Inter-Element Crack Propagation with High-Order Stress Equilibrium Element

The present contribution proposes a formulation based on the use of hybrid equilibrium elements (HEEs), for the analysis of inter-element delamination and fracture propagation problems. HEEs are defined in terms of quadratic stress fields, which strongly verify both the homogeneous and inter-element equilibrium equations and they are employed with interfaces, initially exhibiting rigid behavior, embedded at the elements’ sides. The interface model is formulated in terms of the same degrees of freedom of the HEE, without any additional burden. The cohesive zone model (CZM) of the extrinsic interface is rigorously developed in the damage mechanics framework, with perfect adhesion at the pre-failure condition and with linear softening at the post-failure regime. After a brief review, the formulation is computationally tested by simulating the behavior of a double-cantilever-beam with diagonal loads; the obtained numerical results confirm the accuracy and potential of the method.

Coupling BEM and VEM for the Analysis of Composite Materials with Damage

Numerical tools which are able to predict and explain the initiation and propagation of damage at the microscopic level in heterogeneous materials are of high interest for the analysis and design of modern materials. In this contribution, we report the application of a recently developed numerical scheme based on the coupling between the Virtual Element Method (VEM) and the Boundary Element Method (BEM) within the framework of continuum damage mechanics (CDM) to analyze the progressive loss of material integrity in heterogeneous materials with complex microstructures. VEM is a novel numerical technique that, allowing the use of general polygonal mesh elements, assures conspicuous simplification in the data preparation stage of the analysis, notably for computational micro-mechanics problems, whose analysis domain often features elaborate geometries. BEM is a widely adopted and efficient numerical technique that, due to its underlying formulation, allows reducing the problem dimensionality, resulting in substantial simplification of the pre-processing stage and in the decrease of the computational effort without affecting the solution accuracy. The implemented technique has been applied to an artificial microstructure, consisting of the transverse section of a circular shaped stiff inclusion embedded in a softer matrix. BEM is used to model the inclusion that is supposed to behave within the linear elastic range, while VEM is used to model the surrounding matrix material, developing more complex nonlinear behaviors. Numerical results are reported and discussed to validate the proposed method.

Investigation of Rotating Eddy Current Testing Simulation Using Simplified Model

To reduce the time of simulation for rotating Eddy current testing (RECT) technique, a simplified model without modeling probe was proposed previously. However, the applicability of the simplified simulation model was unknown. In this paper, the applicability of the simplified model for the RECT technique was investigated. The application condition of the simplified model was provided by comparing it with the results of the traditional simulation model. The simplified model was suitable for the study of cracks shorter than 70% size of the uniform Eddy current induced by the probe in a traditional model or experiment. The experiment was conducted to validate the simplified model. Moreover, using the simplified model, the effects of crack depth, orientation, and exciting frequency were studied. The deeper the crack depth was, the greater peak value of [Formula: see text] signal was. The crack angle was linear with the phase of signal. The exciting frequency affected the amplitude and phase of the signal at the same time.

An Integrated Multiscale Simulation Routine to Predict Mechanical Performance from Manufacturing Effects

Structural performance of unidirectional composites (UD) is directly dependent on its ingredient’s properties, ply configurations and the manufacturing effects. Prediction of mechanical properties using multiscale manufacturing simulation and micromechanical models is the focus of this study. Particular problem of coupled dual-scale deformation-flow process such as the one arising in RTM, Vacuum-Assisted Resin Infusion (VARI) and Vacuum Bag Only (VBO) prepregs is considered. A finite element formulation of porous media theory framework is employed to predict the element-wise local volume fractions and the deformation of a preform in a press forming process. This formulation considers coupling effects between macro-scale preform processes and mesoscale ply processes as well as coupling effects between the solid and fluid phases. A number of different micromechanical models are assessed and the most suitable one is used to calculate mechanical properties from volume fractions. Structural performance of the “deformed” geometry is then evaluated in mechanical analysis. An integrated platform is designed to cover the whole chain of analysis and perform the properties’ calculation and transfer them between the modules in a smooth mapping procedure. The paper is concluded with a numerical example, where a compression-relaxation test of a planar fluid filled prepreg at globally un-drained condition is considered followed by a mechanical loading analysis. The development is user friendly and interactive and is established to enable design and optimization of composites.

Investigation on Thrust and Torque Generation During Drilling of Hybrid Laminates Composite with Different Stacking Sequences Using Multiobjective Optimization Module

This paper highlights the reinforcement of two different fibers in the manufacturing of hybrid laminate composites. The feasibility of glass and carbon fiber-based hybrid composites is proposed for various high performances due to their versatile mechanical properties. However, anisotropic and non-homogeneity nature creates several machining challenges for manufacturers. It can be regulated through the selection of proper cutting conditions during the machining test. The effect of process constraints like spindle speed (rpm), feed rate (mm/min), and stacking sequences ([Formula: see text] was evaluated for the optimum value of thrust force and Torque during the drilling test. The cost-effective method of hand layup has been used to fabricate the composites. Four different hybrid composites were developed using different layers of carbon fiber and glass fiber layers. The outcomes of variables on machining performances were analyzed by variation of feed rate and speed to acquire the precise holes in the different configurations. The application potential of the proposed composites is evaluated through the machining (drilling) efficiency. The optimal condition for the drilling procedure was investigated using the multiobjective optimization-Grey relation analysis (MOO-GRA) approach. The findings of the confirmatory test show the feasibility of the MOO-GRA module in a machining environment for online and offline quality control.

ANFIS-based Models for Coating Quality Prediction for Thin-Film Deposition Processes

Thin-film deposition processes have gained much popularity due to their unique capability to enhance the physical and chemical properties of various materials. Identification of the best parametric combination for a deposition process to achieve desired coating quality is often considered to be challenging due to the involvement of a large number of input process parameters and conflicting responses. This study discusses the development of adaptive neuro-fuzzy inference system-based models for the prediction of quality measures of two thin-film deposition processes, i.e., SiCN thin-film coating using thermal chemical vapor deposition (CVD) process and Ni–Cr alloy thin-film coating using direct current magnetron sputtering process. The predicted response values obtained from the developed models are validated and compared based on actual experimental results which exhibit a very close match between both the values. The corresponding surface plots obtained from the developed models illustrate the effect of each process parameter on the considered responses. These plots will help the operator in selecting the best parametric mix to achieve enhanced coating quality. Also, analysis of variance results identifies the importance of each process parameter in the determination of response values. The proposed approach can be applied to various deposition processes for modeling and prediction of observed response values. It will also assist as an operator in selecting the best parametric mix for achieving desired response values.

Finite Element Analysis and Life Prediction of Pre-stressed Composed Dies in Cold Extrusion Process

Improving and stabilizing the life of the die has always been the key to increasing the output of cold precision forging products and reducing the production cost of forgings. The stress state in pre-stressed composed dies during cold extrusion process is investigated in this paper, it shows that the combined die can greatly reduce the tangential tensile stress of the inner wall of the die and reduce the strain energy density of the die, thereby improving the strength of the die and extending the life of the die. By increasing the number of pre-stressed rings, the amount of interference can be changed, which indirectly changes the pre-stress applied to the die. The relationship between the die fatigue life and the number of pre-stressed rings indicates that the design of the pre-stressed composed structure above the inflection point is an excess design, and the optimal design should be near the inflection point.