On short glass fiber reinforced thermoplastics with high fiber orientation and the influence of surface roughness on mechanical parameters

Injection molding is a common process for manufacturing thermoplastic polymers. Preconnected to fabrication, mechanically loaded parts are examined in structural simulation. A crucial prerequisite for a valid structural simulation for any material is the underlying material data. To determine this data, different phenomena must be considered such as influences of load type, strain rate, environmental conditions and in case of fiber reinforced materials the fiber orientation (FO) in the considered area. Because of rheological effects, injection molded parts often possess a non-homogeneous FO distribution. This makes it challenging to create testing plates for specimen extraction with a well-defined FO over thickness and width in the considered area. In this paper, a novel testing part is introduced with an unidirectionally oriented testable area. It shows a FO degree of more than 0.75, which has been validated with μ-CT measurement and two thermoplastic materials: polyamide and polybutylene terephthalate, both reinforced with 30 weight percent of short glass fibers. In order to resolve influences of the already addressed FO distribution in injection molded parts, tensile test specimens need to be extracted out of specially designed plates via milling and cannot be injection molded directly. Experiments were carried out to study possible effects of preparation on the mechanical properties of specimens with both materials and two milling parameter sets. The first milling parameter set creates reproducible surface roughnesses, whereas the second parameter set shows a correlation between FO and roughness value: when milling perpendicularly to the main FO lower roughnesses are reached than milling in fiber direction. Uncertainties of the normalized rupture strain from orthogonally extracted specimens seem to be larger than the values from those extracted in fiber direction.

Validation of a Novel Floating Wind Turbine Simulation Tool via Benchmarking: Case Study of a Semi-Submersible Platform

This paper describes the validation of a novel floating wind turbine simulation tool based on an existing finite element offshore structural analysis solver that recently has been extended to simulate offshore wind turbines. Given the growing importance of offshore wind in the decarbonization strategy of many countries, and particularly the predicted exponential future growth in floating offshore wind, the requirement for validated numerical modelling tools to support detailed engineering design is now greater than ever. The tool combines a unique structural analysis solver incorporating a 3D hybrid beam-column element featuring fully-coupled axial, torsional and bending deformation modes, with the open-source aerodynamic modelling software FAST, to enable it to perform fully coupled aero-hydro-structural simulation of offshore wind turbines. The validation process focuses on a floating semi-submersible platform hosting a 5MW turbine, which is the reference model used in the international research project Offshore Code Comparison Collaboration Continuation (OC4). This is a code-to-code verification project sponsored by the International Energy Agency (IEA) which benchmarks a range of simulation codes for offshore wind turbine modelling. Beginning with fundamental test cases, such as static equilibrium, eigen-analysis, and free-decay simulations, the scenarios advance in complexity to include current loading, regular and random wave excitation, in conjunction with both steady and turbulent wind inflow. The new tool generates results which exhibit a close correlation with the OC4 benchmark data, thereby validating the numerical modelling approach. Although primarily focused on the semi-submersible, the validation programme also considers the same 5MW turbine hosted by a jacket substructure in shallower water, illustrating the versatility of the modelling tool to simulate fixed support structures in addition to floating. Given the scope of the validation effort, this paper presents a representative sample of results only. A more comprehensive report covering the other load cases can be provided to interested readers by the authors. This paper complements the research work undertaken in OC4, further substantiating its insights into the dynamic responses of floating offshore wind turbines. The new tool offers advantages for non-linear structural simulation via its innovative finite element solution technique, and detailed hydrodynamic modelling via its established and proven numerical models. The combination underlines the benefits of exploiting synergies between offshore oil and gas and offshore wind.

Design, simulation, testing and application of laser-sintered conformal lattice structures on component level

Purpose Laser sintering of polyamide lattice-based lightweight fairing components for subsequent racetrack testing requires a high quality and a reliable design. Hence, the purpose of this study was to develop a design methodology for such additively manufactured prototypes, considering efficient generation and structural simulation of boundary conformal non-periodic lattices, optimization of production parameters as well as experimental validation. Design/methodology/approach Multi-curved, sandwich structure-based demonstrators were designed, simulated and experimentally tested with boundary conformal lattice cells. The demonstrator’s non-periodic lattice cells were simplified by forward homogenization processes. To represent the stiffness of the top and bottom face sheet, constant isotropic and mapped transversely isotropic simulation approaches were compared. The dimensional accuracy of lattice cells and demonstrators were measured with a gauge caliper and a three-dimensional scanning system. The optimized process parameters for lattice structures were transferred onto a large volume laser sintering system. The stiffness of each finite element analysis was verified by an experimental test setup including a digital image correlation system. Findings The stiffness prediction of the mapped was superior to the constant approach and underestimated the test results with −6.5%. Using a full scale fairing the applicability of the development process was successfully demonstrated. Originality/value The design approach elaborated in this research covers aspects from efficient geometry generation over structural simulation to experimental testing of produced parts. This methodology is not only relevant in the context of motor sports but is transferrable for all additively manufactured large scale components featuring a complex lattice sub-structure and is, therefore, relevant across industries.