Spur gear, helical gear, worm gear, and bevel gear are all important components in industrial applications such as vehicles, pushes, conveyors, elevators, bowl mill, rolling mills, ribbon blender, machine tools, aeroplanes, and windmills. When various types of defects, such as wear, tooth breakage, corrosion, and scratches on bearings, appear in gearboxes, normal machine function may be abruptly terminated. As a result, output and dependability suffer. As a result, several quality tracking and evaluation approaches have been adopted by companies. Finite element analysis (FEA) is one of the approaches. This research paper presents the FEA of a ribbon blender worm gear pair by using Ansys 18.0 to identify the weak gear of the worm gear pair, natural frequency, and deformation. Proe-5 utilized for creation of three-dimensional geometry of threaded worm and toothed worm wheels, as well as other related elements such as shafts and bearings. Steel is used for the worm, shaft, and bearing, whereas bronze is used for the worm wheel. Ansys 18.0 is implemented to carry out worm gear pair model analysis. The results demonstrate that the worm wheel had the most deformation when compared to the worm, and that the natural frequency is greater than the operational frequency of the worm gear pair. The findings of the research study, worm wheel deteriorate early than worm, model analysis plays a significant role in vibration monitoring of worm gear pair, and this work is valuable for further fault analysis of ribbon blender worm gearbox utilising vibration response.
Additive manufacturing (AM) technologies have been gaining popularity in recent years due to patent releases – and in effect – better accessibility of the technology. One of the most popular AM technologies is fused deposition modeling (FDM), which is used to manufacture products out of thermoplastic polymers in a layer-by-layer manner. Due to the specificity of the method, parts manufactured in this manner tend to have non-isotropic properties. One of the factors influencing the part’s mechanical behavior and quality is the thermoplastic material’s bonding mechanism correlated with the processing temperature, as well as thermal shrinkage during processing. In this research, the authors verified the suitability of finite element method (FEM) analysis for determining PET-G thermal evolution during the process, by creating a layer transient heat transfer model, and comparing the obtained modelling results with ones registered during a real-time process recorded with a FLIR T1020 thermal imaging camera. Our model is a valuable resource for providing thermal conditions in existing numerical models that connect heat transfer, mesostructure and AM product strength, especially when experimental data is lacking. The FE model presented reached a maximum sample-specific error of 11.3%, while the arithmetic mean percentage error for all samples and layer heights is equal to 4.3%, which the authors consider satisfactory. Model-to-experiment error is partially caused by glass transition of the material, which can be observed on the experimental cooling rate curve after processing the temperature signal.
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The mechanical overloading of temporomandibular joint (TMJ) is generally linked to temporomandibular disorders (TMD). However, in patients with a typical combination of maxillofacial morphology and occlusal features, the reduction of joint load and treatment with general occlusal splints are often ineffective. This study investigates the biomechanical behavior of the stomatognathic system in a TMD patient with personalized splints by finite element analysis. The therapeutic position, determined based on the intercuspal position, served as the basis for designing personalized customized splints. The design of occlusal contact and splint structure was evaluated in terms of their impact on the maximum stress level in the TMJ and the biting forces on the dentition. The relationship between joint stress and biting force was further examined during treatment with different customized splints. In preoperative case, there was a significant increase in stress level and stress concentration in the medial to posterior band of the articular disc. However, in all customized splint cases, the highest stress area shifted to the intermediate zone and exhibited a decrease. Notably, the bi-splints demonstrated superior ability in relieving overloading and balancing the occlusal force on both sides of the dentition, as verified by clinical treatment. The predictable simulated results offer valuable interactive information regarding TMJ overload, aiding doctors in making better-informed clinical decisions in future.
The effective thermal conductivity and air permeability of a multifilament polyester yarn used in sports T-shirts was investigated by computer modeling using finite element analysis (COMSOL Multiphysics, ABAQUS/CAE). It has been shown that the number of fibers, the porosity of the yarn and the proportion of fibers in the volume fraction of the yarn have a direct effect on the effective thermal conductivity and air permeability of the multifilament yarn. It was found that with the increase in the number of fibers, the porosity of the yarn decreases linearly, while the volume fraction of the fibers increases, and thus the effective thermal conductivity increases. In addition, air permeability decreases exponentially.
PL
Zbadano efektywne przewodzenie ciepła i przepuszczalność powietrza wielowłókienkowej przędzy poliestrowej stosowanej w koszulce sportowej poprzez modelowanie obliczeniowe z użyciem analizy elementów skończonych (COMSOL Multiphysics, ABAQUS/CAE). Wykazano, że liczba włókien, porowatość przędzy oraz udział objętościowy włókien w przędzy mają bezpośredni wpływ na przewodzenie ciepła i przepuszczalność powietrza przędzy wielowłókienkowej. Wraz ze wzrostem liczby włókien porowatość przędzy maleje liniowo, natomiast zwiększa się udział objętościowy włókien, a tym samym efektywne przewodnictwo cieplne. Ponadto przepuszczalność powietrza maleje wykładniczo.
Mechanical vibrations are a common problem encountered in many machines, especially for vertical turbine pumps. These pumps are generally difficult to stiffen or damp, but the effective diagnosis must begin with an understanding of the underlying vibratory sources. In the present work, a deep well vertical turbine pump experienced extremely high vibrations for a long time although it still being new. It hasn't been in operation for over 6 months. The pump system suffers from extremely high vibration levels relative to the rotational speed (1X motor dominant frequency). An efficient strategy was implemented by using well-conceived techniques. The experimental modal analysis confirmed a presence of a natural frequency. Modifications were carried out to overcome resonance. Finite element analysis was done to determine the reed critical frequencies as a powerful tool to identify and mitigate vibration issues. On-site motor balancing was done to remove vibrations due to the residual imbalance. Results revealed decreasing vibration level by about 66% after solving all problems.
In order to study the mechanical behavior of concrete-filled steel tube(CFST) short column with different void ratios under a certain eccentricity. A fiber model of concrete-filled steel tube section with different void heights was established. Compared with existing model test data, the axial force and flexural moment strength models of concrete-filled steel tube columns with different void ratios were established. The results show that, in the case of different void ratios, the cross-section strength envelope shows an overall contraction tendency with the increase of void ratio, and each line is basically parallel. A model for calculating the coefficient of axial load degradation was established. The Han’s flexural moment strength model of the flexural component was revised, and the strength model of concrete-filled steel tube column under eccentric compression considering void ratio was established, which provides a theoretical basis and method for the safety assessment during the operation of concrete-filled steel tube arch bridges.
A quantitative study is performed to determine the performance degradation of Y-shaped reinforced concrete bridge piers owing to long-term freeze-thaw damage. The piers are discretized into spatial solid elements using the ANSYS Workbench finite element analysis software, and a spatial model is established. The analysis addresses the mechanical performance of the piers under monotonic loading, and their seismic performance under low-cycle repeated loading. The influence of the number of freeze-thaw cycles, axial compression ratio, and loading direction on the pier bearing capacity index and seismic performance index is investigated. The results show that freeze-thaw damage has an adverse effect on the ultimate bearing capacity and seismic performance of Y-shaped bridge piers in the transverse and longitudinal directions. The pier peak load and displacement ductility coefficient decrease with increasing number of freeze-thaw cycles. The axial compression ratio is an important factor that affects the pier ultimate bearing capacity and seismic performance. Upon increasing the axial compression ratio, the pier peak load increases and the displacement ductility coefficient decreases, the effects of which are more significant in the longitudinal direction.
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The material deformation behaviour during the innovative SPD process called DRECE (Dual Rolls Equal Channel Extrusion) has been analysed by FEM simulations. In the process, a workpiece in the form of a strip is subjected to plastic deformation by passing through the angular channel; however, the workpiece dimensions remain the same after a pass is finished. Performing consecutive passes allow for increasing the effective strain in the material to a required level. In the conducted simulations two various channel angles (108° and 113°) have been taken into consideration, as well as two processing routes, A and C (without and with turning the strip upside-down between consecutive passes, respectively). The analysis of simulation results has revealed that significant strain and stress inhomogeneities across the strip thickness are generated in a single DRECE pass. The die design (the inner and outer corner radius) and friction conditions affect the material flow, reducing significantly the shear strain in the near-surface regions of the strip. The strain inhomogeneity can be effectively reduced by choosing the processing route C. The strain distributions and the corresponding tensile test results have confirmed that the smaller channel die angle allows to generate larger strain and higher strength of the strip but also reduces its ductility more than the die setup with the larger channel die angle.
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To improve the punching shear resistance, an enhanced embedded column base for concrete-filled steel tubes has been proposed, where a pair of strengthening beams are installed on the embedded region of the steel tube by the diaphragm plates. Punching tests were first conducted on eight specimens to investigate the working mechanism of this kind of column base. The test parameters included the length and embedded depth of the strengthening beam. The test results indicated that the punching shear section initiated from the diaphragm plate, which enlarged the punching cone and improved the punching shear resistance. The numerical modelling was also performed. First, finite element models were established and validated against the test results. Full-scale models were then developed to conduct the parametric studies and enrich the database. Finally, a calculation method to evaluate the punching shear resistance of the enhanced embedded column base was proposed and validated. This calculation method takes into account the bonding force, the resistance of the concrete and stirrups on the critical section, and the contribution of the diaphragm plates and strengthening beams.
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In order to study the influence of load position and chamfer opening on the shear performance of reinforced concrete (RC) beams with double openings, five 1/3 RC beams were subjected to three equal point loading tests and ABAQUS finite element analysis. The study revealed that the position of the opening in the structure has a significant impact. When the opening is located in the bend-shearing section, shear force cannot be transmitted, resulting in brittle shear failure of the top chord. In contrast, if the opening is in the pure bending section, bending failure of the specimen occurs. The top chord's cross section exhibits a neutral axis, resembling a short beam, leading to the redistribution of normal stress at the opening. Shear capacity decreases as the loading point moves inward from the outside of the opening. Rectangular openings demonstrate better mechanical properties compared to chamfered openings. The findings from finite element analysis (FEA) suggest that the shear performance of RC beams with double openings is mainly influenced by the length of the opening in the bend-shearing section. The shear capacity relies on the presence of shear stirrups with the same length of the opening in the bend-shearing section. As a result, a revised calculation method for the shear bearing capacity of RC beams with double openings, based on different countries' standards, has been proposed. The revised approach was validated using experimental and FE specimens from this study, along with 32 RC beams with double openings from the previous literature. The calculated results demonstrate a satisfactory level of safety, with the revised Chinese standard deviation within 10%.
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This paper presents an experimental and numerical investigation on the buckling behaviour of corroded cold-formed steel (CFS) channel section columns under axial compression. 7 stub columns and 7 medium long columns were accelerated corrosion by the outdoor periodic spray test. Prior to compression tests, the mass, residual thickness, surface morphology and initial geometric imperfection of the corroded CFS columns were measured. The failure modes, load-strain curves and load-axial displacement curves obtained from axial compression tests were discussed. Based on the corrosion morphology, the non-linear finite element (FE) model for the corroded CFS columns was then developed. Finally, the calculation method for corroded CFS channel section columns was proposed. The results indicated that with the increasing mass loss rate, the irregularity of residual thickness increased rapidly at first, and then increased slowly due to uniform corrosion. The failure mode of the corroded specimens may change from distortional buckling to local buckling as the mass loss rate increased. With the increase in mass loss rate, the buckling critical load, ultimate load, post-buckling strength and axial displacement corresponding to ultimate load decreased. The failure positions of distortional buckling and local buckling were mainly related to the corrosion degree of the flange and web, respectively. The FE results were compared against the experiment results showing a good match in terms of both the ultimate strength and failure modes.
Titanium alloys are difficult-to-machine materials due to their complex mechanical and thermophysical properties. An essential factor in ensuring the quality of the machined surface is the analysis and recommendation of vibration processes accompanying cutting. The analytical description of these processes for machining titanium alloys is very complicated due to the complex adiabatic shear phenomena and the specific thermodynamic state of the chip-forming zone. Simulation modeling chip formation rheology in Computer-Aided Forming systems is a practical method for studying these phenomena. However, dynamic research of the cutting process using such techniques is limited because the initial state of the workpiece and tool is a priori assumed to be "rigid", and the damping properties of the fixture and machine elements are not taken into account at all. Therefore, combining the results of analytical modeling of the cutting process dynamics with the results of simulation modeling was the basis for the proposed research methodology. Such symbiosis of different techniques will consider both mechanical and thermodynamic aspects of machining (specific dynamics of cutting forces) and actual conditions of stiffness and damping properties of the “Machine-Fixture-Tool-Workpiece” system.
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The automobile sector has been making increasing efforts to reduce the weight of automobiles, aiming at mitigating pollutant gas emissions. The use of innovative concepts, such as bimetallic components, has become attractive because it makes it possible to increase the strength-to-weight ratio of the components. In this study, the hot forging of a bimetallic crosshead is investigated. In the process, a billet with a cylindrical core of the magnesium alloy AZ61 is enclosed with a hollow cylinder of the aluminum alloy AA 6351 and forged at 400°C. The objective is to reconcile the low density of Mg alloys with the high corrosion resistance of Al alloys. In parallel, a finite element analysis of the process was carried out.
In this paper, the authors show the results of numerical simulations representing the test of an aluminum sandwich panel with an auxetic anti-tetrachiral core on an exciter. Steady-state vibration analyses utilizing modal superposition (linear dynamics) were performed. The bottom of the panel had all the degrees of freedom constrained and excitation in form of base acceleration in the vertical direction was applied. The obtained results were in form of contour plots of selected output variables in the frequency domain. In addition, curves showing the variation of acceleration, velocity and displacement of a selected representative point in frequency were generated. The results were compared with those obtained for the panel with a non-auxetic core, in the form of a standard hexagonal honeycomb. It was found that the auxetic panel is not superior in the whole range of frequencies but a workflow useful in the design of sandwich panels for operating conditions involving vibrations was developed.
Soil is an anisotropic, heterogeneous, and inelastic complex material. It is difficult to represent the exact behavior of soil by numerical modelling in practice. Conventionally, soil is simplified to an idealized model where it is considered isotropic, homogeneous, and behaves elastically under loads. The idealization, in this case, is done using the proper elastic modulus, Poisson’s ratio, and unit weight of soil depending upon the soil type. Although the exact soil behavior is simplified, using Finite Element Analysis (FEA) a more effective result can be obtained. A superstructure was modelled using ETABS using a fixed-base system and the base reaction forces were obtained. A mat and a soil element on which the mat was laid were modelled as a flexible-base system in Midas GTS NX. The base reactions obtained from ETABS were applied to the mat in the soil model to determine the settlements and, consequently, the spring stiffness. The superstructure was then modelled again, incorporating springs under the respective columns. Convergence in settlement, and base reactions were reached by iteration, and the final results from the flexible-base system were then compared with the fixed-base system. The center column settled the most, about 60 mm, and there was a decrease in settlement by 15% between the first model and the final iterated model. The base reaction for center columns decreased by 24% in the flexible base system compared to the fixed base system. However, an increase in base reaction was observed for both side and edge columns. There was an extremely erratic change in grade beams under a flexible base system, which shows that the superstructure elements are also affected by the change in the base system. It is recommended to use this approach, for the analysis of structures considering flexible base systems instead of fixed bases because it enhances the accuracy of analysis with feasible time consumption and less complex effort.
PL
Gleba jest materiałem złożonym anizotropowym, niejednorodnym i nieelastycznym. W praktyce trudno jest dokładnie odwzorować zachowanie gleby za pomocą modelowania numerycznego. Konwencjonalnie glebę upraszcza się do wyidealizowanego modelu, w którym uważa się ją za izotropową, jednorodną i zachowującą się elastycznie pod obciążeniem. Idealizacja w tym przypadku odbywa się za pomocą odpowiedniego modułu sprężystości, współczynnika Poissona i masy jednostkowej gruntu w zależności od rodzaju gruntu. Chociaż dokładne zachowanie gleby jest uproszczone, można uzyskać bardziej efektywne wyniki za pomocą analizy elementów skończonych (FEA). Konstrukcja nośna została wymodelowana za pomocą ETABS przy użyciu systemu stałej podstawy i uzyskano siły reakcji podstawy. Matę i element gruntu, na którym została położona, zamodelowano jako układ o elastycznej podstawie w programie Midas GTS NX. Reakcje bazowe uzyskane z ETABS naniesiono na matę w modelu gruntowym w celu określenia osiadań, a co za tym idzie sztywności sprężystej. Następnie ponownie wymodelowano konstrukcję nośną, włączając sprężyny pod odpowiednimi kolumnami. Zbieżność osiadania i reakcji bazowych została osiągnięta przez iterację, a końcowe wyniki z systemu o elastycznej podstawie zostały następnie porównane z systemem o stałej podstawie. Kolumna środkowa osiadła najbardziej, około 60 mm, a między pierwszym modelem a ostatecznym modelem iterowanym nastąpił spadek osiadania o 15%. Reakcja podstawy dla kolumn centralnych zmniejszyła się o 24% w systemie z podstawą elastyczną w porównaniu z systemem z podstawą stałą. Zaobserwowano jednak wzrost odczynu zasadowego zarówno dla kolumn bocznych, jak i krawędziowych. Nastąpiła bardzo nieregularna zmiana belek niwelacyjnych pod elastycznym systemem bazowym, co pokazuje, że zmiany w systemie bazowym mają również wpływ na elementy konstrukcji nośnej. Zaleca się stosowanie tego podejścia do analizy konstrukcji z uwzględnieniem elastycznych systemów bazowych zamiast stałych baz, ponieważ zwiększa to dokładność analizy przy możliwej czasochłonności i mniejszym wysiłku.
Purpose: The aim of the work was to test the contact stresses in the model system of the turbine hub cooperating with the fuel pump drive shaft. The hypothesis of the work was that, by means of FEA, it is possible to assess the contact stresses in the materials of the turbine hub and the fuel pump shaft during torque transmission. Design/methodology/approach: A turbine with fibre-reinforced polyphenylene sulphide (PPS) composite cooperating with a stainless steel shaft (X46Cr13/1.4034) in a commonly used D-flat shape joint was selected for the experimental research. To assess contact stresses, the CAD model (NX, Siemens) of the entire turbine was limited to the hub area. The drive shaft is supported in accordance with the bearing in the fuel pump, and the possibility of rotation about the axis along the length of the torque-producing magnet is taken away. The system was loaded with a torque of 200 Nmm on the turbine. The turbine hub and shaft were calculated, taking into account the phenomenon of contact detachment or slip at the value of the friction coefficient of 0.1. Findings: The pressure transmission area was found in the area at the edge of the flat surface D-flat and on the opposite side of the D-convexity. The contact stresses on the D-flat side reached values close to the composite strength. Research limitations/implications: The studies did not take into account the technological inaccuracies, thermal deformation, local material properties, and wear. The value of the friction coefficient was not measured in realistic conditions with fuel lubrication. Practical implications: FEA has been achieved, which allows to reduce the cost of experimental research. Originality/value: The proposed model allows for further studies of the influence of elasticity of various materials and structures on contact stresses in order to assess wear resistance.
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An evacuation shelter provides simple living facilities made of lightweight materials for repeated use and ensures that the shelters provide a safe and suitable long-term environment. Improving the shelter material in terms of thermal quality in the Malaysian climate is one requirement when evacuating victims to emergency shelters in open areas. The article aims to investigate the effect of using local natural fibers for composite honeycomb skin on the thermal and mechanical performance. The composite skin is a natural fiber processed in a concrete panel to make a honeycomb sandwich. This work introduces a model of natural fiber distribution embedded in a concrete panel, which is subjected to thermal analysis and three-point bending (TPB) to optimize the honeycomb structure. In order to understand the thermal interaction of the panel sheet for an insulating system, the model provides a six-level range of the number of fibers (100, 200, 300, 400, 500 and 600) to analyze the fiber network. The simulation demonstrated that improvement in the insulating panel of about 2.58% could be achieved by using the number of 600 coconut fibers, which is much lower compared to plain concrete. The morphology study successfully demonstrates the understanding of the fiber distribution and thermal absorption by the concrete. Moreover, the mechanical performance is also positively affected by using fiber in the panel, especially sugar cane, which achieved a 47% improvement. This successfully simulated model provides a promising solution to promote local products for shelter material applications.
The following work gives the details of the modelling, simulation, and testing of a small portable gravitational water vortex (GWV) based power plant. The gravitation water vortex is an ideal source of renewable energy for rural areas that have a small body of flowing water. For this purpose, we have selected a small size for the vortex chamber that enables it to form a vortex with limited amounts of water. The paper gives the details of the simulation of the GWV in COMSOL FEA software and the parameters that were chosen for optimization. These parameters were the height of the vortex chamber, the number of blades, the length of the blades, and the tilt angle of the blades. These parameters were systematically varied step by step, to observe their effect on the speed of the rotor. The results of the parametric sweep that was performed on all the parameters are also presented. Based on the simulation results an optimal set of parameters was chosen for the physical implementation of the GWV. The paper also goes into the details of the construction of the physical GWV, the experimental setup that was devised for the testing and verification of the simulation results.
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The stress-strain characteristics of a clot during loading/unloading mechanical cycles are significant features to assess the underlying mechanisms of thrombectomy, especially when multiple thrombectomy attempts are required. We investigated a damage model to predict loading/unloading response of clots. To study the validity of the model, we tested theoretical models to reproduce the experimentally obtained mechanical characteristics of clots under various conditions. Three types of clot analogs with different red blood cell (RBC) compositions were prepared. Cylindrical clot analogs were formed for the tensile and compression tests. Loading/unloading tests at 80% of strain were conducted, where the material parameters were determined by fitting the results to a theoretical curve combining the damage model and the elasto-plastic constitutive model. Through the computation for theoretical curves, unique characteristics of clots were revealed such that the hysteresis loss rate did not change by varying RBC contents, except for the clot created with 0% RBC composition, under compressive loading. In addition, the plastic strain decreased as the RBC content decreased under tensile loading, whereas it increased as the RBC content decreased under compressive loading. A three-dimensional finite element method (FEM) was employed with the determined parameters. The FEM could accurately reproduce the experimental stress-strain curves for all types of clot analogs and for both loading types up to a strain of 80%. The results indicate that the theoretical model which incorporates and combines the damage model and the elasto-plastic constitutive model is applicable to predict the non-linear stress–strain behavior of clots under loading and unloading.
The fracture reason of steel wire cable is complex, and the corrosion and local bending effect of anchorage end of steel wire cable under tension are one of the main factors. Taking the steel wire of an arch bridge cable as the research object, the notch method was used to simulate the corrosion pits on the surface of the steel wire, and the tension and bending mechanical properties of the high strength notched steel wire were tested. The bending finite element model of the high strength steel wire was established by ANSYS WORKBENCH, and the tension and bending mechanical properties of the notched steel wire under different vertical loads and pretension were studied. The test and calculation results show that the test data are close to the finite element calculation results and the variation law is consistent. Under the same vertical load, the deformation of steel wire notch decreases with the increase of pretension; The stress at the bottom of the notch is the largest at 180° direction and the smallest at 90° direction of the vertical load. Under the same vertical load and pretension, the stress of spherical shape at the notch is the largest, followed by ellipsoid shape, and groove shape is the smallest, and there is a high stress zone at the edge of groove shape. When the pretension is applied, the initial stress increases with the increase of pretension, while the stress at the notch caused by bending decreases with the increase of pretension.
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