Coupled CFD-FEM Simulation of Steel Box Bridge Exposed to Fire

Increasing fire-induced bridge failures are demanding more precise behavior prediction for the bridges subjected to fires. However, current numerical methods are limited to temperature curves prescribed for building structures, which can misestimate the fire impact significantly. This paper developed a framework coupling the computational dynamics (CFD) method and finite element method (FEM) to predict the performance of fire-exposed bridges. The fire combustion was simulated in CFD software, Fire Dynamic Simulator, to calculate the thermal boundary required by the thermomechanical simulation. Then, the adiabatic surface temperatures and heat transfer coefficient were applied to the FEM model of the entire bridge girder. A sequential coupled thermomechanical FEM simulation was then carried out to evaluate the performance of the fire-exposed bridge, thermally and structurally. The methodology was then validated through a real fire experiment on a steel beam. The fire performance of a simply supported steel box bridge was simulated using the proposed coupled CFD-FEM methodology. Numerical results show that the presented method was able to replicate the inhomogeneous thermomechanical response of box bridges exposed to real fires. The girder failed due to the buckling of a central diaphragm after the ignition of the investigated tanker fire in no more than 10 min. The framework presented in this study is programmatic and friendly to researchers and can be applied for the estimation of bridges in different fire conditions.

Implementation of a viscoplastic substrate creep model in the thermomechanical simulation of the WAAM process

This research work focusses on the implementation of a viscoplastic creep model in the thermomechanical simulation of the wire arc additive manufacturing (WAAM) process for Ti-6Al-4 V structures. Due to the characteristic layer by layer manufacturing within the WAAM process, viscoplastic material effects occur, which can be covered by implementing a creep model in the thermomechanical simulation. Experimental creep tests with a wide temperature, load and time range were carried out to examine short-term creep behaviour in particular. A Norton-Bailey creep law is used to accurately fit the experimental data and describe the base material’s creep behaviour. Subsequently, the fitted Norton-Bailey creep law was implemented in the thermomechanical simulation of the WAAM process. Finally, to determine the effect of creep on global distortion and local residual stress state in the substrate, simulations of a simplified linear, three-layer WAAM structure, with and without applying the implemented creep law, were carried out and compared to experimental data. The thermomechanical simulation with implemented creep model reveals a significant improvement in the numerical estimation of distortion and residual stress state in the substrate. The maximum distortion is reduced by about 13% and respectively the mean absolute percentage error between simulation and experiment decreases by about 34%. Additionally, the estimation accuracy with respect to the local residual stress state in the substrate improved by about 10%.

Redistribution of Grain Boundary Misorientation and Residual Stresses of Thermomechanically Simulated Welding in an Intercritically Reheated Coarse Grained Heat Affected Zone

A study of the migration of the grain boundary misorientation and its relationship with the residual stresses through time immediately after the completion of a thermomechanical simulation has been carried out. After physically simulating an intercritically overheated welding heat affected zone, the variation of the misorientation of grain contours was observed with the electron backscatter diffraction (EBSD) technique and likewise the variation of the residual stresses of welding with RAYSTRESS equipment. It was observed that the misorientation of the grain contours in an ASTM DH36 steel was modified after the thermomechanical simulation, which corresponds to the measured residual stress variation along the first week of monitoring, with compressive residual stresses ranging from 195 MPa to 160 MPa. The changes in misorientation indicate that the stress relaxation phenomenon is associated with the evolution of the misorientation in the microstructure caused by the welding procedure. On the first day, there was a fraction of 4% of the kernel average misorientation (KAM) values at 1° misorientation and on the fourth day, there was a fraction of 7% of the KAM values at 1° misorientation.

Ion Source—Thermal and Thermomechanical Simulation

The main purpose of this work is to conduct ground development testing of the ion source intended for use the space debris contactless transportation system. In order to substantiate the operating capability of the developed ion source, its thermal and thermomechanical simulation was carried out. The ion source thermal model should verify the ion source operating capability under thermal loading conditions, and demonstrate the conditions for ion source interfacing with the systems of the service spacecraft with the ion source installed as a payload. The mechanical and mathematical simulation for deformation of the ion source ion-extraction system profiled electrodes under thermal loading in conjunction with the prediction of the strained state based on the numerical simulation of the ion source ion-extraction system units, making it possible to ensure the stability of the ion source performance. Good agreement between the thermal and thermo-mechanical ion source simulation results and experimental data has been demonstrated. It is shown that the developed ion source will be functional in outer space and can be used as an element of the space debris contactless transportation system into graveyard orbits.

A Sequential Approach for Simulation of Thermoforming and Squeeze Flow of Glass Mat Thermoplastics

In this study, a sequential thermoforming and squeeze flow simulation approach for Glass Mat Thermoplastic (GMT) material is proposed and applied to a hat section geometry using input properties based upon Tepex flowcore, a long glass fiber reinforced polyamide (PA/GF) mat manufactured by Lanxess. First, a fully-coupled thermomechanical simulation is conducted based on a purely Lagrangian description, to efficiently capture thermoforming. Subsequently, relevant state variables are mapped and initialized for a Coupled-Eulerian-Lagrangian (CEL) approach. The CEL approach is adopted to accurately capture squeeze flow, which is not possible by a purely Lagrangian description. While numerical techniques differ, both approaches use the same three-dimensional and thermomechanical constitutive equations including an equation of state, a nonlinear viscosity model, and crystallization kinetics, implemented through a material user-subroutine (VUMAT) for the commercially available simulation software package ABAQUS/Explicit.