Browsing by Subject "Finite element method"

Now showing 1 - 5 of 5
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    Coupled thermal-fluid analysis with flowpath-cavity interaction in a gas turbine engine
    (2013-12) Fitzpatrick, John Nathan; Wasfy, Tamer; Nalim, M. Razi; Yu, Huidan (Whitney); Anwar, Sohel
    This study seeks to improve the understanding of inlet conditions of a large rotor-stator cavity in a turbofan engine, often referred to as the drive cone cavity (DCC). The inlet flow is better understood through a higher fidelity computational fluid dynamics (CFD) modeling of the inlet to the cavity, and a coupled finite element (FE) thermal to CFD fluid analysis of the cavity in order to accurately predict engine component temperatures. Accurately predicting temperature distribution in the cavity is important because temperatures directly affect the material properties including Young's modulus, yield strength, fatigue strength, creep properties. All of these properties directly affect the life of critical engine components. In addition, temperatures cause thermal expansion which changes clearances and in turn affects engine efficiency. The DCC is fed from the last stage of the high pressure compressor. One of its primary functions is to purge the air over the rotor wall to prevent it from overheating. Aero-thermal conditions within the DCC cavity are particularly challenging to predict due to the complex air flow and high heat transfer in the rotating component. Thus, in order to accurately predict metal temperatures a two-way coupled CFD-FE analysis is needed. Historically, when the cavity airflow is modeled for engine design purposes, the inlet condition has been over-simplified for the CFD analysis which impacts the results, particularly in the region around the compressor disc rim. The inlet is typically simplified by circumferentially averaging the velocity field at the inlet to the cavity which removes the effect of pressure wakes from the upstream rotor blades. The way in which these non-axisymmetric flow characteristics affect metal temperatures is not well understood. In addition, a constant air temperature scaled from a previous analysis is used as the simplified cavity inlet air temperature. Therefore, the objectives of this study are: (a) model the DCC cavity with a more physically representative inlet condition while coupling the solid thermal analysis and compressible air flow analysis that includes the fluid velocity, pressure, and temperature fields; (b) run a coupled analysis whose boundary conditions come from computational models, rather than thermocouple data; (c) validate the model using available experimental data; and (d) based on the validation, determine if the model can be used to predict air inlet and metal temperatures for new engine geometries. Verification with experimental results showed that the coupled analysis with the 3D no-bolt CFD model with predictive boundary conditions, over-predicted the HP6 offtake temperature by 16k. The maximum error was an over-prediction of 50k while the average error was 17k. The predictive model with 3D bolts also predicted cavity temperatures with an average error of 17k. For the two CFD models with predicted boundary conditions, the case without bolts performed better than the case with bolts. This is due to the flow errors caused by placing stationary bolts in a rotating reference frame. Therefore it is recommended that this type of analysis only be attempted for drive cone cavities with no bolts or shielded bolts.
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    Fatigue Analysis of 3D Printed 15-5 PH Stainless Steel - A Combined Numerical and Experimental Study
    (2019-08) Padmanabhan, Anudeep; Zhang, Jing; Wei, Xiaoliang; Tovar, Andres
    Additive manufacturing (AM) or 3D printing has gained significant advancement in recent years. However the potential of 3D printed metals still has not been fully explored. A main reason is the lack of accurate knowledge of the load capacity of 3D printed metals, such as fatigue behavior under cyclic load conditions, which is still poorly understood as compared with the conventional wrought counterpart. The goal of the thesis is to advance the knowledge of fatigue behavior of 15-5 PH stainless steel manufactured through laser powder bed fusion process. To achieve the goal, a combined numerical and experimental study is carried out. First, using a rotary fatigue testing experiment, the fatigue life of the 15-5 PH stainless steel is measured. The strain life curve shows that the numbers of the reversals to failure increase from 13,403 to 46,760 as the applied strain magnitudes decrease from 0.214\% from 0.132\%, respectively. The micro-structure analysis shows that predominantly brittle fracture is presented on the fractured surface. Second, a finite element model based on cyclic plasticity including the damage model is developed to predict the fatigue life. The model is calibrated with two cases: one is the fatigue life of 3D printed 17-4 stainless steel under constant amplitude strain load using the direct cyclic method, and the other one is the cyclic behavior of Alloy 617 under multi-amplitude strain loads using the static analysis method. Both validation models show a good correlation with the literature experimental data. Finally, after the validation, the finite element model is applied to the 15-5 PH stainless steel. Using the direct cyclic method, the model predicts the fatigue life of 15-5 PH stainless steel under constant amplitude strain. The extension of the prediction curve matches well with the previously measured experimental results, following the combined Coffin-Manson Basquin Law. Under multi-amplitude strain, the kinematic hardening evolution parameter is incorporated into the model. The model is capable to capture the stresses at varied strain amplitudes. Higher stresses are predicted when strain amplitudes are increased. The model presented in the work can be used to design reliable 3D printed metals under cyclic loading conditions.
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    Integrated multibody dynamics and fatigue models for predicting the fatigue life of poly-V ribbed belts
    (2013-05) Elmaraghi, Omar A.; Wasfy, Tamer; El-Mounayri, Hazim; Anwar, Sohel
    Belt-drives are used in many applications such as industrial machines, washing ‎machines, and accessory drives for automobiles and other vehicles. Multibody dynamics/finite ‎element numerical models have become an effective way to predict the dynamic response of ‎belt-drives. In this thesis, a high fidelity numerical model was built using a multibody ‎dynamics/finite element code to simulate a belt-drive. The belt-drive transmits power from a ‎turbine of a Rankin cycle (that uses the exhaust waste heat of the internal combustion engine as ‎heat source) to the crank shaft of the engine. The code uses a time-accurate explicit numerical ‎integration technique to solve the multibody dynamics differential equations. The belt was ‎modeled using three-node beam elements to account for the belt axial and bending ‎stiffness/damping, while the pulleys, shafts and tensioner body were modeled as rigid bodies. ‎The penalty technique was used to model normal contact between the belt and the pulleys. An ‎asperity-based friction model was used to approximate Coulomb friction between the belt and ‎the pulleys. The dynamic response predicted using the model was validated by comparing it to ‎experimental results supplied by Cummins Inc. A parameter sensitivity study was performed to ‎evaluate the change in response due to change in various belt-drive parameters. A fatigue ‎model was developed to predict the belt fatigue life using output from the explicit finite ‎element code including normal and tangential forces between the belt and the pulleys and belt ‎tension. The belt fatigue life was evaluated for alternative belt-drive configurations in order to ‎find the configuration with the longest life.‎
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    Mechanical environment for lower canine T-loop retraction compared to en-masse space closure with a power-arm attached to either the canine bracket or the archwire
    (EH Angle Education and Research Foundation, 2020-11-01) Jiang, Feifei; Roberts, W. Eugene; Liu, Yanzhi; Shafiee, Abbas; Chen, Jie; Mechanical and Energy Engineering, School of Engineering and Technology
    Objectives: To assess the mechanical environment for three fixed appliances designed to retract the lower anterior segment. Materials and methods: A cone-beam computed tomography scan provided three-dimensional morphology to construct finite element models for three common methods of lower anterior retraction into first premolar extraction spaces: (1) canine retraction with a T-loop, (2) en-masse space closure with the power-arm on the canine bracket (PAB), and (3) power-arm directly attached to the archwire mesial to the canine (PAW). Half of the symmetric mandibular arch was modeled as a linear, isotropic composite material containing five teeth: central incisors (L1), lateral incisor (L2), canine (L3), second premolar (L4), and first molar (L5). Bonded brackets had 0.022-in slots. Archwire and power-arm components were 0.016 × 0.022 in. An initial retraction force of 125 cN was used for all three appliances. Displacements were calculated. Periodontal ligament (PDL) stresses and distributions were calculated for four invariants: maximum principal, minimum principal, von Mises, and dilatational stresses. Results: The PDL stress distributions for the four invariants corresponded to the displacement patterns for each appliance. T-loop tipped the canine(s) and incisors distally. PAB rotated L3 distal in, intruded L2, and extruded L1. PAW distorted the archwire resulting in L3 extrusion as well as lingual tipping of L1 and L2. Maximum stress levels in the PDL were up to 5× greater for the PAW than the T-loop and PAB methods. Conclusions: T-loop of this type is more predictable because power-arms can have rotational and archwire distortion effects that result in undesirable paths of tooth movement.
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    Structural Optimization of Thin Walled Tubular Structure for Crashworthiness
    (2014) Shinde, Satyajeet Suresh; Tovar, Andrés; Anwar, Sohel; Wasfy, Tamer
    Crashworthiness design is gaining more importance in the automotive industry due to high competition and tight safety norms. Further there is a need for light weight structures in the automotive design. Structural optimization in last two decades have been widely explored to improve existing designs or conceive new designs with better crashworthiness and reduced mass. Although many gradient based and heuristic methods for topology and topometry based crashworthiness design are available these days, most of them result in stiff structures that are suitable only for a set of vehicle components in which maximizing the energy absorption or minimizing the intrusion is the main concern. However, there are some other components in a vehicle structure that should have characteristics of both stiffness and flexibility. Moreover, the load paths within the structure and potential buckle modes also play an important role in efficient functioning of such components. For example, the front bumper, side frame rails, steering column, and occupant protection devices like the knee bolster should all exhibit controlled deformation and collapse behavior. This investigation introduces a methodology to design dynamically crushed thin-walled tubular structures for crashworthiness applications. Due to their low cost, high energy absorption efficiency, and capacity to withstand long strokes, thin-walled tubular structures are extensively used in the automotive industry. Tubular structures subjected to impact loading may undergo three modes of deformation: progressive crushing/buckling, dynamic plastic buckling, and global bending or Euler-type buckling. Of these, progressive buckling is the most desirable mode of collapse because it leads to a desirable deformation characteristic, low peak reaction force, and higher energy absorption efficiency. Progressive buckling is generally observed under pure axial loading; however, during an actual crash event, tubular structures are often subjected to oblique impact loads in which Euler-type buckling is the dominating mode of deformation. This undesired behavior severely reduces the energy absorption capability of the tubular structure. The design methodology presented in this paper relies on the ability of a compliant mechanism to transfer displacement and/or force from an input to desired output port locations. The suitable output port locations are utilized to enforce desired buckle zones, mitigating the natural Euler-type buckling effect. The problem addressed in this investigation is to find the thickness distribution of a thin-walled structure and the output port locations that maximizes the energy absorption while maintaining the peak reaction force at a prescribed limit. The underlying design for thickness distribution follows a uniform mutual potential energy density under a dynamic impact event. Nonlinear explicit finite element code LS-DYNA is used to simulate tubular structures under crash loading. Biologically inspired hybrid cellular automaton (HCA) method is used to drive the design process. Results are demonstrated on long straight and S-rail tubes subject to oblique loading, achieving progressive crushing in most cases.