
Xiao Kai Shen
Keyword(s):  
High Speed ◽  
Simulation Analysis ◽  
Response Analysis ◽  
Improved Method ◽  
Analysis Software ◽  
Element Analysis ◽  
Harmonic Response ◽  
Machining Center ◽  
Calculation Results ◽  
Harmonic Response Analysis

Purpose, with the application of workbench finite element analysis software, get the analysis results of DVG 850 high-speed vertical machining center via the modal analysis and harmonic response analysis. Use the calculation results for reference, put forward the improved method, and prove the credibility of the simulation analysis by testing DVG 850 prototype.

scholarly journals A new evaluation and prediction model of sound quality of high-speed permanent magnet motor based on genetic algorithm-radial basis function artificial neural network

2021 ◽  
Vol 104 (3) ◽  
pp. 003685042110311
Author(s):  
Kai Hu ◽  
Guangming Zhang ◽  
Wenyi Zhang
Keyword(s):  
Neural Network ◽  
Genetic Algorithm ◽  
Artificial Neural Network ◽  
Basis Function ◽  
High Speed ◽  
Objective Evaluation ◽  
Sound Quality ◽  
Average Error ◽  
Permanent Magnet Motor ◽  
Predicted Model

Sound quality (SQ) has become an important index to measure the competitiveness of motor products. To better evaluate and optimize SQ, a novelty SQ evaluation and prediction model of high-speed permanent magnet motor (HSPMM) with better accuracy is presented in this research. Six psychoacoustic parameters of A-weighted sound pressure level (ASPL), loudness, sharpness, roughness, fluctuation strength (FS), and perferred-frequency speech interference (PSIL) were adopted to objectively evaluate the SQ of HSPMM under multiple operating conditions and subjective evaluation was also conducted by the combination of semantic subdivision method and grade scoring method. The evaluation results show that the SQ is poor, which will have a certain impact on human psychology and physiology. The correlation between the objective evaluation parameters and the subjective scores is analyzed by coupling the subjective and objective evaluation results. The average error of multiple linear regression (MLR) model is 7.10%. It has good accuracy, but poor stability. In order to improve prediction accuracy, a new predicted model of radial basis function (RBF) artificial neural network was put forward based on genetic algorithm (GA) optimization. Compared with MLR, its average error rate is reduced by 3.16% and the standard deviation is reduced by 1.841. In addition, the weight of each objective parameter was analyzed. The new predicted model has a better accuracy. It can evaluate and optimize the SQ exactly. The research methods and conclusions of this paper can be extended to the evaluation, prediction, and optimization of SQ of other motors.

scholarly journals Optimization of Air Gap Length and Capacitive Auxiliary Winding in Three-Phase Induction Motors Based on a Genetic Algorithm

Energies ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4407
Author(s):  
Mbika Muteba
Keyword(s):  
Genetic Algorithm ◽  
Design Process ◽  
Power Factor ◽  
High Speed ◽  
High Efficiency ◽  
Air Gap ◽  
Element Analysis ◽  
Three Phase ◽  
High Torque ◽  
Cage Induction Motor

There is a necessity to design a three-phase squirrel cage induction motor (SCIM) for high-speed applications with a larger air gap length in order to limit the distortion of air gap flux density, the thermal expansion of stator and rotor teeth, centrifugal forces, and the magnetic pull. To that effect, a larger air gap length lowers the power factor, efficiency, and torque density of a three-phase SCIM. This should inform motor design engineers to take special care during the design process of a three-phase SCIM by selecting an air gap length that will provide optimal performance. This paper presents an approach that would assist with the selection of an optimal air gap length (OAL) and optimal capacitive auxiliary stator winding (OCASW) configuration for a high torque per ampere (TPA) three-phase SCIM. A genetic algorithm (GA) assisted by finite element analysis (FEA) is used in the design process to determine the OAL and OCASW required to obtain a high torque per ampere without compromising the merit of achieving an excellent power factor and high efficiency for a three-phase SCIM. The performance of the optimized three-phase SCIM is compared to unoptimized machines. The results obtained from FEA are validated through experimental measurements. Owing to the penalty functions related to the value of objective and constraint functions introduced in the genetic algorithm model, both the FEA and experimental results provide evidence that an enhanced torque per ampere three-phase SCIM can be realized for a large OAL and OCASW with high efficiency and an excellent power factor in different working conditions.

scholarly journals Study on the High-Speed Milling Performance of High-Volume Fraction SiCp/Al Composites

Materials ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4143
Author(s):  
Youzheng Cui ◽  
Shenrou Gao ◽  
Fengjuan Wang ◽  
Qingming Hu ◽  
Cheng Xu ◽  
...  
Keyword(s):  
High Speed ◽  
Large Scale ◽  
Volume Fraction ◽  
Simulation Analysis ◽  
Cutting Temperature ◽  
High Volume ◽  
Cutting Parameters ◽  
High Volume Fraction ◽  
High Wear Resistance ◽  
Element Analysis

Compared with other materials, high-volume fraction aluminum-based silicon carbide composites (hereinafter referred to as SiCp/Al) have many advantages, including high strength, small change in the expansion coefficient due to temperature, high wear resistance, high corrosion resistance, high fatigue resistance, low density, good dimensional stability, and thermal conductivity. SiCp/Al composites have been widely used in aerospace, ordnance, transportation service, precision instruments, and in many other fields. In this study, the ABAQUS/explicit large-scale finite element analysis platform was used to simulate the milling process of SiCp/Al composites. By changing the parameters of the tool angle, milling depth, and milling speed, the influence of these parameters on the cutting force, cutting temperature, cutting stress, and cutting chips was studied. Optimization of the parameters was based on the above change rules to obtain the best processing combination of parameters. Then, the causes of surface machining defects, such as deep pits, shallow pits, and bulges, were simulated and discussed. Finally, the best cutting parameters obtained through simulation analysis was the tool rake angle γ0 = 5°, tool clearance angle α0 = 5°, corner radius r = 0.4 mm, milling depth ap = 50 mm, and milling speed vc= 300 m/min. The optimal combination of milling parameters provides a theoretical basis for subsequent cutting.

Numerical Calculation of Aerodynamic Noise for the Nose Cone Surface in High Speed Airflow Field

2014 ◽  
Vol 488-489 ◽  
pp. 886-891
Author(s):  
Ai Jian Zheng ◽  
Feng Niu ◽  
Hai Jiang Zhu
Keyword(s):  
Numerical Calculation ◽  
High Speed ◽  
Aerodynamic Noise ◽  
Element Analysis ◽  
Analysis Theory ◽  
Nose Cone ◽  
Flow Induced Noise ◽  
Airflow Field ◽  
Boundary Element Analysis ◽  
Acoustic Boundary Element

This paper presents two nose cones models and their numerical calculation of aerodynamic noise in high speed airflow field combining the analysis theory of fluid dynamics with the acoustic boundary element analysis method. The noise sound pressure levels (SPL) of these two models are calculated under the different speed airflow. And we compare the SPL of the better model with that of commercial nose cone models. These simulated results show that the aerodynamic noise of the nose cone with a ellipsoid head has lower flow-induced noise than that of commercial nose cone models at relative high air flow velocities at most frequencies.

Sign in / Sign up

Export Citation Format

Share Document