3D Modelling and Simulation of Gun Drilling

2011 ◽  
Vol 223 ◽  
pp. 12-19 ◽  
Author(s):  
Fritz Klocke ◽  
Mustapha Abouridouane ◽  
Klaus Gerschwiler ◽  
Dieter Lung
Keyword(s):  
Three Dimensional ◽  
Material Model ◽  
Element Model ◽  
Drilling Process ◽  
Fe Model ◽  
Workpiece Material ◽  
Good Surface ◽  
Feed Force ◽  
Gun Drill ◽  
Quenched And Tempered Steel

The main objective of this paper is the development and validation of a three dimensional thermomechanically coupled finite element model for gun drilling AISI 4150 quenched and tempered steel. The Lagrangian formulation proposed in the FE code DEFORM 3DTMand the constitutive Johnson-Cook material model were utilized to simulate the chip formation and to predict the cutting reaction forces as well as the temperature in gun drilling process using carbide gun drills with two different diameters. During gun drilling simulation, modified gun drill cutting edge rounding and friction law are performed to investigate the effect of tool wear and lubrication on feed force and torque respectively. Experimental gun drilling tests were carried out in steel AISI 4150 for the validation of the developed 3D FE model. The developed and validated 3D FE model can be used for optimizing the cutting process in gun drilling (good surface finish and straightness) taking into account the complex gun drill geometry, cutting conditions, heat transfer and the thermo-mechanical behaviour of the workpiece material.

scholarly journals Condensation method in practical modal analysis of hull vibration with application of 3D FE model

2019 ◽  
pp. 162-169
Author(s):  
Valeriy Sutyrin
Keyword(s):  
Modal Analysis ◽  
Three Dimensional ◽  
Element Model ◽  
Fe Model ◽  
Structural Elements ◽  
Natural Vibrations ◽  
Condensation Method ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element ◽  
Analytical Approaches

This paper gives modal analysis results for mid-body of a refrigerator carrier ship by means of combined three-dimensional finite-element model with 1.5 million DOF. The study estimates the error of modal analysis for the ship structure if its boundary conditions are specified in advance, i.e. approximately, as well as analyses the gain in time offered by structuring the analytical model as per reduction (condensation) method. Analytical approaches thus transformed can be successfully applied in filtering lower frequencies and modes of natural vibrations for structural elements and joints of hull in the direct vicinity of exciting force application points.

A Biomechanical Model of Lumbar Spine

2000 ◽  
Author(s):  
Subramanya Uppala ◽  
Robert X. Gao ◽  
Scott Cowan ◽  
K. Francis Lee
Keyword(s):  
Finite Element ◽  
Lumbar Spine ◽  
Experimental Studies ◽  
Three Dimensional ◽  
Biomechanical Model ◽  
Element Model ◽  
Fe Model ◽  
Flexion Extension ◽  
Cortical Shell ◽  
Three Dimensional Finite Element

Abstract The strength and stability of the lumbar spine are determined not only by the bone and muscles, but also by the visco-elastic structures and the interplay between the different components of the spine, such as ligaments, capsules, annulus fibrosis, and articular cartilage. In this paper we present a non-linear three-dimensional Finite Element model of the lumbar spine. Specifically, a three-dimensional FE model of the L4-5 one-motion segment/2 vertebrae was developed. The cortical shell and the cancellous bone of the vertebral body were modeled as 3D isoparametric eight-nodal elements. Finite element models of spinal injuries with fixation devices are also developed. The deformations across the different sections of the spine are observed under the application of axial compression, flexion/extension, and lateral bending. The developed FE models provided input to both the fixture design and experimental studies.

Experimental and numerical investigation of damping in a hybrid automotive damper combining viscous and multiple-impact mechanisms

2021 ◽  
pp. 107754632110381
Author(s):  
Yousif Badri ◽  
Sadok Sassi ◽  
Mohammed Hussein ◽  
Jamil Renno
Keyword(s):  
Viscous Fluid ◽  
Frequency Response ◽  
Piecewise Linear ◽  
Material Model ◽  
Element Model ◽  
Fe Model ◽  
Combination Process ◽  
Hybrid Damper ◽  
Multiple Impact ◽  
Steel Balls

One of the least investigated approaches in passive vibration control is the possibility of combining different types of dampers that use different damping principles. Such a combination process, if wisely designed and implemented, has the potential to increase the damping performance and extend the damper’s application. The primary purpose of this work is to experimentally and numerically investigate the damping behavior of a novel Fluid-Impact Hybrid Damper. This damper combines a conventional Viscous Fluid Damper with a Particle-Impact Damper. The Fluid-Impact Hybrid Damper comprises a 3D-printed plastic box attached to the Viscous Fluid Damper’s moving rod and filled with stainless steel balls. An experimental setup was designed to drive the Viscous Fluid Damper’s rod into harmonic oscillations at different frequencies (1, 2, 4, 6, and 8 Hz). The number of balls was changed three times (5, 10, and 15) to assess the effect of this parameter on the damping performance of the Fluid-Impact Hybrid Damper. A finite element model of the Fluid-Impact Hybrid Damper was developed using LS-Dyna explicit simulation program. The objective of the FE model is to investigate the elastoplastic balls-box collisions using a piecewise-linear plasticity material model. For both the experimental and numerical results, the Frequency Response Function was considered as the main comparison component for a set of force-independent results. The measured Frequency Response Functions showed a noticeable reduction in amplitude at the system’s natural frequency (2 Hz), with an acceptable accuracy between the two approaches.

scholarly journals A robust 3D finite element model for concrete columns confined by FRCM system

2019 ◽  
Vol 281 ◽  
pp. 01006 ◽  
Author(s):  
Majid M.A. Kadhim ◽  
Mohammed J Altaee ◽  
Ali Hadi Adheem ◽  
Akram R. Jawdhari
Keyword(s):  
Finite Element ◽  
Cement Mortar ◽  
Three Dimensional ◽  
Concrete Columns ◽  
Element Model ◽  
Fe Model ◽  
3D Finite Element ◽  
Composite Failure ◽  
Global Buckling ◽  
Fibre Reinforced Polymer

Fibre reinforced cementitious matric (FRCM) is a recent application of fibre reinforced polymer (FRP) reinforcement, developed to overcome several limitations associated with the use of organic adhesive [e.g. epoxies] in FRPs. It consists of two dimensional FRP mesh saturated with a cement mortar, which is inorganic in nature and compatible with concrete and masonry substrates. In this study, a robust three-dimensional (3D) finite element (FE) model has been developed to study the behaviour of slender reinforced concrete columns confined by FRCM jackets, and loaded concentrically and eccentrically. The model accounts for material nonlinearities in column core and cement mortar, composite failure of FRP mesh, and global buckling. The model response was validated against several laboratory tests from literature, comparing the ultimate load, load-lateral deflection and failure mode. Maximum divergence between numerical and experimental results was 12%. Following the validation, the model will be used later in a comprehensive parametric analysis to gain a profound knowledge of the strengthening system, and examine the effects of several factors expected to influence the behaviour of confined member.

A finite element model to study the effect of porosity location on the elastic modulus of a cantilever beam

2019 ◽  
Vol 43 (4) ◽  
pp. 443-453
Author(s):  
Stephen M. Handrigan ◽  
Sam Nakhla
Keyword(s):  
Finite Element ◽  
Elastic Modulus ◽  
Focused Ion Beam ◽  
Mechanical Response ◽  
Ion Beam ◽  
Three Dimensional ◽  
Beam Theory ◽  
Element Model ◽  
Fe Model ◽  
Three Dimensional Finite Element

An investigation to determine the effect of porosity concentration and location on elastic modulus is performed. Due to advancements in testing methods, the manufacturing and testing of microbeams to obtain mechanical response is possible through the use of focused ion beam technology. Meanwhile, rigorous analysis is required to enable accurate extraction of the elastic modulus from test data. First, a one-dimensional investigation with beam theory, Euler–Bernoulli and Timoshenko, was performed to estimate the modulus based on load-deflection curve. Second, a three-dimensional finite element (FE) model in Abaqus was developed to identify the effect of porosity concentration. Furthermore, the current work provided an accurate procedure to enable accurate extraction of the elastic modulus from load-deflection data. The use of macromodels such as beam theory and three-dimensional FE model enabled enhanced understanding of the effect of porosity on modulus.

FE Modeling of the Three-Layer Human Carotid Artery Under Impact Loadings

2007 ◽  
Author(s):  
Aihong Zhao ◽  
Ken Digges ◽  
Mark Field ◽  
David Richens
Keyword(s):  
Finite Element ◽  
Carotid Artery ◽  
Model Simulation ◽  
Material Model ◽  
Element Model ◽  
Traumatic Rupture ◽  
Aortic Tissue ◽  
Fe Model ◽  
Arbitrary Lagrangian Eulerian ◽  
The Impact

Blunt traumatic rupture of the carotid artery is a rare but life threatening injury. The histology of the artery is key to understanding the aetiology of this injury. The carotid artery is composed of three layers known as the tunica intima, media, and adventitia, with distinct biomechanical properties. In order to examine the behaviour of the carotid artery under external load we have developed a three layer finite element model of this vessel. A rubber-like material model from LS-DYNA was selected for the FE model. The Arbitrary-Lagrangian Eulerian (ALE) approach was adopted to simulate the interaction between the fluid (blood) and the structure (carotid). To verify the FE model, the impact bending tests are simulated using this FE model. Simulation results agree with tests results well. Furthermore, the mechanical behaviour of carotid artery tissues under impact loading were revealed by the simulations. The results provide a basis for a more in-depth investigation of the carotid artery in vehicle crashes. In addition, it provides a basis for further work on aortic tissue finite element modeling.

Studying the Effect of Tangential Forces on Rolling Contact Fatigue in Rails Considering Microstructure

2019 ◽  
Author(s):  
Mohamad Ghodrati ◽  
Mehdi Ahmadian ◽  
Reza Mirzaeifar
Keyword(s):  
Rolling Contact Fatigue ◽  
Three Dimensional ◽  
Contact Fatigue ◽  
Material Model ◽  
Element Model ◽  
Rolling Contact ◽  
Traction Forces ◽  
Steel Microstructure ◽  
Initiation And Propagation ◽  
Tangential Forces

In this paper, the micro-mechanical mechanisms behind the initiation and propagation of rolling contact fatigue (RCF) damages caused by the large traction forces are investigated. This study provides a three-dimensional (3D) model for studying the rolling contact fatigue in rails. Since rolling contact fatigue is highly dependent on the rail’s steel microstructure behavior, a proper 3D approach to capture the microstructure- and orientation-dependent mechanical behavior is required. A precise material model known as crystal plasticity is used for this purpose. Additionally, a cohesive zone approach is implemented to capture the crack initiation and propagation at the grain boundaries. Using the 3D finite element model which is developed for this study, we evaluate the effect of various parameters such as traction forces along the rail, and also the normal forces on the RCF response. The results reveal that the RCF cracks initiate slightly below the rail surface. These cracks start propagating toward the rail surface when the contact force is applied in repeated load cycles. The results also indicate that the depth at which RCF initiates depends on the ratio between the longitudinal traction forces and the normal loads. With larger traction forces, the cracks initiate closer, or at the rail surface, whereas larger normal loads promote the cracks initiation beneath the surface.

3D Simulation of Laser Assisted Side Milling of Ti6Al4V Alloy Using Modified Johnson-Cook Material Model

2013 ◽  
Vol 554-557 ◽  
pp. 2054-2061 ◽  
Author(s):  
Hassan Zamani ◽  
Jan Patrick Hermani ◽  
Bernhard Sonderegger ◽  
Christof Sommitsch
Keyword(s):  
Tool Wear ◽  
Laser Beam ◽  
Cutting Forces ◽  
Three Dimensional ◽  
Material Model ◽  
Element Model ◽  
Milling Process ◽  
Machining Processes ◽  
Side Milling ◽  
Three Dimensional Finite Element

During machining of hard materials, one approach to reduce tool wear is using a laser beam to preheat the material in front of the cutting zone. In this study, a new concept of laser-assisted milling with spindle and tool integrated laser beam guiding has been tested. The laser beam is located at the cutting edge and moving synchronously with the cutter. In experiment, a reduction in the resulting process cutting forces and tool wear has been observed in comparison to milling without laser. A three-dimensional finite element model in DEFORM 3D was developed to predict the cutting forces in the milling process with and without an additional laser heat source, based on a Johnson-Cook-type material constitutive model adapted for high strains and strain rates. Both in experiment and simulation, the deformation behavior of a Ti-6Al-4V workpiece has been investigated. The comparison of the resulting cutting forces showed very good agreement. Thus the new model has great potential to further optimize laser assisted machining processes.

scholarly journals Microstructure-Based 3D FE Modeling for Micro Cutting Ferritic-Pearlitic Carbon Steels

2014 ◽  
Author(s):  
M. Abouridouane ◽  
F. Klocke ◽  
D. Lung
Keyword(s):  
Size Effects ◽  
Chip Thickness ◽  
Rake Angle ◽  
Carbon Steels ◽  
Micro Milling ◽  
Fe Model ◽  
Two Phase ◽  
Workpiece Material ◽  
Micro Cutting ◽  
Feed Force

The mechanics of the cutting process on the microscopic level differ fundamentally from the conventional macro cutting. For example, the tool edge radius influences the cutting mechanism in micro machining significantly with regard to the effective rake angle, the minimum chip thickness, the dominance of ploughing, and the related elasto-plastic deformation of the workpiece material. These phenomena, known as size effects, have a profound impact on the cutting force, process stability, and resulting surface finish in micro cutting. Therefore, microstructural effects in microscale cutting require quite different assumptions to be made concerning underlying material behaviour during micro cutting and have led to the need for new modeling approaches to account for such effects. This paper presents a three-dimensional finite element approach to incorporate microstructure into micro cutting simulation based on the concept of a representative volume element (RVE) and constitutive material modeling as well as using the Lagrangian formulation proposed in the implicit FE code Deform 3D™. Micro drilling and micro milling tests using solid carbide tools with different diameters (d = 50 μm − 1 mm) were performed on ferrite-pearlite two-phase steel AISI 1045 for the verification of the developed 3D multiphase FE computation model regarding chip formation, feed force, and torque. The developed 3D multiphase FE model was successfully used to predict size effects in micro cutting.

A STRUCTURAL ANALYSIS AND TOPOLOGY OPTIMIZATION ON CYLINDER BLOCK OF HEAVY DUTY DIESEL ENGIN

2010 ◽  
Vol 24 (15n16) ◽  
pp. 2676-2681 ◽  
Author(s):  
HYUN-SEUNG LEE ◽  
YOUNG-SHIN LEE ◽  
JAE-HOON KIM ◽  
JOON-TAK JUN ◽  
JAE-OK LEE ◽  
...  
Keyword(s):  
Diesel Engine ◽  
Structural Analysis ◽  
Three Dimensional ◽  
Element Model ◽  
Cylinder Block ◽  
Fe Model ◽  
Heavy Duty ◽  
Compacted Graphite ◽  
Heavy Duty Diesel Engine ◽  
Heavy Duty Diesel

The heavy duty diesel engine must have a large output for maintaining excellent mobility. In this study, a three-dimensional finite element model of a heavy-duty diesel engine was developed to conduct the stress analysis by using property of CGI. The compacted graphite iron (CGI) is a material currently under study for the engine demanded for high torque, durability, stiffness, and fatigue. The FE model of the heavy duty diesel engine section consisting of four half cylinders was selected. The heavy duty diesel engine section includes a cylinder block, a cylinder head, a gasket, a liner, a bearing cap, bearing and bolts. The loading conditions of engine are pre-fit load, assembly load, and gas load. A structural analysis on the result was performed in order to optimize on the cylinder block of the diesel engine.

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