scholarly journals Finite Element Modeling and Mechanical Testing of Metal Composites Made by Composite Metal Foil Manufacturing

2019 ◽  
Vol 3 (3) ◽  
pp. 81 ◽  
Author(s):  
Butt ◽  
Ghorabian ◽  
Mohaghegh ◽  
Shirvani
Keyword(s):  
Finite Element ◽  
Galvanic Corrosion ◽  
Pure Copper ◽  
Element Model ◽  
Layered Composite ◽  
Metal Foil ◽  
Metal Foils ◽  
Flexural Testing ◽  
Time Required ◽  
Aluminum 1050

Foils of aluminum 1050 H14 ½ hard temper and 99.9% copper with 500-micron thickness have been used to manufacture similar and dissimilar composites by composite metal foil manufacturing (CMFM). The metal foils are bonded to each other using a special 80% zinc and 20% aluminum by weight brazing paste. A 3D finite element model has been developed to numerically analyze the time required to heat the metal foils so that a strong bond can be developed by the paste. The numerical simulations run in ANSYS 19.1 have been validated through experiments and rectangular layered composite products have been developed for flexural testing. The flexural test results for layered Al and Al/Cu composites are compared with solid samples of Al 1050 and 99.9% pure copper made by subtractive method. The results show that the layered Al composite is 5.2% stronger whereas the Al/Cu sample is 11.5% stronger in resisting bending loads compared to a solid Al 1050 sample. A higher bend load indicates the presence of a strong intermetallic bond created by the brazing paste between the metal foils. Corrosion testing was also carried out on the composite samples to assess the effect of corrosion on flexural strength. The tests revealed that the composites made by CMFM are not affected by galvanic corrosion after 7 days of testing and the flexural loads remained consistent with composites that were not immersed in a solution of distilled water and NaCl.

scholarly journals Finite Element Modelling and Validation of Thermomechanical Behaviour for Layered Aluminium Parts Made by Composite Metal Foil Manufacturing

2018 ◽  
Vol 2 (4) ◽  
pp. 68 ◽  
Author(s):  
Javaid Butt ◽  
Mohammad Ghorabian ◽  
Abed Ahmed ◽  
Hassan Shirvani
Keyword(s):  
Finite Element ◽  
Tensile Properties ◽  
Thermal Effects ◽  
Finite Element Modelling ◽  
Corrosion Testing ◽  
Metal Foil ◽  
Element Modelling ◽  
Metal Foils ◽  
Dog Bone ◽  
Thermomechanical Behaviour

The paper presents finite element modelling and thermomechanical analysis on the tensile properties of layered aluminium 1050 metal foil parts made by composite metal foil manufacturing. In this paper, a three-dimensional finite element model was developed and validated through experiments to analyse thermal effects on the tensile properties of 200-μm-thick aluminium 1050 metal foils. The effects of thermal stress and strain were studied by carrying out transient thermal analysis on the heated plates used to join the 200-μm-thick metal foils together using a special brazing paste. A standard tensile test at ambient temperature was carried out on the resulting layered dog bone specimens to analyse the thermal effects on the individual layers of metal. The investigations were precisely designed to assess the effect of heat provided amid the brazing operation to join the metal thwarts together as a layered structure and whether it assumed a part in affecting the tensile properties of the final products when contrasted to a solid aluminium 1050 dog bone specimen of the same dimensions. Corrosion testing was also carried out on dog bone specimens made from varying thickness foils (50 μm, 100 μm, and 200 μm) of aluminium 1050 to assess the effect of corrosion on the tensile strength and elongation. The results showed that the specimens did not face the problem of galvanic corrosion of the foil–bond interface. Microstructural analysis was also carried out to analyse the fracture modes of the tested specimens after corrosion testing.

Finite Element Modeling of Effect of Adhesive Layer and Carrier Thickness Used for Strain Gauge Mounting

2015 ◽  
Vol 1119 ◽  
pp. 828-832
Author(s):  
K. Vadivuchezhian ◽  
K. Subrahmanya ◽  
N. Chockappan
Keyword(s):  
Finite Element ◽  
Strain Gauge ◽  
Adhesive Layer ◽  
Element Model ◽  
Strain Gauges ◽  
Single Element ◽  
Metal Foil ◽  
Engineering Structures ◽  
Element Analysis ◽  
Typical Strain

Metal foil strain gauges are most widely used for the stress analysis in engineering structures. Typical strain gauge system includes strain sensitive grid, carrier material, and adhesive layer. Strain measurement from the strain gauge is partially affected by carrier and adhesive materials and their thickness. In the present work, a Finite Element Model is developed in order to study the effect of both adhesive layer and carrier thickness on strain measurements while using strain gauges. To understand the behavior of the adhesive material, mechanical characterization is done on bulk adhesive specimen. Finite Element Analysis (FEA) is carried out with different materials namely epoxy and polyurethane. Initially a single element foil loop is considered for the analysis and further this is extended to metal foil strain gauge with nine end-loops. Finally, the strain variation through thickness of adhesive layer, carrier and strain sensitive grid is obtained from FEA. The results thus obtained are compared with analytical results from Basic Strength of Materials approach.

scholarly journals A Finite Element Model for Dynamic Analysis of Triple-Layer Composite Plates with Layers Connected by Shear Connectors Subjected to Moving Load

Materials ◽  
2019 ◽  
Vol 12 (4) ◽  
pp. 598 ◽  
Author(s):  
Hoang-Nam Nguyen ◽  
Tan-Y. Nguyen ◽  
Ke Tran ◽  
Thanh Tran ◽  
Truong-Thinh Nguyen ◽  
...  
Keyword(s):  
Finite Element ◽  
Moving Load ◽  
Composite Plates ◽  
Element Model ◽  
Layered Composite ◽  
Ship Building ◽  
Shear Connectors ◽  
Composite Layers ◽  
Layer Composite ◽  
Mindlin’S Theory

Triple-layered composite plates are created by joining three composite layers using shear connectors. These layers, which are assumed to be always in contact and able to move relatively to each other during deformation, could be the same or different in geometric dimensions and material. They are applied in various engineering fields such as ship-building, aircraft wing manufacturing, etc. However, there are only a few publications regarding the calculation of this kind of plate. This paper proposes novel equations, which utilize Mindlin’s theory and finite element modelling to simulate the forced vibration of triple-layered composite plates with layers connected by shear connectors subjected to a moving load. Moreover, a Matlab computation program is introduced to verify the reliability of the proposed equations, as well as the influence of some parameters, such as boundary conditions, the rigidity of the shear connector, thickness-to-length ratio, and the moving load velocity on the dynamic response of the composite plate.

Finite Element Analysis of the Effect of Flexible Pad on the Deformation of Metal Foils in Flexible Pad Laser Shock Microforming

2014 ◽  
Vol 611-612 ◽  
pp. 581-588 ◽  
Author(s):  
Balasubramanian Nagarajan ◽  
Sylvie Castagne ◽  
Zhong Ke Wang ◽  
Hong Yu Zheng
Keyword(s):  
Finite Element Analysis ◽  
Plastic Deformation ◽  
Finite Element ◽  
Elastic Recovery ◽  
Crater Depth ◽  
Metal Foil ◽  
Laser Shock ◽  
Element Analysis ◽  
Metal Foils ◽  
Metallic Foils

Flexible Pad Laser Shock Forming (FPLSF) is a new microforming process using laser-induced shock pressure and a flexible pad. This process involves high strain-rate (~105 s-1) plastic deformation of metallic foils along with the hyperelastic deformation of the flexible elastomer pad over which the foil is positioned. This paper studies the influence of flexible pad on the shockwave propagation behavior and the plastic deformation of metal foil in FPLSF using finite element analysis. The effect of flexible pad materials such as silicone rubber, polyurethane rubber and natural rubber on the deformation of copper foils has been analysed in detail. An increase in crater depth is observed with the reduction in flexible pad hardness. However, it is found that there exists an optimum hardness of the flexible pad to achieve perfect hemispherical craters on metal foils, as bending of foils at non-deformed region is observed with softer pads whereas flattening of crater surface occurs with harder pads. The effect of flexible pad thickness on the foil deformation was analyzed at six different thickness levels: 300 μm, 600 μm, 900 μm, 1200 μm, 1500 μm, and 2000 μm. Similarly, there exists an optimum flexible pad thickness to maximize the crater depth and achieve the hemispherical shapes. Analysis of flexible pad thickness indicates that the pad thickness influences the elastic recovery of the flexible-pad and hence the plastic deformation of the metallic foils.

Use of extended finite element method and statistical analysis for modelling the corrosion-induced cracking in reinforced concrete containing metakaolin

2018 ◽  
Vol 45 (3) ◽  
pp. 167-178 ◽  
Author(s):  
Hossam S. Al-alaily ◽  
Assem A.A. Hassan ◽  
Amgad A. Hussein
Keyword(s):  
Finite Element ◽  
Statistical Analysis ◽  
Prediction Model ◽  
Element Model ◽  
Concrete Cover ◽  
Binder Content ◽  
Extended Finite Element ◽  
Accelerated Corrosion ◽  
Factors Affecting ◽  
Time Required

This study presents an improved technique to predict the time for corrosion-induced cracking in concrete containing metakaolin (MK) based on combining extended finite element model (XFEM) and statistical analysis. The prediction model was developed based on the percentage of MK in the mixture, binder content, water-to-binder (W/B) ratio, and concrete cover thickness. The developed model was also validated experimentally using an accelerated corrosion test. Moreover, design charts were developed in this study using statistical analysis to facilitate and simplify the use of the prediction model. The results indicated that the corrosion pressure required to crack the concrete cover increased with higher percentages of MK, higher binder content, and (or) lower W/B ratio. The most significant factors affecting the time for corrosion-induced cracking was found to be the concrete cover, W/B ratio, MK replacement, and binder content, respectively, in order of significance. The results also indicated that the time required for corrosion-induced cracking obtained from the developed prediction model showed a good agreement with the experimental results of the accelerated corrosion samples. Also, the cracks predicted by the XFEM showed a similar trend of variation with that found in the accelerated corrosion samples.

A Different Approach for Obtaining the Shear Moduliof a Composite Material

2020 ◽  
Vol 70 (12) ◽  
pp. 4470-4476
Keyword(s):  
Finite Element ◽  
Composite Material ◽  
Elastic Modulus ◽  
Shear Modulus ◽  
Finite Element Model ◽  
Element Model ◽  
Layered Composite ◽  
Element Analysis ◽  
Shear Elastic Modulus ◽  
Elastic Characteristics

In recent years the composites materials gained a major importance in all fields of engineering, because they offer a successful replacement for classical materials conferring similar elastic-mechanical properties to metal or non-metal alloys presenting several advantages such as reduced mass, chemical resistance etc. Considering this, during the design, dull knowledge of the elastic-mechanical characteristics is of high importance. The present paper aims to create a finite element model able to predict the shear elastic modulus of a double-layered composite material based on the elastic characteristics of its constituents. For this, once the elastic characteristics of the constituents determined, they could be used in the finite element analysis obtaining consequently the shear modulus for the composite material. Also, the shear elastic modulus of the resultant composite was determined experimentally. The results of the finite element model were compared to the experimental values in order to validate the finite element analyses results. Keywords: composites, fiberglass, shear modulus, FEM

Friction Stir Butt Welding of Commercially Pure Copper Plates

2014 ◽  
Author(s):  
Gihad Karrar ◽  
A. N. Shuaib ◽  
F. A. Al-Badour ◽  
N. Merah ◽  
A. K. Mahgoub
Keyword(s):  
Finite Element ◽  
Pure Copper ◽  
Welding Process ◽  
Element Model ◽  
Butt Joint ◽  
Fe Model ◽  
Weld Quality ◽  
Element Analysis ◽  
Butt Welding ◽  
Friction Stir

This paper presents the results of studying friction stir butt welding of commercial pure copper plates using both experimental and finite element analysis methods. The experimental work consisted of making a butt joint to 4 mm copper plates using friction stir welding process at constant rotational speed of the pin tool to evaluate the effect of welding speed on weld quality. Weld quality was evaluated by the joints tensile strength, micro hardness, as well as evolution of the developed microstructure across the welding zone. A coupled Eulerian Lagrangian (CEL) finite element (FE) model had been developed to simulate the friction stir butt welding process, and predict the temperature distributions across the weld, as well as developed welding stresses. Axial load and temperature measurements results from the experiments have been used to validate the finite element model.

A Finite Element Model to Predict the Part Strength of Fused Deposition Modeling Printed Parts

2016 ◽  
Author(s):  
Vivek Velivela ◽  
Saravana Kumar Gurunathan
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Computational Model ◽  
Fused Deposition Modeling ◽  
Load Condition ◽  
Element Model ◽  
Layered Composite ◽  
Deformation And Failure ◽  
Fused Deposition ◽  
3D Printers

This paper aims at creating a computational finite element model, which will be used for prediction of deformation and failure of specimen under static loads for specimens prepared using FDM based 3D printers with different raster fill patterns and density. The work is divided as follows: a) understanding heterogeneity in specimen printed using FDM; b) conducting strength testing experiments to estimate stiffness and failure corresponding to particular infill configuration; c) creating and validating computational finite element model of FDM printed specimen with various raster fill pattern and density. In this work, the computational model of FDM parts is created as a multi-layered composite model. The computational model generated in this work can be used to estimate the deformation of a specimen printed using FDM process under a specific load condition. This model can further be used within an optimization framework to maximize part strength for a part with any geometry by suitably selecting part orientation and slicing parameters for a given service load condition.

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