scholarly journals Numerical Simulation and Experimental Validation of the Cladding Material Distribution of Hybrid Semi-Finished Products Produced by Deposition Welding and Cross-Wedge Rolling

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1336
Author(s):  
Jens Kruse ◽  
Maximilian Mildebrath ◽  
Laura Budde ◽  
Timm Coors ◽  
Mohamad Yusuf Faqiri ◽  
...  
Keyword(s):  
High Performance ◽  
Experimental Validation ◽  
Ball Bearing ◽  
Major Influence ◽  
Cross Wedge Rolling ◽  
Element Analysis ◽  
Welding Seam ◽  
Rolling Contacts ◽  
Tailored Forming ◽  
Cladding Material

The service life of rolling contacts is dependent on many factors. The choice of materials in particular has a major influence on when, for example, a ball bearing may fail. Within an exemplary process chain for the production of hybrid high-performance components through tailored forming, hybrid solid components made of at least two different steel alloys are investigated. The aim is to create parts that have improved properties compared to monolithic parts of the same geometry. In order to achieve this, several materials are joined prior to a forming operation. In this work, hybrid shafts created by either plasma (PTA) or laser metal deposition (LMD-W) welding are formed via cross-wedge rolling (CWR) to investigate the resulting thickness of the material deposited in the area of the bearing seat. Additionally, finite element analysis (FEA) simulations of the CWR process are compared with experimental CWR results to validate the coating thickness estimation done via simulation. This allows for more accurate predictions of the cladding material geometry after CWR, and the desired welding seam geometry can be selected by calculating the cladding thickness via CWR simulation.

A Finite Element Analysis on Metal Ball Effect on Dynamics of a Ball Bearing

2018 ◽  
Vol 875 ◽  
pp. 100-104
Author(s):  
Bo Wun Huang ◽  
Jia Sheng Chen ◽  
Zhi Yin Huang ◽  
Nan Wen Lin
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Dynamic Characteristic ◽  
High Performance ◽  
Ball Bearing ◽  
Dynamic Properties ◽  
Element Model ◽  
Element Analysis ◽  
Rotating Speed ◽  
The Finite Element Analysis

The bearings are widely used in the rotating machinery systems to support the mechanical, structural for system. In a high rotating speed, the spindle to be stable rotating is dependent on a high performance bearing. Therefore, the dynamic characteristic of a ball bearing is very importance and need to study. In this work, the dynamic characteristic of a ball bearing is focused to study. Because the geometric of ball bearing are so complex, the finite element analysis is employed to investigate. By using the finite element analysis software ANSYS, the bearings meshed model can be setup. The dynamic properties, natural frequency and mode shape of ball and global system, can be studied to improve the high spindle rotating stable performance. Numerical indicates that the stress, strain and dynamics of the ball bearing system can be investigated in this finite element model.

scholarly journals Topology and Response Surface Optimization of a Bicycle Crank Arm with Multiple Load Cases

2020 ◽  
Vol 10 (6) ◽  
pp. 2201 ◽  
Author(s):  
Ahmad Yusuf Ismail ◽  
Gangta Na ◽  
Bonyong Koo
Keyword(s):  
Topology Optimization ◽  
Response Surface ◽  
Response Surface Method ◽  
High Performance ◽  
Experimental Validation ◽  
Three Dimensional ◽  
Optimization Methods ◽  
Stress Constraint ◽  
Element Analysis ◽  
Surface Method

This paper presents an application of topology optimization and response surface method to optimize the geometry of a bicycle crank arm and the experimental validation of it. This is purposely to reduce the crank arm mass and create a preliminary design of a lightweight structure necessary for the high-performance bicycle development. A three-dimensional bike crank arm model was made in the SpaceClaim software followed by a static finite element analysis using ANSYS Workbench 2019 R1. A multiple cycling load was applied simultaneously in seven crank angles of 30, 45, 60, 90, 120, 135, and 150° relative to the horizontal position to create the multiple loads to the crank. From there, topology optimization was then conducted to investigate the effect of mass constraint, stress constraint, angle of cycling, and crank materials on the topological pattern result. To minimize stress concentration at corners, a shape optimization using the response surface method was conducted and obtained the final geometry. From the result, it is shown that both optimization methods not only successfully reduce the crank arm mass and provide several optimum design options but also are able to reduce the maximum stress in the crank arm up to 20% after the optimization process. The experimental validation using a newly developed wireless measurement system shows a considerable agreement to the numerical results.

Parallel Computing for Tire Simulations

2011 ◽  
Vol 39 (3) ◽  
pp. 193-209 ◽  
Author(s):  
H. Surendranath ◽  
M. Dunbar
Keyword(s):  
High Performance ◽  
Effective Means ◽  
Cost Effective ◽  
Turnaround Time ◽  
Careful Consideration ◽  
Rolling Contact ◽  
Element Analysis ◽  
Parallel Solvers ◽  
Design Changes ◽  
Highly Nonlinear

Abstract Over the last few decades, finite element analysis has become an integral part of the overall tire design process. Engineers need to perform a number of different simulations to evaluate new designs and study the effect of proposed design changes. However, tires pose formidable simulation challenges due to the presence of highly nonlinear rubber compounds, embedded reinforcements, complex tread geometries, rolling contact, and large deformations. Accurate simulation requires careful consideration of these factors, resulting in the extensive turnaround time, often times prolonging the design cycle. Therefore, it is extremely critical to explore means to reduce the turnaround time while producing reliable results. Compute clusters have recently become a cost effective means to perform high performance computing (HPC). Distributed memory parallel solvers designed to take advantage of compute clusters have become increasingly popular. In this paper, we examine the use of HPC for various tire simulations and demonstrate how it can significantly reduce simulation turnaround time. Abaqus/Standard is used for routine tire simulations like footprint and steady state rolling. Abaqus/Explicit is used for transient rolling and hydroplaning simulations. The run times and scaling data corresponding to models of various sizes and complexity are presented.

Accelerated testing of super lightweight UHPC waffle deck under heavy vehicle simulator

2021 ◽  
Vol 16 (2-3) ◽  
pp. 61-74
Author(s):  
Sahar Ghasemi ◽  
Amir Mirmiran ◽  
Yulin Xiao ◽  
Kevin Mackie
Keyword(s):  
High Performance ◽  
Failure Modes ◽  
High Performance Concrete ◽  
High Strength ◽  
Heavy Vehicle ◽  
Wheel Load ◽  
Element Analysis ◽  
Vehicle Simulator ◽  
Pavement Testing ◽  
Heavy Vehicle Simulator

A super lightweight deck can enhance load rating and functionality of a bridge, especially those identified as structurally deficient. This study was aimed to develop and experimentally validate a novel bridge deck as an ultra-lightweight low-profile waffle slab of ultra-high-performance concrete (UHPC) with either carbon fiber reinforced polymer (CFRP) or high strength steel (HSS) reinforcement. The proposed system lends itself to accelerated bridge construction, rapid deck replacement in bridges with load restrictions, and bridge widening applications without the need to replace girders. Performance and failure modes of the proposed deck were initially assessed through extensive lab experiments and finite element analysis, which together confirmed that the proposed deck panel meets the AASHTO LRFD requirements. The proposed deck system is not susceptible to punching shear of its thin slab and fails in a rather ductile manner. To evaluate its long-term performance, the system was further tested under the dynamic impact of wheel load at the Accelerated Pavement Testing (APT) facility of the Florida Department of Transportation using a Heavy Vehicle Simulator (HVS).

scholarly journals Electromagnetic-Thermal Integration Design of Permanent Magnet Motor for Vehicles

2019 ◽  
Vol 2019 ◽  
pp. 1-8 ◽  
Author(s):  
Shijun Chen ◽  
Qi Zhang ◽  
Surong Huang
Keyword(s):  
Permanent Magnet ◽  
High Performance ◽  
Design Method ◽  
Electromagnetic Properties ◽  
Permanent Magnet Motor ◽  
Element Analysis ◽  
Experiment Platform ◽  
Motor Design ◽  
Dimensional Parameters ◽  
Thermal Integration

To more efficiently design high performance vehicular permanent magnet motor, an electromagnetic-thermal integration design method is presented, which considers both the electromagnetic properties and the temperature rise of motor winding when determining the main dimensional parameters of the motor. Then a 48-slot and 8-pole vehicular permanent magnet motor is designed with this method. The thermomagnetic coupling design is simulated and validated on the basis of multiphysical domain on finite element analysis. Then the prototype is analyzed and tested on a newly built motor experiment platform. It is shown that the simulation results and experimental results are consistent, which validate the accuracy and effectiveness of the new design method. Also this method is proved to well improve the efficiency of permanent magnet motor design.

scholarly journals High-performance magneto-rheological clutches for direct-drive actuation: Design and development

2021 ◽  
pp. 1045389X2110069
Author(s):  
Sergey Pisetskiy ◽  
Mehrdad Kermani
Keyword(s):  
High Performance ◽  
Degrees Of Freedom ◽  
Dynamic Range ◽  
Complete Analysis ◽  
Mass Ratio ◽  
Direct Drive ◽  
Element Analysis ◽  
Prototype Development ◽  
Magneto Rheological ◽  
Hall Sensors

This paper presents an improved design, complete analysis, and prototype development of high torque-to-mass ratio Magneto-Rheological (MR) clutches. The proposed MR clutches are intended as the main actuation mechanism of a robotic manipulator with five degrees of freedom. Multiple steps to increase the toque-to-mass ratio of the clutch are evaluated and implemented in one design. First, we focus on the Hall sensors’ configuration. Our proposed MR clutches feature embedded Hall sensors for the indirect torque measurement. A new arrangement of the sensors with no effect on the magnetic reluctance of the clutch is presented. Second, we improve the magnetization of the MR clutch. We utilize a new hybrid design that features a combination of an electromagnetic coil and a permanent magnet for improved torque-to-mass ratio. Third, the gap size reduction in the hybrid MR clutch is introduced and the effect of such reduction on maximum torque and the dynamic range of MR clutch is investigated. Finally, the design for a pair of MR clutches with a shared magnetic core for antagonistic actuation of the robot joint is presented and experimentally validated. The details of each approach are discussed and the results of the finite element analysis are used to highlight the required engineering steps and to demonstrate the improvements achieved. Using the proposed design, several prototypes of the MR clutch with various torque capacities ranging from 15 to 200 N·m are developed, assembled, and tested. The experimental results demonstrate the performance of the proposed design and validate the accuracy of the analysis used for the development.

Evaluation of Compressive Strengths of HPS Plate Systems Stiffened with Trapezoidal Stiffeners

2013 ◽  
Vol 671-674 ◽  
pp. 1025-1028
Author(s):  
Dong Ku Shin ◽  
Kyungsik Kim
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
High Performance ◽  
Nonlinear Finite Element ◽  
Linear Strain ◽  
Element Analysis ◽  
Geometric Imperfections ◽  
Eurocode 3 ◽  
Initial Geometric Imperfections ◽  
Plate System

The ultimate compressive strengths of high performance steel (HPS) plate system stiffened longitudinally by closed stiffeners have been investigated by the nonlinear finite element analysis. Both conventional and high performance steels were considered in models following multi-linear strain hardening constitutive relationships. Initial geometric imperfections and residual stresses were also incorporated in the analysis. Numerical results have been compared to compressive strengths from Eurocode 3 EN 1993-1-5 and FHWA-TS-80-205. It has been found that although use of Eurocode 3 EN 1993-1-5 and FHWA-TS-80-205 may lead to highly conservative design strengths when very large column slenderness parameters are encountered

The Strain Analysis at the Broadening Stage of the Hollow Railway Axle by Multi-Wedge Cross Wedge Rolling

2014 ◽  
Vol 494-495 ◽  
pp. 457-460 ◽  
Author(s):  
Bin Hu ◽  
Xue Dao Shu ◽  
Peng Hui Yu ◽  
Wen Fei Peng
Keyword(s):  
Production Efficiency ◽  
Strain Analysis ◽  
Cross Wedge Rolling ◽  
Forming Process ◽  
Element Analysis ◽  
Forming Mechanism ◽  
Railway Axle ◽  
The Finite Element Analysis ◽  
Scientific Significance ◽  
Deform 3D

The paper is based on the newest hollow railway axle, which utilizes the Pro/E designed multi-wedge cross wedge rolling (MCWR) model, utilizes the finite element analysis software DEFORM-3D to complete the numerical simulation about the whole stage of the hollow railway axle forming process, and analyzes the strain rule at the broadening stage of the hollow railway axle, especially conducts a detailed research on forming character into the strain rule at the multi-wedge transition stage, and finally gets the strain forming mechanism of the hollow railway axle at the broadening stage. The result of the research on the strain rule poses great scientific significance on enhancing the product quality and the production efficiency of the hollow railway axle, and improving the theory of multi-wedge cross wedge rolling.

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