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Friction And Heat Transfer Modeling Of The Tool And Workpiece Interface In Friction Stir Welding Of Aa 6061-T6 For Improved Simulation Accuracy, Ryan Melander

Theses and Dissertations

Friction stir welding (FSW) is a solid-state joining process that offers advantages over traditional fusion welding. The amount of heat generated during a FSW process greatly influences the final properties of the weld. The heat is generated through two main mechanisms: friction and plastic deformation, with friction being the larger contributor in a FSW process. There is a need to develop better predictive models of the heat generation and heat transfer in FSW. Almost all models seen in the literature validate temperature predictions on only one side of the tool/workpiece interface, thus ignoring possible inaccuracy that comes from incorrect partitioning …

U-Splines: Splines Over Unstructured Meshes, Steven K. Schmidt

Theses and Dissertations

U-splines are a novel approach to the construction of a spline basis for representing smooth objects in Computer-Aided Design (CAD) and Computer-Aided Engineering (CAE). A spline is a piecewise-defined function that satisfies continuity constraints between adjacent cells in a mesh. U-splines differ from existing spline constructions, such as Non-Uniform Rational B-splines (NURBS), subdivision surfaces, T-splines, and hierarchical B-splines, in that they can accommodate local variation in cell size, polynomial degree, and smoothness simultaneously over more varied mesh configurations. Mixed cell types (e.g., triangle and tetrahedron and quadrilateral and hexahedral cells in the same mesh) and T-junctions are also supported. The …

Spline-Based Contact: Algorithms And Applications, Pulama Bhattacharya

Theses and Dissertations

Contact is one of the most challenging nonlinearities to solve in solid mechanics. In traditional linear finite element analysis, the contact surface is only C^0 continuous, as a result, the normal to the contact surface is not continuous. The normal contact force is directed along the normal in the direction of the contact surface, and therefore, the contact force is discontinuous. This issue is tackled in linear finite element analysis using various surface smoothing techniques, however, a better solution is to use isogeometric analysis where the solution space is spanned by smooth spline basis functions. Unfortunately, spline-based isogeometric contact analysis …

Evaluation Of Additively Manufactured Lattices Under High Strain Rate Impact, Derek G. Spear

Theses and Dissertations

Several additively manufactured lattice designs and configurations were evaluated under compression loads under various strain rates from quasi-static to highly dynamic. These experiments examined how the mechanical behavior of the lattice changed based on the lattice design properties and the applied strain rates. The modulus of elasticity, yield strength, plateau stress, and toughness were observed to decrease with an increase in strain rate, revealing that the lattice designs exhibit a negative strain rate sensitivity. A new lattice flow stress model was developed to account for the mechanical response of the lattice and was incorporated into a computational model for simulation. …

Linear And Nonlinear Dimensionality-Reduction-Based Surrogate Models For Real-Time Design Space Exploration Of Structural Responses, Gregory David Bird

Theses and Dissertations

Design space exploration (DSE) is a tool used to evaluate and compare designs as part of the design selection process. While evaluating every possible design in a design space is infeasible, understanding design behavior and response throughout the design space may be accomplished by evaluating a subset of designs and interpolating between them using surrogate models. Surrogate modeling is a technique that uses low-cost calculations to approximate the outcome of more computationally expensive calculations or analyses, such as finite element analysis (FEA). While surrogates make quick predictions, accuracy is not guaranteed and must be considered. This research addressed the need …

Computational Materials Science And Engineering: Model Development And Case Study, Yihan Xu

Theses and Dissertations

This study presents three tailored models for popular problems in energy storage and biological materials which demonstrate the application of computational materials science in material system development in these fields. The modeling methods can be extended for solving similar practical problems and applications.

In the first application, the thermo-mechanical stress concentrated region in planar sodium sulfur (NaS) cells with large diameter and different container materials has been estimated as well as the shear and normal stresses in these regions have been quantified using finite-element analysis (FEA) computation technique. It is demonstrated that the primary failure mechanism in the planar NaS …

Influence Of Dynamic Multiaxial Transverse Loading On Ultrahigh Molecular Weight Polyethylene Single Fiber Failure, Frank David Thomas

Theses and Dissertations

High performance fibers such as ultrahigh molecular weight polyethylene (UHMWPE) are often used for ballistic impact applications in the form of textile fabrics and composite laminates. In order to predict the ballistic performance of such materials, single-fiber experiments are performed to quantify the material behavior at smaller length scales, which can be applied to larger length scales as a result. Failure of UHMWPE is well understood as a function of simple tension at low and high strain rates, as well as under various multiaxial loading states. However, experimental characterization of single UHMWPE fibers under transverse loading at high strain rates …

Characterization And Modeling Of The Martensite Transformation In Advanced High-Strength Steels, Stephen Roy Cluff

Theses and Dissertations

Multiple studies on the microstructures of advanced high-strength steels are presented here that seek to add to the already substantial body of knowledge on martensite in steel. These studies seek to gain additional insight into the role that the martensite transformation has on the observed mechanical properties of modern steels. Crystallographic Reconstruction of Parent Austenite Twin Boundaries in a Lath Martensitic Steel The study of post-transformation microstructures and their properties can be greatly enhanced by studying their dependence on the grain boundary content of parent microstructures. Recent work has extended the crystallographic reconstruction of parent austenite in steels to include …

Predicting Hardness Of Friction Stir Processed 304l Stainless Steel Using A Finite Element Model And A Random Forest Algorithm, Tyler Alan Mathis

Theses and Dissertations

Friction stir welding is an advanced welding process that is being investigated for use in many different industries. One area that has been investigated for its application is in healing critical nuclear reactor components that are developing cracks. However, friction stir welding is a complicated process and it is difficult to predict what the final properties of a set of welding parameters will be. This thesis sets forth a method using finite element analysis and a random forest model to accurately predict hardness in the welding nugget after processing. The finite element analysis code used and ALE formulation that enabled …

Application And Evaluation Of Full-Field Surrogate Models In Engineering Design Space Exploration, Christopher Murray Thelin

Theses and Dissertations

When designing an engineering part, better decisions are made by exploring the entire space of design variations. This design space exploration (DSE) may be accomplished manually or via optimization. In engineering, evaluating a design during DSE often consists of running expensive simulations, such as finite element analysis (FEA) in order to understand the structural response to design changes. The computational cost of these simulations can make thorough DSE infeasible, and only a relatively small subset of the designs are explored. Surrogate models have been used to make cheap predictions of certain simulation results. Commonly, these models only predict single values …

A Computational Assessment Of Lisfranc Injuries And Their Surgical Repairs, Michael Perez

Theses and Dissertations

While Lisfranc injuries in the mid foot are less common than other ankle and mid foot injuries, they pose challenges in both properly identifying them and treating them. When Lisfranc injuries are ligamentous and do not include obvious fractures, they are very challenging for clinicians to identify unless weight bearing radiographs are used. The result is that 20%-40% of Lisfranc injuries are missed in the initial evaluation. Even when injuries are correctly identified the outcomes of surgical procedures remain poor. Existing literature has compared the different surgical procedures but has not had a standard approach or procedures across studies. This …

Parametric Study On Multi-Story, Partially Grouted, Perforated, Masonry Shear Walls By Finite Element Analysis, Kyle Henry Chavez

Theses and Dissertations

In this study, parameters related to material properties, geometry, and external stimuli were examined individually to determine their influence on multi-story, partially grouted, perforated (openings), masonry shear walls using a finite element software FormWorks. The parameters studied were: the strength of grouted masonry prisms f'_m,grouted; the strength of un-grouted (hollow) masonry prisms f'_m,ungrouted; the ratio of mortar shear strength to masonry compressive strength; vertical and horizontal reinforcement ratios in terms of size and spacing of reinforcement; axial load; aspect ratio; and openings that were vertically and horizontally altered. To perform this study, finite element models were …

Parametric Study On Multi-Story, Partially Grouted, Perforated, Masonry Shear Walls By Finite Element Analysis, Kyle Henry Chavez

Theses and Dissertations

In this study, parameters related to material properties, geometry, and external stimuli were examined individually to determine their influence on multi-story, partially grouted, perforated (openings), masonry shear walls using a finite element software FormWorks. The parameters studied were: the strength of grouted masonry prisms f<&trade>m,grouted; the strength of un-grouted (hollow) masonry prisms f<&trade>m,ungrouted; the ratio of mortar shear strength to masonry compressive strength; vertical and horizontal reinforcement ratios in terms of size and spacing of reinforcement; axial load; aspect ratio; and openings that were vertically and horizontally altered. To perform this study, finite element models were validated against …

Comprehensive Comparison Of Steel Framed Fabric And Conventionally Constructed Aircraft Hangars, Justin M. Iungerich

Theses and Dissertations

Through the life of the United States Air Force (USAF), the accepted method for constructing permanent aircraft hangars is the use of materials such as steel and concrete. However, the emerging type of construction known as steel framed fabric (SFF) construction shows potential to meet the requirements of the USAF at a lower life-cycle cost and with faster construction delivery. A comprehensive comparison to conventional hangars is conducted through the means of an extensive literature review, case study analysis, structural analysis with the use of finite element analysis (FEA) software, and a life-cycle cost comparison. Through examination of Department of …

Study Of Abnormal Grain Growth In Beta Annealed Ti-6al-4v Forgings, Lee R. Morris

Theses and Dissertations

Beta annealed Ti-6Al-4V has been used extensively in current aerospace platforms due to properties such as high strength to weight ratio. Recent inspections during aircraft production have revealed regions of excessive grain sizes, resulting in quarantined parts and excessive time spent on root cause analysis and risk mitigation efforts. Uncertainty surrounding these parts has led to increased costs and may cause future aircraft production delays. Part manufacturers have intermittently reported problems with abnormal grain growth in these alloys for years, but to date no supplier has been able to determine the source of this microstructural phenomenon. Leveraging common Finite Element …

Quasi-Static Nonlinear Analysis Of A Celestial Icosahedron Shaped Vacuum Lighter Than Air Vehicle, Kyle D. Moore

Theses and Dissertations

Due to the many drawbacks associated with a traditional lighter than air vehicle (LTAV), there is a desire for a LTAV which generates lift from an internal vacuum. To date, two feasible designs (the icosahedron and the hexakis icosahedron) for this so called vacuum lighter than air vehicle (VLTAV) have been studied at the Air Force Institute of Technology (AFIT). This research looks to show the feasibility of a new design for a VLTAV, the celestial icosahedron. This research includes a boundary condition study which proves the symmetric nature of the celestial icosahedron's frame with laterally constrained and unconstrained vertices. …

Finite Element Modeling Of Shallowly Embedded Connections To Characterize Rotational Stiffness, Trevor Alexander Jones

Theses and Dissertations

Finite element models were created in Abaqus 6.14 to characterize the rotational stiffness of shallowly embedded column-foundation connections. Scripts were programmed to automate the model generation process and allow study of multiple independent variables, including embedment length, column size, baseplate geometry, concrete modulus, column orientation, cantilever height, and applied axial load. Three different connection types were investigated: a tied or one part model; a contact-based model; and a cohesive-zone based model. Cohesive-zone modeling was found to give the most accurate results. Agreement with previous experimental data was obtained to within 27%. Baseplate geometry was found to affect connection stiffness significantly, …

Numerical Analysis Of Passive Force On Skewed Bridge Abutments, Zifan Guo

Theses and Dissertations

Accounting for seismic forces and thermal expansion in bridge design requires an accurate passive force-deflection relationship for the abutment wall. Current design codes make no allowance for skew effects on passive force; however, large scale field tests indicate that there is a substantial reduction in peak passive force as skew angle increases. A reduction in passive force also reduces the transverse shear resistance on the abutment. The purpose of this study is to validate three-dimensional model using PLAXIS 3D, against large scale test results performed at Brigham Young University and to develop a set of calibrated finite element models. The …

Ligament Model Fidelity In Finite Element Analysis Of The Human Lumbar Spine, Mitchell Scott Hortin

Theses and Dissertations

The purpose of this project is to quantify the effects of increasing spinal ligament fidelity on the mechanics of the human lumbar spine using finite element analysis (FEA). In support of this goal, a material characterization study was completed to provide anisotropic, nonlinear material parameters for the human anterior longitudinal ligament. (ALL). Cadaveric samples of the human ALL were tested using a punch test technique. Multi- axial force-deformation data were gathered and fit to a commonly used transversely isotropic material model using an FEA system identification routine. The resulting material parameters produced a curve that correlated well with the experimental …

Modeling Stokes Flow Using Hierarchical Structure-Preserving B-Splines, Kendrick Monroe Shepherd

Theses and Dissertations

A new spline space, the hierarchical structure-preserving B-spline space, is introduced and implemented in the analysis of Stokes flow. The space, when properly constrained, is shown to be stable and to have at least optimal convergence rates in the velocity field and suboptimal convergence rates in the pressure field. However, results show that superoptimal convergence can often be expected in the pressure field, likely due to error reduction in the velocity field. Like other hierarchical spline spaces, these splines are shown to greatly increase accuracy and to drastically lower computation times for analyses on domains whose solution fields have singularities …

Shear-Dominated Bending Behavior Of Carbon/Epoxy Composite Lattice Isobeam Structures, Kirsten Bramall Hinds

Theses and Dissertations

Composite lattice structures known as the IsoBeam™ made with unidirectional carbon/epoxy were manufactured and tested in shear-dominated bending. The manufacturing process consisted of placing tows of carbon fiber pre-impregnated with epoxy resin onto a pin-type mandrel to create members with interwoven joints. The members were consolidated with a half spiral aramid sleeve. The IsoBeam structure consists of two main types of members: longitudinal and diagonal members measuring nominally 0.4 in. (10.2 mm) and 0.2 in. (5.1 mm) in diameter, respectively. The hand-manufactured specimens measured nominally 6 in. (152.4 mm) high by 3 in. (76.2 mm) wide by 2 ft (0.61 …

Effect Of Leg Geometries, Configurations, And Dimensions On Thermo-Mechanical And Power-Generation Performance Of Thermoelectric Devices, Ugur Erturun

Theses and Dissertations

Environmental challenges, such as global warming, growing demand on energy, and diminishing oil sources have accelerated research on alternative energy conversion methods. Thermoelectric power generation is a promising method to convert wasted heat energy into useful electrical energy form. A temperature gradient imposed on a thermoelectric device produces a Seebeck potential. However, this temperature gradient causes thermal stresses due to differential thermal expansions and mismatching of the bonded components of the device. Thermal stresses are critical for thermoelectric devices since they can generate failures, including dislocations, cracks, fatigue fractures, and even breakdown of the entire device. Decreases in power-generation performance …

Developing An Architecture Framework For Cloud-Based, Multi-User, Finite Element Pre-Processing, Jared Calvin Briggs

Theses and Dissertations

This research proposes an architecture for a cloud-based, multi-user FEA pre-processing system, where multiple engineers can access and operate on the same model in a parallel environment. A prototype is discussed and tested, the results of which show that a multi-user preprocessor, where all computing is done on a central server that is hosted on a high performance system, provides significant benefits to the analysis team. These benefits include a shortened preprocessing time, and potentially higher-quality models.

Design Exploration And Analysis Of Carbon-Infiltrated Carbon Nanotube Vascular Stents, Darrell John Skousen

Theses and Dissertations

The purpose of this research was to design, develop, and test coronary stent designs composed of carbon-infiltrated carbon nanotubes (CI-CNTs). Coronary stents currently have two major complications: restenosis and thrombosis. CI-CNT stents have potential to address both of these issues, and therefore may provide improved clinical outcomes. CI-CNT stent geometry is patterned using high-resolution photolithography that provide advantages in design possibilities.To develop a coronary stent, a standard design process was followed including: background, design specifications, concept generation, development, analysis, and testing. Background research was first completed and general design specifications for coronary stent performance were compiled. Multiple design concepts were …

Real-Time Visualization Of Finite Element Models Using Surrogate Modeling Methods, Ryan C. Heap

Theses and Dissertations

Finite element analysis (FEA) software is used to obtain linear and non-linear solutions to one, two, and three-dimensional (3-D) geometric problems that will see a particular load and constraint case when put into service. Parametric FEA models are commonly used in iterative design processes in order to obtain an optimum model given a set of loads, constraints, objectives, and design parameters to vary. In some instances it is desirable for a designer to obtain some intuition about how changes in design parameters can affect the FEA solution of interest, before simply sending the model through the optimization loop. This could …

The Biomechanical Implications Of An Intrinsic Decompressive Pre-Load On A Posterior Dynamic Stabilization System, Jeffrey Ellis Harris

Theses and Dissertations

The purpose of this research was to investigate the influence of applying an intrinsic decompressive pre-load to a particular dynamic stabilization device on the biomechanical response of the lumbar spine. The FlexSPAR, which supports this ability, was used as a test case. A finite element model of a full lumbar spine was developed and validated against experimental data, and tested in the primary modes of spinal motion. The model was used to compare five lumbar spine test cases: healthy, degenerate, implanted with a pre-loaded device, implanted with a device without a pre-load, and implanted with rigid fixators. Results indicated that …

Finite Element Analysis Of Transverse Medial Malleolar Fracture Fixation, Ruchi Chande

Theses and Dissertations

Injury to the medial malleolus, the distal end of the tibia and one of the bones comprising the ankle joint, can occur in various loading scenarios. Open reduction/internal fixation (ORIF) to reattach the malleolar fragment to the proximal tibia can be achieved via various devices, however small fragments are particularly challenging to treat. In this study, computational finite element analysis (FEA) was utilized to investigate the fixation of transverse medial malleolar fractures by two cancellous screws or by a new fixation device, the Medial Malleolar Sled™. Cadaveric testing assessed the performance of the two constructs in both tension and torsion. …

Biomechanical Implications Of Lumbar Spinal Ligament Transectiona Finite Element Study, Gregory Allen Von Forell

Theses and Dissertations

The purpose of this work was to determine the possible effects of isolated spinal ligament transection on the biomechanics of the lumbar spine. A finite element model of a lumbar spine was developed and validated against experimental data. The model was tested in the primary modes of spinal motion in the intact condition, followed by comparative analysis of isolated removal of each spinal ligament. Results showed that stress increased in the remaining ligaments once a ligament was removed, potentially leading to ligament damage. Results also showed changes in bone remodeling "stimulus" which could lead to changes in bone density. Isolated …

Development Of Physiologic Contact Models For Articular Surfaces, John Owen

Theses and Dissertations

The superficial tangential zone (STZ) plays a significant role in normal articular cartilage’s ability to support loads and retain fluids. To date, tissue engineering efforts have not replicated normal STZ function in cartilage repairs. Finite element models were developed to examine the STZ’s role in normal and repaired articular surfaces under different contact conditions. Models were developed by incrementally adding improvements which culminated in contact loading of curved models by permeable and impermeable rigid surfaces and a normal cartilage layer. In the normal STZ, permeability was strain-dependent on volumetric strain; tension-compression nonlinearity modeled collagen behavior. Nonlinear geometry accounted for finite …

Using Buckling-Restrained Braces In Eccentric Configurations, Gary S. Prinz

Theses and Dissertations

Ductile braced frames are often used to resist lateral earthquake loads in steel buildings; however the presence of a brace element can sometimes interfere with architectural features. One common type of ductile braced frame system sometimes used to accommodate architectural features is the eccentrically braced frame (EBF). In order to dissipate seismic forces, EBF beam regions (called links) must sustain large inelastic deformations. EBF links with column connections must transmit large moments and shear forces to facilitate link rotation. Experiments have shown that welded link-to-column connections tend to fracture in the link flange prior to large link rotations. This study …