Advanced Zig-Zag Beam Theories for Sandwich Structures Analyses

This work aims at evaluating the capabilities of several higher-order beam formulations for stress and dynamic analyses of layered sandwich structures. The structural models are conceived within the framework of the Carrera Unified Formulation (CUF) that allows one to generate (and compare) an infinite number of displacement fields. The number and the type of functions that are selected to generate the kinematic expansions are input parameters of the problem. Besides the well-known Taylor- and Lagrange-type expansions, great attention is paid to a new class of advanced higher-order zig-zag theories, which are written as combinations of continuous piecewise polynomial functions. Numerical simulations are performed on laminated and sandwich beams with very low length-to-depth ratio values. Also, structures with soft layers made of viscoelastic materials are considered to investigate the different dissipation mechanisms.

Finite Element Modelling of TBC Failure Mechanisms by Using XFEM

Thermal Barrier Coatings have been widely used in modern turbine engines to protect the nickel based metal substrate from the high temperature service conditions, 1600–1800 K. In this study, some of the failure mechanisms of typical Air Plasma Sprayed Thermal Barrier Coatings (TBC) used in after-burner structures composed of three major layers: Inconel 718 substrate, NiCrAlY based metallic bond coat (BC) and Yttria Stabilized Zirconia (YSZ) based ceramic top coat (TC) are investigated. Investigation of the cracking mechanism of TBC in terms of design and performance is very important because the behavior of TBCs on ductile metallic substrates is brittle. To this end, four-point bending experiments conducted in Kütükoğlu (2015) is analyzed by using the Extended Finite Element Method (XFEM). All the analyses are conducted with the commercial finite element software ABAQUS. Three different models with varying TC and BC thicknesses are studied under four-point bending. It is observed that multiple vertical cracks are initiated in the TC. Cracks initiate at the top of YSZ and propagate through the whole TC. It is observed that the average crack spacing increases with the increasing thickness of the TC. Numerical results are found to be consistent with the experimental results. In other words, the average crack spacing for three different models are similar with the experimental results.

A Comparative Study Between Selective Laser Melting and Electron Beam Additive Manufacturing Based on Thermal Modeling

Selective Laser Melting (SLM) and Electron Beam Additive Manufacturing (EBAM) are two of the most promising additive manufacturing technologies that can make full density metallic components using layer-by-layer fabrication methods. In this study, three-dimensional computational fluid dynamics models with Ti-6Al-4V powder were developed to conduct numerical simulations of both the SLM and EBAM processes. A moving conical volumetric heat source with Gaussian distribution and temperature-dependent thermal properties were incorporated in the thermal modeling of both processes. The melt-pool geometry and its thermal behavior were investigated numerically and results for temperature profile, cooling rate, variation in specific heat, density, thermal conductivity, and enthalpy were obtained with similar heat source specifications. Results obtained from the two models at the same maximum temperature of the melt pool were then compared to describe their deterministic features to be considered for industrial applications. Validation of the modeling was performed by comparing the EBAM simulation results with the EBAM experimental results for melt pool geometry.

Real Time Loading Test Rig for Flight Control Actuators Under PHM Experimentation

The article deals with the architecture, performance, and experimental tests of a test bench for servo-actuators used in flight controls. After the state of the art on the subject, the innovative architecture of the built bench is described, in which flight control actuator under test and load actuator are not in line but mounted perpendicularly. The model of the bench actuating systems is then presented, consisting of the servo-controlled hydraulic actuator, load cell, speed transducer, angular position transducer of the coupling and pressure transducers. For each of these components the nonlinear multi-physics mechatronic model is described, according to the adopted solutions. The adopted force control algorithm is discussed, showing the integrative compensation on the action line and proportional-derivative on the feedback, with speed feedforward. The experimental tests carried out on the bench under stalled conditions are also presented, whose results concerning time and frequency responses are compared with those obtained through the linearized and non-linear numerical model. Finally, the non-linear models of the flight control actuator under test, controlled in position, and of the loading servo-actuator of the bench are joined together, and the results of various simulations are described.

Determination of Johnson Cook Material Model Constants and Their Influence on Machining Simulations of Tungsten Heavy Alloy

Tungsten Heavy Alloys (WHA) are used in counterbalance and ballast weights for aerodynamic balancing in fixed and rotary wing aircraft. Manufacturing these components for closer tolerances using machining is a challenging task. The present work aims to develop a 2D Finite Element (FE) model to simulate the chip formation process during machining of WHA using Johnson Cook Material Model (JCMM). The model constants for 95%WHA are determined based on the high strain rate test data using least square method. The calculated values are further optimized using Genetic Algorithm (GA) and Artificial Bee Colony (ABC) algorithm, which are then used as material inputs for FE simulation of machining WHA. The predicted results such as cutting force, chip geometry, shear stress, shear angle are presented and compared with the experimental results under similar cutting conditions. It has been observed that the constants obtained from ABC algorithm show minimum error in the cutting performance measures for all the experimental results.

The Effects of Layer-by-Layer Thickness and Fiber Volume Fraction Variation on the Mechanical Performance of a Pressure Vessel

Due to high stiffness/weight ratio, composite materials are widely used in aerospace applications such as motor case of rockets which can be regarded as a pressure vessel. The most commonly used method to manufacture the pressure vessels is the wet filament winding. However, the mechanical performance of a filament wound pressure vessel directly depends on the manufacturing process, manufacturing site environmental condition and material properties of matrix and fiber. The designed ideal pressure vessel may not be manufactured because of the mentioned issues. Therefore, manufacturing of filament wound composite structures are based on manufacturing experience and experiment. In this study, the effect of layer-by-layer thickness and fiber volume fraction variation due to manufacturing process on the mechanical performance was investigated for filament wound pressure vessel with unequal dome openings. First, the finite element model was created for designed thickness dimensions and constant material properties for all layers. Then, the model was updated. The updated finite element model considered the layer-by-layer thickness and fiber volume fraction variation. Effects of the thickness and fiber volume fraction on the stress distribution along the motor axial direction were shown. Also hydrostatic pressurization test was performed to verify finite element analysis in terms of fiber direction strain through the motor case outer surface. Important aspects of analyzing a filament wound pressure vessel were addressed for designers.

Experimental Analysis of Alternative Dielectric Materials for DBD Plasma Actuators

Dielectric Barrier Discharge plasma actuators are simple devices with great potential for active flow control applications. They have very interesting features which have made them a topic of interest for many researchers, for instance they present very low mass, fast response time, low cost, easy implementation and they are fully electronic with no moving parts. The dielectric material used in the construction of these devices present an important role in their performance. The variety of dielectrics studied in the literature is very restrict and the majority of the authors make use of Kapton, Teflon, Macor ceramic or PMMA. Furthermore, several authors reported difficulties in the durability of the dielectric layer when actuators operate at high levels of voltage and frequency. Considering this background, the present study focus on the experimental testing of alternative dielectric materials which can be used for DBD plasma actuators fabrication. Considering this, plasma actuators with dielectric layers made of Poly-Isobutylene rubber, Poly-Lactic acid and Acetoxy Silicon were experimentally tested. Although these dielectric materials are not commonly used in plasma actuators, their values of dielectric strength and dielectric permittivity indicate they can be good solutions. The plasma actuators facbricated with these alternative dielectric materials were experimentally analysed in terms of electrical characteristics and induced flow velocity, and the obtained results were compared with an actuator made of Kapton which is, currently, the most common dielectric material for plasma actuators. The effectiveness of the actuators was estimated and the advantages and disadvantages of the use of each dielectric material were discussed.

Nonlinear Dynamics of Rotating Structures and Helicopter Blades

This work explores the effects of geometrical nonlinearities in the vibration analysis of rotating structures and helicopter blades. Structures are modelled via higher-order beam theories with variable kinematics. These theories fall in the domain of the Carrera Unified Formulation (CUF), according to which the nonlinear equations of motion of rotating blades can be written in terms of fundamental nuclei, whose formalism is an invariant of the theory approximation. The inherent three-dimensional nature of CUF enables one to include all Green-Lagrange strain components as well as all coupling effects due to the geometrical features and the three-dimensional constitutive law. Numerical solutions are considered and opportunely discussed. Also, linearized and full nonlinear solutions for vibrating rotating blades are compared both in case of small amplitudes and in the large deflections/rotations regime.

Effect of Different Cutting Depths to the Cutting Forces and Machining Quality of CFRP Parts in Orthogonal Cutting: A Numerical and Experimental Comparison

The necessity of understanding the influence of cutting variables in orthogonal cutting of Carbon Fiber Reinforced Polymer (CFRP) is vital because of their significant influences to the quality of manufactured parts. In this present research work the influences of different cutting depths to the cutting and thrust forces have been analyzed and a comparison between an equivalent homogeneous material (EHM) macro-model and experimental results have been made. The reasons of the beginning high cutting and thrust forces have been studied and explained. The post analysis of the experimental machined surfaces has been done to analyze the generated surface roughness and fiber-matrix interface crack generation. Five different cutting depths and four individual fiber orientations have been tested both numerically and experimentally. Significant influence of cutting depths to the cutting force has been found and the surface quality of newly generated machined part is discovered as a function of cutting depth and fiber orientation.

About the Immediate Shift From Large-Sized Machine Boeing 747 to Boeing 777

For aircraft, Airport facilities are indispensable infrastructure. Looking at the arrival and departure capabilities of Haneda / Narita airport which is said to be a crowded airport in japan, in 1992, Haneda Airport got 210,000 a year (40 departures / hours at departure and arrival), Haneda airport reached 130,000 a year, Totaling 340,000 times in total. In 2004 (2014), Haneda Airport had 447 thousand times and Narita airport had 300 thousand times, a total of 747 thousand times, showing more than doubling(1). Business opportunities of the air craft industry are expanding due to due to the start of sharing of Haneda’s new runway and new international passenger terminal. The development of modern IT promotes convenient air development of computers is greatly related to the transition from the Boeing 747 which was the theme this time to Boeing 777 promptly. I decided to investigate the fact that cooperation customers is changing in Boeing 747 and Boing 777.