FEA model based cautious automatic optimal shape control for fuselage assembly

In a half fuselage assembly process, shape control is vital for achieving ultra-high precision assembly. To achieve better shape adjustment, we need to determine the optimal location and force of each actuator to push and pull a fuselage to compensate for its initial shape distortion. The current practice achieves this goal by solving a surrogate model based optimization problem. However, there are two limitations of this surrogate model based method: (1) Low efficiency: Collecting training data for surrogate modeling from many FEA replications is time-consuming. (2) Non-optimality: The required number of FEA replications for building an accurate surrogate model will increase as the potential number of actuator locations increases. Therefore, the surrogate model can only be built on a limited number of prespecified potential actuator locations, which will lead to sub-optimal control results. To address these issues, this paper proposes an FEA model based automatic optimal shape control (AOSC) framework. This method directly loads the system equation from the FEA simulation platform to determine the optimal location and force of each actuator. Moreover, the proposed method further integrates the cautious control concept into the AOSC system to address model uncertainties in practice. The case study with industrial settings shows that the proposed Cautious AOSC method achieves higher control accuracy compared to the current industrial practice.

Effects of plate contouring quality on the biomechanical performance of high tibial osteotomy fixation: A parametric finite element study

Locking plates have threaded holes, in which threaded-head screws are affixed. Hence, they do not need to be in intimate contact with underlying bone to provide fixation. There are, however, reports that a large distance between the plate and the bone might cause clinical complications such as delayed union or nonunion, screw pull out, and screw and plate breakage. Considering the diversity in the capabilities and costs of different plate customization techniques, the purpose of this study was to investigate the effect of the plate contouring quality on the biomechanical performance of high tibial osteotomy (HTO) fixation. A finite element model of proximal tibia was developed in Abaqus, using the QCT data of a cadaver. The model was then subjected to open-wedge HTO (correction angle 12°) with TomoFix plate fixation. The sagittal curvature of the plate was changed parametrically to provide certain levels of geometrical fit, and the biomechanical performance parameters of fixation were assessed. Results indicated 5%, 9% and 38% increase in the stiffness of the construct, and the von Mises stress in the plate and locking screw just above the osteotomy site, respectively, when the level of fit of plate changed from 0% (initial non-contoured initial shape) to 100% (fully adapted shape). The same change decreased the pressure at the lateral hinge of the osteotomy by 61%, and the mean of the tensile stress on the screw shaft by 12%. It was concluded that the level of fit has conflicting effects on the biomechanical parameters of the HTO fixation system, that is, the structural stiffness, the pressure at the lateral hinge, the stresses in the plate and screws, and the pull out resistance of the screws. In particular, for HTO patients with high quality bone, the optimal level of fit should provide a tradeoff between these parameters.

Solving Generalized Nonlinear Schrödinger Equation by Adomian Decomposition Technique

In this paper, using a suitable change of variable and applying the Adomian decomposition method to the generalized nonlinear Schr¨odinger equation, we obtain the analytical solution, taking into account the parameters such as the self-steepening factor, the second-order dispersive parameter, the third-order dispersive parameter and the nonlinear Kerr effect coefficient, for pulses that contain just a few optical cycle. The analytical solutions are plotted. Under influence of these effects, pulse did not maintain its initial shape.

Longitudinal-transverse thermal- force bending and stability layered inhomogeneous profiled rod

The solution to the problem of the stress-strain state of an inhomogeneous profiled rod is based on the use of nonlinear equilibrium conditions and physical relations of a layered thermo elastic thin rod. A differential equation of bifurcation inhomogeneous rod stability of variable cross-section is obtained. The equation has variable functional coefficients. In the initial state, the rod is subjected to bending with the implementation of one of the asymmetric shapes. The critical state occurs under the action of a longitudinal load corresponding to one of the lowest symmetrical shapes, orthogonal to the initial shape. In the first series, numerical calculations of an inhomogeneous I-rod with a variable cross section height are performed. Shelves and wall I-rod are made of steel, aluminum and titanium alloys. The graphs of maximum deflection and normal stresses acting at the calculate points at the boundaries of the layers are plotted depending on the longitudinal load at the given levels of transverse loads and thermal field. A significant influence of the rod physical structure, the profiling its form and the factor of nonlinearity of static relations on the stress fields has been established. A homogeneous temperature field with a nominal value of 80°C creates fields of self-balanced stresses in an inhomogeneous rod. The components of normal stresses in this case reach 20-40% of the materials permissible resistance level. The presence of rod parts with a significant difference in the coefficients of thermal expansion in the composition enhances this effect. In the second, the stability analysis of an inhomogeneous I-rod with a variable width cross section was performed. The transition of the initial S-shaped bend to an unstable state is shown.

Shearing Effects on the Phase Coarsening of Binary Mixtures Using the Active Model B

The phase separation of a two-dimensional active binary mixture is studied under the action of an applied shear through numerical simulations. It is highlighted how the strength of the external flow modifies the initial shape of growing domains. The activity is responsible for the formation of isolated droplets which affect both the coarsening dynamics and the morphology of the system. The characteristic dimensions of domains along the flow and the shear direction are modulated in time by oscillations whose amplitudes are reduced when the activity increases. This induces a broadening of the distribution functions of domain lengths with respect to the passive case due to the presence of dispersed droplets of different sizes.

Calculation model for the evaluation of tired defect development in the freight wagon side frame

The reliability and safe operation of mechanical elements of rail transport is an important and relevant scientific and technical issue since high-loaded units and elements of its chassis are exposed to prolonged operation and their failure can lead to damage with catastrophic consequences. To prevent the possible failure of such objects, there is a necessity for a reliable estimation of their residual life. Among the cast parts of the freight car trolley, the side frames are one of the most loaded elements, which take on dynamic loads that cause vibrations of the unsprung parts of the freight car. The side frame of the 18-100 trolley, as a typical representative of a number of trolleys of freight cars, does not have a sufficient margin of resistance to fatigue and survivability, so it is sensitive to some deviations and defects (different wall thickness, sinks, and pores, residual stresses) that are detected during the operation process. Based on the energy approach of the mechanics of materials fatigue failure, the calculation models for estimating the dynamics of the development of crack-like defects under the action of operational load are developed in this work. The calculation models constructed using modern information technologies, and the software developed for their numerical implementation allow predicting the impact of irregular cyclic loading and complex stress on the growth of surface fatigue crack in the side frame of the carriage, which significantly brings the problem closer to real operating conditions. Numerical calculations were performed using a computer program of our own development in the Python programming language. At the first stage of the program functioning the spectrum of amplitudes of irregular cyclic loading is built, at the second - the program module of numerical solution construction for systems of usual differential equations of the proposed mathematical model of fatigue defect development is started. Calculations of the fatigue crack growth dynamics taking into account the action of shear stresses in the section with the crack of the side frame showed a slight effect of shear stresses on the residual durability of the frame. It is demonstrated that the dynamics of surface crack development significantly depend on its initial geometry. The proposed calculation method for determining the initial shape of the surface crack with a minimum period to critical growth can be effectively used to predict the residual durability during the technical diagnosis of the running gear parts of railway rolling stock. Keywords: wagon side frame; fatigue crack; probability distribution function; load amplitude spectrum; numerical method.

Numerical Simulation of the Influence of Different Surface Morphologies on Molten Pool Flow under Moving Heat Source

In order to study the influence of different initial topography on the molten pool flow under a moving heat source, the finite element analysis method was used to establish a two-dimensional transient model of laser polishing to simulate the evolution of the surface topography of the material during laser polishing. In the simulation process, a moving laser beam was used as the heat source, and the free surface of the actual material was profiled through a three-dimensional profiler. A very similar simulation model surface was constructed, coupled with the flow field and temperature field in the laser polishing process, and the capillary force was considered comprehensively. Combined with thermocapillary force. The results show that under the combined action of capillary force and thermocapillary force, the surface of the polished material has a peak-filling effect, which makes the surface of the material achieve a good polishing effect. The initial shape will affect the polishing effect, the greater the curvature, the faster the flow rate of the molten pool. In molten pools with large spatial curvatures, capillary forces dominate. Keywords: Laser polishing; molten pool; surface topography; numerical analysis; capillary force; thermocapillary force.

Numerical Analysis of the Bonded Composite Shape Effects under Thermal Loading in Aircraft Structures

The design of the optimal shape of patch with a good compromise between mechanical performances and manufacturing aspects can be sought in order to get the maximum structural safety-cost ratio. In this work an analysis has been conducted for development of a finite element methodology to circumvent the thermal effect problem in the bonded repair. Physical and geometrical parameters of the repair material were assumed to be variables, this method are based on two approaches: The first, have modified the patch shape by removing the two isosceles notches (h varied) for minimisation the heating size in the direction of loading. For the second step of the study, the same surface previously deduced are compensate in the other direction with varied the property module for the adhesive layer, for inducing a larger the area covering of crack tip and reduce the thermal stress. The values of thermal stresses obtained from the variation of these two parameters were found to be low compared to the obtained values for initial shape.

Design Optimization of Diffuser Augmented Wind Turbine

The wind turbine power decreases at low wind speed. A flanged diffuser plays a role of a device for collecting and accelerating the approaching wind, and thus the optimization of the diffuser shape presents an important way to enhance the wind turbine power. In this work, a numerical parametric study was conducted on the diffuser to obtain the initial optimum form of flanged diffuser. Then, the Simplex algorithm is used to obtain the optimal diffuser shape starting from the obtained initial shape. Finally, the obtained optimum diffuser shape is used with conventional wind turbine blade. The diffuser shape is defined by four variables: open angle, flange height, centerbody length, and flange angle. The numerical simulation of flanged diffuser is carried out using the “CFDRC package. The results indicated that, the optimum diffuser shape can be obtained using simplex algorithm which maximizes the entrance average velocity to reach 1.77 times wind speed. The power augmented by a factor about 2.76:5.26 of a selected small wind turbine using the obtained diffuser shape compared to that without diffuser.