Optimal Design and Experimental Investigations of Aluminium Extrusion Profiles for Lightweight of Car Bumper

2013 ◽  
Vol 585 ◽  
pp. 157-164 ◽  
Author(s):  
Jia Zhou ◽  
X.M. Wan ◽  
Y. Li ◽  
Q.J. Zhao
Keyword(s):  
Weight Reduction ◽  
Experimental Studies ◽  
Fem Simulation ◽  
Optimization Method ◽  
Bending Test ◽  
Crash Test ◽  
Experimental Investigations ◽  
Optimized Design ◽  
Extrusion Dies ◽  
Aluminium Extrusion

The present study aimed at developing an aluminium car bumper unit to replace the steel ones by using optimization based on experimental and FEM simulation results. The topology optimization method and response surface methodology (RSM) were applied in order to achieve an optimized design for the cross section of the crossbeam and the crash box, respectively. The three-points bending test and crash test for bumper unit were simulated to evaluate the optimization processes. The 6061 and 6063 aluminium alloy bumper unit has a weight reduction of 67% compared to the steel ones. The new extrusion dies were manufactured to produce profiles for the crossbeam and the crash box, respectively. Then the optimized extrusion profiles of crossbeam and crash box were verified by experimental studies. The performance tests were arranged to validate the experimental product. The mechanical properties of extruded aluminium crossbeam and crash box can satisfy the design requirements of products. The results indicate that the new designed unit can change the whole design of automotive parts for crash energy absorption, and definitely contribute to drastic weight reduction of steel parts.

scholarly journals Additive Manufacturing-Based In Situ Consolidation of Continuous Carbon Fibre-Reinforced Polycarbonate

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2450
Author(s):  
Andreas Borowski ◽  
Christian Vogel ◽  
Thomas Behnisch ◽  
Vinzenz Geske ◽  
Maik Gude ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Carbon Fibre ◽  
Bending Test ◽  
Thermoplastic Composites ◽  
Experimental Investigations ◽  
Material Structure ◽  
Three Point Bending ◽  
Continuous Fibre ◽  
Local Material

Continuous carbon fibre-reinforced thermoplastic composites have convincing anisotropic properties, which can be used to strengthen structural components in a local, variable and efficient way. In this study, an additive manufacturing (AM) process is introduced to fabricate in situ consolidated continuous fibre-reinforced polycarbonate. Specimens with three different nozzle temperatures were in situ consolidated and tested in a three-point bending test. Computed tomography (CT) is used for a detailed analysis of the local material structure and resulting material porosity, thus the results can be put into context with process parameters. In addition, a highly curved test structure was fabricated that demonstrates the limits of the process and dependent fibre strand folding behaviours. These experimental investigations present the potential and the challenges of additive manufacturing-based in situ consolidated continuous fibre-reinforced polycarbonate.

scholarly journals Experimental Evaluation of Airlift Performance for Vertical Pumping of Water in Underground Mines

2021 ◽  
Author(s):  
Parviz Enany ◽  
Oleksandr Shevchenko ◽  
Carsten Drebenstedt
Keyword(s):  
Water Flow ◽  
High Efficiency ◽  
Experimental Studies ◽  
Theoretical Models ◽  
Injection System ◽  
Experimental Investigations ◽  
Flow Mode ◽  
New Device ◽  
Riser Pipe ◽  
Airlift Pump

AbstractThis paper presents experimental studies on the optimization of air–water flow in an airlift pump. Airlift pumps use compressed gas to verticall transport liquids and slurries. Due to the lack of theoretical equations for designing and predicting flow regimes, experimental investigations must be carried out to find the best condition to operate an airlift pump at high efficiency. We used a new air injection system and different submergence ratios to evaluate the output of a simple pump for vertical displacement of water in an underground mine. The tests were carried out in a new device with 5.64 m height and 10.2 cm circular riser pipe. Three air-jacket pipes, at different gas flows in the range of 0.002–0.09 m3/s were investigated with eight submergence ratios. It was found that with the same air flow rate, the most efficient flow of water was achieved when an air jacket with 3 mm diameter holes was used with a submergence ratio between 0.6 and 0.75. In addition, a comparison of practical results with two theoretical models proposed by other investigators showed that neither was able to accurately predict airlift performance in air–water flow mode.

Increased Productivity in Hot Aluminum Extrusion by Using Extrusion Dies with Inner Cooling Channels Manufactured by Rapid Tooling

2014 ◽  
Vol 611-612 ◽  
pp. 981-988 ◽  
Author(s):  
Ramona Hölker ◽  
Matthias Haase ◽  
Nooman Ben Khalifa ◽  
A. Erman Tekkaya
Keyword(s):  
Surface Defects ◽  
Experimental Investigations ◽  
Extrusion Force ◽  
Aluminum Extrusion ◽  
Thermally Induced ◽  
Manufacturing Method ◽  
Cooling Channels ◽  
Extrusion Dies ◽  
Exit Temperature ◽  
Tooling Technology

The influence of local inner die cooling on the heat balance in hot aluminum extrusion was investigated. For the manufacturing of the die with cooling channels close to the forming zone, the layer-laminated manufacturing method was applied. The new tooling technology was applied in order to decrease the profiles exit temperature and to avoid thermally induced surface defects with the aim to raise the productivity in hot aluminum extrusion processes. Numerical and experimental investigations revealed that, while maintaining the exit temperature of the extrudate, a distinct increase of the production speed up to 300% can be realized, while the extrusion force increases only slightly. An effect on the profiles microstructure was also detected. By applying die cooling, grain coarsening can be significantly limited or even be avoided.

scholarly journals ДОСЛІДЖЕННЯ ГІГІЄНІЧНИХ ВЛАСТИВОСТЕЙ МАТЕРІАЛІВ НАТІЛЬНОЇ ЛІКАРНЯНОЇ БІЛИЗНИ

2020 ◽  
Vol 140 (6) ◽  
pp. 38-47
Author(s):  
І. О. Іванов ◽  
Н. П. Супрун ◽  
Ю. О. Ващенко
Keyword(s):  
Comparative Analysis ◽  
Materials Science ◽  
Experimental Studies ◽  
Operating Conditions ◽  
Raw Material ◽  
Experimental Investigations ◽  
Textile Materials ◽  
Composition And Structure ◽  
Innovative Materials ◽  
Basic Functions

Investigation of the influence of the peculiarities of raw material composition and structure of traditional and innovative linen textile materials on their hygienic properties. Theoretical and experimental investigations are based on the main positions of textile materials science. In experimental studies, modern standardized methods for determining the hygienic properties of textile materials were used, as well as techniques specially developed taking into account the peculiarities of the operating conditions of underwear. The peculiarities of the operating conditions and the basic functions of hospital underwear were determined. The comparative analysis of hygienic properties of traditional and modern fabrics for underwear was carried out. Using the standardized and the developed methods, adapted to the peculiarities of the conditions of use of the products, the indicators characterizing the processes of water absorption of the materials were experimentally determined. On the basis of the obtained values of quality indicators, a comprehensive assessment of the ability of materials to transfer moisture and air, with the calculation of the arithmetic complex quality index was done. This allowed to determine the material that is optimal in properties, which provides thermophysiological comfort when operating hospital underwear. Using the developed methods, which take into account the specifics of the operating conditions, a comparative analysis of the hygienic properties of traditional and innovative materials for underwear was carried out. A new range of textile materials for underwear has been proposed, taking into account the peculiarities of the operational situation of consumption.

scholarly journals Design and Experimental Investigations on NOx Emission Control Using FOCDM (Fractional-Order-Based Coefficient Diagram Method)-PIλDµ Controller

2020 ◽  
Vol 53 (5) ◽  
pp. 695-703
Author(s):  
Maheswari Chennippan ◽  
Priyanka E. Bhaskaran ◽  
Thangavel Subramaniam ◽  
Balasubramaniam Meenakshipriya ◽  
Kasilingam Krishnamurthy ◽  
...  
Keyword(s):  
Fractional Order ◽  
Packed Column ◽  
Experimental Studies ◽  
Pso Algorithm ◽  
Experimental Investigations ◽  
Nox Removal ◽  
Diagram Method ◽  
Coefficient Diagram Method ◽  
Fractional Order Controller ◽  
G Ratio

This paper aims to explore experimental studies on the NOx removal process by using pilot plant packed column experimental hardware. Physical modeling based on chemical absorption equations is used to estimate the diameter concerning the height and L/G ratio. Hydrogen peroxide is used as the additive for achieving high NOx removal efficiency. The absorbent entering into the packed column has been controlled by varying its flow rate through the fractional order controller. The FOCDM-PIλDµ controller tuning parameters such as KP, τI, τD are determined using CDM (Coefficient Diagram Method) PID control strategy and the additional parameters of FOCDM-PIλDµ controller such as λ and µ are determined based on the PSO algorithm. The comparative analysis is performed with classical controllers like ZN-PID along with the CDM-PID controllers.

Development of Upper Extremity Finite Element Model for Elderly Female: Validated Against Dynamic Loading Conditions

2017 ◽  
Author(s):  
Anand Hammad ◽  
Anil Kalra ◽  
Prashant Khandelwal ◽  
Xin Jin ◽  
King H. Yang
Keyword(s):  
Finite Element ◽  
Upper Extremity ◽  
Injury Risk ◽  
Experimental Studies ◽  
Upper Extremities ◽  
Whole Body ◽  
Crash Test ◽  
Fe Model ◽  
Long Term Effects ◽  
Elderly Female

Injuries to the upper extremities that are caused by dynamic impacts in crashes, including contact with internal instrument panels, has been a major concern, especially for smaller female occupants, and the problem worsens with increasing age due to reduced strength of the bones. From the analysis of 1988–2010 CDS unweighted data, it was found that risk of AIS ≥ 2 level for the arm was 58.2±20.6 percent higher in females than males, and the injury risk for a 75-year-old female occupant relative to a 21-year-old subjected to a similar physical insult was 4.2 times higher. Although injuries to upper extremities are typically not fatal, they can have long-term effects on overall quality of life. Therefore, it is important to minimize risks of injuries related to upper extremities, especially for elderly females, who are most at risk. Current anthropomorphic surrogates, like crash-test dummies, cannot be directly used to study injury limits, as these dummies were developed mainly to represent the younger population. The current study is focused on the development of a finite element (FE) model representing the upper extremity of an elderly female. This can be further used to analyze the injury mechanisms and tolerance limits for this vulnerable population. The FE mesh was developed through Computer Tomography (CT) scanned images of an elderly female cadaver, and the data included for validation of the developed model were taken from the experimental studies published in scientific literature, but only the data directly representing elderly females were used. It was found that the developed model could predict fractures in the long bones of elderly female specimens and could be further used for analyzing injury tolerances for this population. Further, it was determined that the developed segmental model could be integrated with the whole body FE model of the elderly female.

Discrete sizing, cross-sectional shape, topology optimization, and material selection of a framed automotive body

2021 ◽  
pp. 095440702110626
Author(s):  
Chao Ma
Keyword(s):  
Weight Reduction ◽  
Material Selection ◽  
Extreme Points ◽  
Optimization Method ◽  
Test Problems ◽  
Manufacturing Cost ◽  
Cross Sectional ◽  
Automotive Body ◽  
Discrete Design Variables ◽  
Sectional Shape

This study proposed a discrete structural optimization method for a framed automotive body. Up to four types of discrete design variables are considered simultaneously, that is, the sizing, cross-sectional shape, topology, and material variables. Firstly, to solve the nonconvex and nonlinear optimization problem, the original non-dominated sorting genetic algorithm, the third version (NSGA-III), is adapted. An improved extreme points identification scheme and a new mutation operator are proposed to stabilize the normalization of the population and accommodate the manufacturing constraints, respectively. Two test problems demonstrate that the modified NSGA-III can handle continuous and discontinuous multiple objective optimization. Subsequently, the classical 10-bar truss is used to illustrate the proposed method. A weight reduction of 4.5 kg is achieved as compared to previous optimal designs in the literature. Finally, a framed automotive body is optimized for maximizing the first order natural frequency and minimizing the total mass, the maximum stresses and the maximum displacements in different load cases and the manufacturing cost. The results obtained by different optimization procedures are presented and discussed. The results demonstrate the feasibility and effectiveness of the proposed method. A weight reduction of 17.59% is achieved while other structural performances satisfy the design requirements.

Large-scale three-dimensional anisotropic topology optimization of variable-axial lightweight composite structures

2021 ◽  
pp. 1-15
Author(s):  
Yuqing Zhou ◽  
Tsuyoshi Nomura ◽  
Enpei Zhao ◽  
Kazuhiro Saitou
Keyword(s):  
Topology Optimization ◽  
Composite Structures ◽  
Large Scale ◽  
Volume Fraction ◽  
Three Dimensional ◽  
Optimization Method ◽  
Optimized Design ◽  
Adaptive Meshing ◽  
Design Synthesis ◽  
Fiber Placement

Abstract Variable-axial fiber-reinforced composites allow for local customization of fiber orientation and thicknesses. Despite their significant potential for performance improvement over the conventional multiaxial composites and metals, they pose challenges in design optimization due to the vastly increased design freedom in material orientations. This paper presents an anisotropic topology optimization method for designing large-scale, 3D variable-axial lightweight composite structures subject to multiple load cases. The computational challenges associated with large-scale 3D anisotropic topology optimization with extremely low volume fraction are addressed by a tensor-based representation of 3D orientation that would avoid the 2π periodicity of angular representations such as Euler angles, and an adaptive meshing scheme, which, in conjunction with PDE regularization of the density variables, refines the mesh where structural members appear and coarsens where there is void. The proposed method is applied to designing a heavy-duty drone frame subject to complex multi-loading conditions. Finally, the manufacturability gaps between the optimized design and the fabrication-ready design for Tailored Fiber Placement (TFP) is discussed, which motivates future work toward a fully-automated design synthesis.

scholarly journals Experimental Investigations of Impact Damage Influence on Behavior of Thin-Walled Composite Beam Subjected to Pure Bending

Materials ◽  
2019 ◽  
Vol 12 (7) ◽  
pp. 1127 ◽  
Author(s):  
Tomasz Kubiak ◽  
Lukasz Borkowski ◽  
Nina Wiacek
Keyword(s):  
Impact Damage ◽  
Full Range ◽  
Image Correlation ◽  
Bending Test ◽  
Beam Deflection ◽  
Experimental Investigations ◽  
Pure Bending ◽  
Channel Section ◽  
Thin Walled ◽  
The Impact

The paper deals with buckling, postbuckling, and failure of pre-damaged channel section beam subjected to pure bending. The channel section beams made of eight-layered GFRP laminate with different symmetrical layups have been considered. The specimens with initially pre-damaged web or flange were investigated to access the influence of impact damage on work of thin-walled structure in the full range of load till failure. The bending tests of initially pre-damage beams have been performed on a universal tensile machine with especially designed grips. The digital image correlation system allowing to follow the beam deflection have been employed. The experimentally obtained results are presented in graphs presenting load-deflection or load vs. angle of rotation relations and in photos presenting impact damages areas before and after bending test. The results show that the impact pre-damages have no significant influence on the work of channel section beams.

scholarly journals Experimental studies and numerical modelling of heat and mass transfer process in shell-and-tube heat exchangers with compact arrangements of tube bundles

2018 ◽  
Vol 240 ◽  
pp. 02006 ◽  
Author(s):  
Valery Gorobets ◽  
Yurii Bohdan ◽  
Viktor Trokhaniak ◽  
Ievgen Antypov
Keyword(s):  
Mass Transfer ◽  
Numerical Modelling ◽  
Heat And Mass Transfer ◽  
Heat Exchangers ◽  
Experimental Studies ◽  
Mass Transfer Process ◽  
Experimental Investigations ◽  
Transfer Processes ◽  
Tube Bundles ◽  
Shell And Tube

Shall-and-tube heat exchangers based on the bundles with in-line or staggered arrangements have been widely used in industry and power engineering. A large number of theoretical and experimental works are devoted to study of hydrodynamic and heat transfer processes in such bundles. In that, works the basic studies of heat and mass transfer for these bundles are found. However, heat exchangers of this type can have big dimensions and mass. One of the ways to improve the weight and dimensions of the shell-and-tube heat exchangers is to use compact arrangement of tube bundles. A new design of heat exchanger is proposed, in which there are no gaps between adjacent tubes that touch each other. Different geometry of these tube bundles with displacement of adjacent tubes in the direction of transverse to the flow is considered. Numerical modelling and experimental investigations of hydrodynamic, heat and mass transfer processes in such tube bundles has been carried out. The distribution of velocities, temperatures, and pressure in inter-tube channels have been obtained.

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