Search Results (11)

This study examines the mechanical, thermal, and electrical properties of copper tool electrodes processed via Equal Channel Angular Pressing (ECAP), with a specific focus on their performance in Electrical Discharge Machining (EDM) applications. A novel Crystal Plasticity Finite Element Method (CPFEM) framework is employed to model anisotropic slip behavior and microscale deformation mechanisms. The primary objective is to elucidate how initial crystallographic orientation influences hardness, thermal conductivity, and electrical conductivity. Simulations are performed on single-crystal copper for three representative Face Centered Cubic (FCC) orientations. Using an explicit CPFEM model, the study examines texture evolution and deformation heterogeneity during the ECAP process of single-crystal copper. The results indicate that the <100> single-crystal orientation exhibits the highest Taylor factor and the most homogeneous distribution of plastic equivalent strain (PEEQ), suggesting enhanced resistance to plastic flow. In contrast, the <111> single-crystal orientation displays localized deformation and reduced hardening. A decreasing Taylor factor correlates with more uniform slip, which improves both electrical and thermal conductivity, as well as machinability, by minimizing dislocation-related resistance. These findings make a novel contribution to the field by highlighting the critical role of crystallographic orientation in governing slip activity and deformation pathways, which directly impact thermal wear resistance and the fabrication efficiency of ECAP-processed copper electrodes in EDM. Full article

This study conducts a high-resolution forensic evaluation of stern structural damage resulting from a tugboat collision during berthing, integrating real-world measurement data with calibrated nonlinear finite element analysis. Based on field-acquired deformation geometry and residual dent profiles at Frame 76, five distinct collision scenarios varying in impact orientation, contact area, and load path were simulated using shell-based nonlinear plastic analysis. Particular attention is given to comparing the plastic equivalent strain (PEEQ), von-Mises stress fields, and residual deformation contours at Point A—the critical zone identified from damage surveys. Among the five cases, Case-2, defined by a vertically eccentric external impact, demonstrated the highest plastic strain intensity (PEEQ > 2.0%), the sharpest post-yield drops in stiffness, and the closest match to the residual dent profile observed in the actual structure. The integrated correlation between field damage and some of the results (strain, stress, and deformed shape) enabled clear identification of the most probable accident mechanism with engineering accuracy. This study proposes a validated, measurement-calibrated nonlinear finite element analysis framework to diagnose stern damage from tugboat collisions, enhancing repair decision-making and structural safety assessment. Such a calibrated forensic strategy enhances the reliability of structural safety predictions in marine collision incidents and supports eco-friendly rescue engineering by minimizing unnecessary structural renewal through precise damage localization. The proposed approach establishes a new benchmark for scenario-driven collision assessment, particularly relevant to sustainable, automation-compatible, and damage-tolerant ship design practices. Full article

Through the ferrite single-phase parameters of M50 bearing steel obtained based on nanoindentation experiments and the representative volume element (RVE) model established based on the real microstructure of M50, this paper established a multiscale finite element model for the cold ring rolling of M50 and verified its accuracy. The macroscale and mesoscale flow behaviors of the ring during the cold rolling deformation process were examined and explained. The macroscopic flow behavior demonstrated that the stress distribution was uniform following rolling. The equivalent plastic strain (PEEQ) grew stepwise over time, with the raceway showing the highest PEEQ. The mesoscopic simulation revealed that the stress was concentrated in the cementite, and the maximum occurred at the junction of the ferrite and cementite. The largest PEEQ was found in the ferrite matrix positioned between the two adjacent cementites. The cementite flew with the deformation of the ferrite. The radial displacement of the cementite decreased from the edge of the raceway to both ends and decreased from the inner to the outer surface. Its axial displacement was basically the same on the inner surface and decreased from the inner to the outer surface. Its circumferential displacement decreased from the inner and outer surfaces to the intermediate thickness region. Full article

An intelligent optimization technique has been presented to enhance the multiple structural performance of PA6-20CF carbon fiber-reinforced polymer (CFRP) plastic injection molding (PIM) products. This approach integrates a deep neural network (DNN), Non-dominated Sorting Genetic Algorithm II (NSGA-II), and Monte Carlo simulation (MCS), collectively referred to as the DNN-GA-MCS strategy. The main objective is to ascertain complex process parameters while elucidating the intrinsic relationships between processing methods and material properties. To realize this, a numerical study on the PIM structural performance of an automotive front engine hood panel was conducted, considering fiber orientation tensor (FOT), warpage, and equivalent plastic strain (PEEQ). The mold temperature, melt temperature, packing pressure, packing time, injection time, cooling temperature, and cooling time were employed as design variables. Subsequently, multiple objective optimizations of the molding process parameters were employed by GA. The utilization of Z-score normalization metrics provided a robust framework for evaluating the comprehensive objective function. The numerical target response in PIM is extremely intricate, but the stability offered by the DNN-GA-MCS strategy ensures precision for accurate results. The enhancement effect of global and local multi-objectives on the molded polymer–metal hybrid (PMH) front hood panel was verified, and the numerical results showed that this strategy can quickly and accurately select the optimal process parameter settings. Compared with the training set mean value, the objectives were increased by 8.63%, 6.61%, and 9.75%, respectively. Compared to the full AA 5083 hood panel scenario, our design reduces weight by 16.67%, and achievements of 92.54%, 93.75%, and 106.85% were obtained in lateral, longitudinal, and torsional strain energy, respectively. In summary, our proposed methodology demonstrates considerable potential in improving the, highlighting its significant impact on the optimization of structural performance. Full article

This article raises the topic of the critical examination of polypropylene, a key polymeric material, and its extensive application within the automotive industry, particularly focusing on the manufacturing of brake fluid reservoirs. This study aims to enhance the understanding of polypropylene’s behavior under mechanical stresses through a series of laboratory destruction tests and numerical simulations, emphasizing the finite element method (FEM). A novel aspect of this research is the introduction of the PEAK parameter, a groundbreaking approach designed to assess the material’s resilience against varying states of strain, known as triaxiality. This parameter facilitates the identification of critical areas prone to crack initiation, thereby enabling the optimization of component design with a minimized safety margin, which is crucial for cost-effective production. The methodology involves conducting burst tests to locate crack initiation sites, followed by FEM simulations to determine the PEAK threshold value for the Sabic 83MF10 polypropylene material. The study successfully validates the predictive capability of the PEAK parameter, demonstrating a high correlation between simulated results and actual laboratory tests. This validation underscores the potential of the PEAK parameter as a predictive tool for enhancing the reliability and safety of polypropylene automotive components. The research presented in this article contributes significantly to the field of material science and engineering by providing a deeper insight into the mechanical behavior of polypropylene and introducing an effective tool for predicting crack initiation in automotive components. The findings hold promise for advancing the design and manufacturing processes in the automotive industry, with potential applications extending to other sectors. Full article

Information on the flyer deformation during laser impact welding (LIW) is an important aspect to consider when high reliability of the welded components is required. For this reason, accurate numerical models simulating thermal and mechanical aspects are needed. In the present work, the cross-section morphology during LIW of Ti/Brass joints at varying laser pulse energies is modeled by a 2D finite element (FE) model. A hydrodynamic plasma pressure model able to describe the evolution of the pressure load step by step, taking into account the progressive deformation of the flyer, was implemented. Hence, this paper proposes an alternative method to the conventional node concentrated forces or predefined velocity as flyer boundary conditions. The levels of the equivalent plastic strain (PEEQ), shear stress, and critical flyer velocity at the collision point were used as reference parameters to predict the success of the welding bond, distinguishing the welded area from the unwelded area. The model was validated by comparison with the experimental data, which showed the effectiveness of the proposed FE code in predicting the cross-section morphology of the welded materials. Moreover, practical industrial information such as variation in the flyer impact velocity, collision angle, and process temperatures was predicted by varying the process laser pulse energy according to the basic principle of the process. Full article

NiCoCrAlY coatings are commonly used as bond-coat in thermal barrier coatings due to their excellent high-temperature oxidation resistance and suitable thermal expansion coefficient between the superalloy substrate and ceramic top layer. Previous studies have shown that the NiCoCrAlY coatings prepared by cold spray (CS) exhibit excellent comprehensive properties. In the process of cold spray, the solid particles impact onto the substrate with a high velocity, powder particles and the substrate undergo plastic deformation, and the coating is deposited finally. When the velocity of the impacted particles reaches a certain value (critical velocity), the particles can be effectively deposited on the substrate. Due to the short impact time and large plastic deformation of the cold spray process, the process is difficult to be observed in the actual experiment process in real time. Therefore, the current work has used the explicit dynamics method in finite element numerical simulation to simulate the deposition behavior of the particle during the cold spray process. By changing the impact velocities and sizes of particles, the changes in temperature (TEMP), equivalent plastic strain (PEEQ), deformation characteristics of the particle and substrate after particles being completely deposited on the substrate have been obtained. The critical velocity of particle deposition is about 600 m/s, and the larger the particle, the easier it is to deposit. And the current modeling and simulation work provided the theory instruction for the preparation of NiCoCrAlY coatings with excellent performance via cold spray. Full article

In the oil and gas drilling industry, cemented carbide teeth are one of the most widely used rock-breaking elements. In order to reveal the rock damage mechanism of tooth indentation, a series of tooth indentation experiments were conducted in this study, and an indentation simulation was also conducted as a supplement to the experiment. In the experiment, a new method to observe the inner damage status of the rock was put forward, i.e., utilizing the splitting action of the teeth to avoid unexpected rock damage that may affect the actual experiment results. The load-displacement curves and the damage status of the rock revealed that the wedge tooth was more efficient in fracturing and damaging the rock because the load requirement of the wedge tooth was lower, the narrow tooth crown generated larger specific stress in the rock; that rock-breaking advantage of the wedge tooth resulted from the occurrence of the compacted core and the tension stress generated by the core. According to the simulation results, the plastic strain in the intermediate area between the wedge teeth appeared more concentrated and increased faster, and the rock material beneath the wedge teeth was removed earlier than beneath the conical teeth, indicating that wedge teeth, disposed with proper spacing, can break rock more effectively than the conical teeth. The experiment and simulation results in this paper have proved the advantages of the wedge tooth in rock fracturing and damaging, which will provide technical support for the design and development for the drill bits applied in oil and gas drilling. Full article

The additive technologies widely used in recent years provide enormous flexibility in the production of cellular structures. Material extrusion (MEX) technology has become very popular due to the increasing availability of relatively inexpensive desktop 3D printers and the capability of fabricating parts with complex geometries. Poly-lactic acid (PLA) is a biodegradable and commonly applied thermoplastic material in additive manufacturing (AM). In this study, using a simulation method based on the user subroutine titled “user subroutine to redefine field variables at a material point” (USDFLD) in the finite element method (FEM) ABAQUS software, the elastic stiffness (ES) of a cylindrical lightweight cellular PLA sample with a 2.4 mm infill line distance (ILD), which was designed as a layered structure similar to the laboratory mode with a MEX method and was subjected to cyclic compressive loading, was investigated by considering the variation of the Young’s modulus depending on the variation of the equivalent plastic strain (PEEQ). It was observed that the PLA sample’s elastic stiffness increases during cyclic loading. This increase is high in the initial cycles and less in the subsequent cycles. It was also observed that the simulation results are in good agreement with the experimental results. Full article

Modular steel construction (MSC) consists of the off-site prefabrication of a fully finished module and the on-site assembling of the module unit. The popularity of MSC is on the rise, attributable to its technical advantages of speed and quality of buildings with repetitive units. Inter-module connection is critical for the overall stability and load-bearing capacity of MSC. An innovative, fully prefabricated liftable connection (FPLC) using standard corner fittings and long stay bolts is proposed in this paper. This paper focuses on the axial compressive behavior and design of FPLC. Five full-scale specimens were tested under axial compression. Local buckling of the column and shear of the long stay bolts were observed during the test. It can be concluded from the test results that the load-bearing capacity may decrease as the number and diameter of the stay bolts increase. A three-dimensional nonlinear finite element model (FEM) was developed and validated against the test results by general purpose finite element software ABAQUS. Furthermore, a parametric study was conducted using the verified FEM to provide a better understanding of the axial compressive behavior of the FPLC. The results of the parametric study indicated that the corner fitting can be up to 15% lighter for columns with thicknesses of 6 mm and 8 mm without substantial reduction of the axial load-bearing capacity of the FPLC. Moreover, the location of the column can be adjusted to achieve a uniform Von Mises stress and equivalent plastic strain (PEEQ) distribution of the connection. The presented research work provides an engineering-practical inter-module connection on its axial compressive behavior, which will provide helpful references for further application of MSC. Full article

Shot peening (SP) is a controlled and systematic process of surface treatment that has a large number of controllable process parameters that make its application highly challenging. It involves the shooting of small and hard metallic balls at a targeted surface, with the aim of enhancing the fatigue strength of the workpiece under unfavorable service conditions. The compressive residual stress (CRS) induced by this application is expensive to evaluate experimentally. This paper presents a numerical model of the impact of a single-shot on a metallic surface, with the aim to set the stage for a realistic multiple shots peening simulation. The approach proposed herein is a sequential Discrete Element-Finite Element (DE-FE) coupled simulation, based on the use of different types of coefficients of restitution (CoRs) with emphasis on the energetic CoR. The energetic CoR relates the shot/target contact forces to the fractional strain energy needed for localized plastic deformation of the near-surface layer in the workpiece. The generated results of the induced compressive residual stresses (CRS) and equivalent plastic strain (PEEQ) from single-shot simulations are validated with similar results from the literature. Our study clarifies the strain energy aspects of a single-shot impact responsible for the desired effects of CRS and PEEQ, thereby laying the groundwork for accurate and realistic modeling of the SP process via the DEM-FEM approach. Full article