Digital Commons Network^™

Manufacture Of Complex Geometry Component For Advanced Material Stiffness, David Russell Bydalek

Master's Theses

The manufacture, laminate design, and modeling of a part with complex geometry are explored. The ultimate goal of the research is to produce a model that accurately predicts part stiffness. This is validated with experimental results of composite parts, which refine material properties for use in a final prototype part model. The secondary goal of this project is to explore manufacturing methods for improved manufacturability of the complex part. The manufacturing portion of the thesis and feedback into material model has incorporated a senior project team to perform research on manufacturing and create composite part to be used for experimental …

Thermal-Fatigue And Thermo-Mechanical Equivalence For Transverse Cracking Evolution In Laminated Composites, Javier Cabrera Barbero

Graduate Theses, Dissertations, and Problem Reports

Carbon fiber reinforced plastics (CFRP) are potential materials for many aerospace and aeronautical applications due to their high specif strength/weight and a low coeffcient of thermal expansion (CTE) resulting in a high long-term stability. Among candidate structures, the re-entry reusable launch vehicles (RLV), the fuel oxidant storage and transportation at cryogenic temperature, space satellites, and aircraft structure (frame, wings, etc...) can be highlighted. However, CFRP are prone to internal damage as a result of high residual stresses and thermal fatigue loading. In this study, micro-cracking damage evolution in laminated composites subjected to monotonic cooling and thermal cyclic loads is developed …

High Temperature Polymer Composites Using Out-Of-Autoclave Processing, Sudharshan Anandan

Doctoral Dissertations

"High performance polymer composites possess high strength-to-weight ratio, corrosion resistance, and have design flexibility. Carbon/epoxy composites are commonly used aerospace materials. Bismaleimide based composites are used as a replacement for epoxy systems at higher service temperatures. Aerospace composites are usually manufactured, under high pressure, in an autoclave which requires high capital investments and operating costs. In contrast, out-of-autoclave manufacturing, specifically vacuum-bag-only prepreg process, is capable of producing low cost and high performance composites. In the current study, out-of-autoclave processing of high temperature carbon/bismaleimide composites was evaluated. The cure and process parameters were optimized. The properties of out-of-autoclave cured laminates compared …

Design Optimization And High Cycle Fatigue Analysis And Of A Differential Case, Praveen Bulusu Surya Naga

Dissertations, Master's Theses and Master's Reports

Lightweight Innovations for Tomorrow (LIFT) is a consortium with several industries, universities and research institutes. It is operated by the American Lightweight Materials Manufacturing Innovation Institute (ALMMII). One of their projects, melt 5a, is to develop high silicon ductile iron (DI) alloys with improved mechanical properties and thin walled DI castings. These alloys have high strength to weight ratio compared to that of standard ductile iron (7003). Using these alloys, components can be re-designed that are much lighter which results in improved fuel efficiency, and reduced manufacturing costs and emissions. I

In this project, a differential case is being re-designed …

Bmi, Tumor Lesion And Probability Of Femur Fracture: A Probabilistic Biomechanics Approach, Zhi Gao

Masters Theses

found that most of these factors are directly or indirectly linked to subjects’ BMI (body mass index). Thus, from a statistical perspective, BMI could be an overall indicator of the probability of femur fracture from a sideways fall. Using a biomechanics approach coupled with statistical data we investigate this relationship with a large cohort of postmenopausal women aged 50-79 from WHI-OS (Women’s Health Initiative Observational Cohort). The cohort is divided into six sub-cohorts by BMI where each fall-related factor is examined and compared with each other. Significant differences are discovered among cohorts in terms of femur size, aBMD (areal bone …

Evaluation Of Concrete Constitutive Models For Impact Simulations, Guillermo A. Mata

Mechanical Engineering ETDs

The research documented in this thesis deals with computational analysis of reinforced concrete impacted by both hollow and solid missiles as a continuing effort on the work conducted by the Committee on the Safety of Nuclear Installations (CSNI) and Nuclear Energy Agency (NEA). The analysis focuses on comparing two similar material models and their ability to capture the mechanistic response of a reinforced concrete slab subjected to impact loads. The analysis was performed using the Sandia National Laboratories computing software SIERRA Solid Mechanics to run the finite element model. The two constitutive models studied were the Holmquist-Johnson-Cook and Johnson-Holmquist 2 …

Bio Inspired Lightweight Composite Material Design For 3d Printing, Kaushik Thiyagarajan

Electronic Theses and Dissertations

Lightweight material design is an indispensable subject in product design. The lightweight material design has high strength to weight ratio which becomes a huge attraction and an area of exploration for the researchers as its application is wide and increasing even in every day-to-day product. Lightweight composite material design is achieved by selection of the cellular structure and its optimization. Cellular structure is used as it has wide multifunctional properties in addition to the lightweight characteristics. Applications of light weight cellular structures are wide and is witnessed in all industries from aerospace to automotive, construction to product design. In this …

Fea Analysis And Optimization Of Differential Housing For Fatigue Stresses And Fatigue Test Design To Study Skin Effect In Ductile Iron, Swapnil A. Pandey

Dissertations, Master's Theses and Master's Reports

Automotive emission standards are getting more stringent day by day and governments worldwide are moving to reduce emissions from automobiles. In this scenario reducing the weight of automobile components becomes an important design objective to reduce emissions. A 10% reduction of weight in the complete automobile leads to 6-8 percent improvement in mileage (Mhapankar 2015). Also, powertrain components make up for approximately 27% of the total automobile weight and thus optimizing the design of components in the powertrain is an important task (Mhapankar 2015). Statistics show that 26% of component failures in automobiles are part of powertrain and 21% of …

Minimizing Run Time Of Finite Element Analyses: Applications In Conformable Cng Tank Modeling, Paul M. Roehm

Dissertations, Master's Theses and Master's Reports

REL Inc. has proposed a CNG tank that deviates from typical cylindrical storage methods. The goal of REL working with Michigan Tech is to minimize mass and meet NGV2 safety standards for pressure and drop testing for this tank.

The model has undulated outer surfaces and Schwarz P-surface internal geometry. To accurately mesh this, a small element size is necessary; this creates a model with millions of elements. In explicit analyses, this requires a large amount of computational resources to run.

This report focuses on methods to reduce model run time without reducing accuracy. Methods covered include creating symmetric building …

Design And Analysis Of The Impact Diffusion Helmet Through A Finite Element Analysis Approach, Steven Paul Warnert

Master's Theses

By applying the finite element approach to the design and analysis of the impact diffusion helmet, many helmet configurations were able to be analyzed. Initially it was important to determine what design variables had an influence on the impact reducing abilities of the helmet design. The helmet was run through a series of Abaqus simulations that determined that a design with two oval shaped channels running along the length of the helmet was best. Next, these options were optimized to generate the helmet that produced the greatest impact reduction. The optimization simulations determined that a helmet that pushed the channels …

Continuum Modeling Of The Densification Of W-Ni-Fe During Selective Laser Sintering, Connor M. West

Master's Theses

The purpose of this thesis is to effectively model the time history of the temperature distribution during the selective laser sintering process and use this information to investigate the resulting relative density. The temperature is a critical parameter of the process because it directly effects the overall quality of the part. First, an efficient, affordable, and reliable simulation was developed within the finite element software, Abaqus. Next, the results from the simulations were compared to the experimental results performed by Wang et al. (2016). The FEA model consisted of a 3 layer simulation. Multiple simulations at various laser recipes were …

Damage Tolerance And Assessment Of Unidirectional Carbon Fiber Composites, Mark David Flores

Open Access Theses & Dissertations

Composites are beginning to be used in a variety of different applications throughout industry. However, certification and damage tolerance is a growing concern in many aerospace and marine applications. Although compression-after-impact have been studied thoroughly, determining a damage tolerance methodology that accurately characterizes the failure of composites has not been established. An experimental investigation was performed to study the effect of stacking sequence, low-velocity impact response, and residual strength due to compression and fatigue. Digital Image Correlation (DIC) captured the strains and deformation of the plate due to compression. Computational investigations integrated non-destructive techniques (C-Scan, X-Ray) to determine the extent …

Optimization Of Formula Sae Electric Vehicle Frame With Finite Element Analysis, Alexander Prorok

Williams Honors College, Honors Research Projects

Optimization of Formula SAE Electric Vehicle Frame with Finite Element Analysis

Simulation Of Magnetic Field Induced Current And Neuron Spiking For Magnetic Seizure Therapy, Abhijeet R. Wadkar

Electronic Thesis and Dissertation Repository

Magnetic seizure therapy (MST) is currently on trial to treat severe cases of depression. This thesis is concerned with getting a deeper understanding of the mechanics behind MST by employing FEA of brain. The simulations performed via COMSOL helped identify the dimensions and coil types of the MST device as well as the angular probing orientations. Largest induced current due to the externally imposed magnetic field was found in the cerebrospinal fluid which was found to act as a barrier to induce current in the gray matter. In an attempt to relate the induced current to the neuron spiking, a …

Analysis Of A Carbon Fiber Reinforced Polymer Impact Attenuator For A Formula Sae Vehicle Using Finite Element Analysis, John T. Rappolt

Master's Theses

The Hashin failure criteria and damage evolution model for laminated fiber reinforced polymers are explored. A series of tensile coupon finite element analyses are run to characterize the variables in the physical model as well as modeling techniques for using an explicit dynamic solver for a quasi-static problem. An attempt to validate the model on an axial tube crush is presented. It was found that fiber buckling was not occurring at the impactor-tube interface. Results and speculation as to why the failure initiation is incorrect are discussed. Lessons learned from the tube crush are applied successfully to the quasi-static Formula …

Concurrent Engineering Through Parallelization Of The Design-Analysis Process, Eric Joseph Wardell

Theses and Dissertations

The disconnect between the way CAD and analysis applications handle model geometry has long been a hindrance to engineering design. Current industry practices often utilize outdated forms of geometry transfer between these different engineering software applications such as neutral file formats and direct translations. Not only to these current practices slow the engineering design process but they also hinder the integration of design and analysis programs.This thesis proposes a new, multi-user, integrated design-analysis architecture which allows auxiliary functions such as analysis and computer-aided manufacturing to be better connected with the computer-aided design. It is hypothesized that this new architecture will …

Development Of A Finite Element Model For Predicting The Impact Energy Absorbing Performance Of A Composite Structure, Matthew Lowell Roberts

Master's Theses

Because of their high strength-to-weight ratio, Fiber Reinforced Composite (FRC) materials are well suited for use in high performance racing applications where weight must be kept to a minimum. Formula SAE (FSAE) race cars are designed and built by college students, roughly following the model of a scaled down Formula One car. Strict regulations are placed on specific components of the car in the interest of equalizing competition and ensuring the safety of the drivers. Students are required to construct a survival cell (the chassis), which can resist large amounts of energy in the event of a crash, with an …

The Interfacial Fracture Of Bonded Materials And Composites, Kai Zhao

Open Access Theses & Dissertations

Adhesive bonding and composite materials have been widely used in manufacturing industry. Failure results from the weakest link in a structure and this is often the interface between two materials. In case of composites, it becomes the fiber and matrix interface. In case of bonded polymers, the bonding line is the interface. This Dissertation is focused on the interfacial fracture of bonded materials and composites. First, a systematic experimental investigation on adhesive bonding strengths of polymer/polymer and polymer/metal joints was conducted and the experimental results were compared with other researchers' work. Then, a modified short-beam shear approach is developed to …

Relating Microstructure To Process Variables In Beam-Based Additive Manufacturing Of Inconel 718, John Ryan Thompson

Browse all Theses and Dissertations

The advancement of laser or electron beam-based additive manufacturing requires the ability to control solidification microstructure. Previous work combined analytical point source solutions and nonlinear thermal finite element analysis (FEA) to explore the effects of deposition process variables on Ti-6Al-4V solidification microstructure. The current work seeks to extend the approach to Inconel 718, with the addition of Cellular Automaton-Finite Element (CAFE) models. Numerical data from finite element results are extracted in order to calculate accurate melt pool geometry, thus leading to corresponding cooling rates and thermal gradients. The CAFE models are used to simulate grain grown and nucleation, providing a …

Vibration And Acoustic Properties Of Honeycomb Sandwich Structures Subject To Variable Incident Plane-Wave Angle Pressure Loads, Jiaxue Yan

All Theses

Honeycomb structures are widely used in many areas for their material characteristics such as high strength-to-weight ratio, stiffness-to-weight, sound transmission, and other properties. Honeycomb structures are generally constructed from periodically spaced tessellations of unit cells. It can be shown that the effective stiffness and mass properties of honeycomb are controlled by the local geometry and wall thickness of the particular unit cells used. Of particular interest are regular hexagonal (6-sided) honeycomb unit cell geometries which exhibit positive effective Poisson's ratio, and modified 6-sided auxetic honeycomb unit cells with Poisson's ratio which is effectively negative; a property not found in natural …

Analytical And Numerical Modeling Of Assembly Procedures Of Steel Fulcra Of Bascule Bridges, Sriharsha Garapati

USF Tampa Graduate Theses and Dissertations

To model shrink-fitting in metal components, an analytical model for two long compound cylinders with temperature dependent material properties and interference between them is developed for calculating transient temperatures and stresses. A finite element model is developed for the same geometry which incorporated the temperature dependent material properties. A convergence study is performed on the finite element and analytical model. The finite element model is validated by comparing the approximations of finite element model with the analytical solution.

In an assembly procedure of fulcrums for bascule bridges, called AP1, the trunnion is shrink-fitted into a hub, followed by shrink fitting …

Development Of A New Temporary Fastener For Aerospace Automation, Xiangwen Zhang

Masters Theses

"Temporary fasteners are required in aircraft assembly, especially in the assembly of wings, fuselage, and aircraft skin's substructure prior to drilling holes for permanent fasteners by automated drilling machines. The objective was to develop a temporary fastener that can be installed, clamped, loosened, and removed from one side with a short head length. Published papers, web pages and patents relating to temporary fasteners were reviewed. Then by considering the ability to meet the operation requirements and concerns, a temporary fastener was designed with the following advantages:

• a simple structure that can be easily fabricated
• a short head length to save …

Explicit Finite Element Modeling Of The Human Lumbar Spine, Milind Rao

Electronic Theses and Dissertations

Validated finite element (FE) models of the functional spinal unit (FSU) and lumbar spine are essential in design-phase device development and in assessing the mechanics associated with normal spine function and degenerative disc disease (DDD), as well as the impact of fusion and total disc replacement (TDR). Although experimental data from fully intact specimens can be used for model calibration and validation, the contributions from the individual structures (disc, facets, and ligaments) may be inappropriately distributed. Hence, creation of decompression conditions or device implantations that require structure removal may not have the proper resulting mechanics. An explicit FE formulation may …

Computationally Efficient Finite Element Models Of The Lumbar Spine For The Evaluation Of Spine Mechanics And Device Performance, Sean D. Smith

Electronic Theses and Dissertations

Finite Element models of the lumbar spine are commonly used for the study of spine mechanics and device performance, but have limited usefulness in some applications such as clinical and design phase assessments due to long analysis times. In this study a computationally efficient L4-L5 FSU model and a L1-Sacrum multi-segment model were developed and validated. The FSU is a functional spine unit consisting of two adjacent vertebral bodies, in this case L4 and L5. The multi-segment model consists of all lumbar vertebrae and the sacrum. The models are able to accurately predict spine kinematics with significantly reduced analysis times, …

Poroelastic Finite Element Analysis Of A Heterogeneous Articular Cartilage Explant Under Dynamic Compression In Abaqus, Kelsey Kiyo Kam

Master's Theses

A poroelastic finite element model of a heterogeneous articular cartilage disc was

created to examine the tissue response to low amplitude (± 2% strain), low

frequency (0.1 Hz) dynamic unconfined compression (UCC). A strong correlation

has been made between the relative fluid velocity and stimulation of

glycosaminoglycan synthesis. A contour plot of the model shows the relative fluid

velocity during compression exceeds a trigger value of 0.25 μm/s at the radial

periphery. Dynamic UCC biochemical results have also reported a higher

glycosaminoglycan content in this region versus that of day 0 specimens. Fluid

velocity was also found not to be …

Modeling And Finite Element Analysis Methods For The Dynamic Crushing Of Honeycomb Cellular Meso-Structures, Jesse Schultz

All Theses

The effective static mechanical properties, such as the moduli of elasticity and rigidity and Poisson's ratio, of honeycomb cellular meso-structures are capable of control due to variations of their cellular geometry. While the dynamic properties of these structures are a popular topic of research, there is a lack of both consistent modeling methods and generalizations in terms of honeycomb cellular geometry. In order to fill these gaps, this study presents a standard set of methods for the finite element analysis (FEA) of honeycomb cellular materials subject to dynamic loading conditions, as well as illustrates the effects of the cellular geometry …

Determination Of Cap Model Parameters Using Numerical Optimization Method For Powder Compaction, Cong Lu

Dissertations (1934 -)

Many advantages are inherent to the successful powder metallurgy (P/M) process especially in high volume manufacturing. The strength/density distribution of the compacted product is crucial to overall success. The finite element analysis (FEA) method has become an effective way to numerically simulate strength/density distribution in a P/M compact. The modified Drucker-Prager cap (DPC) model has been shown to be a suitable constitutive relationship for metal powder compaction simulation. The calibration of the modified DPC model involves a procedure known as a triaxial compression test. Equipment for completing a triaxial compression test on metal powders is neither readily available nor standardized …

Thermal Analysis Of Railroad Bearings: Effect Of Wheel Heating, Lariza A. Navarro

Theses and Dissertations - UTB/UTPA

Catastrophic bearing failure is a major concern for the railroad industry because it can lead to costly train stoppages. Excessive heat buildup within the bearing is one of the main factors that can warn of impending failure. The work presented in this thesis is motivated by the need to understand the heat transfer paths to the bearing when wheel heating occurs. A series of experiments and finite element analyses were conducted in order to quantify the different heat transfer mechanisms, with emphasis on radiation. The results indicate that the effect of thermal radiation is minimal when the wheel tread temperature …

A Prediction Of The Acoustical Output Of A Golf Driver Head Using Finite Elements, Roger Sharpe

Master's Theses

A simulation was created using LS-DYNA® to determine the acoustical properties of a golf ball and golf driver head impact. LS-DYNA® has a coupled finite element analysis (FEA) and boundary element method (BEM) solver that uses the integral form of Helmholtz’s acoustic wave equation to deliver predicted sound pressure levels at predetermined acoustic points. Validation of the modeling was done on a simple plate donated by Titleist Golf. The plate was modeled and meshed using TrueGrid and impacted by a three layer golf ball model derived from “Tanka’s” paper on multilayered golf balls. The final converging model consisted of 10,900 …

Short-Term Failure Analysis Of Aluminum Conducting Composite Core Transmission Lines, Brian Burks

Electronic Theses and Dissertations

Recently the inefficiency and lack of capabilities of electric energy transmission have been put in the global spotlight; a transmission line design known as the Aluminum Conducting Composite Core Trapezoidal Wire (ACCC/TW^TM) attempts to eliminate the deficiencies. The ACCC core is comprised of a new hybrid composite material. The most probable causes of short-term damage to the ACCC core were investigated through a series of finite element models. It was found that excessive bending was the most likely cause of short-term damage to the core. During bending of the ACCC core, stresses are concentrated at the interface in …