Process modeling, joint-property characterization and construction of joint connectors for mechanical fastening by self-piercing riveting

2014 ◽  
Vol 10 (4) ◽  
pp. 631-658 ◽  
Author(s):  
Mica Grujicic ◽  
Jennifer Snipes ◽  
S. Ramaswami ◽  
Fadi Abu-Farha
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Large Scale ◽  
Constitutive Relations ◽  
Computational Cost ◽  
Three Dimensional ◽  
Modeling And Simulations ◽  
Content Type ◽  
Material Parameters ◽  
Computational Analyses

Purpose – The purpose of this paper is to propose a computational approach in order to help establish the effect of various self-piercing rivet (SPR) process and material parameters on the quality and the mechanical performance of the resulting SPR joints. Design/methodology/approach – Toward that end, a sequence of three distinct computational analyses is developed. These analyses include: (a) finite-element modeling and simulations of the SPR process; (b) determination of the mechanical properties of the resulting SPR joints through the use of three-dimensional, continuum finite-element-based numerical simulations of various mechanical tests performed on the SPR joints; and (c) determination, parameterization and validation of the constitutive relations for the simplified SPR connectors, using the results obtained in (b) and the available experimental results. The availability of such connectors is mandatory in large-scale computational analyses of whole-vehicle crash or even in simulations of vehicle component manufacturing, e.g. car-body electro-coat paint-baking process. In such simulations, explicit three-dimensional representation of all SPR joints is associated with a prohibitive computational cost. Findings – It is found that the approach developed in the present work can be used, within an engineering optimization procedure, to adjust the SPR process and material parameters (design variables) in order to obtain a desired combination of the SPR-joint mechanical properties (objective function). Originality/value – To the authors’ knowledge, the present work is the first public-domain report of the comprehensive modeling and simulations including: self-piercing process; virtual mechanical testing of the SPR joints; and derivation of the constitutive relations for the SPR connector elements.

Process and product-performance modeling for mechanical fastening by flow drilling screws

2016 ◽  
Vol 7 (3) ◽  
pp. 370-396 ◽  
Author(s):  
Mica Grujicic ◽  
Jennifer Snipes ◽  
S Ramaswami
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Large Scale ◽  
Constitutive Relations ◽  
Computational Cost ◽  
Three Dimensional ◽  
Content Type ◽  
Material Parameters ◽  
Computational Analyses ◽  
Flow Drilling

Purpose – The purpose of this paper is to propose a computational approach to establish the effect of various flow drilling screw (FS) process and material parameters on the quality and the mechanical performance of the resulting FS joints. Design/methodology/approach – Toward that end, a sequence of three distinct computational analyses is developed. These analyses include: (a) finite-element modeling and simulations of the FS process; (b) determination of the mechanical properties of the resulting FS joints through the use of three-dimensional, continuum finite-element-based numerical simulations of various mechanical tests performed on the FS joints; and (c) determination, parameterization and validation of the constitutive relations for the simplified FS connectors, using the results obtained in (b) and the available experimental results. The availability of such connectors is mandatory in large-scale computational analyses of whole-vehicle crash or even in simulations of vehicle component manufacturing, e.g. car-body electro-coat paint-baking process. In such simulations, explicit three-dimensional representation of all FS joints is associated with a prohibitive computational cost. Findings – Virtual testing of the shell components fastened using the joint connectors validated the ability of these line elements to realistically account for the strength, ductility and toughness of the three-dimensional FS joints. Originality/value – The approach developed in the present work can be used, within an engineering-optimization procedure, to adjust the FS process and material parameters (design variables) in order to obtain a desired combination of the FS-joint mechanical properties (objective function).

Process modeling, joint virtual testing and construction of joint connectors for mechanical fastening by flow-drilling screws

2015 ◽  
Vol 231 (6) ◽  
pp. 1048-1061 ◽  
Author(s):  
Mica Grujicic ◽  
JS Snipes ◽  
S Ramaswami
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
Large Scale ◽  
Mechanical Performance ◽  
Constitutive Relations ◽  
Computational Cost ◽  
Three Dimensional ◽  
Material Parameters ◽  
Computational Analyses ◽  
Flow Drilling

In this work, a computational approach is proposed in order to help establish the effect of various flow-drilling screw process and material parameters on the quality and the mechanical performance of the resulting flow-drilling screw joints. Toward that end, a sequence of three distinct computational analyses is developed. These analyses include the following: (a) finite element modeling and simulations of the flow-drilling screw process; (b) determination of the mechanical properties of the resulting flow-drilling screw joints through the use of three-dimensional, continuum finite element–based numerical simulations of various mechanical tests performed on the flow-drilling screw joints and (c) determination, parameterization and validation of the constitutive relations for the simplified flow-drilling screw connectors, using the results obtained in (b) and the available experimental results. The availability of such connectors is mandatory in large-scale computational analyses of whole-vehicle crash or even in simulations of vehicle component manufacturing, for example, car-body electro-coat paint-baking process. In such simulations, explicit three-dimensional representation of all flow-drilling screw joints is associated with a prohibitive computational cost. The approach developed in this work can be used, within an engineering-optimization procedure, to adjust the flow-drilling screw process and material parameters (design variables) in order to obtain a desired combination of the flow-drilling screw joint mechanical properties (objective function).

scholarly journals Prediction of Residual Stresses in a Multipass Pipe Weld by a Novel 3D Finite Element Approach

2018 ◽  
Author(s):  
Hui Huang ◽  
Jian Chen ◽  
Blair Carlson ◽  
Hui-Ping Wang ◽  
Paul Crooker ◽  
...  
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
High Performance ◽  
Large Scale ◽  
Graphics Processing Unit ◽  
Computational Cost ◽  
Three Dimensional ◽  
Processing Unit ◽  
Girth Welds ◽  
Welding Processes

Due to enormous computation cost, current residual stress simulation of multipass girth welds are mostly performed using two-dimensional (2D) axisymmetric models. The 2D model can only provide limited estimation on the residual stresses by assuming its axisymmetric distribution. In this study, a highly efficient thermal-mechanical finite element code for three dimensional (3D) model has been developed based on high performance Graphics Processing Unit (GPU) computers. Our code is further accelerated by considering the unique physics associated with welding processes that are characterized by steep temperature gradient and a moving arc heat source. It is capable of modeling large-scale welding problems that cannot be easily handled by the existing commercial simulation tools. To demonstrate the accuracy and efficiency, our code was compared with a commercial software by simulating a 3D multi-pass girth weld model with over 1 million elements. Our code achieved comparable solution accuracy with respect to the commercial one but with over 100 times saving on computational cost. Moreover, the three-dimensional analysis demonstrated more realistic stress distribution that is not axisymmetric in hoop direction.

Finite element implementation of viscoelastic and viscoplastic models

2020 ◽  
Vol 37 (8) ◽  
pp. 2561-2585
Author(s):  
Hossein Sepiani ◽  
Maria Anna Polak ◽  
Alexander Penlidis
Keyword(s):  
Finite Element ◽  
Material Properties ◽  
Three Dimensional ◽  
Small Strain ◽  
Test Time ◽  
Nonlinear Behaviour ◽  
Content Type ◽  
Material Parameters ◽  
Viscoplastic Models

Purpose The purpose of this study is to present a finite element (FE) implementation of phenomenological three-dimensional viscoelastic and viscoplastic constitutive models for long term behaviour prediction of polymers. Design/methodology/approach The method is based on the small strain assumption but is extended to large deformation for materials in which the stress-strain relation is nonlinear and the concept of incompressibility is governing. An empirical approach is used for determining material parameters in the constitutive equations, based on measured material properties. The modelling process uses a spring and dash-pot and a power-law approximation function method for viscoelastic and viscoplastic nonlinear behaviour, respectively. The model improvement for long term behaviour prediction is done by modifying the material parameters in such a way that they account for the current test time. The determination of material properties is based on the non-separable type of relations for nonlinear materials in which the material properties change with stress coupled with time. Findings The proposed viscoelastic and viscoplastic models are implemented in a user material algorithm of the FE general-purpose program ABAQUS and the validity of the models is assessed by comparisons with experimental observations from tests on high-density polyethylene samples in one-dimensional tensile loading. Comparisons show that the proposed constitutive model can satisfactorily represent the time-dependent mechanical behaviour of polymers even for long term predictions. Originality/value The study provides a new approach in long term investigation of material behaviour using FE analysis.

Thermo-mechanical coupling particle simulation of three-dimensional large-scale non-isothermal problems

2017 ◽  
Vol 34 (5) ◽  
pp. 1551-1571 ◽  
Author(s):  
Ming Xia
Keyword(s):  
Large Scale ◽  
Three Dimensional ◽  
Simulation Method ◽  
Particle Simulation ◽  
Similarity Criteria ◽  
Particle Model ◽  
Length Scale ◽  
Content Type ◽  
Mechanical Coupling ◽  
Particle Simulation Method

Purpose The main purpose of this paper is to present a comprehensive upscale theory of the thermo-mechanical coupling particle simulation for three-dimensional (3D) large-scale non-isothermal problems, so that a small 3D length-scale particle model can exactly reproduce the same mechanical and thermal results with that of a large 3D length-scale one. Design/methodology/approach The objective is achieved by following the scaling methodology proposed by Feng and Owen (2014). Findings After four basic physical quantities and their similarity-ratios are chosen, the derived quantities and its similarity-ratios can be derived from its dimensions. As the proposed comprehensive 3D upscale theory contains five similarity criteria, it reveals the intrinsic relationship between the particle-simulation solution obtained from a small 3D length-scale (e.g. a laboratory length-scale) model and that obtained from a large 3D length-scale (e.g. a geological length-scale) one. The scale invariance of the 3D interaction law in the thermo-mechanical coupled particle model is examined. The proposed 3D upscale theory is tested through two typical examples. Finally, a practical application example of 3D transient heat flow in a solid with constant heat flux is given to illustrate the performance of the proposed 3D upscale theory in the thermo-mechanical coupling particle simulation of 3D large-scale non-isothermal problems. Both the benchmark tests and application example are provided to demonstrate the correctness and usefulness of the proposed 3D upscale theory for simulating 3D non-isothermal problems using the particle simulation method. Originality/value The paper provides some important theoretical guidance to modeling 3D large-scale non-isothermal problems at both the engineering length-scale (i.e. the meter-scale) and the geological length-scale (i.e. the kilometer-scale) using the particle simulation method directly.

Synthesis and properties of modified PBT for FDM

2017 ◽  
Vol 23 (4) ◽  
pp. 804-810 ◽  
Author(s):  
Shiqing Cao ◽  
Dandan Yu ◽  
Weilan Xue ◽  
Zuoxiang Zeng ◽  
Wanyu Zhu
Keyword(s):  
Mechanical Properties ◽  
Impact Strength ◽  
Fused Deposition Modeling ◽  
Complex Structure ◽  
Three Dimensional ◽  
Sebacic Acid ◽  
Wire Drawing ◽  
Content Type ◽  
Fused Deposition ◽  
Deposition Modeling

Purpose The purpose of this paper is to prepare a new modified polybutylene terephalate (MPBT) for fused deposition modeling (FDM) to increase the variety of materials compatible with printing. And the printing materials can be used to print components with a complex structure and functional mechanical parts. Design/methodology/approach The MPBT, poly(butylene terephalate-co-isophthalate-co-sebacate) (PBTIS), was prepared for FDM by direct esterification and subsequent polycondensation using terephthalic acid (PTA), isophthalic acid (PIA), sebacic acid (SA) and 1,4-butanediol (BDO). The effects of the content of PIA (20-40 mol%) on the mechanical properties of PBTIS were investigated when the mole per cent of SA (αSA) is zero. The effects of αSA (0-7mol%) on the thermal, rheological and mechanical properties of PBTIS were investigated at nPTA/nPIA = 7/3. A desktop wire drawing and extruding machine was used to fabricate the filaments, whose printability and anisotropy were tested by three-dimensional (3D) printing experiments. Findings A candidate content of PIA introducing into PBT was obtained to be about 30 per cent, and the Izod notched impact strength of PBTIS increased with the increase of αSA. The results showed that the PBTIS (nPTA/nPIA = 7/3, αSA = 3-5mol%) is suitable for FDM. Originality/value New printing materials with good Izod notched impact strength were obtained by introducing PIA and SA (nPTA/nPIA = 7/3, αSA = 3-5 mol%) into PBT and their anisotropy are better than that of ABS.

Finite Element Simulation of Cartilage Mechanics During Diarthrodial Joint Motion Using Physiological Data

2000 ◽  
Author(s):  
Kerem Ün ◽  
Peter S. Donzelli ◽  
Robert L. Spilker
Keyword(s):  
Finite Element ◽  
Large Scale ◽  
Glenohumeral Joint ◽  
Three Dimensional ◽  
Physiological Data ◽  
Cartilage Mechanics ◽  
Moving Contact ◽  
Diarthrodial Joint ◽  
Element Simulation ◽  
Diarthrodial Joints

Abstract Moving contact is fundamental to understanding the mechanical environment of articular cartilage in diarthrodial joints. This study presents a method for approximating three-dimensional (3D) moving contact of biphasic tissue layers using a time-dependent penetration method. This technique has been implemented in a custom finite element solution framework for large-scale simulation that includes a graphical user interface, automatic meshing, and visualization tools. Thus, physiological geometry and load levels can be simulated by this approximate technique. The method is illustrated for canonical and physiological problems representing the glenohumeral joint (GHJ) of the shoulder.

scholarly journals Approximate Dynamic Programming Based Control of Proppant Concentration in Hydraulic Fracturing

Mathematics ◽  
2018 ◽  
Vol 6 (8) ◽  
pp. 132 ◽  
Author(s):  
Harwinder Singh Sidhu ◽  
Prashanth Siddhamshetty ◽  
Joseph Kwon
Keyword(s):  
Mechanical Properties ◽  
Dynamic Programming ◽  
Hydraulic Fracturing ◽  
Young’S Modulus ◽  
Large Scale ◽  
Approximate Dynamic Programming ◽  
Young's Modulus ◽  
Computational Cost ◽  
Control Technique ◽  
Rock Mechanical Properties

Hydraulic fracturing has played a crucial role in enhancing the extraction of oil and gas from deep underground sources. The two main objectives of hydraulic fracturing are to produce fractures with a desired fracture geometry and to achieve the target proppant concentration inside the fracture. Recently, some efforts have been made to accomplish these objectives by the model predictive control (MPC) theory based on the assumption that the rock mechanical properties such as the Young’s modulus are known and spatially homogenous. However, this approach may not be optimal if there is an uncertainty in the rock mechanical properties. Furthermore, the computational requirements associated with the MPC approach to calculate the control moves at each sampling time can be significantly high when the underlying process dynamics is described by a nonlinear large-scale system. To address these issues, the current work proposes an approximate dynamic programming (ADP) based approach for the closed-loop control of hydraulic fracturing to achieve the target proppant concentration at the end of pumping. ADP is a model-based control technique which combines a high-fidelity simulation and function approximator to alleviate the “curse-of-dimensionality” associated with the traditional dynamic programming (DP) approach. A series of simulations results is provided to demonstrate the performance of the ADP-based controller in achieving the target proppant concentration at the end of pumping at a fraction of the computational cost required by MPC while handling the uncertainty in the Young’s modulus of the rock formation.

Additive manufactured multi-material structure with directional specific mechanical properties based upon classical lamination theory

2018 ◽  
Vol 24 (7) ◽  
pp. 1212-1220 ◽  
Author(s):  
Sugavaneswaran M. ◽  
Arumaikkannu G.
Keyword(s):  
Mechanical Properties ◽  
Three Dimensional ◽  
Additive Manufacture ◽  
Material Structure ◽  
Loading Conditions ◽  
Content Type ◽  
Three Dimensional Printing ◽  
Classical Lamination Theory ◽  
Innovative Methodology ◽  
Lamination Theory

Purpose This paper aims to additive manufacture (AM) the multi-material (MM) structure with directional-specific mechanical properties based on the classical lamination theory of composite materials. Design/methodology/approach The polyjet three-dimensional printing (3DP) process is used to fabricate the MM structure with directional-specific mechanical properties. MMs within a layer are positioned and oriented based on the classical lamination theory to achieve directional-specific properties. Mechanical behavior of the AM structure was examined under various loading conditions to justify the directional-specific properties. Findings With MM processing capabilities of the polyjet 3DP machine, AM MM structures with directional-specific mechanical properties were fabricated. From experimentation, it was observed that the AM MM structure with a quasi-isotropic laminate has superior tensile and flexural strength, and the AM MM structure with an angle ply laminate has superior shear strength. Various mechanical properties determined through testing will be useful for the selection of an appropriate layup arrangement within a structure for appropriate loading conditions. Originality/value This study presents the innovative methodology for the fabrication of AM MM structures with tailor-made mechanical properties. The developed methodology paves way for using the polyjet 3DP MM structure for applications such as the complaint mechanism, snap fits and thin features, which require directional-specific properties.

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