Experimental and numerical study on static and dynamic axial crushing of square aluminum tubes: Effects of cutouts

The collapse of tubes under axial load is an important subject from the safety point of view, particularly in the design of energy absorbing devices used in many engineering applications. In this study, quasi-static and dynamic experiments were carried out on square thin-walled aluminum extrusions to investigate the effects of circular holes. Cutouts were introduced in the four corners of the square-section tube, not far from the end boundary of the tube, in order both to decrease the first peak load on the load-displacement characteristic and to control the collapse mode. Different aspects, such as the buckling modes and the energy absorption in quasi-static axial crushing tests, as well as dynamic effects and material rheology contributions in dynamic crushing tests, have been examined. For the dynamic tests, the parameters were the impacting mass and its velocity. The results showed a drop in the first peak function of the openings’ radius and the tube’s energy absorption capacity was kept. A comparison between static and dynamic tests results was carried out and the interpretation of the results in terms of deformation mechanism and energy absorption was discussed. Numerical simulations with the finite element code ABAQUS were conducted to confirm the experimental findings. The results of different numerical models, implicit and explicit calculations, that contribute to a basic understanding of the buckling and prediction of the crash behavior of the aluminum components without and with the cutouts are presented.

Design and Development of Innovative Steam Injection for High-Temperature Short-Time Liquid Foods

Jet impingement has been effective in reducing the process time and improvement of product quality in various industrial applications, such as textile and paper drying, electronic cooling, glass quenching and food processing. The current work applied innovative steam injection to liquid food continuous sterilization. The multiple impingement jets of steam and product came together in the impingement tank. The effects were investigated on the Reynolds number, steam temperature and jet-to-target spacing (H/d), sterilization temperature and heat transfer efficiency in water and pineapple juice tests. The Reynolds number was based on the nozzle configuration and liquid flow rate. The study investigated product injection plates formed using two, three or four circular holes (diameter 2 mm), steam injection plates with six, nine or twenty circular holes (diameter 1 mm), steam temperatures of 120, 125 or 130 °C and H/d values of 1, 3, 5 or 7. The different options were tested with water to determine the optimal conditions, and then tested with pineapple juice. The results showed that the optimal conditions from water testing that provided the highest heat transfer efficiency occurred with two jet nozzles, six steam injection plates, a steam temperature of 120 °C and an H/d value of 1.

Failure Criteria for Brittle Notched Specimens

Recently, new failure criteria were proposed for brittle materials to predict their failure loads regardless of the shapes of a notch or a crack in the material. This paper is to further evaluate the failure criteria for different shapes of notches and different materials. A circular hole, elliptical hole or crack-like slit with a different angle with respect to the loading direction was considered. Double circular holes were also studied. The materials studied were an isotropic material like polymethyl methacrylate (PMMA) as well as laminated carbon fiber composites. Both cross-ply and quasi-isotropic layup orientations were examined. The lamination theory was used for the composite materials so that they can be modelled as an anisotropic and homogeneous material. The test results were compared to the theoretical predictions using the finite element analysis with 2-D plane stress models. Both theoretical failure stresses agreed well with the experimental data for the materials and notch geometries studied herein.

Open holes in composite laminates with finite dimensions: structural assessment by analytical methods

Open circular holes are an important design feature, for instance in bolted joint connections. However, stress concentrations arise whose magnitude depends on the material anisotropy and on the defect size relative to the outer finite plate dimensions. To design both safe and light-weight optimal structures, precise means for the assessment are crucial. These can be based on analytical methods providing efficient computation. For this purpose, the focus of the present paper is to provide a comprehensive stress and failure analysis framework based on analytical methods, which is also suitable for use in industry contexts. The stress field for the orthotropic finite-width open-hole problem under uniform tension is derived using the complex potential method. The results are eventually validated against Finite-Element analyses revealing excellent agreement. Then, a failure analysis to predict brittle crack initiation is conducted by means of the Theory of Critical Distances and Finite Fracture Mechanics. These failure concepts of different modelling complexity are compared to each other and validated against experimental data. The size effect is captured, and in this context, the influence of finite width on the effective failure load reduction is investigated.

Evaluation of formulations for predicting the shear strength of concrete filled circular holes in steel plates

Since the development of perforated plate shear connectors, different formulations have been proposed to predict their shear strength. Most of these formulations were derived from standard push-tests on multiple concrete filled holes (CFH) specimens simulating specific steel-concrete composite beam applications. Aiming at a more general application of these connectors in composite structures and the understanding of the physical and geometric parameters that influence their shear strength, the present work evaluated the use of 12 different formulations to predict 92 test results of single-hole specimens extracted from the literature. Such tests were chosen because the single-hole configuration allows better isolation of the connection behavior which facilitates comparative analysis. The predictions were statistically evaluated, and it was considered that the best formulations were those that showed lower scatter of data and a correction factor closer to one. Also, it was investigated if the individual terms that constitute the formulations adequately describe or show relation to the mechanics that govern the connection. It was verified that the best statistically rated formulations were also the ones showing clearer relation to the connector mechanical behavior. Among the evaluated formulations, three were significantly better than the others for strength prediction, however, it was noted that they can be further improved by considering the influence of concrete confinement and plate thickness on the hole’s strength.

Investigation on Orbital EDM for Double-Hole Thin Wall of Integrated Flexible Joint

The thin neck structure of integrated flexible joint is the key factor to realize high-precision navigation in dynamically tuned gyroscope. The thin neck structure is composed of two adjacent circular holes and the thin wall between the two holes. The thin wall is easy to deform under the external force and vibration exerted by the tool when using traditional machining methods such as drilling and boring, and the cutting tools are easily to be damaged for the machining of small holes in superhard materials, inducing high processing cost. Aiming at these problems, the machining method of double-hole thin wall in the step-by-step orbital electrical discharge machining (EDM) with a high rotation speed electrode is proposed. The procedure for EDM of double-hole flexible thin wall is designed, and the process parameters of each step machining are optimized using orthogonal experiment and signal-to-noise ratio analysis. The machining experiments of double-hole thin wall of 3J33B material are proceed using the optimized parameters. The results show that the hole diameter of the double-hole flexible thin wall is 2 mm, the hole depth is 8mm, and the average thickness of the thin wall is about 46.5 μm. The thickness range between the measured point and the average is 1.55 μm, that compared with average thickness of 46.5 μm, the error is less than 3%, the overall thickness is uniform relatively.

Experimental Study and Proposal to Improve the EWM Design of Cold-Formed Steel Lipped Channel Columns with Circular Holes under Axial Compression

The cold-formed steel (CFS) lipped channel section with circular holes has been widely used in low-rise and multistory building structures as the column. However, the circular hole in the web makes the lipped channel column become susceptible to buckle. A total of 54 CFS lipped channel axial compression columns with and without circular holes were used to study the buckling behavior and the effective width design method. The interaction of the local buckling and the distortional buckling were observed for the short and intermediate columns, while the slender columns were controlled by the interaction of the local buckling, distortional buckling, and flexural buckling or flexural-torsional buckling. The experimental failure loads were gradually decreased with the increase in the diameter of the circular hole for the specimens with the same section. The failure loads of the specimens with two holes were lower than those of the specimens with one hole with same section and same diameter of holes. Then, the experimental results were used to validate a nonlinear finite element model (FEM) previously developed by the authors. The validated FEM was subsequently used to obtain additional 36 numerical failure results concerning the effects of the length, the section, and the diameter and the number of the circular holes. Furthermore, the proposal to calculate the distortional buckling coefficient of the CFS lipped channel section with circular holes were put forward based on numerical analysis considering the reduction of effect of holes. Finally, a proposal to improve the effective width method (EWM) design approach for CFS lipped channel sections with circular holes under axial compression was presented. The comparisons between experimental and numerical capacities and their calculations provided by the proposed EWM design method illustrate a great application of the proposed approach.

Theoretical and Experimental Research on a Novel Method of Cluster Magnetorheological Finishing Based on Array Circular Holes Polishing Disk

with the high performance of microelectronic and optoelectronic devices, the new generation of optoelectronic wafers is developing in the direction of large size and ultra-thinning, which requires ultra-smooth surfaces with sub-nanometer surface roughness. It puts forward new requirements and challenges for the efficient and ultra-smooth planarization processing of optoelectronic wafers. This paper proposes a novel method of cluster magnetorheological finishing based on array circular holes polishing disk, which can effectively improve the polishing shear force and polishing efficiency. The appropriate polishing shear force and material removal rate are the keys to achieve low roughness and low damage processing of optoelectronic wafers. Therefore, the shear force model of solid particles in magnetorheological finishing fluid is established based on the tribological principle. The material removal rate model is established by combining the polishing shear force model with the velocity model. The correctness of the above model is verified by the rotary dynamometer and repeated single-factor experiments. The errors between theoretical and experimental values of polishing shear force and material removal rate are 8.8% and 10.8%, respectively. The new magnetorheological finishing method can realize the efficient and ultra-smooth planarization of optoelectronic wafers. The established model can theoretically guide the optimization of the surface structure and polishing process of polishing disks.

Modelling of Microperforated Panel Absorbers with Circular and Slit Hole Geometries

Although the original proposal of microperforated panels by Maa consisted of an array of minute circular holes evenly distributed in a thin plate, other hole geometries have been recently suggested that provide similar absorption curves to those of circular holes. With the arrival of modern machining technologies, such as 3D printing, panels microperforated with slit-shaped holes are being specially considered. Therefore, models able to predict the absorption performance of microperforated panels with variable hole geometry are needed. The aim of this article is to analyze three models for such absorbing systems, namely, the Maa model for circular holes, the Randeberg–Vigran model for slit-shaped holes, and the Equivalent Fluid model for both geometries. The absorption curves predicted for these three models are compared with the measured curves of three panels microperforated with spirally shaped slits.