Search Results (28)

In this study, a three-dimensional simulation of a walking-beam reheating furnace was developed to improve the steel slab reheating process and reduce surface oxidation kinetics using computational fluid dynamics (CFD). Combustion, heat transfer, fluid dynamics, and chemical reaction models were integrated into the numerical framework of this study. In addition, dynamic mesh remeshing was coupled through user-defined functions (UDFs), enabling the simultaneous simulation of slab movement and evolution of the involved transport phenomena. Turbulence was modeled with the realizable k-ε formulation, combustion with the Eddy Dissipation model, and radiation with the P-1 model coupled with WSGGM to include CO₂ and H₂O gas radiation. Scale formation was modeled using customized functions based on Arrhenius-type kinetics and Wagner’s oxidation model, evaluating its growth as a function of time, temperature, and furnace atmosphere. The predicted thermal evolution inside the furnace was validated using industrial data, yielding an average deviation of 5%. Furthermore, the proposed operating conditions led to an average slab temperature of 1289.77 °C at the exit of the homogenization zone, which was 16 °C higher than that under the current operation but still within the target range (1250 ± 50 °C). The reduction in combustion air decreased energy losses and improved product quality, lowering the molar oxygen content in the furnace atmosphere from 4.9 × 10² mol to 6.7 × 10¹ mol. Additionally, annual savings of 4,793,472 kg of natural gas and 13,884 tons of steel were estimated owing to reduced oxidation losses. The proposed air–fuel adjustment led to estimated annual energy savings (equivalent to 4,793,472 kg of natural gas) and a reduction in material loss due to oxidation from 4.5% to 3.75% (an absolute reduction of 0.75 percentage points; relative reduction ≈ 16.7%), which has a significant industrial impact on metal conservation and descaling cost reduction. Although there are CFD studies on plate overheating and scale growth separately, this work presents three main contributions: (1) the integration, within a single numerical framework, of combustion, radiation, species transport, oxidation kinetics, and actual plate movement using a dynamic mesh; (2) validation against continuous industrial records (16 thermocouples) and quantification of operational benefits such as fuel savings and reduced material loss; and (3) a comparative analysis between actual and optimized conditions, which standardize the air–methane ratio. Full article

The kinetics and evolution of hydrogen-induced cracking (HIC) were modeled using a theoretical model developed by Gonzalez to calculate the individual crack growth rate and a computational algorithm based on a Poisson distribution to generate the initial spatial distribution of HIC nuclei. Additionally, the Monte Carlo method was used to model the interconnection of individual HIC cracks. The results of the computational model were compared versus experimental results of HIC induced by cathodic charging experiments in low-carbon steel plates. The model was capable of accurately emulating the kinetics of HIC, considering the first stage of nucleation and growth of randomly dispersed individual HIC cracks, followed by a second stage where the individual cracks interconnect with each other to form large cracks that subsequently grow. The study was complemented with the fractographic examination of the HIC cracks to verify if the fracture mechanism is consistent with the crack morphology and propagation mode in the proposed model. The results indicate that HIC propagation occurs by cleavage and quasi-cleavage mechanisms, with crack interconnection by ductile shear tearing, where the driving force for HIC is the accumulated hydrogen pressure within the internal HIC cracks, explaining why the crack growth rates are nearly constant in each stage of HIC growth. Full article

This study presents a unique and comprehensive application of ANSYS Mechanical R19.2’s SMART crack growth feature, leveraging its capabilities to conduct an unprecedented parametric investigation into fatigue crack propagation behavior under a wide range of positive and negative stress ratios, and to provide detailed insights into the influence of hole positioning on crack trajectory. By uniquely employing an unstructured mesh method that significantly reduces computational overhead and automates mesh updates, this research overcomes traditional fracture simulation limitations. The investigation breaks new ground by comprehensively examining an unprecedented range of both positive (R = 0.1 to 0.5) and negative (R = −0.1 to −0.5) stress ratios, revealing previously unexplored relationships in fracture mechanics. Through rigorous and extensive numerical simulations on two distinct specimen configurations, i.e., a notched plate with a strategically positioned hole under fatigue loading and a cracked rectangular plate with dual holes under static loading, this work establishes groundbreaking correlations between stress parameters and fatigue behavior. The research reveals a novel inverse relationship between the equivalent stress intensity factor and stress ratio, alongside a previously uncharacterized inverse correlation between stress ratio and von Mises stress. Notably, a direct, accelerating relationship between stress ratio and fatigue life is demonstrated, where higher R-values non-linearly increase fatigue resistance by mitigating stress concentration, challenging conventional linear approximations. This investigation makes a substantial contribution to fracture mechanics by elucidating the fundamental role of hole positioning in controlling crack propagation paths. The research uniquely demonstrates that depending on precise hole location, cracks will either deviate toward the hole or maintain their original trajectory, a phenomenon attributed to the asymmetric stress distribution at the crack tip induced by the hole’s presence. These novel findings, validated against existing literature, represent a significant advancement in predictive modeling for fatigue life assessment, offering critical new insights for engineering design and maintenance strategies in high-stakes industries. Full article

The accurate, robust, and efficient prediction of transition in viscous flows is a significant challenge in computational fluid dynamics. We present a coupled high-fidelity iterative approach that leverages the FUN3D flow solver and the LASTRAC stability code to predict transition in low-disturbance environments, initiated by the linear growth of boundary-layer instability modes. Our method integrates the ability of FUN3D to compute mixed laminar–transitional–turbulent mean flows via transition-sensitized Reynolds-Averaged Navier–Stokes equations with the ability of LASTRAC to perform linear stability analysis, all within an automated framework that requires no intermediate user involvement. Unlike conventional frameworks that rely on classical stability theory or reduced-order metamodels, our approach employs parabolized stability equations to provide more accurate and reliable estimates of disturbance growth for multiple instability mechanisms, including Tollmien–Schlichting, Kelvin–Helmholtz, and crossflow modes. By accounting for the effects of mean-flow nonparallelism as well as the surface curvature, this approach lays the foundation for improved N-factor correlations for transition onset prediction in a broad class of flows. We apply this method to three distinct flow configurations: (1) flow over a zero-pressure-gradient flat plate, (2) the NLF-0416 airfoil with both natural and separation-induced transition, and (3) a 6:1 prolate spheroid, where transition is primarily driven by crossflow instability. For two-dimensional cases, a formulated intermittency distribution is used to model the transition zone between the laminar and fully turbulent flows. The results include comparisons with experimental measurements, similar numerical approaches, and transport-equation-based models, demonstrating good agreement in surface pressure coefficients, transition onset locations, and skin-friction coefficients for all three configurations. In addition to contributing a couple of new insights into boundary-layer transition in these canonical cases, this study presents a powerful tool for transition modeling in both research and design applications in aerodynamics. Full article

The size of ships has increased considerably in recent decades. This growth impacts the stress magnitude in the bottom hull plates, which constantly suffer from biaxial compression and lateral water pressure, potentially leading to buckling. Adding stiffeners is an effective alternative to increase mechanical buckling resistance if placed in a proper way. Several researchers have investigated the influence of stiffeners on plates under different loading conditions. However, the behavior under combined biaxial compression and lateral pressure has not yet been widely explored. This work aims to verify and validate a computational model to analyze the elastoplastic buckling of plates under biaxial compression and lateral pressure, applying it in a case study to define the ideal geometric configuration to increase ultimate buckling resistance, using the constructal design method and exhaustive search technique. In this study, a portion of the volume from a reference plate without stiffeners was converted into stiffeners to determine the optimal geometry for maximizing ultimate buckling resistance. The numerical model was verified and validated, and the case study identified the optimal plate configuration with five longitudinal and four transverse stiffeners, with a height-to-thickness ratio of 8.70, achieving a 284% increase in ultimate buckling resistance compared to the reference plate. These results highlight the importance of geometric evaluation in structural engineering problems. Full article

Energy storage systems play a vital role in balancing solar- and wind-generated power. However, the uncertainty of their lifespan is a key factor limiting their large-scale applications. While currently reported battery aging models, empirical or semi-empirical, are capable of accurately assessing battery decay under specific operating conditions, they cannot reliably predict the battery lifespan beyond the measured data. Moreover, these models generally require a tedious procedure to determine model parameters, reducing their value for onsite applications. This paper, based on Newman’s pseudo-2D performance model and incorporating microparameters obtained from cell disassembly, developed a mechanistic model accounting for three major aging mechanisms of lithium iron phosphate/graphite cells, i.e., solid electrolyte interphase growth, lithium plating, and gas generation. The prediction of this mechanistic model agrees with the experimental results within an average error of ±1%. The mechanistic model was further simplified into an engineering model consisting of only two core parameters, loss of active lithium and loss of active material, and was more suitable for large-scale applications. The accuracy of the engineering model was validated in a 100 MW/200 MWh energy storage project. When the actual State of Health (SOH) of the battery degraded to 89.78%, the simplified model exhibited an error of −0.17%, and the computation time decreased from 8.12 h to 10 s compared to the mechanistic model. Full article

Shock-to-detonation transition (SDT) is the detonation of explosive charge triggered by the shock pressure from a nearby detonated explosive or an impact at high speed. A good prediction of SDT is a key in the design of explosives’ use, storage, and transportation. Typically, SDT simulation must use designated commercial software; therefore, a high license cost is necessary. This paper presents a simulation of SDT by a cost-effective hydrodynamic code developed on an open-source code framework, OpenFOAM. The code adopted the multi-material Eulerian method, Ignition and Growth reaction rate model, and Riemann solver to solve the shock-induced detonation phenomenon. The code was verified by a Pop plot calculation and a sympathetic detonation simulation. In the Pop plot calculation, the distance-of-run to the detonation of Composition B depending on the initial shock pressure was simulated. The reactant and product phases of Composition B were modeled by the Jone–Wilkins–Lee (JWL) equation of state (EOS). The aluminum plate used to create the initial shock pressure was modeled by shock Mie–Gruneisen (MG) EOS. The predicted distance-of-run against the initial shock pressure was in good agreement with an empirical correlation and experimental data. In the sympathetic detonation simulation, the charge explosive and nearby explosive were Composition B and were modeled by JWL EOS as in the Pop plot calculation and the plexiglass gap was modeled by MG EOS. The simulated critical gap for the sympathetic detonation was well predicted as in the other published data. This implies that the code is valid for SDT simulation. In addition, it is a cost-effective simulation, since the code was developed on open-source code, so massive computation can then be run without license costs. Full article

This work presents numerical modeling-based investigations for detecting and monitoring damage growth and material nonlinearity in plate structures using topological acoustic (TA) and sideband peak count (SPC)-based sensing techniques. The nonlinear ultrasonic SPC-based technique (SPC-index or SPC-I) has shown its effectiveness in monitoring damage growth affecting various engineering materials. However, the new acoustic parameter, “geometric phase change (GPC)” and GPC-index (or GPC-I), derived from the TA sensing technique adopted for monitoring damage growth or material nonlinearity has not been reported yet. The damage growth modeling is carried out by the peri-ultrasound technique to simulate nonlinear interactions between elastic waves and damages (cracks). For damage growth with a purely linear response and for the nonlinearity arising from only the nonlinear stress–strain relationship of the material, the numerical analysis is conducted by the finite element method (FEM) in the Abaqus/CAE 2021 software. In both numerical modeling scenarios, the SPC- and GPC-based techniques are adopted to capture and compare those responses. The computed results show that, from a purely linear scattering response in FEM modeling, the GPC-I can effectively detect the existence of damage but cannot monitor damage growth since the linear scattering differences are small when crack thickness increases. The SPC-I does not show any change when a nonlinear response is not generated. However, the nonlinear response from the damage growth can be efficiently modeled by the nonlocal peri-ultrasound technique. Both the GPC-I and SPC-I techniques can clearly show the damage evolution process if the frequencies are properly chosen. This investigation also shows that the GPC-I indicator has the capability to distinguish nonlinear materials from linear materials while the SPC-I is found to be more effective in distinguishing between different types of nonlinear materials. This work can reveal the mechanism of GPC-I for capturing linear and nonlinear responses, and thus can provide guidance in structural health monitoring (SHM). Full article

Estimates of physical and mechanical characteristics of materials at high strain rates play a key role in enhancing the accuracy of prediction of the stress–strain state of structures operating in extreme conditions. This article presents the results of a combined experimental–numerical study on the mechanical response of a thin-sheet rolled Ti-5Al-2.5Sn alloy to dynamic penetration. A specimen of a titanium alloy plate underwent punching with a hemispherical indenter at loading rates of 10, 5, 1, and 0.5 m/s. The evolution of the rear surface of specimens and crack configuration during deformation were observed by means of high-speed photography. Numerical simulations were performed to evaluate stress distribution in a titanium plate under specified loading conditions. To describe the constitutive behavior and fracture of the Ti-5Al-2.5Sn alloy at moderate strain rates, a physical-based viscoplastic material model and damage nucleation and growth relations were adopted in the computational model. The results of simulations confirm a biaxial stress state in the center of specimens prior to fracture initiation. The crack shapes and plate deflections obtained in the calculations are similar to those observed in experiments during dynamic punching. Full article

With the world moving towards low-carbon and environmentally friendly development, the rapid growth of new-energy vehicles is evident. The utilization of deep-learning-based license-plate-recognition (LPR) algorithms has become widespread. However, existing LPR systems have difficulty achieving timely, effective, and energy-saving recognition due to their inherent limitations such as high latency and energy consumption. An innovative Edge–LPR system that leverages edge computing and lightweight network models is proposed in this paper. With the help of this technology, the excessive reliance on the computational capacity and the uneven implementation of resources of cloud computing can be successfully mitigated. The system is specifically a simple LPR. Channel pruning was used to reconstruct the backbone layer, reduce the network model parameters, and effectively reduce the GPU resource consumption. By utilizing the computing resources of the Intel second-generation computing stick, the network models were deployed on edge gateways to detect license plates directly. The reliability and effectiveness of the Edge–LPR system were validated through the experimental analysis of the CCPD standard dataset and real-time monitoring dataset from charging stations. The experimental results from the CCPD common dataset demonstrated that the network’s total number of parameters was only 0.606 MB, with an impressive accuracy rate of 97%. Full article

This paper presents a new analytical approach to the embedding of delamination in the layerwise theory, which can be applied to determine the stress–strain state in the cross-section of laminated plates with internal delamination. The new approach is based on the layerwise theory, which transfers considerations from the level of the laminated plate to the level of the lamina. The paper presents a mathematical model and defines a calculation procedure for determining the state of the stress and strain in a cross-section with an internal delamination that occurred during plate production. The convergence and stability of the computational procedure, based on a new approach to the embedding of delamination in layerwise theory, are proven. It is also proven that the existence of internal delamination on the bond between layers of laminated plates significantly changes the stress-strain state of the cross-section, in relation to a cross-section without delamination. In numerical examples, the value of delamination in the plane (x, y) is determined and considered. The initial state after a static load or “zero state” of stress and strain in a cross-section with delamination represent the input for further and future nonlinear analyses that involve the growth, development, and propagation of delamination. Full article

Bone tumors, such as osteosarcomas, can occur anywhere in the bones, though they usually occur in the extremities of long bones near metaphyseal growth plates. Osteosarcoma is a malignant lesion caused by a malignant osteoid growing from primitive mesenchymal cells. In most cases, osteosarcoma develops as a solitary lesion within the most rapidly growing areas of the long bones in children. The distal femur, proximal tibia, and proximal humerus are the most frequently affected bones, but virtually any bone can be affected. Early detection can reduce mortality rates. Osteosarcoma’s manual detection requires expertise, and it can be tedious. With the assistance of modern technology, medical images can now be analyzed and classified automatically, which enables faster and more efficient data processing. A deep learning-based automatic detection system based on whole slide images (WSIs) is presented in this paper to detect osteosarcoma automatically. Experiments conducted on a large dataset of WSIs yielded up to 99.3% accuracy. This model ensures the privacy and integrity of patient information with the implementation of blockchain technology. Utilizing edge computing and fog computing technologies, the model reduces the load on centralized servers and improves efficiency. Full article

(1) Background: Thermal ablation has been demonstrated to affect the bone growth of osteoid osteoma in adolescents. Growth modulation due to thermal heat in children is conceivable, but has not yet been established. We used lamb extremities as a preclinical model to examine the effect of thermal ablation on growth plates in order to evaluate its potential for axial or longitudinal growth modulation in pediatric patients. (2) Methods: Thermal ablation was performed by electrocautery on eight different growth plates of the legs and distal radii of a stillborn lamb. After treatment, target hits and the physical extent of the growth plate lesions were monitored using micro-computed tomography (micro-CT) and histology. (3) Results: Lesions and their physical extent could be quantified in 75% of the treated extremities. The histological analysis revealed that the disruption of tissue was confined to a small area and the applied heat did not cause the entire growth plate to be disrupted or obviously damaged. (4) Conclusions: Thermal ablation by electrocautery is minimally invasive and can be used for targeted disruption of small areas in growth plates in the animal model. The results suggest that thermal ablation can be developed into a suitable method to influence epiphyseal growth in children. Full article

One of the most frequent bone deformities in dogs is antebrachial growth deformity (AGD), which results from malunion of the distal growth plates. The objective of the present study was to re-align the limbs, which can correct the length mismatch and reset the coherence of the joint with the aid of a 3-D phantom model for surgical preplanning. A 14-month-old, intact female Golden Retriever with an angular deformity of the left radius and ulna was selected for the study. The diagnosis was confirmed by orthogonal radiographs. Moreover, computed tomography (CT) scans revealed a multiplane deformity with valgus, procurator, and external rotation of the left radius. The pre-surgical planning started with the quantification of the angular deformity, followed by a simulated virtual osteotomy, and concluded with an in vitro rehearsal surgery on 3-D printed phantom bone models. In the operating room, prefabricated patient-specific instrumentation (PSI) was attached at the planned site of the radial bone surface for a precise closing wedge osteotomy. Then two locking plates were fixed routinely. Post-operative radiographs showed accurate correction of the deformity as we had planned. At 12 weeks post-operatively, the follow-up surveys revealed improved gait, weight-bearing, and progression of bone healing. Our PSI design, based on novel surgical planning, was steady yet straightforward during the osteotomy. The osteotomy was performed without difficulty since the PSI that pre-determined the sites and angles let the surgeon perform the antebrachial malformation surgery. This method of operation reduces stress on the operator and helps to improve accuracy, repeatability, and surgery time. Full article

Several approaches have been used in the past to predict fatigue crack growth rates in T-joints of the offshore structures, but there are relatively few cases of applying structural health monitoring during the non-destructive testing of jacket platforms. This paper presents an experimental method based on the sensing of the piezoelectric sensors and finite element analysis method for studying the fatigue cracks in the offshore steel jacket structure. Three types of joints are selected in the current research work: T-type plate, T-type tube-plate, and T-type tube joints. The finite element analysis model established in the current study computes and analyzes the high stress and high strain regions in the T-type joints. The fatigue damage in the T-type joints was successfully detected by utilizing both the finite element analysis and experimental methods. The results showed that fatigue cracks of the three types of joints are prone to appear at the weld toe and spread in the welding direction. The fatigue damage location of T-type plate and T-type tube-plate joints is more concentrated in the upper weld toe area, and the fatigue damage location of the T-type tube joint is closer to the lower weld toe area. Full article