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.

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.

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.

scholarly journals High-performance magneto-rheological clutches for direct-drive actuation: Design and development

2021 ◽  
pp. 1045389X2110069
Author(s):  
Sergey Pisetskiy ◽  
Mehrdad Kermani
Keyword(s):  
High Performance ◽  
Degrees Of Freedom ◽  
Dynamic Range ◽  
Complete Analysis ◽  
Mass Ratio ◽  
Direct Drive ◽  
Element Analysis ◽  
Prototype Development ◽  
Magneto Rheological ◽  
Hall Sensors

This paper presents an improved design, complete analysis, and prototype development of high torque-to-mass ratio Magneto-Rheological (MR) clutches. The proposed MR clutches are intended as the main actuation mechanism of a robotic manipulator with five degrees of freedom. Multiple steps to increase the toque-to-mass ratio of the clutch are evaluated and implemented in one design. First, we focus on the Hall sensors’ configuration. Our proposed MR clutches feature embedded Hall sensors for the indirect torque measurement. A new arrangement of the sensors with no effect on the magnetic reluctance of the clutch is presented. Second, we improve the magnetization of the MR clutch. We utilize a new hybrid design that features a combination of an electromagnetic coil and a permanent magnet for improved torque-to-mass ratio. Third, the gap size reduction in the hybrid MR clutch is introduced and the effect of such reduction on maximum torque and the dynamic range of MR clutch is investigated. Finally, the design for a pair of MR clutches with a shared magnetic core for antagonistic actuation of the robot joint is presented and experimentally validated. The details of each approach are discussed and the results of the finite element analysis are used to highlight the required engineering steps and to demonstrate the improvements achieved. Using the proposed design, several prototypes of the MR clutch with various torque capacities ranging from 15 to 200 N·m are developed, assembled, and tested. The experimental results demonstrate the performance of the proposed design and validate the accuracy of the analysis used for the development.

Finite Element Analysis of the Hydro-Mechanical Punching Process

2006 ◽  
Vol 505-507 ◽  
pp. 871-876
Author(s):  
Jong Hun Yoon ◽  
Hoon Huh ◽  
Yong Sin Lee ◽  
Seung Soo Kim ◽  
E.J. Kim ◽  
...  
Keyword(s):  
Hydrostatic Pressure ◽  
Ductile Fracture ◽  
Sheet Material ◽  
Middle Surface ◽  
Initial Crack ◽  
Fracture Criteria ◽  
Element Analysis ◽  
Final Fracture ◽  
Ductile Fracture Criteria ◽  
Punching Process

This paper investigates the characteristics of a hydro-mechanical punching process. The hydro-mechanical punching process is divided into two stages: the first stage is the mechanical half piercing in which an upper punch goes down before the initial crack is occurred; the second stage is the hydro punching in which a lower punch goes up until the final fracture is occurred. Ductile fracture criteria such as the Cockcroft et al., Brozzo et al. and Oyane et al. are adopted to predict the fracture of a sheet material. The index value of ductile fracture criteria is calculated with a user material subroutine, VUMAT in the ABAQUS Explicit. The hydrostatic pressure retards the initiation of a crack in the upper region of the blank and induces another crack in the lower region of the blank during the punching process. The final fracture zone is placed at the middle surface of the blank to the thickness direction. The result demonstrates that the hydro-mechanical punching process makes a finer shearing surface than the conventional one as hydrostatic pressure increases.

The Study of CAD/CAE Integrated Technology in Network Environment

2010 ◽  
Vol 145 ◽  
pp. 567-572
Author(s):  
Hua Ding ◽  
Zhao Jian Yang ◽  
Xue Wen Wang ◽  
Zhi Yong Ding
Keyword(s):  
Parametric Design ◽  
Parametric Modeling ◽  
Component Technology ◽  
Secondary Development ◽  
Element Analysis ◽  
Development Tool ◽  
Database Technology ◽  
Remote Design ◽  
Parametric Finite Element Analysis ◽  
Analysis Platform

Based on the concept of parametric design, this paper realizes the parametric modeling and parametric finite element analysis by utilizing UG/OPEN secondary development tool and APDL module of ANSYS software respectively. This paper also achieves data sharing of CAD/CAE through compiling interface program between UG6.0 and ANSYS10.0. In addition, the remote design and analysis platform has been built by using ASP.NET technology, component technology, and database technology. We take piston-piston rod part of coal mining machine’s cutting unit as an example to verify the system. Meanwhile, it proves system can effectively shorten design and analysis cycle time, and reduce workload of designer. Therefore, this software has potential application value in engineering.

scholarly journals Analysis for Wrinkling Behavior of Girth-Welded Line Pipe

1996 ◽  
Author(s):  
Luiz T. Souza ◽  
David W. Murray
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Finite Element Model ◽  
Internal Pressure ◽  
Experimental Test ◽  
Element Model ◽  
Element Analysis ◽  
Line Pipe ◽  
New Era ◽  
Analytical Tools

The paper presents results for finite element analysis of full-sized girth-welded specimens of line pipe and compares these results with the behavior exhibited by test specimens subjected to constant axial force, internal pressure and monotonically increasing curvatures. Recommendations for the ‘best’ type of analytical finite element model are given. Comparisons between the behavior predicted analytically and the observed behavior of the experimental test specimens are made. The mechanism of wrinkling is explained and the evolution of the deformed configurations for different wrinkling modes is examined. It is concluded that the analytical tools now available are sufficiently reliable to predict the behavior of pipe in a manner that was not previously possible and that this should create a new era for the design and assessment of pipelines if the technology is properly exploited by industry.

Evolutionary Topology Optimization of Spatial Steel-Concrete Structures

2021 ◽  
Vol 62 (2) ◽  
pp. 102-112
Author(s):  
Yu Li ◽  
Yi Min Xie
Keyword(s):  
Topology Optimization ◽  
Composite Structures ◽  
Optimization Technique ◽  
Optimization Techniques ◽  
Principal Stresses ◽  
Element Analysis ◽  
Floor Systems ◽  
Beso Method ◽  
Multiple Materials ◽  
Single Material

Topology optimization techniques based on finite element analysis have been widely used in many fields, but most of the research and applications are based on single-material structures. Extended from the bi-directional evolutionary structural optimization (BESO) method, a new topology optimization technique for 3D structures made of multiple materials is presented in this paper. According to the sum of each element's principal stresses in the design domain, a material more suitable for this element would be assigned. Numerical examples of a steel- concrete cantilever, two different bridges and four floor systems are provided to demonstrate the effectiveness and practical value of the proposed method for the conceptual design of composite structures made of steel and concrete.

Novel Experimental Method to Determine the Performance of Vacuum Insulated Tubing VIT for Deepwater Applications

2021 ◽  
Author(s):  
I.. Ceyhan ◽  
S.. Vasantharajan ◽  
P. V. Suryanarayana ◽  
U. B. Sathuvalli ◽  
A.. Helou ◽  
...  
Keyword(s):  
Experimental Method ◽  
Experimental Testing ◽  
Element Analysis ◽  
Sample Test ◽  
Geothermal Wells ◽  
Different Temperatures ◽  
Measured Flow ◽  
Annular Pressure Buildup ◽  
Data Reduction Method ◽  
Analytical Tools

Abstract Vacuum insulated tubing (VIT) is a specialized tubular designed to minimize heat loss from production or injection fluids to the environment in oil, gas and geothermal wells. VIT strings are used in deepwater wells for flow assurance or to mitigate annular pressure buildup. VIT use requires accurate knowledge of its insulating performance. Although VIT performance can be estimated from analytical tools, such as finite element analysis (FEA), an experimental approach provides a more direct measurement and can be used to validate analytical tools. We have developed a new experimental method to address this need. In this method, one or two VIT joints are placed in an ice-water bath. A precisely measured flow of heated air flows inside the VIT. The temperature change of the flowing air is measured between the inlet and outlet of the VIT test specimen. The insulating performance of the VIT is then calculated from this temperature difference using heat exchanger theory with effectiveness-number of transfer units (&#ξ03B5;-NTU) approach. A proportional-integral-derivative (PID) controller is used to control the air temperature at the VIT inlet by regulating power to the heater. This paper illustrates the data reduction method and uncertainty analysis using sample test data. The method allows for rapid measurement of VIT performance at many different temperatures, with the air flow rate being used to optimize the test sensitivity and to reduce experimental uncertainty. As currently designed, the apparatus is able to test single- and double-joint VITs with effective body conductivities between 0.002-0.1 W/m/°C (0.001-0.06 Btu/hr/ft/°F) and temperatures up to 400°C (750°F); however, the design allows the apparatus to be modified easily for higher or lower conductivities. Although designed for VIT, this method may be applied to other types of tubulars. Currently, there is no widely accepted standard method for experimental testing of VIT performance, and it is hoped that this new method may evolve to an industry standard.

scholarly journals New Dental Implant with 3D Shock Absorbers and Tooth-Like Mobility—Prototype Development, Finite Element Analysis (FEA), and Mechanical Testing

Materials ◽  
2019 ◽  
Vol 12 (20) ◽  
pp. 3444
Author(s):  
Avram Manea ◽  
Grigore Baciut ◽  
Mihaela Baciut ◽  
Dumitru Pop ◽  
Dan Sorin Comsa ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Mechanical Testing ◽  
Alveolar Bone ◽  
Mechanical Performance ◽  
Implant Design ◽  
Element Analysis ◽  
Prototype Development ◽  
Second Stage ◽  
Testing Protocol

Background: Once inserted and osseointegrated, dental implants become ankylosed, which makes them immobile with respect to the alveolar bone. The present paper describes the development of a new and original implant design which replicates the 3D physiological mobility of natural teeth. The first phase of the test followed the resistance of the implant to mechanical stress as well as the behavior of the surrounding bone. Modifications to the design were made after the first set of results. In the second stage, mechanical tests in conjunction with finite element analysis were performed to test the improved implant design. Methods: In order to test the new concept, 6 titanium alloy (Ti6Al4V) implants were produced (milling). The implants were fitted into the dynamic testing device. The initial mobility was measured for each implant as well as their mobility after several test cycles. In the second stage, 10 implants with the modified design were produced. The testing protocol included mechanical testing and finite element analysis. Results: The initial testing protocol was applied almost entirely successfully. Premature fracturing of some implants and fitting blocks occurred and the testing protocol was readjusted. The issues in the initial test helped design the final testing protocol and the new implants with improved mechanical performance. Conclusion: The new prototype proved the efficiency of the concept. The initial tests pointed out the need for design improvement and the following tests validated the concept.

Sign in / Sign up

Export Citation Format

Share Document